Tweco 81 with SL100SV Manuel d'utilisateur

81Rev. AD.01 Date: April 2, 2007 Manual # 0-4641Operating Features:Operating ManualAUTOMATEDPLASMA CUTTING SYSTEMCUTMAS

GENERAL INFORMATION 1-2 Manual 0-4641ELECTRIC SHOCKElectric Shock can injure or kill. The plasma arc process usesand produces high voltage electrical

SERVICE 5-36 Manual 0-46415B. Main Input Contactor (W1) Replacement1. Remove the power supply cover per Section 5.09-A.2. Label all wires connected t

Manual 0-4641 5-37 SERVICE5C. Logic PC Board ReplacementFollow the antistatic instructions provided with the replacement part. The Logic PC Board

SERVICE 5-38 Manual 0-464158. Install replacement components as follows:For Input Diodes:Diode Assembly Art # A-03950Thermal PadSlotInput Diode Repla

Manual 0-4641 5-39 SERVICE5For IGBTs:a. Apply a round thermal pad to the heatsink with a small piece of light-duty tape. The tape must cover no more

SERVICE 5-40 Manual 0-46415E. Main PC Board ReplacementFollow the antistatic procedures provided with the replacement part.1. Remove the power supply

Manual 0-4641 5-41 SERVICE5F. Input Power Cable Replacement1. Remove the power supply cover per Section 5.09-A.2. Locate and label the input power ca

SERVICE 5-42 Manual 0-464155.12 Right Side Internal Parts ReplacementA. Fan Replacement (M1, M2)1. Remove the power supply cover per Section 5.09-A.2

Manual 0-4641 5-43 SERVICE5B. Work Cable Replacement1. Remove the cover per Section 5.09-A.2. Disconnect the Work Cable from the E61 (WORK) terminal

SERVICE 5-44 Manual 0-46415D. Pressure Switch/Solenoid Assembly ReplacementThe Pressure Switch and Solenoid Valve are one Assembly. Disconnect prima

Manual 0-4641 5-45 SERVICE5E. Heatsink Shroud Assembly RemovalThe Heatsink Shroud Assembly must be disengaged for access to either the Main Transform

Manual 0-4641 1-3 GENERAL INFORMATION1.03 PublicationsRefer to the following standards or their latest revisions formore information:1. OSHA, SAFETY A

SERVICE 5-46 Manual 0-46415F. Main Transformer Removal and Replacement1. Disengage the Heatsink Shroud per Paragraph E.2. Disconnect wires #27 and 32

Manual 0-4641 5-47 SERVICE5H. Heatsink Shroud Assembly Replacement1. Pass transformer wires #45 and 49 through the upper hole in the right (rear) edg

SERVICE 5-48 Manual 0-46415This Page Left Blank

Manual 0-4641 6-1 PARTS LISTS6SECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provide a breakdown of all replaceable compo

PARTS LISTS 6-2 Manual 0-464166.04 Power Supply Basic Replacement PartsQty Description Catalog #Fuse1 for 208 / 230VAC Power Supply 9-85881 for 400 /

Manual 0-4641 6-3 PARTS LISTS6NOTE: Illustration may vary slightly from unit.6.06 Power Supply Major External Replacement PartsItem # Qty Description

PARTS LISTS 6-4 Manual 0-464166.07 Power Supply Front Panel Replacement PartsItem# Qty Description Ref. # Catalog #1 1 Knob, Fluted, Skirted, 0.250 I

Manual 0-4641 6-5 PARTS LISTS66.08 Rear Panel Replacement PartsItem # Qty Description Ref. Catalog #1 1 Assembly, Filter/Regulator 9-75142 1 Regulato

PARTS LISTS 6-6 Manual 0-464166.09 Power Supply Left Side Internal Replacement PartsItem # Qty Description Ref # Catalog #1 1 Fuse F1for 208/230-Volt

Manual 0-4641 6-7 PARTS LISTS6NOTE: Illustration may vary slightly from unit.354175Art # A-03717622AOR8

GENERAL INFORMATION 1-4 Manual 0-46411.05 Precautions De SecuriteImportantesAVERTISSEMENTSL’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC

PARTS LISTS 6-8 Manual 0-464166.10 Right Side Internal Replacement PartsItem # Qty Description Ref #. Catalog #1 1 Assembly, Pressure Switch/Solenoid

Manual 0-4641 6-9 PARTS LISTS6NOTE: Illustration may vary slightly from unit.2351746Art # A-07120Work CableOutput DiodeHeatsinkIGBT HeatsinkHeatsinkSh

PARTS LISTS 6-10 Manual 0-464166.11 Torch Replacement PartsSL100 TorchItem No. Qty Description Catalog No.1 1 Torch Head Assembly without leads (incl

Manual 0-4641 6-11 PARTS LISTS6Art # A-03872614235891012117102219151416171820212113

PARTS LISTS 6-12 Manual 0-464166.12 Torch Replacement PartsSL100SV Torch (with Solenoid on Mounting Tube)Item No. Qty Description Catalog No.1 1 Torc

Manual 0-4641 6-13 PARTS LISTS6Art # A-071136142358101211710221915141617182021211392423

PARTS LISTS 6-14 Manual 0-464166.13 Torch ConsumablesThe illustration shows all SL100 torch consumable parts for use with the CutMaster 81 Automated

Manual 0-4641 6-15 PARTS LISTS6Art # A-043838-34878-3486StartCartridge9-8213Electrode9-8215Shield Cap, Deflector9-8243Shield Cap, Machine40A 9-824560

PARTS LISTS 6-16 Manual 0-464166.15 Complete Torch Assembly ReplacementQty Description Catalog #100 - Amp Machine Torch and Leads Assemblies, Unshield

Manual 0-4641 6-17 PARTS LISTS6PATENT INFORMATIONThe following parts are licensed under U.S. Patent No(s). 5120930 and 5132512Catalog Number Descripti

Manual 0-4641 1-5 GENERAL INFORMATIONINCENDIE ET EXPLOSIONLes incendies et les explosions peuvent résulter des scorieschaudes, des étincelles ou de l’

PARTS LISTS 6-18 Manual 0-46416This Page Left Blank

Manual 0-4641 A-1 APPENDIXAAPPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)ACTION:ON / OFF switch to ON RESULT:AC indicator ON. Fan(s

APPENDIX A-2 Manual 0-4641AAPPENDIX 2: DATA TAG INFORMATION1/3ff12West Lebanon, NH USA 03784Made in USAModel:U1111max 1effIIU23Ø3Ø1Ø1ØS/NU0=XStanda

Manual 0-4641 A-3 APPENDIXAAPPENDIX 3: MAINTENANCE SCHEDULEThis schedule applies to all types of non-liquid cooled plasma cutting systems. Some syst

APPENDIX A-4 Manual 0-4641AAPPENDIX 4: TORCH PIN - OUT DIAGRAMSA. Power Supply and SL100 Torch (without Solenoid)ATC Female Receptacle - Front ViewAT

Manual 0-4641 A-5 APPENDIXAAPPENDIX 5: TORCH CONNECTION DIAGRAMSA. Power Supply and SL100 Torch (without Solenoid)Automated CutMaster Power Supply w

APPENDIX A-6 Manual 0-4641AAPPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM1 / Black 12 / White - Black / OK to Mov

Manual 0-4641 A-7 APPENDIXAAPPENDIX 7: INTERFACE PCB SWITCH SETTINGS(MOST COMMON SETTINGS)1234567800000000 6.00 12.00 16.3:100010110 5.00 10.00 20:10

APPENDIX A-8 Manual 0-4641ASwitch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor00000000 16.5600000001 16.7000000010 1

Manual 0-4641 A-9 APPENDIXAAPPENDIX 9: INTERFACE PCB SWITCH SETTINGS(Division Factors 24-30)Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Swi

GENERAL INFORMATION 1-6 Manual 0-46414. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AU TRA-VAIL ET DANS LES ECOLES, disp

APPENDIX A-10 Manual 0-4641AAPPENDIX 10: INTERFACE PCB SWITCH SETTINGS(Division Factors 30-33)Switch 1Switch 2Switch 3Switch 4Switch 5Switch 6Switch

Manual 0-4641 A-11 APPENDIXAAPPENDIX 11: INTERFACE PCB SWITCH SETTINGS(Division Factors 33-36)Switch 1Switch 2Switch 3Switch 4Switch 5Switch 6Switch

APPENDIX A-12 Manual 0-4641AAPPENDIX 12: INTERFACE PCB SWITCH SETTINGS(Division Factors 36-43)Switch 1Switch 2Switch 3Switch 4Switch 5Switch 6Switch

Manual 0-4641 A-13 APPENDIXAAPPENDIX 13: INTERFACE PCB SWITCH SETTINGS(Division Factors 43-50)Switch 1Switch 2Switch 3Switch 4Switch 5Switch 6Switch

APPENDIX A-14 Manual 0-4641AAPPENDIX 14: AUTOMATION INTERFACE PC BOARDWIRING LAYOUTJ-1Automation Interface PC BoardPilot Board8 7 6 5 4 3 2 1 321E1E3

Manual 0-4641 A-15 APPENDIXAAPPENDIX 15: AUTOMATION INTERFACE PC BOARDLAYOUT and TEST POINTSTP1TP3TP2TP4Art # A-03903J1J4J2J3SignalsConnector J2 (T

APPENDIX A-16 Manual 0-4641AAPPENDIX 16: AUTOMATION INTERFACE PC BOARDWIRING CONNECTIONS TO OEM CNC HARNESS1 2 3 4 5 6 7 8 9

Manual 0-4641 A-17 APPENDIXAAPPENDIX 17: AUTOMATION INTERFACE PC BOARDWIRING CONNECTIONS TO ALTERNATE CNC HARNESS3954126781013191514111216171820Art #

APPENDIX A-18 Manual 0-4641AAPPENDIX 18: MAIN PC BOARD LAYOUTArt # A-03651INPUTDIODEE22E1E2E3TP1E7E15TP4U1J24J32J29E10E20E4J30E33J18J26E27J23E30J33J3

Manual 0-4641 A-19 APPENDIXAJ25-1 Gate DriveJ25-2 Gate DriveJ26-1 Gate DriveJ26-2 Gate DriveJ27-1 Pot HighJ27-2 Pot WiperJ27-3 Pot LowJ27-4 +12VJ27-5

Manual 0-4641 1-7 GENERAL INFORMATIONAYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W.LeJeune Rd., Mi

APPENDIX A-20 Manual 0-4641AAPPENDIX 19: MAIN PC BOARD WIRING LAYOUT(208 /230-Volt POWER SUPPLIES)INPUTDIODEE2E3E1Art # A-04224To InputContactorTo Ch

Manual 0-4641 A-21 APPENDIXAAPPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-Volt, 415-Volt, 460-Volt, 600-Volt POWER SUPPLIES)INPUTDIODEArt # A-04225#2

APPENDIX A-22 Manual 0-4641AAPPENDIX 21: LOGIC BOARD LAYOUTTP9TP10TP11TP3TP7TP8TP5TP1TP2TP4D13TP6Art # A-03654D25D33P1-7P1-9Logic Board SignalsP1-1

Manual 0-4641 A-23 APPENDIXAAPPENDIX 22: POT / LED BOARD LAYOUTJ14D4D5D7D6A-03712Pot/LED PC Board SignalsJ14-1 from Main PC Board (J27-1) Pot HighJ1

APPENDIX A-24 Manual 0-4641AAPPENDIX 23: OUTPUT BOARD WIRING DIAGRAMArt # A-04382E36OutputDiode AOutputDiode BE32To Output InductorE45E49E61Work Cabl

Manual 0-4641 A-25 APPENDIXAAPPENDIX 24: OUTPUT DIODE BOARD LAYOUTA-03152E48E50E54E53E34E39E60E56Output Diode AOutput Diode BE34E39E60E56E48E50E54E53

APPENDIX A-26 Manual 0-4641AAPPENDIX 25: PILOT BOARD LAYOUTPilot Board SignalsJ1-1 +12 vdc to Automation Interface PC Board J1-3J1-2 DC Common to Au

Manual 0-4641 A-27 APPENDIXAAPPENDIX 26: 28VAC CIRCUIT DIAGRAM1 2 5 63 4 5 6 Main Power PC BoardAuxiliaryTransformerVoltageProtectionCRT/+

APPENDIX A-28 Manual 0-4641AAPPENDIX 27: INPUT DIODE LAYOUTArt # A-03703E18E13E5E14E16E8E619x1811

Manual 0-4641 A-29 APPENDIXAThis Page Left Blank

GENERAL INFORMATION 1-8 Manual 0-46411.08 Statement of WarrantyLIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynam

APPENDIX A-30 Manual 0-4641AAPPENDIX 28: 208/230V SYSTEM SCHEMATICFor Power Supplies and SL100 Torches (without solenoid on mounting tube)1122334455A

Manual 0-4641 A-31 APPENDIXA667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Information Propriet

APPENDIX A-32 Manual 0-4641AAPPENDIX 29: 208/230V SYSTEM SCHEMATICFor Power Supplies and SL100SV Torches (with solenoid on mounting tube)1122334455A

Manual 0-4641 A-33 APPENDIXA667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Information Propriet

APPENDIX A-34 Manual 0-4641AAPPENDIX 30: 400 / 415V / 460V SYSTEM SCHEMATICFor Power Supplies and SL100 Torches (without solenoid on mounting tube)A

Manual 0-4641 A-35 APPENDIXAArt # A-03600667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Informa

APPENDIX A-36 Manual 0-4641AAPPENDIX 31: 400 / 415V / 460V SYSTEM SCHEMATICFor Power Supplies and SL100SV Torches (with solenoid on mounting tube)11

Manual 0-4641 A-37 APPENDIXA667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Information Propriet

APPENDIX A-38 Manual 0-4641AAPPENDIX 32: 600V SYSTEM SCHEMATICFor Power Supplies and SL100 Torches (without solenoid on mounting tube)1122334455ABCDE

Manual 0-4641 A-39 APPENDIXA667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Information Propriet

Manual 0-4641 2-1 INTRODUCTION2SECTION 2: SPECIFICATIONS2.01 Scope of ManualThis manual contains descriptions, operating instructions and basic maint

APPENDIX A-40 Manual 0-4641AAPPENDIX 33: 600V SYSTEM SCHEMATICFor Power Supplies and SL100SV Torches (with solenoid on mounting tube)1122334455ABCDEF

Manual 0-4641 A-41 APPENDIXA667788991010ABCDEFDWG No:SheetofSupersedesScaleDate:Drawn: ReferencesDateByRevisionsRevPCB No:Assy No:Information Propriet

APPENDIX 34: Publication HistoryRelease Rev. Changes1/3/05 - Released to production.2/14/05 - Updated per ECO 101610, adding parts to Spare parts kits

Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: [email protected] Canada

Corporate Headquarters16052 Swingley Ridge RoadSuite 300St. Louis, MO 63017Telephone: 636-728-3000Email: [email protected]

INTRODUCTION 2-2 Manual 0-46412Power Supply Dimensions & Weight Ventilation Clearance RequirementsA-0357227.5 in / 696 mm12.4 in / 315 mm17.3 in /

Manual 0-4641 2-3 INTRODUCTION22.04 Power Supply FeaturesArt # A-04214Input Power CordGas Inlet PortGas Pressure Regulator / Filter AssemblyGas Pressu

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Dynamics product. We areproud to have you as our customer and will strive to provide y

INTRODUCTION 2-4 Manual 0-464122.05 Power Supply Options and AccessoriesSection 6, Parts Lists, provides catalog numbers and ordering information.A. S

Manual 0-4641 2-5 INTRODUCTION22.06 Torch SpecificationsAmbient Temperature 104° F / 40° CDuty Cycle (Refer to NOTE) 100% @ 100 Amps @ 400 scfhMaximu

INTRODUCTION 2-6 Manual 0-46412B. Torch Connector Dimensions8.5" / 216 mm5.375" / 137 mm1.9" / 50 mmArt # A-04056C. Torch PartsStart Ca

Manual 0-4641 2-7 INTRODUCTION22.08 Introduction to PlasmaA. Plasma Gas FlowPlasma is a gas which has been heated to an extremely high temperature an

INTRODUCTION 2-8 Manual 0-46412C. Pilot ArcWhen the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc

Manual 0-4641 3-1 INSTALLATION3SECTION 3: INSTALLATION3.01 Unpacking1. Use the packing lists to identify and account for each item.2. Inspect each it

INSTALLATION 3-2 Manual 0-464133.03 Primary Input Power Connections CAUTIONCheck your power source for correct voltage before plugging in or connectin

Manual 0-4641 3-3 INSTALLATION3C. Connections to 460-Volt Single - Phase Power The 460-Volt Power Supplies will accept 460-VAC, Single-Phase input po

INSTALLATION 3-4 Manual 0-464133.04 Gas ConnectionsA. Connecting Gas Supply to UnitUse only compressed air with this power supply.An in-line pneumatic

Manual 0-4641 3-5 INSTALLATION3B. Optional Air Filters1. Connect the Filter as illustrated. Use only Synflex or equivalent grade hose. The illustra

WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing, operat-ing, or servicing the equipment.While th

INSTALLATION 3-6 Manual 0-46413D. Using High Pressure Air CylindersWhen using high pressure air cylinders as the air supply:1. Refer to the manufactur

Manual 0-4641 3-7 INSTALLATION33.05 Torch ConnectionsIf necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL

INSTALLATION 3-8 Manual 0-46413Connecting the Torch to the Power SupplyB. Check Air QualityTo test the quality of air:1. Put the ON / OFF switch in th

Manual 0-4641 3-9 INSTALLATION33.06 Torch Installation WARNINGDisconnect primary power at the source before disassembling the torch or torch leads.

INSTALLATION 3-10 Manual 0-464133.07 Torch Parts Selection1. Check the torch for proper consumable parts. The parts supplied in the torch may not be

Manual 0-4641 3-11 INSTALLATION33.08 Power Supply Connection to SC-11 Standoff ControlThe power supply includes an Automation Interface PC Board conne

INSTALLATION 3-12 Manual 0-464133.09 Power Supply Connection to Alternate Standoff ControlThe Power Supply rear panel includes a knockout to accept wi

Manual 0-4641 3-13 INSTALLATION35. Connect the wire harness from the alternate CNC Control to the 20-position terminal strip (labeled 'J2')

INSTALLATION 3-14 Manual 0-464133.10 Automation Interface PC Board Set-upThe Automation Interface PC board includes switches that must be set to adapt

Manual 0-4641 3-15 INSTALLATION33.11 Optional Remote Current Control Harness Installation1. Locate the power supply Pot/LED Board just inside the powe

INSTALLATION 3-16 Manual 0-46413This Page Left Blank

Manual 0-4641 4-1 OPERATION4SECTION 4: OPERATION4.01 Product FeaturesA. Power Supply Front Panel Controls and Indicators(A) Output Current ControlSe

OPERATION 4-2 Manual 0-464144.02 Preparations For OperatingPerform the following steps at the start of each operating session:WARNINGDisconnect primar

Manual 0-4641 4-3 OPERATION4F. Power OnPlace the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator tu

OPERATION 4-4 Manual 0-46414G. Set Operating Pressure1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas w

Manual 0-4641 4-5 OPERATION4H. Select Current Output Level1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position.

OPERATION 4-6 Manual 0-464144.03 Selection, Inspection and Replacement of Consumable Torch PartsThe type of operation to be done determines the torch

Manual 0-4641 4-7 OPERATION42. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tipif

OPERATION 4-8 Manual 0-464144.04 Cut QualityNOTESCut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpi

Manual 0-4641 4-9 OPERATION44.05 General Cutting Information WARNINGSDisconnect primary power at the source before disassembling the power supply, t

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.0

OPERATION 4-10 Manual 0-46414E. DrossWhen dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross

Manual 0-4641 4-11 OPERATION4B. Travel SpeedProper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be on

OPERATION 4-12 Manual 0-46414C. Piercing With Machine TorchTo pierce with a machine torch, the arc should be started with the torch positioned as high

Manual 0-4641 4-13 OPERATION4Cut Quality on Various Materials andThicknessesThe following table defines the cut quality on various mate-rials and thic

OPERATION 4-14 Manual 0-464144.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed TipNOTES* Gas pressure shown is for torches with leads up

Manual 0-4641 4-15 OPERATION44.10 Cutting Speed Charts: Stainless Steel, SL100 Torch with Exposed TipNOTES*Gas pressure shown is for torches with lead

OPERATION 4-16 Manual 0-464144.11 Cutting Speed Charts: Aluminum, SL100 Torch with Exposed TipNOTES* Gas pressure shown is for torches with leads up

Manual 0-4641 4-17 OPERATION44.12 Cutting Speed Charts: Mild Steel, SL100 Torch with Shielded TipNOTES* Gas pressure shown is for torches with leads u

OPERATION 4-18 Manual 0-464144.13 Cutting Speed Charts: Stainless Steel, SL100 Torch with Shielded TipNOTES* Gas pressure shown is for torches with le

Manual 0-4641 4-19 OPERATION44.14 Cutting Speed Charts: Aluminum, SL100 Torch with Shielded TipNOTES* Gas pressure shown is for torches with leads up

TABLE OF CONTENTS (continued)SECTION 5:SERVICE ...

OPERATION 4-20 Manual 0-46414Art # A-04381Shield Cap, Machine Electrode Start Cartridge Tip Shield

Manual 0-4641 4-21 OPERATION4Art # A-04381Shield Cap, Machine Electrode Start Cartridge Tip Shield

OPERATION 4-22 Manual 0-46414Art # A-04381Shield Cap, Machine Electrode Start Cartridge Tip Shield

Manual 0-4641 4-23 OPERATION4Art # A-04381Shield Cap, Machine Electrode Start Cartridge Tip Shield

OPERATION 4-24 Manual 0-46414Art # A-04381Shield Cap, Machine Electrode Start Cartridge Tip Shield

Manual 0-4641 5-1 SERVICE5SECTION 5:SERVICE5.01 General MaintenanceA. Filter Element ReplacementThe Regulator/Filter Assembly is on the rear panel.

SERVICE 5-2 Manual 0-46415B. Single-Stage Filter Element ReplacementThese instructions apply to power supplies where the Single-Stage Filter has been

Manual 0-4641 5-3 SERVICE5C. Optional Two-Stage Filter Element ReplacementThe Two-Stage Air Filter has two Filter Elements. When the Filter Elements

SERVICE 5-4 Manual 0-46415D. Cleaning TorchEven if precautions are taken to use only clean air with a torch, eventually the inside of the torch becom

Manual 0-4641 5-5 SERVICE55.02 Common Faults1. Insufficient Penetrationa. Cutting speed too fastb. Torch tilted too muchc. Metal too thickd. Worn tor

TABLE OF CONTENTSAPPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24) ... A-8APPENDIX 9: INTERFACE PCB SWITCH SETT

SERVICE 5-6 Manual 0-464155.03 Basic TroubleshootingWARNINGThere are extremely dangerous voltage and power levels present inside this unit. Do not at

Manual 0-4641 5-7 SERVICE56. Unit internal fuse blown or loosea. If blown, double-check input voltage and replace fuse per Section 5.09-C.7. Actual

SERVICE 5-8 Manual 0-46415G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON1. Start cartridge

Manual 0-4641 5-9 SERVICE5I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DCindicator O

SERVICE 5-10 Manual 0-46415L. Torch cuts but not adequately1. Incorrect setting of output current (A) controla. Check and adjust to proper setting.2.

Manual 0-4641 5-11 SERVICE55.04 Advanced Troubleshooting Guide - General Information WARNINGThere are extremely dangerous voltage and power levels p

SERVICE 5-12 Manual 0-46415C. Main Input and Internal Power Tests1. Connect main AC power to the unit.2. Set the Power Supply ON/OFF switch to ON (up

Manual 0-4641 5-13 SERVICE55.05 Main Input and Internal Power ProblemsA. Opening Power Supply EnclosureThe cover of the Power Supply must be removed

SERVICE 5-14 Manual 0-46415Locate your symptom below:A. Main power line fuses blow as soon as main disconnect is closed1. Input power cable installed

Manual 0-4641 5-15 SERVICE56. Improper input power cable connections inside Power Supplya. Refer to System Schematic and correct if needed.7. Defecti

TABLE OF CONTENTS (continued)APPENDIX 32: 600V SYSTEM SCHEMATIC ... A-38APPEND

SERVICE 5-16 Manual 0-46415E. No gas flow; AC indicator ON; TEMP , GAS and DC indicators OFF1. RUN / RAPID AUTO RESTART / SET swi

Manual 0-4641 5-17 SERVICE53. Faulty Logic PCB.a. Measure for approximately 12 vdc between P1-7 and TP-1 on the Logic PCB.• If 12 vdc is present, r

SERVICE 5-18 Manual 0-46415H. Gas flows continuously when power is turned on; AC indicator flashes1. Torch switch is activated (closed) before us

Manual 0-4641 5-19 SERVICE55.06 Pilot Arc Problems WARNINGThe following tests must be performed with the power supply connected to primary input

SERVICE 5-20 Manual 0-46415C. Torch will not pilot; AC , GAS , and TEMP indicators ON1. Air flow blockeda. Check for blocked air flow aro

Manual 0-4641 5-21 SERVICE5D. Torch will not pilot when torch switch is activated; AC and GAS indicators ON; Temp and DC indicators O

SERVICE 5-22 Manual 0-46415F. Gas flows; No arc in torch; AC , GAS , and DC indicators ON; TEMP indicator off1. Faulty IGBT(s)a. Measure

Manual 0-4641 5-23 SERVICE5G. No arc or intermittent arc in torch; Gas flows; AC , GAS , and DC indicators ON; TEMP indica-tor off1. G

SERVICE 5-24 Manual 0-464155.07 Main Arc ProblemsLocate your symptom below:A. Main cutting arc will not start1. Work cable not connected.a. Connect w

Manual 0-4641 5-25 SERVICE56. Faulty Main PC Board or Logic Board.a. Measure for ±0 vdc at TP2 to TP1 on the Logic Board when attempting to transfer.

Manual 0-4641 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and warnin

SERVICE 5-26 Manual 0-46415B. Diode Testing Basics WARNINGDisconnect primary power at the source before disassembling the power supply, torch, or to

Manual 0-4641 5-27 SERVICE5C. Diode Module Board Tests WARNINGDisconnect primary power at the source before taking any resistance checks.1. Input Di

SERVICE 5-28 Manual 0-464152. Output Diode Module Board Circuit Testa. Use an ohmmeter set on the diode function and make the following measurements

Manual 0-4641 5-29 SERVICE5D. Main Input Power Test WARNINGThe following tests must be performed with the power supply connected to primary input p

SERVICE 5-30 Manual 0-46415E. Gas Solenoid Circuit TestMake the following voltage checks and replace the faulty part as required.1. Place the RUN / R

Manual 0-4641 5-31 SERVICE55.09 Power Supply Major External Parts ReplacementWARNINGDisconnect primary power to the system before disassembling the t

SERVICE 5-32 Manual 0-46415B. Tube Handle Replacement1. Remove the power supply cover per Section 5.09-A.2. Remove the four bolts and star washers se

Manual 0-4641 5-33 SERVICE55.10 Front Panel Parts ReplacementWARNINGDisconnect input power at the source and bleed down the system before attempting

SERVICE 5-34 Manual 0-46415C. RUN / RAPID AUTO RESTART / SET Switch (SW2) Replacement1. Remove the power supply cover per Section 5.09-A.2. Disconne

Manual 0-4641 5-35 SERVICE55.11 Left Side Internal Parts ReplacementA. Fuse (F1) Replacement1. Remove the power supply cover per Section 5.09-A.2. Lo