Thermal Dynamics CUTMASTER Service Manual

TABLE OF CONTENTS
PATENT INFORMATION .....................................................................................................4T-20
SECTION 5 SYSTEM: SERVICE .............................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Maintenance Schedule ...............................................................................5-2
5.03 Common Faults ..........................................................................................5-2
5.04 Fault Indicator .............................................................................................5-3
5.05 Basic Troubleshooting Guide ......................................................................5-6
5.06 Circuit Fault Isolation ..................................................................................5-8
5.07 Main Input and Internal Power Problems ..................................................5-12
5.08 Pilot Arc Problems ....................................................................................5-16
5.09 Main Arc and Controls Problems ..............................................................5-19
5.10 CNC Interface Problems ........................................................................... 5-20
5.11 Test Procedures .......................................................................................5-20
5.12 Main PCB Layout & Signals ......................................................................5-26
5.13 Capacitor PCB Layout & Signals ..............................................................5-30
5.14 Logic PCB Layout & Signals ..................................................................... 5-32
5.15 40AMP Logic PCB Layout & Signals ........................................................5-34
5.16 Right Side Wiring Diagram .......................................................................5-36
SECTION 5 TORCH: SERVICE .............................................................................................5T-1
5T.01 General Maintenance ...............................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts .......................5T-2
SECTION 6: PARTS LISTS......................................................................................................6-1
6.01 Introduction .................................................................................................6-1
6.02 Ordering Information ................................................................................... 6-1
6.03 Power Supply Replacement .......................................................................6-1
6.04 Major External Replacement Parts .............................................................6-2
6.05 Front Panel Replacement Parts ..................................................................6-3
6.06 Left Side Replacement Parts .....................................................................6-4
6.07 Right Side Replacement Parts ...................................................................6-5
6.08 Options and Accessories ............................................................................6-6
6.09 Replacement Parts for Hand Torch ...........................................................6-7
6.10 Replacement Parts - for Machine Torches with Unshielded Leads ............6-8
6.11 Replacement Shielded Machine Torch Leads Assemblies ......................6-10
6.12 Torch Consumable Parts (SL100 SV) ......................................................6-11
SECTION 7: REPLACEMENT PROCEDURES ......................................................................7-1
7.01 Scope ..........................................................................................................7-1
7.02 Anti-Static Handling Procedures ................................................................. 7-1
7.03 Parts Replacement - General Information ..................................................7-1
7.04 Major External Parts ...................................................................................7-2
7.05 Front Panel Parts Replacement ..................................................................7-3
7.06 Left Side Internal Parts Replacement .........................................................7-4
7.07 Rear Panel Parts Replacement ..................................................................7-6
7.08 Right Side Internal Parts Replacement .......................................................7-8

Thermal Dynamics CUTMASTER Specifications

General

Brand	Thermal Dynamics
Model	CUTMASTER
Category	Welding System
Language	English