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Thermal Dynamics
Welding System
81 CUTMASTER
Thermal Dynamics 81 CUTMASTER Service Manual
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TROUBLESHOO
TING
4-10
Manual 0-2957
Main Printed Circuit Board Layout (Logic PCB Not Shown)
Art # A-03651
INPUT
DIODE
E22
E1
E2
E3
TP1
E7
E15
TP4
U1
J24
J32
J29
E10
E20
E4
J30
E33
J18
J26
E27
J23
E30
J33
J31
E23
E32
J27
J25
IGBT A
IGBT B
J43
J34
J11
J15
J16
J17
E6
E5
FUSE
29
31
Table of Contents
Service Manual
1
Table of Contents
5
General Information
7
Notes, Cautions and Warnings
7
Important Safety Precautions
7
Section
7
Publications
8
Note, Attention Et Avertissement
9
Precautions de Securite Importantes
9
Documents de Reference
11
Declaration of Conformity
13
Statement of Warranty
14
Introduction
15
Scope of Manual
15
General Service Philosophy
15
Service Responsibilities
15
Section 3: Description
17
Scope
17
Power Supply Specifications
17
Air Regulator/Filter Assembly Specifications
19
Troubleshooting
21
Introduction
21
Periodic Inspection & Cleaning Procedures
21
System Theory
21
Common Operating Problems
22
Troubleshooting Guide - General Information
23
Circuit Fault Isolation
24
Main Input and Internal Power Problems
25
Pilot Arc Problems
31
Main Arc Problems
34
Test Procedures
35
Replacement Procedures
41
Scope
41
Anti-Static Handling Procedures
41
Parts Replacement - General Information
41
Major External Parts Replacement
42
Front Panel Parts Replacement
43
Left Side Internal Parts Replacement
44
Rear Panel Parts Replacement
47
Right Side Internal Parts Replacement
48
Parts Lists
53
Introduction
53
Ordering Information
53
Major External Replacement Parts
54
Front Panel Replacement Parts
55
Left Side Internal Component Replacement Parts
56
Rear Panel Replacement Parts
58
Right Side Internal Component Replacement Parts
59
Options and Accessories
60
Patent Information
61
Appendix 1: Input Wiring Requirements
63
Appendix 2: Sequence of Operation (Block Diagram
64
Appendix 3: Logic Pc Board Layout
65
Appendix 4: Main Power Pc Board Layout
66
APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT - 208/230-Volt Units
68
APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT - 400-Volt, 415-Volt 460-Volt, and 600-Volt Units
69
Appendix 6: Led/Pot Pc Board Layout
70
Appendix 7: Input Diode Pc Board Layout
71
Appendix 8: Igbt Circuit Pc Board Layout
72
Appendix 9: Output Diode Pc Board Layout
73
Appendix 10: Output Board Wiring Diagram
74
Appendix 11: Pilot Pc Board Layout
75
Appendix 12: 28Vac Circuit Diagram
76
Appendix 13: Data Tag Information
77
Appendix 14: Torch Pin-Out Diagrams
78
Appendix 15: Torch Connection Diagrams
79
APPENDIX 16A: SYSTEM SCHEMATIC, 208/230-Volt Units
80
APPENDIX 16B: SYSTEM SCHEMATIC, 400-Volt, 415-Volt and 460-Volt Units
82
APPENDIX 16C: APPENDIX 16C: SYSTEM SCHEMATIC, 600-Volt Units
86
APPENDIX 17: Publication History
86
Global Customer Service Contact Information
87
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Thermal Dynamics 81 CUTMASTER Specifications
General
Brand
Thermal Dynamics
Model
81 CUTMASTER
Category
Welding System
Language
English
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