Thermadyne CutMaster 75 Manuale utente

Service Manual

Plasma Cutting

Power Supply

CutMaster™ 75

CE CutMaster™ 75

March 22, 2004 Manual No. 0-2869

A-02990

Plasma Cutting Power Supply

CutMaster™ 75

CE CutMaster™ 75

Service Manual Number 0-2869

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written per-

mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to

any party for any loss or damage caused by any error or omission in

this Manual, whether such error results from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: Date: March 22, 2004

RecordthefollowinginformationforWarrantypurposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-

ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

TABLE OF CONTENTS

SECTION1:

GENERALINFORMATION ................................................................................................ 1-1

1.01 Notes,CautionsandWarnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 PrecautionsDe SecuriteImportantes ........................................................... 1-3

1.06 DocumentsDeReference ............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 StatementofWarranty .................................................................................. 1-8

SECTION2:

INTRODUCTION ............................................................................................................... 2-1

2.01 ScopeOf Manual.......................................................................................... 2-1

2.02 GeneralServicePhilosophy.......................................................................... 2-1

2.03 ServiceResponsibilities................................................................................ 2-1

SECTION3:

DESCRIPTION.................................................................................................................. 3-1

3.01 Scope........................................................................................................... 3-1

3.02 General Description ...................................................................................... 3-1

3.03 Specifications/DesignFeatures .................................................................... 3-1

3.04 Power Supply Options and Accessories ....................................................... 3-2

SECTION4:

SERVICETROUBLESHOOTING DIAGNOSTICS.............................................................. 4-1

4.01 Introduction................................................................................................... 4-1

4.02 Periodic Inspection & CleaningProcedures................................................... 4-1

4.03 SystemTheory ............................................................................................. 4-1

4.04 Common OperatingProblems ....................................................................... 4-2

4.05 TroubleshootingGuide -GeneralInformation................................................. 4-3

4.06 Circuit Fault Isolation .................................................................................... 4-4

4.07 MainInput and Internal PowerProblems....................................................... 4-5

4.08 Pilot Arc Problems........................................................................................ 4-8

4.09 Main Arc Problems ......................................................................................4-10

4.10 TestProcedures...........................................................................................4-10

SECTION5:

SERVICE .......................................................................................................................... 5-1

5.01 Scope........................................................................................................... 5-1

5.02 Anti-Static Handling Procedures ................................................................... 5-1

5.03 Parts Replacement - GeneralInformation ..................................................... 5-1

5.04 MajorExternal Parts Replacement ............................................................... 5-2

5.05 Front Panel PartsReplacement..................................................................... 5-3

5.06 LeftSide Internal Component PartsReplacement......................................... 5-4

5.07 Rear Panel Parts Replacement ..................................................................... 5-7

5.08 RightSideInternalComponentPartsReplacement....................................... 5-9

TABLE OF CONTENTS (continued)

SECTION6:

PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction................................................................................................... 6-1

6.02 OrderingInformation ..................................................................................... 6-1

6.03 MajorExternalReplacementParts ............................................................... 6-2

6.04 Front PanelReplacement Parts..................................................................... 6-3

6.05 LeftSide InternalReplacement Parts ........................................................... 6-4

6.06 RearPanelReplacementParts ..................................................................... 6-6

6.07 RightSide InternalReplacement Parts ......................................................... 6-8

6.08 Options and Accessories.............................................................................6-10

APPENDIX1: INPUTWIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... A-2

APPENDIX 3: LOGIC PC BOARD LAYOUT .............................................................................. A-3

APPENDIX 4: MAIN POWER PC BOARD LAYOUT.................................................................. A-4

APPENDIX 5-A: 208/230VOLT MAIN PC BOARDWIRING ...................................................... A-6

APPENDIX 5-B: 400-V 460-V, and 600-V MAIN PC BOARDWIRING ....................................... A-7

APPENDIX 6: CD PC BOARD LAYOUT .................................................................................... A-8

APPENDIX 7: LED/POT PC BOARD LAYOUT .......................................................................... A-9

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT ............................................................... A-10

APPENDIX 9: INPUT DIODE PC BOARD LAYOUT ................................................................ A-11

APPENDIX 10: OUTPUT DIODE PC BOARD LAYOUT .......................................................... A-12

APPENDIX11:POWEROUTPUT PCBWIRINGDIAGRAM.................................................... A-13

APPENDIX 12: 28VAC CIRCUIT DIAGRAM ........................................................................... A-14

APPENDIX13: MAINTENANCESCHEDULE ......................................................................... A-15

APPENDIX 14: SYSTEM SCHEMATIC, 208/230-VOLT UNITS ............................................... A-16

APPENDIX 15: SYSTEM SCHEMATIC, 400-V, 460-V UNITS ................................................. A-18

APPENDIX 16: SYSTEM SCHEMATIC, 600-V UNITS............................................................ A-20

Date: January27,2004 1-1 GENERALINFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

areused to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structionsbeforeusing the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

onthe metal, and the differentprocesses. Youmust

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formationregardingthe kindandamount of fumes

and gases that may be dangerous to your health.

• For information on how to test for fumes and gases

inyour workplace, referto item 1inSubsection 1.03,

Publications in this manual.

• Usespecialequipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

GENERALINFORMATION 1-2 Date: January27,2004

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publica-

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial in the workplace. Any material that cannot

be removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provideafire watchwhenworking in an areawhere

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noisecancausepermanenthearing loss. Plasma arcpro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noiselevels should be measuredto be surethedeci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMAARC RAYS

PlasmaArcRayscaninjure your eyesandburnyour skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyesand burn your skin if you arenotproperlyprotected.

• To protect your eyes, always wear a welding hel-

metorshield. Alsoalwayswear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Thesevaluesapplywherethe actual arcisclearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETYAND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from theAmerican Welding So-

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONALEYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOEFOOTWEAR, obtainablefromtheAmeri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: January27,2004 1-3 GENERALINFORMATION

6. ANSI StandardZ49.2, FIRE PREVENTION IN THEUSE

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS StandardA6.0, WELDINGAND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable from American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPAStandard 51B, CUTTINGAND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSAStandard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding SocietyStandardAWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDINGAND CUTTING OF CONTAIN-

ERSAND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from theAmerican Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupantà l’arc au jetdeplasma produitde l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

lesavertissements, toutes les précautionsdesécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

GENERALINFORMATION 1-4 Date: January27,2004

• Eloignez toute fumée et gaz de votre zone de respira-

tion. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air

sil’aérationfournienepermet pas d’éliminer la fumée

et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un ou

plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des gaz

pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une

zone où se trouvent des matières ou des gaz combus-

tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,

produit de la fumée ou des gaz pouvant contenir des

éléments reconnu dans L’état de la Californie, qui

peuvent causer des défauts de naissance et le cancer.

(La sécurité de santé en Californie et la code sécurité

Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voiremortels,pourl’opérateur

et les autres personnes sur le lieu de travail.

• Netouchezjamaisune pièce “sous tension” ou “vive”;

portez des gants et des vêtements secs. Isolez-vous

de la pièce de travail ou des autres parties du circuit

de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la page

5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de

consignes.

INCENDIE ET EXPLOSION

Lesincendies et les explosionspeuventrésulter desscories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail. Protégez

toute telle matière qu’il est impossible de retirer de la

zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyezune veilled’incendielors de tout travail dans

une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous

les pièces de travail en aluminium lorsqu’elles sont

coupées sous l’eau ou sur une table d’eau. NE PAS

couper les alliages en aluminium sous l’eau ou sur

une table d’eau à moins que le gas hydrogène peut

s’échapperousedissiper. Le gas hydrogèneaccumulé

explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de

plasma produit une lumière infra-rouge et des rayons

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