Thermal Dynamics CutMaster 50 - Service Manual

Thermal Dynamics CutMaster 50

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Plasma Cutting

Power Supply

CutMaster™ 50

A-02766

April 21, 2003 Manual No. 0-2806

Service Manual

Table of Contents

Table of Contents4
General Information7
- Important Safety Precautions7
- Notes, Cautions and Warnings7
- Publications8
- Note, Attention Et Avertissement9
- Precautions de Securite Importantes9
- Documents de Reference11
- Declaration of Conformity13
- Statement of Warranty14
- General Service Philosophy15
- Scope of Manual15
- Section 2 Introduction15
- Service Responsibilities15
Introduction15
- General Description17
- Scope17
- Section 3 Description17
- Specifications/Design Features17
- Power Supply Options and Accessories18
Description17
Service Troubleshooting Diagnostics19
- Introduction19
- Periodic Inspection & Cleaning Procedures19
- System Theory19
- Common Operating Problems20
- Troubleshooting Guide - General Information21
- Circuit Fault Isolation21
- Main Input and Internal Power Problems22
- Pilot Arc Problems24
- Main Arc Problems26
- Test Procedures26
Repairs & Replacement Procedures31
- Introduction31
- Anti-Static Handling Procedures31
- Parts Replacement - General Information31
- Major External Parts Replacement32
- Front Panel Parts Replacement32
- Left Side Internal Parts Replacement33
- Rear Panel Parts Replacement37
- Right Side Internal Parts Replacement40
- Parts Lists43
Appendix 1: Input Wiring Requirements53
Appendix 2: Sequence of Operation (Block Diagram54
APPENDIX 3-A: LOGIC PC BOARD LAYOUT (for Rev AA Logic Boards55
APPENDIX 3-B: LOGIC PC BOARD LAYOUT (for Rev AB Boards or Later56
APPENDIX 4-A: MAIN POWER PC BOARD LAYOUT (for 208/230-Volt Units with Boards to Rev. G58
APPENDIX 4-B: MAIN POWER PC BOARD LAYOUT (for 208/230-Volt Units with Boards Rev. H and I60
APPENDIX 4-C: MAIN POWER PC BOARD LAYOUT (for 208/230-Volt Units with Boards Rev. J62
APPENDIX 4-D: MAIN POWER PC BOARD LAYOUT (for 400-Volt and 460-Volt Units64
APPENDIX 5-A: CD PC BOARD LAYOUT (for 208/230-Volt Units through Unit Rev al66
APPENDIX 5-B: CD PC BOARD LAYOUT (for 400-Volt and 460-Volt Units, and 208/230-Volt Units Rev am and Later67
Appendix 6: Led/Pot Pc Board Layout68
Appendix 7: Igbt Circuit Pc Board Layout69
APPENDIX 8-A: INPUT DIODE PC BOARD LAYOUT for 208/230-Volt Units70
APPENDIX 8-B: INPUT DIODE PC BOARD LAYOUT for 400-Volt and 460-Volt Units71
Appendix 9: Output Diode Pc Board Layout72
APPENDIX 10-A: MAIN PC BOARD WIRING (208/230-Volt Units with Boards Rev. G or Earlier73
APPENDIX 10-B: MAIN PC BOARD WIRING (208/230-Volt Units with Boards Rev. H and I74
APPENDIX 10-C: MAIN PC BOARD WIRING (208/230-Volt Units with Boards Rev. J75
APPENDIX 10-D: MAIN PC BOARD WIRING (for 400-Volt and 460-Volt Units76
Appendix 11: 28Vac Circuit Diagram77
Appendix 12: Maintenance Schedule78
APPENDIX 13-A: SYSTEM SCHEMATIC (208/230-Volt Units with Main PC Boards Rev. G or Earlier80
APPENDIX 13-B: SYSTEM SCHEMATIC (208/230-Volt Units with Main PC Board Rev. H or I82
APPENDIX 13-C: SYSTEM SCHEMATIC (208/230-Volt Units with Main PC Board Rev. J or Later84
APPENDIX 13-D: SYSTEM SCHEMATIC (400-Volt and 460-Volt Units86

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