Thermal Dynamics 51 cutmaster Service Manual
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Thermal Dynamics 51 cutmaster Service Manual

Thermal Dynamics 51 cutmaster Service Manual

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51
™
CUTMASTER
PLASMA CUTTING SYSTEM
Art # A-04611

Service Manual

Date: June 15, 2007
Rev. AB.02
Manual # 0-2972
Operating Features:

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Summary of Contents for Thermal Dynamics 51 cutmaster

  • Page 1: Service Manual

    ™ CUTMASTER PLASMA CUTTING SYSTEM Art # A-04611 Service Manual Date: June 15, 2007 Rev. AB.02 Manual # 0-2972 Operating Features:...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ 51 Service Manual Number 0-2972 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2004, 2005, 2006 by Thermadyne Corporation All rights reserved.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • Page 6 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................6-1 6.01 Introduction ....................6-1 6.02 Ordering Information ..................6-1 6.03 Major External Replacement Parts ............... 6-2 6.04 Front Panel Replacement Parts ..............6-3 6.05 Left Side Internal Replacement Parts ............6-4 6.06 Right Side Internal Replacement Parts ............

  • Page 7: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.

  • Page 13: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 14: Statement Of Warranty

    Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

  • Page 15: Introduction

    C. Customer/Operator Responsibilities It is the customer/operator's responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the operating manual, and to protect the equipment from accidental or mali- cious damage.
  • Page 16 This Page Left Blank INTRODUCTION Manual 0-2972...

  • Page 17: Section 3: Description

    SECTION 3: DESCRIPTION 3.01 Scope The purpose of this section is: • To familiarize the service technician with the capabilities and limitations of the equipment; • To provide an overall understanding which will allow the technician, in turn, to properly train customer oper- ating personnel.

  • Page 18: Power Supply Features

    3.03 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-03578 Work Cable and Clamp Gas Pressure Regulator / Filter Assembly Gas Inlet Port Ports for Optional Automation Interface Cable Gas Pressure Gauge Art # A-03738 Input Power Cord DESCRIPTION Manual 0-2972...
  • Page 19 1. Front Panel Controls and Features • Main Power ON / OFF Switch • RUN /RAPID AUTO RESTART Switch • Output Current Control (A) Sets output current for drag cutting (up to 40 Amps for drag cutting (with the torch tip in contact with the workpiece), or for standoff cutting. 2.

  • Page 20: Air Regulator/Filter Assembly Specifications

    3.04 Air Regulator/Filter Assembly Specifications The following specifications apply to the Air Regulator/Filter Assembly only: 1. Operating Pressure 65 psi (4.5 bar) 2. Maximum input air supply pressure 125 psi (8.6 bar) DESCRIPTION Manual 0-2972...

  • Page 21: Troubleshooting

    SECTION 4: 4.03 System Theory TROUBLESHOOTING A. Logic PC Board Functions The Logic PC Board controls the timing and sequenc- ing of the system. It monitors gas pressure and power 4.01 Introduction supply internal temperatures, and controls the gas flow. The Logic Board also controls the safety latch circuit.

  • Page 22: Common Operating Problems

    Non-Genuine Thermal Dynamics parts used cut is to start. When starting at the edge of the plate, 2. Main Arc Extinguishes do not pause at the edge and force the arc to “reach”...

  • Page 23: Troubleshooting Guide - General Information

    Section 4.08 - Pilot Arc Problems d. Improper cutting current Section 4.09 - Main Arc Problems e. Non-Genuine Thermal Dynamics parts used Section 4.10 - Test Procedures 4. Short Torch Parts Life Subsection 4.10 includes specific test procedures and in- a.

  • Page 24: Circuit Fault Isolation

    B. Initial Setup Conditions 4.06 Circuit Fault Isolation This section is to help isolate the defective circuit before A. Controls and Indicators troubleshooting, identify symptoms, and test the unit for proper operation. Follow the instructions as given to iden- tify the possible symptom(s) and the defective circuit. Af- ter repairs are complete, run the following tests again to verify that the unit is fully operational.

  • Page 25: Main Input And Internal Power Problems

    D. Pilot Arc Test 3. Carefully lift the cover off the unit, and remove the nut securing the ground wire to the side panel. 1. Activate the torch (press torch switch on the handle, 4. Re-install the cover by reversing the above steps. send START signal from CNC Control, or press the torch switch on the Remote Pendant) to establish a pilot arc and note the following:...
  • Page 26 B. Main power line fuses blow immediately after the 4. Shield cup not fully tightened on torch head. ON/OFF Switch is turned on. a. Check shield cup for proper installation. Do 1. Faulty Input Diode not overtighten. a. Test Input Diode per Subsection 4.10-C; repair 5.
  • Page 27 10. Faulty Auxiliary Transformer (refer to Appendix pages, 4. Faulty Temperature Sensor / Switch 28 V AC Circuit Diagram) a. Shut input power off. Check IGBT Heatsink Measure for 28 VAC on Main PC Board from J5-1 Temp Sensor (TS1). Disconnect wire connector to J5-3.
  • Page 28 F. RUN / RAPID AUTO RESTART /SET switch in 2. Faulty Components in Unit RUN or RAPID AUTO RESTART position; AC Measure for 12 vdc from wire #10 to wire #11 at the Gas Pressure Switch, located on the right side of indicator ON;...
  • Page 29 G. Gas continues to flow with RUN / RAPID AUTO I. Gas cycles on and off when power is turned on; AC RESTART / SET switch in RUN position. indicator flashes; TEMP indicator off, 1. Damaged gas solenoid. a. Turn the front panel ON/OFF switch to OFF. GAS indicator •...
  • Page 30 TP18 Fuse TP10 (F1) Output Diode IGBT TP14 TP13 Art #A-03751 Main Printed Circuit Board Layout (Logic PCB Not Shown) TROUBLESHOOTING 4-10 Manual 0-2972...

  • Page 31: Pilot Arc Problems

    3. Faulty IGBT 4.08 Pilot Arc Problems a. Measure between the following points on the Main PC Board: WARNING • E4 to E10 • E10 to E20 The following tests must be performed with the power supply connected to primary input power. There Voltage should be approximately 20 vdc before are extremely dangerous voltage and power levels the start signal is active.
  • Page 32 3. Torch starter cartridge is stuck 4. Faulty Temperature Sensor / Switch a. Turn off power supply. Remove shield cup, tip, CAUTION and starter cartridge. Check lower end fitting on starter cartridge for free movement. Replace Turn off input power for the following tests. cartridge if lower end fitting does not move freely.
  • Page 33 a. Reset gas pressure per pressure setting label on D. Gas flows; AC indicator and GAS indicators power supply. 2. Oil/moisture in air lines ON; TEMP indicator off; DC indicator off or a. Put the ON / OFF switch in the ON (up) posi- blinks on/off once.

  • Page 34: Main Arc Problems

    a. Install a jumper between wires 58 and 62 on Pilot • If not, replace Main PC Board. Board and retry piloting. If torch pilots with jumper 5. Faulty Main Input Contactor. installed, replace Pilot Board. If torch does not pilot, replace Logic Board.

  • Page 35: Test Procedures

    B. Opening Power Supply Enclosure 4.10 Test Procedures The cover of the Power Supply must be removed to gain The test procedures in this subsection are referenced in access to the input power connections. the troubleshooting section. A. Safety Precautions WARNING 1.
  • Page 36 C. Diode Testing Basics Testing of diode modules requires a digital volt/ohm- Art # A-00306 meter that has a diode test scale. Remember that even if the diode module checks good, it may still be bad. If in doubt, replace the diode module. 1.
  • Page 37 D. Input Diode Test E. Main Input Contactor (W1) Test Check Input Diode for shorted input diode. Reconnect power and observe proper start-up procedure. AC Indicator on the Front Panel should be ON. If indica- Remove AC power and with an ohmmeter set on the diode tor is OFF there is no voltage to the Power Supply or an range make the following checks on Main PC Board: overvoltage condition exists.
  • Page 38 Measure for approximately 28 VAC on coil of Con- 2. Output Diode Circuit Test tactor between wires #11 and #12. • If voltage is correct, replace Main Contactor. If WARNING voltage is incorrect, replace Main PC Board. F. Gas Solenoid Circuit Test Disconnect primary power at the source before tak- ing any resistance checks.
  • Page 39 3. IGBT Circuit Test 4. Gate Drive & DC Sensing Use an ohmmeter set to the diode function and make After checking all previous steps in Subsection the following measurements on the IGBT Board to 4.09-G, jumper TP1 to TP2 on the Logic PCB. the Main Power Board.
  • Page 40 This Page Left Blank TROUBLESHOOTING 4-20 Manual 0-2972...

  • Page 41: Replacement Procedures

    B. Procedure SECTION 5: 1. Open the wrist strap and unwrap the first two folds REPLACEMENT of the band. Wrap the adhesive side firmly around PROCEDURES your wrist. 2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

  • Page 42: Major External Parts Replacement

    B. Tube Handle Replacement 5.04 Major External Parts Replacement Remove the cover per Subsection 5.04-A. Remove the four bolts and star washers securing Refer to Section 6.03 for Major External Replacement Parts the tube handles to the base of the unit. and overall detailed drawing.

  • Page 43: Left Side Internal Parts Replacement

    B. ON/OFF Switch (SW1) Replacement D. POT/LED PC Board Replacement Remove the power supply cover per Subsection Follow the antistatic procedures in Subsection 5.02. 5.04-A. Remove the cover per Subsection 5.04-A. Disconnect the wires on the rear of the Switch, not- Remove Current Knob per procedures in Subsec- ing the location and orientation of each wire as tion 5.05-A.
  • Page 44 B. Main Input Contactor (W1) Replacement D. Logic PC Board Replacement Remove the cover per Subsection 5.04-A. Follow the antistatic procedures provided in Subsection 5.02. Label and disconnect all wiring leading to the con- tactor. 1. Remove the cover per Subsection 5.04-A. Remove the hardware securing the Input Contac- Unlock the two tabs on the card guides protruding tor to the base of the power supply.
  • Page 45 The thermal pad, provided with the replacement 11. Reconnect the wiring per the applicable chart. part, is a thin metal pad. Remove and discard any loose protective paper coverings from the pad. CutMaster 51 IGBT Wiring Connections CAUTION From IGBT To Main PCB Terminals Terminals...
  • Page 46 F. Input Diode Replacement Input Diode Mounting Plate WARNINGS Thermal Pad Input Diode Follow the electrostatic discharge instructions in- cluded with the component to prevent damage to the component. Thermal pads and the large flat surface on the back of diodes must be kept clean. Thermal pads must not be allowed to pick up any foreign material.
  • Page 47 G. Main PC Board Replacement H. EMI Filter Replacement (CE Units Only) Follow the antistatic procedures provided in Subsection Refer to Subsection 6.05 for parts list and overall detailed 5.02. drawing. Remove cover per Subsection 5.04-A. WARNING Remove the Logic PC Board per Subsection 5.06-D. Remove the POT/LED PC Board per Subsection Disconnect input power at the source and bleed down 5.05-D.

  • Page 48: Rear Panel Parts Replacement

    Note the correct assembly of the filter/spool then 5.07 Rear Panel Parts Replacement remove the filter from the spool. Either clean or replace the filter element. Refer to Subsection 6.07 for parts list and overall detailed drawing. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring WARNING...
  • Page 49 Replace Housing on Cover. F. Input Power Cable Replacement Attach gas supply hose. 1. Remove the cover per Subsection 5.04-A. NOTE Label and disconnect the wires from the Main In- put Contactor. If unit leaks between housing and cover, inspect the O-Ring for cuts or other damage.

  • Page 50: Right Side Internal Parts Replacement

    Install the replacement Pressure Switch/Solenoid 5.08 Right Side Internal Parts Assembly by reversing the above steps. Once in- Replacement stalled, the Solenoid Assembly should fit securely under the Fan Shroud and should not be move- Refer to Section 6.07 Right Side Internal Parts List and able.
  • Page 51 C. Pilot PC Board Replacement 7. Label and disconnect cables at the following points on the Main Power PC Board. Refer to the Appen- The Pilot PC Board mounts to the Power Supply center dix pages for wiring details. chassis. Refer to Pilot Board Layout in theAppendix. •...
  • Page 52 E. Output Inductor Assembly (L1) Replacement Remove the cover per Subsection 5.04-A. Disconnect the two wires connected to terminals E5 and E10 located on the right side of the Main Power PC Board. Pull through the bottom hole in the Center Chassis. 3.

  • Page 53: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Major External Replacement Parts Section 6.04 Front Panel Replacement Parts Section 6.05 Left Side Internal Replacement Parts Section 6.06 Right Side Internal Replacement Parts Section 6.07 Rear Panel Replacement Parts Section 6.08 Options and Accessories...

  • Page 54: Major External Replacement Parts

    6.03 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-7999 Tube, roll handle 9-8320 Hardware: Screw, 10-32 x 1/2 PPH Swageform See Note 1 Washer, 1/4 External Star See Note 1 Screw, 1/4 - 20 x 3/4" Hex See Note 1 Art # A-02819 NOTES...

  • Page 55: Front Panel Replacement Parts

    6.04 Front Panel Replacement Parts Item # Description Catalog # Knob, Fluted, Skirted, 0.250 I.D. 9-8527 On/Off Rocker Switch 8-3258 Run/Rapid Auto Restart / Set Switch 8-3259 Assembly, Pot/LED PCB 9-8004 Cable, Work, #6 awg with Clamp, 20 Ft (6.1 m) 9-8528 Art # A-02850 NOTE...

  • Page 56: Left Side Internal Replacement Parts

    6.05 Left Side Internal Replacement Parts Item # Description Catalog # Fuse 1/2A, 250V (For 208/230-Volt units) 9-8110 1/2A, 600V (For 400-Volt and 460-Volt units) 9-8583 Main Input Contactor For 208/230-Volt Units 9-8522 For 400-Volt and 460-Volt Units 9-8554 PCB Kit, Input Diode 9-7088 Input Diode Thermal Pad...
  • Page 57 Center Chassis Input Diode Mounting Plate (part of Center Chassis) Art # A-03904 NOTE Illustration may vary slightly from unit. Manual 0-2972 PARTS LISTS...

  • Page 58: Right Side Internal Replacement Parts

    6.06 Right Side Internal Replacement Parts Item # Description Catalog # Assembly, Pressure Switch/Solenoid SOL1, PS1 9-8329 Assembly, Pilot PCB 9-8337 Fan, 220V, 115 CFM 9-7687 Assembly, Main Transformer 9-8544 Assembly, Output Inductor 9-8560 Hardware: 10-32 x 1/2 pph screw See Note #10 External star washer See Note...
  • Page 59 A, B Heatsink Art # A-03905 NOTE Illustration may vary slightly from unit. Manual 0-2972 PARTS LISTS...

  • Page 60: Rear Panel Replacement Parts

    6.07 Rear Panel Replacement Parts Item # Description Catalog # Assembly, Filter/Regulator 9-7514 Regulator/Filter Replacement Element 9-4414 Regulator Mounting Bracket 9-7589 Input Power Cable For 208/230-Volt Units 8-4384 For 400-Volt Units (non-CE) 9-8562 For 400-Volt CE Units 9-8553 For 460-Volt Units 9-8593 Mounting Nut 9-5804...

  • Page 61: Options And Accessories

    6.08 Options and Accessories Description Catalog # Single-Stage Filter Kit (Includes Filter And Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Element 9-7741 Replacement Filter Hose (Not Shown) 9-7742 Two-Stage Air Line Filter Kit (Includes Hose & Mounting Screws) 7-7500 Bracket, Filter Mounting (Not Shown) 9-7535 Two-Stage Air Filter Assembly...

  • Page 62: Patent Information

    PATENT INFORMATION The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512 Catalog Number Description 9-8235 Shield Cap, Drag 50-60A 9-8236 Sheild Cap, Drag 70-100A 9-8237 Shield Cup, Body 9-8238 Shield Cap, Machine 50-60A 9-8239 Shield Cap, Machine 70-100A 9-8244 Shield Cap, Drag 40A 9-8245...

  • Page 63: Appendix 1: Input Wiring Requirements

    APPENDIX 1: INPUT WIRING REQUIREMENTS CutMaster 51 Power Supply Input Wiring Requirements Input Power Input Current Input Suggested Sizes (See Notes) Fuse (Amps) Wire (AWG) Wire (Canada) Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph (Volts) (Hz.) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph...

  • Page 64: Appendix 2: Sequence Of Operation (Block Diagram

    APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / ON / OFF switch to ON Close external RUN / Rapid Auto Restart / SET disconnect switch. Rapid Auto Restart / RESULT: switch to RUN SET switch RESULT: to SET AC indicator...
  • Page 65 This Page Left Blank Manual 0-2972 APPENDIX...

  • Page 66: Appendix 3: Logic Pc Board Layout

    APPENDIX 3: LOGIC PC BOARD LAYOUT P1-1 to P1-36 P1-7 TP10 Art # A-03883 APPENDIX Manual 0-2972...
  • Page 67 Logic Board Signals P1-1 +12vdc from Main PCB P1-2 +12vdc from Main PCB P1-26 Gate Drive B Return P1-3 Ground P1-27 Gate Drive B Signal P1-4 Ground P1-28 Gate Drive A Return P1-5 Logic Low - W1 on Signal P1-29 Gate Drive A Signal P1-6 Ground...

  • Page 68: Appendix 4: Main Power Pc Board Layout

    APPENDIX 4: MAIN POWER PC BOARD LAYOUT TP18 Fuse TP10 (F1) Output Diode IGBT TP14 TP13 Art #A-03751 Main Power PC Board Signals J1-1 +12vdc to Logic PCB J1-15 Logic Low = CSR Signal to Logic PCB J1-16 Ground Signal J1-2 +12vdc to Logic PCB J1-3...
  • Page 69 J1-30 Negative out J21-1 Gate Drive A Return J1-31 Current Sense J21-2 Gate Drive A J1-32 Current Sense J1-33 Current Sense Return J22-1 Pot High J1-34 Current Sense Return J22-2 Pot Wiper J1-35 I Sense J22-3 Pot Low J1-36 Tip (PIP?) J22-4 +12V J22-5...

  • Page 70: Appendix 5: Pilot Board Layout

    APPENDIX 5: PILOT BOARD LAYOUT 2 - Pin Receptacle (J1) No Receptacle Art # A-03880 Pilot PC Board Signals J28-1 + 12V to Main PC Board Connector J4-7 J28-2 Ground J28-3 Logic Low = Rapid Auto Restart OFF J28-4 Not Used J28-5 CSR to Main PC Board Connector J4-9 J28-6...

  • Page 71: Appendix 6: Led/Pot Pc Board Layout

    APPENDIX 6: LED/POT PC BOARD LAYOUT A-03712 Pot/LED PC Board Signals J14-1 +10 vdc from Logic PC Board (J22-1) Pot High J14-2 Current Control to Logic PC Board (J22-2) Pot Wiper J14-3 Return for Current Control from Logic PC Board (J22-3) Pot Low J14-4 12vdc (J22-4) J14-5...

  • Page 72: Appendix 7: Igbt Circuit Pc Board Layout

    APPENDIX 7: IGBT CIRCUIT PC BOARD LAYOUT TP13 TP14 A-02851 APPENDIX A-10 Manual 0-2972...

  • Page 73: Appendix 8: Input Diode Pc Board Layout

    APPENDIX 8: INPUT DIODE PC BOARD LAYOUT Art # A-03882 Manual 0-2972 A-11 APPENDIX...

  • Page 74: Appendix 9: Output Diode Pc Board Layout

    APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT A-02853 APPENDIX A-12 Manual 0-2972...
  • Page 75 This Page Left Blank Manual 0-2972 A-13 APPENDIX...

  • Page 76: Appendix 10-A: Main Pc Board Wiring (208/230-Volt Units

    APPENDIX 10-A: MAIN PC BOARD WIRING (208/230-Volt units) Copper To IGBT Heatsink To ON/OFF Switch Solenoid / Pressure Switch Strap Temp Sensor and Mode Switch To Chassis Contactor Harness Test To Inductor Ground Connection (Open) Temp Switch Fuse Logic Board Connector (J1) To POT/LED PCB Secondary...

  • Page 77: Appendix 10-B: Main Pc Board Wiring (400-Volt And 460-Volt Units

    APPENDIX 10-B: MAIN PC BOARD WIRING (400-Volt and 460-Volt units) To IGBT Heatsink To ON/OFF Switch Solenoid / Pressure Switch Temp Sensor and Mode Switch To Chassis Contactor Harness Test To Inductor Ground Connection (Open) Temp Switch Fuse Logic Board Connector (J1) To POT/LED PCB (or to Optional...

  • Page 78: Appendix 11: 28Vac Circuit Diagram

    APPENDIX 11: 28VAC CIRCUIT DIAGRAM Line Voltage 0.5A Fuse 3 4 5 6 ON/OFF Switch 1 2 5 6 primary Auxiliary Transformer Voltage Protection CRT/+12 Regulator +12vdc Main Power PC Board A-02770 APPENDIX A-16 Manual 0-2972...

  • Page 79: Appendix 12: Maintenance Schedule

    APPENDIX 12: MAINTENANCE SCHEDULE This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Cutting Hours: Check torch consumable parts, replace if damaged or worn.

  • Page 80: Appendix 13: Torch Pin - Out Diagrams

    APPENDIX 13: TORCH PIN - OUT DIAGRAMS Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green / Switch 4 - Switch 3 - Switch 7 - Open...

  • Page 81: Appendix 14: Torch Connection Diagrams

    APPENDIX 14: TORCH CONNECTION DIAGRAMS Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Power Receptacle Connector Torch Torch Supply Head Leads Black To Power Supply Switch Circuitry...

  • Page 82: Appendix 15: System Schematic (208/230-Volt Units

    APPENDIX 15: SYSTEM SCHEMATIC (208/230-Volt Units) 208 / 230V INPUT INPUT DIODE ASSY 19X2073 COPPER STRAP CHASSIS (FILTERING) F1 (6/10A 600V) FAN1 (0 ohm) 28VAC B 28VAC A 230V GATE DRIVE A RTN GATE DRIVE A GATE DRIVE B RTN GATE DRIVE B 28VAC B (21)
  • Page 83 (E58) Date: Date: Date: ECO B028 01/09/06 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/27/03 (46) Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 84: Appendix 16: System Schematic (400-Volt And 460-Volt Units

    APPENDIX 16: SYSTEM SCHEMATIC (400-Volt and 460-Volt Units) ...OR... 400/460V 400/460V 1 PHASE 3 PHASE INPUT INPUT (44) INPUT DIODE ASSY 19X2073 400V 3 PHASE INPUT CHASSIS (FILTERING) 400V 'CE' VERSION INCLUDES IN-LINE EMC FILTER F1 (1/4A 500V) R94 (460V) R93 (400V) FAN1 230V...
  • Page 85 (E58) Date: Date: Date: ECO B028 01/09/06 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/27/03 (46) Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 86: Appendix 17: Publication History

    APPENDIX 17: Publication History Cover Date Comments 5/5/04 Manual released. 6/23/04 Updated system schematics per ECO 101429. 4/28/06 Updated system schematics per ECO B016. Added c/n for logic board for mechanized units. Updated torque spec for replacement input diode per ECO 101948. Added publica tion history.

  • Page 87: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 88 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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