Thermal Dynamics 81 CUTMASTER Service Manual
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Thermal Dynamics 81 CUTMASTER Service Manual

Plasma cutting system
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81
™
CUTMASTER
PLASMA CUTTING SYSTEM
A-04517

Service Manual

Rev. AC.01
Date: April 13, 2007
Manual # 0-2957
Operating Features:

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M. Philippe Hegele
March 11, 2025

bonjour je recherche la ref de l'embase femelle de raccordement de la torche sur un cutmaster 81 merci d'avance P hegele

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Mr. Anderson
March 11, 2025

The female connection base reference for the Thermal Dynamics Cutmaster 81 torch is the ATC Female Receptacle.

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Summary of Contents for Thermal Dynamics 81 CUTMASTER

  • Page 1: Service Manual

    ™ CUTMASTER PLASMA CUTTING SYSTEM A-04517 Service Manual Rev. AC.01 Date: April 13, 2007 Manual # 0-2957 Operating Features:...
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ 81 Operating Manual Number 0-2957 Covered under U.S. Patents. Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com © Copyright 2003, 2004, 2005, 2006, 2007 by Thermal Dynamics 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 Component Replacement Parts ........6-4 6.06 Rear Panel 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

    • 208/230-Volt Single-Phase Thermal Dynamics in good operating order in accordance with the procedures outlined in the operating manual, • 400-Volt Three-Phase and to protect the equipment from accidental or mali- •...
  • Page 16 This Page Left Blank INTRODUCTION Manual 0-2957...

  • 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 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 0-2957...

  • Page 19: Air Regulator/Filter Assembly Specifications

    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 (up to 60 amps). 2.
  • Page 20 This Page Left Blank DESCRIPTION Manual 0-2957...

  • 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. After 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 C. Fans do not operate; all control panel indicators OFF 6. Improper input power cable connections inside Power Supply 1. Front Panel ON/OFF switch in OFF position a. Refer to System Schematic and correct if needed. a. Place switch to ON (up) position. 7.
  • Page 27 11. Faulty ON/OFF switch 4. Faulty Temperature Sensor / Switch Measure for 28 VAC on the Main PC Board be- a. Shut input power off. Check IGBT Heatsink tween J18-5 to J18-6. Temp Sensor (TS1). Disconnect wire connector P29 from terminal J29 on Main PC Board. Check a.
  • 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 FUSE J32 J29 INPUT DIODE IGBT A IGBT B Art # A-03651 Main Printed Circuit Board Layout (Logic PCB Not Shown) TROUBLESHOOTING 4-10 Manual 0-2957...

  • Page 31: Pilot Arc Problems

    3. Faulty IGBT(s) 4.08 Pilot Arc Problems a. Measure between the following points on the IGBTs: WARNING • IGBT A: E4 to E10 E10 to E20 The following tests must be performed with the power supply connected to primary input power. There •...
  • 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 D. Gas flows; AC indicator and GAS indicators 2. Oil/moisture in air lines a. Put the ON / OFF switch in the ON (up) posi- ON; TEMP indicator off; DC indicator tion. Put the RUN / RAPID AUTO RESTART / off or blinks on/off once.

  • Page 34: Main Arc Problems

    5. Faulty Main Input Contactor. 4.09 Main Arc Problems a. Check per Subsection 4.10-D. Locate your symptom below: B. When operating the amperage drops off after the A. Main cutting arc will not start main cutting arc starts. 1. Work cable not connected. 1.

  • Page 35: Test Procedures

    5. Connect the volt/ohmmeter positive lead to the an- 4.10 Test Procedures ode (+) of the diode and the negative lead to the cathode (-) of the diode for forward bias testing (re- The test procedures in this subsection are referenced in fer to following figure).
  • Page 36 If a diode checks bad, replace the diode module. For 208/230-Volt Power Supplies: Reconnect all cables. 208/230V Input Diode PCB C. Diode Module Board Tests Meter (+) Meter (-) Indication Open Diode Drop WARNING Diode Drop Open Disconnect primary power at the source before tak- Diode Drop * ing any resistance checks.
  • Page 37 3. IGBT Module Board Circuit Test D. Main Input Power Test Use an ohmmeter set on the diode function and make the following measurements on the IGBT WARNING Module Board(s) to the Main PC Board. IGBT PCB A IGBT PCB B Indication The following tests must be performed with the Meter + Meter - Meter + Meter -...
  • Page 38 Check for 28 VAC at J23-1 to J23-3 on the Main PC Contactor Voltage Readings Board. Nominal Contactor Voltage a. If greater than 30 VAC, input line power is too Input Voltage Points Range high. 208/230VAC L1, L2 187-253VAC b. If there is no AC power, check the fuse. If the 400VAC L1, L3 360-440VAC...
  • Page 39 F. Output Power Tests 2. Gate Drive & Sensing Shut off input power. Replace the torch tip and 1. No DC Output electrode. Remove the jumper betweenthe work lead Activate the torch. and terminal E35 or E62 on the Output Power PC Board.
  • Page 40 This Page Left Blank TROUBLESHOOTING 4-20 Manual 0-2957...

  • Page 41: Replacement Procedures

    B. Procedure SECTION 5: 1. Open the wrist strap and unwrap the first two REPLACEMENT folds of the band. Wrap the adhesive side firmly PROCEDURES around 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

    Before disassembling any part of the Power Supply first 3. Remove the nut and washer from the ground stud read the procedure for the part to be replaced, then pro- on the inside of the cover. ceed with the disassembly. 4.

  • Page 43: Front Panel Parts Replacement

    C. RUN RAPID AUTO RESTART / SET Switch 5.05 Front Panel Parts Replacement Replacement Refer to Section 6.04 for Front Panel Replacement Parts 1. Remove the cover per subsection 5.04-A. and overall detailed drawing. 2. Disconnect the wires on the rear of the Switch. Note the location of each wire, as shown: WARNING Top clip...

  • Page 44: Left Side Internal Parts Replacement

    5.06 Left Side Internal Parts Replacement Connections to To E2 Main PCB To E3 Refer to subsection 6.05 Left Side Internal Component Replacement Parts and overall detailed drawing. To E1 WARNING Input Side Disconnect primary power from the source before opening or disassembling the power supply.
  • Page 45 C. Logic PC Board Replacement 5. Remove screw(s) securing PC Board(s) to the heat- sink and remove board(s) from the Power Sup- Follow the antistatic procedures in Subsection 5.02. The ply. Logic PC Board connects to the Main PC Board through 6.
  • Page 46 10. Connect wires per the chart. E. Main Power PC Board Replacement Follow the antistatic procedures in subsection 5.02. CutM as ter 81 Input Diode Connections 1. Remove cover per subsection 5.04-A. 400V , 415V , 460V , 208/230V Units 600V Units 2.

  • Page 47: Rear Panel Parts Replacement

    5. Connect the input power cables and the cable con- B. Filter/Regulator Bracket Replacement nections to the main input contactor. 1. Remove the four bolts securing the Regulator 6. Re-install the Power Supply cover. Bracket to the Rear Panel. 7. Test the Power Supply for proper operation. 2.

  • Page 48: Right Side Internal Parts Replacement

    5. Release the hose from the Adapter Fitting on the 5.08 Right Side Internal Parts output side of the Solenoid Assembly. Replacement 6. Install the replacement Pressure Switch/Solenoid Refer to Section 6.07 Right Side Internal Component Parts Assembly by reversing steps 2-5. Once installed, List and overall detailed drawing.
  • Page 49 7. Remove two bolts per Fan. Set the Fan(s) aside. D. Output Diode PC Board Replacement 8. Install the replacement Fan Assembly as follows: Follow the antistatic procedures in subsection 5.02. a. Fasten Fan(s) in position with the wiring con- 1.
  • Page 50 9. Connect wires as follows. F. Heatsink Shroud Assembly Removal The Heatsink Shroud Assembly must be disengaged for CutMaster 81 Output Diode Connections access to either the Main Transformer or the Output In- Output Diode A Output Diode B ductor. Follow these steps for access to either compo- nent.
  • Page 51 G. Main Transformer Removal and b. Lift out the Inductor through the opening at the rear of the Power Supply. It may be necessary Replacement to lift the Main Transformer slightly to create 1. Disengage the Heatsink Shroud per Paragraph H. room for the Inductor to pass through the rear opening.
  • Page 52 d. Put hex nuts on the studs. Tighten the nuts on the right (rear) top and bottom studs. Leave the nuts on the left (forward) studs loose tem- porarily. 4. Put the Fan Assembly in place per subsection 5.08-C. Reconnect the work cable to terminal E61 on the Power Output PC Board.

  • 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 Component Replacement Parts Section 6.06 Rear Panel Replacement Parts Section 6.07 Right Side Internal Component...

  • Page 54: Major External Replacement Parts

    6.03 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-7997 Rear Panel (provide data tag information when ordering) For 208/230-Volt Power Supplies 9-8323 For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Supplies 9-8322 Tube, roll handle 9-7998 Art # A-03709 NOTE: Illustration may vary slightly from unit.

  • Page 55: Front Panel Replacement Parts

    6.04 Front Panel Replacement Parts Item# Description Ref. # Catalog # Knob, Fluted, Skirted, 0.250 I.D. 9-8527 On/Off Rocker Switch, DPST 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-03008 NOTE: Illustration may vary slightly from unit.

  • Page 56: Left Side Internal Component Replacement Parts

    6.05 Left Side Internal Component Replacement Parts Item # Description Ref # Catalog # Fuse for 208/230-Volt Power Supplies 9-8588 for 400-Volt and 415-Volt Power Supplies 9-8602 for 460-Volt Power Supplies 9-8583 for 600-Volt Power Supplies 9-8638 Main Input Contactor for 208/230-Volt Power Supplies 9-8587 for 400-Volt, 415-Volt 460-Volt and 600-Volt Power Supplies...
  • Page 57 Art # A-03717 NOTE: Illustration may vary slightly from unit. Manual 0-2957 PARTS LISTS...

  • Page 58: Rear Panel Replacement Parts

    6.06 Rear Panel Replacement Parts Item # Description Ref. 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 9-8596 for 400-Volt Three-Phase units 9-8562 for 400-Volt and 415-Volt CE units 9-8553 for 460-Volt Three-Phase units 9-8593...

  • Page 59: Right Side Internal Component Replacement Parts

    6.07 Right Side Internal Component Replacement Parts Item # Description Ref #. Catalog # Assembly, Pressure Switch/Solenoid Sol1, Ps1 9-8329 Assembly, Pilot Board 9-8337 Fan, 220V, 115 CFM 9-7687 Assembly, Main Transformer for 208/230-Volt units 9-8589 for 400 Volt and 415-Volt units 9-8603 for 460-Volt units 9-8584...

  • Page 60: 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 9-7535...

  • Page 61: 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 62 This Page Left Blank PARTS LISTS 6-10 Manual 0-2957...

  • Page 63: Appendix 1: Input Wiring Requirements

    APPENDIX 1: INPUT WIRING REQUIREMENTS CutMaster 81 Input Wiring Requirements Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 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: AC indicator to SET...

  • Page 65: Appendix 3: Logic Pc Board Layout

    APPENDIX 3: LOGIC PC BOARD LAYOUT P1-7 P1-9 TP10 TP11 Art # A-03654 Logic Board Signals P1-27 Current Sense P1-28 Current Sense Return P1-1 +12vdcfrom Main Power PCB P1-29 Current Sense Return P1-2 +12vdcfrom Main PCB P1-30 DC Com P1-3 DC Com P1-31 DC Com P1-4...

  • Page 66: Appendix 4: Main Power Pc Board Layout

    APPENDIX 4: MAIN POWER PC BOARD LAYOUT FUSE J32 J29 INPUT DIODE IGBT B IGBT A Art # A-03651 Main Power PC Board Signals J18-1 Not used J11-1 L1 Input J18-2 Not used J11-4 L3 Input J18-3 28 VAC B J18-4 28 VAC A J15-1...
  • Page 67 J25-1 Gate Drive J25-2 Gate Drive J43-1 + 12 vdc to Logic PCB J43-2 + 12 vdc to Logic PCB J26-1 Gate Drive J43-3 DC Com J26-2 Gate Drive J43-4 DC Com J27-1 Pot High J43-5 MC1 On J27-2 Pot Wiper J43-6 Tip Sense J27-3...

  • Page 68: Appendix 5A: Main Pc Board Wiring Layout - 208/230-Volt Units

    APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT - 208/230-Volt Units To Inductor Temp Sensor To Press Switch/Solenoid/Contactor To Power Output Board To Heat Sink Test Connector To On/Off and To Main Temp Sensor Run/Rapid Restart Input Contactor To Torch Set Switches To Chassis Ground To Fans Connector...

  • Page 69: Appendix 5B: Main Pc Board Wiring Layout - 400-Volt, 415-Volt 460-Volt, And 600-Volt Units

    APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT - 400-Volt, 415-Volt 460-Volt, and 600-Volt Units To Inductor Temp Sensor To Power Output To Press Switch/Solenoid/Contactor Board To Heat Sink To On/Off and Test Temp Sensor To Chassis Run/Rapid Restart Connector Fuse To Torch To Main Ground...

  • Page 70: Appendix 6: Led/Pot Pc Board Layout

    APPENDIX 6: LED/POT PC BOARD LAYOUT A-03712 Pot/LED PC Board Signals J14-1 from Main PC Board (J27-1) Pot High J14-2 Main PC Board (J27-2) Pot Wiper J14-3 from Main PC Board (J27-3) Pot Low J14-4 12vdc (J27-4) J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J27-5) J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J27-6) J14-7...

  • Page 71: Appendix 7: Input Diode Pc Board Layout

    APPENDIX 7: INPUT DIODE PC BOARD LAYOUT 19x1811 Art # A-03703 Manual 0-2957 APPENDIX...

  • Page 72: Appendix 8: Igbt Circuit Pc Board Layout

    APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT E21B E21A E19B E19A E11A E11B E12A E12B E17B E17A A-03704 APPENDIX A-10 Manual 0-2957...

  • Page 73: Appendix 9: Output Diode Pc Board Layout

    APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT Output Diode B Output Diode A A-03152 Manual 0-2957 A-11 APPENDIX...

  • Page 74: Appendix 10: Output Board Wiring Diagram

    APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM To Main PCB To Pilot PCB To Torch To Pilot PCB Output Diode B Chassis Ground Output Diode A To Output Inductor To Pilot Board To Trans- former To Torch To Trans- former To Output Art # A-03655 Work Cable Inductor...

  • Page 75: Appendix 11: Pilot Pc Board Layout

    APPENDIX 11: PILOT PC BOARD LAYOUT No Receptacle 2 - Pin Receptacle (J1) Art # A-03881 CD PC Board Signals J28-1 +12 vdc J28-2 DC Com J28-3 Not Used J28-4 Not Used J28-5 Logic Low CSR J28-6 Not Used J28-7 Not Used J28-8 Not Used...

  • Page 76: Appendix 12: 28Vac Circuit Diagram

    APPENDIX 12: 28VAC CIRCUIT DIAGRAM Line Voltage Fuse 3 4 5 6 ON/OFF Switch 1 2 5 6 primary J23 (Test) Auxiliary Transformer Voltage Protection CRT/+12 Regulator +12vdc Main Power PC Board A-03710 APPENDIX A-14 Manual 0-2957...

  • Page 77: Appendix 13: Data Tag Information

    APPENDIX 13: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...

  • Page 78: Appendix 14: Torch Pin-Out Diagrams

    APPENDIX 14: TORCH PIN-OUT DIAGRAMS A. Hand Torch Pin - Out Diagrams 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 7 - Open...

  • Page 79: Appendix 15: Torch Connection Diagrams

    APPENDIX 15: TORCH CONNECTION DIAGRAMS A. 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 Connector Receptacle Torch Torch Supply Head Leads Black To Power Supply Switch...

  • Page 80: Appendix 16A: System Schematic, 208/230-Volt Units

    APPENDIX 16A: SYSTEM SCHEMATIC, 208/230-Volt Units E12A GATE E17A 208/230V DRIVE 1 PHASE INPUT E11A GATE DRIVE E19A INPUT DIODE ASSY 19X2073 E21A (78) IGBT BOARD ASSY 19X1756 (33) COPPER STRAP E12B GATE E17B (FILTERING) CHASSIS DRIVE E11B GATE DRIVE (0 ohm) E19B FAN1...
  • Page 81 Date: Date: Date: ECO 101614 HAS 03/22/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03 POWER OUTPUT BOARD ASSY 19X1914 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 82: Appendix 16B: System Schematic, 400-Volt, 415-Volt And 460-Volt Units

    APPENDIX 16B: SYSTEM SCHEMATIC, 400-Volt, 415-Volt and 460-Volt Units E12A GATE E17A DRIVE 208/230V 415/400V /460V 1 PHASE 3 PHASE INPUT INPUT E11A GATE DRIVE E19A E21A INPUT DIODE ASSY 19X2073 IGBT BOARD ASSY 19X1756 CHASSIS GND 400V 3 PHASE E12B INPUT GATE...
  • Page 83 603-298-5711 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03 POWER OUTPUT BOARD ASSY 19X1914 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.
  • Page 84 APPENDIX 16C: APPENDIX 16C: SYSTEM SCHEMATIC, 600-Volt Units E12A GATE E17A DRIVE 600VAC 3 PHASE INPUT E11A GATE DRIVE E19A INPUT DIODE ASSY 19X2073 E21A IGBT BOARD ASSY 19X1815 E12B CHASSIS GATE (FILTERING) E17B DRIVE E11B GATE (0 ohm) DRIVE E19B FAN1 (3/10A 600V)
  • Page 85 06/09/04 Date: Date: Date: ECO 101614 03/22/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03 POWER OUTPUT BOARD ASSY 19X1914 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 86: Appendix 17: Publication History

    APPENDIX 17: Publication History Cover Date Rev. Comments 5/5/04 Manual Released. 6/23/04 Updated system schematics per ECO 101429. 6/23/05 Updated 400V systems to include 415V for Australian per ECO101726 4/28/06 Updated per ECO B016 (updated schematics, added c/n for logic board for mechanized units) and per ECO 101948 (torque spec for replacement input diode).

  • 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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