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12+ Service Manual CUTMASTER™

1. 6 6 6 05 GaSe Removal nennen nmn nnne nnns 6 6 6 06 Clear Cover Sheet Removal rs 6 7 OOF 6 7 6 08 Preliminary DC Bus Measurement of the Main Inverter Board 6 7 6 09 Preliminary Check of the Main Inverter 6 8 6 10 Check Main On Off Switch rs 6 9 6 11 Check Pressure Switch ins 6 10 6 12 Regulator nS Cuv o CY tni nn eer os 6 10 6 13 Check Main Input RECETTE etel iori etti item ete 6 11 6 14 DC BUS Voltage Measurement 6 11 CHOCO 0601 Ol ERE PERDRE DUI sea REM Id OE E 6 14 C CU Rm 6 17 6 17 Main Circuit Description 6 18 GA re 6 20 SECTION 7 DISASSEMBLY PROCEDURE 7 1 7 01 Safety Precautions for Disassembly 7 1 7 02 Control Board Removal 7 2 7 03 Front Panel Assembly Removal 7 4 7 04 Front Panel Operator Interface Circuit Board PCB3 Removal 7 5 1 05 DE QAR Te md P omes EEE S EEA DM EUR EUER 7 6 7 06 Power Switch 51 and Power Cord 7 7 REM 7 8 SECTION 8 ASSEMBLY PROCEDURES a 8 1 8 01 Installing Base 9 1 8 02 stalling Back Tr ANC enn ee ce 8 2 6
2. Introduction 2T 2 and secondary gases The plasma gas flows into the torch through the negative lead through the starter cartridge around the electrode and out through the tip orifice The secondary gas flows down around the outside of the torch starter cartridge and out between the tip and shield cup around the plasma arc Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip This pilot arc creates a path for the main arc to transfer to the work Main Cutting Arc DC power is also used for the main cutting arc The negative output is connected to the torch electrode through the torch lead The positive output is con nected to the workpiece via the work cable and to the torch through a pilot wire Parts In Place PIP The torch includes a Parts In Place PIP circuit When the shield cup is properly installed it closes a switch The torch will not operate if this Switch Is open O Torch Switch Lo PIP Switch 7 Shield Cup Parts In Place Circuit Diagram for Hand Torch Trigger Control Cable Wiring 09595 0 5198 INSTALLATION CUTMASTER 12 SECTION 3 INSTALLATION 3 01 Unpacking 1 Use the packing lists to identify and account for each item Contents List Description Quantity CM12 Power source 10ft power input cable installed Work cable and clamp installed 5140 To
3. zumom m mom mum s 4 m umm nunnan m m m m m m sos m M POPP 00 02 c o s nes mu umm A V nis isis ol mm m n m m m u a a n aih Ari A 1825 Disassembly Procedure 7 6 Manual 0 5198 DISASSEMBLY PROCEDURE CUTMASTER 12 7 06 Power Switch 1 and Power Cord Removal Read and follow safety information in Section 6 03 before proceeding with disassembly 1 2 Gas inlet Remove gas inlet from rear panel SW locking tabs Squeeze the locking tabs and push SW out from the rear panel Loose the cable anchorage Remove fan Pull the Input Power out UL ae oe i en ee LI 7 v s s bh es WM Rs aM mE RARE BE 8 B 8 2 8 2 m MR a a aea seszzaz Aria 418154 Manual 0 5198 1 1 Disassembly Procedure CUTMASTER 12 DISASSEMBLY PROCEDURE D pe A i e AALA Base Panel Remova Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Remove Central Panel Screws 2 Remove Main PCB assembly Screws i dome e
4. ANA 18215 Disassembly Procedure 1 8 Manual 0 5198 ASSEMBLY PROCEDURE SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Base Board 1 Main Power PCB assembly 2 Install main PCB assembly screws 3 Install central Panel Screws i p i des Manual 0 5198 8 1 CUTMASTER 12 Art A 10256 Assembly Procedures CUTMASTER 12 ASSEMBLY PROCEDURES 8 02 Installing Back Panel 1 Install ON OFF switch Install wire cord Reconnect Input Wire on the ON OFF switch cO N Reconnect Panel screws Install gas inlet Install fan Install ground wire Reconnect AC input wire on Main Power PCB to power ON OFF switch Reconnect the three screws Art A 10257 Assembly Procedures 8 2 Manual 0 5198 ASSEMBLY PROCEDURE CUTMASTER 12 Art A 10258 Manual 0 5198 0 3 Assembly Procedures CUTMASTER 12 ASSEMBLY PROCEDURES 8 03 Installing Front Panel 1 Place front panel PCB assembly into front panel Install the nut and screw 2 Reconnect three harnesses to control PCB 3 Reconnect two red wires and install the screws 4 Install the front panel screws Art A 10558 Assembly Procedures 8 4 Manual 0 5198 ASSEMBLY PROCEDURE 8 04 Installing Main Control Panel and Clear Cover Sheet 1 Install 4 screws 2 Plug harness into HF QF connector 3 Plug harness into MB connector 4 Plug harness into SOURCE amp TIP connect
5. PA maxi z P meanie A value 496 v 223 0 M 182 8 V 542 V 234 0 V 185 7 V status ad y d Stop 414 250 5 0 Geis Edge Positive 4 0 cle 1 0 0 di 200 0 ofst 200 0 Art A 10248 Manual 0 5198 6 17 Troubleshooting CUTMASTER 12 TROUBLESHOOTING 6 17 Main Circuit Description Turn off power and disconnect mains supply plug from receptacle before working on the unit Allow two minutes for capacitors to discharge after disconnection from mains supply voltage IH R02 ROO 7 1 DC V7 4 4 gt dc S R175 o R177 4 Cum 8 8 1 R18 v12 R DC RI QD6 R38 R38 1 RI89RI90R46 R45 R44 R43 R42 R41 R40 R53 R49 dc C19 C18 c 20 ZBYQ 17 C16 QD6 59 188R187R57 R56 R63 R55 R5 Art A 10249 Troub
6. f there is too much spatter on shield cup replace it K Arc goes out while operating Arc can t be restarted when torch trigger is activated 1 Power Supply is overheated TEMP indicator ON a Let unit cool down for at least 5 minutes Make sure the unit has not been operated beyond duty cycle limit 2 Fan blades blocked TEMP indicator ON a Check and clear blades 3 Air flow blocked a Check for blocked air flow around the unit and correct condition 4 Gas pressure is too low Air indicator ON when torch trigger is activated a Check gas source Adjust to proper setting value 5 Torch parts worn a Check torch shield cup cutting tip start cartridge and electrode Replace as needed 6 Faulty component in unit a Return for repair or have qualified technician repair per service manual L Torch cuts but not well 1 Current control is set too low Increase the current setting 2 Torchis being moved too fast across work piece a Reduce cutting Speed 3 Excessive oil or moisture in torch a Hold torch 1 8 inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch If there are contaminants in the gas additional filtering may be needed 4 Torch parts worn a Check torch shield cup cutting tip start cartridge and electrode Replace as needed M Gas in torch pulsates 3 times and then stops AC indicator light blinking 1 Torch parts not properly installed in
7. 6 2 IGBT s Multimeter set to measure Diode Voltage 6 10 Check Main On Off Switch Read and follow safety information in Section 6 03 before proceeding 1 3 2 4 Art 10245 Switch ON Positive meter lead to testpoint 1 01010 _ _ Switch Positive meter lead to testpoint 3 01010 NMgivemeeredgspon _ Switch OFF Positive meter lead to testpoint 1 gt 1 0 Switch OFF Positive meter lead to testpoint 3 gt 1 0 2 Table 6 3 Power Switch Multimeter set to measure ohms 0 Manual 0 5198 6 9 Troubleshooting CUTMASTER 12 TROUBLESHOOTING 6 11 Check Pressure Switch Art A 10292 1 Pressure switch open When the pressure is up to 3 5kgf cm 49 78 PSI the pressure switch turns off 2 Pressure switch closed When the pressure is less than 2 4kgf cm 34 13 PSI the pressure switch turns on and the resistance between 1 and 2 is about 0 10 6 12 Check Regulator Art A 10293 When solenoid valve is on adjusts the knob 1 If the pressure is continuously adjustable the regulator is ok Troubleshooting 6 10 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 6 13 Check Main Input Rectifier AC1 DC Art A 10291 Input Rectifier Testing Multimeter Lead Placement Diode Voltage Positive meter lead to AC1 pores Negative meter lead to testpoint DC Positive meter lead to AC2 ENS Negative meter lead to testpoint DC Positive meter lead to testpoint DC N
8. A Parts List Breakdown The parts list provides a breakdown of all replaceable components B Returns If a product must be returned for service contact your distributor Materials returned without proper autho rization will not be accepted C Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch Address all inquiries to your authorized distributor Manual 0 5198 9 1 Replacement Parts CUTMASTER 12 REPLACEMENT PARTS 9 02 Power Supply Replacement Parts ltem Qty Description Catalog 1 1 Control PCB assembly 9 0077 2 1 Front Control PCB assembly 9 0076 3 1 Main PCB assembly 9 0079 4 1 Regulator 9 0081 5 1 Solenoid assembly 9 0082 6 1 Pressure Switch 9 0075 7 1 Front Panel with Label 9 0071 8 1 Rear Panel with Label 9 0072 9 1 Cover with Labels 9 0080 10 1 Hall Current Sensor 9 0088 11 1 CM12 Cutting Control Knob 9 0073 12 1 CM12 On Off Switch 9 0074 13 1 ATC Connection 9 0083 14 1 Fan 9 0042 15 1 AC DC Rectifier 9 0049 16 1 Power Cord 9 0025 17 1 CM12 Carry Case not shown 9 0084 18 1 Gloves not shown 9 0086 19 1 Glasses not shown 9 0087 20 1 Replacement Torch not shown 7 0040 Art A 09387 AE Replacement Parts 9 2 Manual 0 5198 THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfr
9. Transportation Methods nne 2 1 209 dte unb edes du 2 1 206 Power Supply Features eret erret reete rte oeste ueteres 2 2 SECTION 2TORCH INTRODUCTION ee en da een 2T 1 21 01 SO 21 1 21002 Specifications 21 1 21 03 Introduction to 0 0446 8080 21 2 SECTION 3 INSTALLATION 3 1 3 01 3 1 HOO OUO uera esci 3 1 3 03 Primary Input Power Connections 3 2 3 04 Air Supply Connections tes taie iui te 3 2 3 05 Power Supply Specifications 3 3 3 06 Input Wiring 3 4 SECTION 4 SYSTEM OPERAHON 4 1 4 01 4 1 4 02 Preparations For Operating 4 2 4 03 Sequence of 4 4 OC 4 6 4 05 4 7 SECTION 5 THEORY OF OPERATION a a 5 1 5 01 PVT ON CSU 5 1 TABLE OF CONTENTS SECTION 6 EN a 6 1 6 01 Basic Troubleshooting Power Source Faults 6 1 6 02 Inspection and Replacement of Consumable Torch Parts 6 4 6 03 Checking Unit Before Applying Power enne 6 6 6 04 Tools Needed for Troubleshooting and
10. is not blown out of the cut area and resolidifies on the plate Excessive dross may require Secondary cleanup operations after cutting Kerf Width The width of the cut or the width of material re moved during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has become elongated 4 05 General Cutting Information WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review the Important Safety Pre cautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operators body comes into contact with the workpiece while the torch is activated CAUTION Sparks from the cutting process can cause damage to coated painted and other sur faces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also signifi cantly affect the bevel angle Reducing standoff will generally result in a more square cut Manual 0 5198 4 7 CUTMASTER 12 Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near n
11. plugging in or connecting the unit The primary power source fuse and any extension cords used must conform to local electrical code and the rec ommended circuit protection and wiring requirements as specified in Section 2 Amps RMS input at rated Input Voltage VAC Rated Output OET OR 115V 16A Circuit 20A 88V 21 sf amp 115V 32A Circuit 27 91 230V 16 Circuit 40A 96V 23 214 3 04 Air Supply Connections A Connecting Air Supply to Unit The connection is the same for compressed air or industrial compressed air in gas cylinders 1 Connect the gas line to the compressed air inlet port at the appropriate pressure On Off Switch Air Inlet gt lt gt s gt lt D gt TG A 09337 Figure 3 2 Gas Connection to Compressed Air input Installation 3 2 Manual 0 5198 INSTALLATION CUTMASTER 12 B Using Industrial Compressed Air In Gas Cylinders When using Industrial compressed air in gas cylinders as the gas supply 1 Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure gas regulators 2 Examine the cylinder valves to be su
12. systems Introduction CUTMASTER 12 21 03 Introduction to Plasma INTRODUCTION B Gas Distribution A Plasma Gas Flow The single gas used is internally split into plasma Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece The metal to be cut or removed is melted by the heat of the arc and then blown away While the goal of plasma arc cutting is separation of the material plasma arc gouging is used to remove metals to a controlled depth and width In a Plasma Cutting Torch a cool gas enters Zone B where a arc between the electrode and the torch tip heats and ionizes the gas The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C By forcing the plasma gas and electric arc througha Small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast slag free cut d auto 1 Workpiece A 00002 Typical Torch Head Detail
13. the back end for Standoff Distance maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement C Keepthe torch in contact with the workpiece during the cutting cycle 0 Hold the torch away from your body Manual 0 5198 4 5 Operation CUTMASTER 12 Slide the trigger release toward the back of the torch handle while simultaneously Squeezing the trigger The arc will start Art A 09342 Trigger Release F Place the torch tip on the work The main arc will transfer to the work NOTE The gas preflow and postflow are char acteristic of the power supply and not a function of the torch Trigger Trigger Release SS 4 Art A 09341 G Cut as usual Simply release the trigger assembly to stop cutting H Follow normal recommended cutting prac tices as provided herein 3 Complete cutting operation NOTE If the torch is lifted too far from the work piece while cutting the main arc will stop and the pilot arc will automatically restart 4 Release the torch trigger a Main arc stops 5 Set the power supply ON OFF switch to OFF down position a AC indicator w turns OFF 6 Setthe main power disconnect to OFF or unplug input power cord a Input power is removed from the system Operation OPERATION 4 04 Cut Quality N
14. the flux produces a high yellow light it is desirable to use a ilter lens that absorbs the yellow or sodium line of the visible light spectrum Table 1 1 General information 12 Manual 0 5198 GENERAL INFORMATION 1 03 Publications Refer to the following standards or their latest revisions for more information 1 SAFETY AND HEALTH STANDARDS 29CFR 1910 obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING ob tainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 787 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd
15. torch There may have been an attempt to remove torch parts without turning off ON OFF power switch to OFF on unit Check to make sure torch parts are properly installed b Turn ON OFF switch to OFF and then back to ON Manual 0 5198 6 3 Troubleshooting CUTMASTER 12 TROUBLESHOOTING 6 02 Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter cartridge shield cup in place Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup 15 removed 1 Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be removed may effect the performance of the system 2 Inspect the cup for damage Wipe it clean or replace if damaged Art A 09345 Torch Head Electrode a Start Cartridge Shield Cup Consumable Parts 3 Remove the tip Check for excessive wear indicated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 09791 Tip Wear Troubleshooting 6 4 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 4 Remove the starter cartridge Check for excessive wear plugged gas holes or dis
16. under these headings These Special annotations are easily recognized as follows WARNING Gives information regarding possible per sonal injury Warnings will be enclosed in box such as this A CAUTION Refers to possible equipment damage Cau tions will be shown in bold type NOTE Offers helpful information concerning certain operating procedures Notes will be shown in italics You will also notice icons from the safety section ap pearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that follows Some may have multiple hazards that apply and would look something like this 2 05 Working Principle 2 02 Equipment Identification The units identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate attached to the machine is identified only by the specification or part number printed on the shipping container Record these num bers for future reference 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the insi
17. within 30 days of any failure at which time Victor Technologies will provide instructions on the warranty procedures to be implemented Victor Technologies will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Distributor LIMITED WARRANTY PERIOD product Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 12 This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry Standards In the event of a claim under this warranty the remedies shall be at the discretion of Victor Technologies 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Victor Technologies 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Victor Technologies and are FOB West Lebanon NH or an authorized Victor Technologies service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMIT
18. 03 Installing Front Panel PP 9 4 8 04 Installing Main Control Panel and Clear Cover Sheet 8 5 8 05 8 8 SECTION 9 REPLACEMENT PARTS 9 1 9 01 Introduction nennen nnne 9 1 9 02 Power Supply Replacement Parts 9 2 GENERAL INFORMATION SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows NOTE An operation procedure or background information Which requires additional emphasis or 15 helpful in efficient operation of the system CAUTION procedure which if not properly followed may cause damage to the equipment WARNING procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02 Important Safety Precautions WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT BE DANGEROUS 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 Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read
19. ATION OF LIABILITY Victor Technologies shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Victor Technologies with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of the goods covered by or furnished by Victor Technologies whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor Technologies product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective March 14 2011 General information 1 10 Manual 0 5198 INTRODUCTION CUTMASTER 12 SECTION 2 SYSTEM INTRODUCTION 2 01 How to Use This Manual To ensure safe operation read the entire manual includ ing the chapter on safety instructions and warnings Throughout this manual the word WARNING CAU TION and may appear Pay particular attention to the information provided
20. Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELD ING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Manual 0 5198 10 11 12 13 14 15 CUTMASTER 12 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Bat terymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Associa tion 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTEC TION obtainable from American National Standards Institute 1430 Broadway New Yo
21. OTE Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Refer to appendix pages for additional infor mation as related to the power supply used Cut quality requirements differ depending on applica tion For instance nitride build up and bevel angle may be major factors when the surface will be welded after cutting Dross free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation The following cut quality characteristics are illustrated in the following figure Kerf Width ur ut me N 7 2 Nr Enge 2 p Cut Surface 00007 Drag Lines Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece 4 6 Manual 0 5198 OPERATION Bottom Dross Buildup Molten material which
22. Positive meter lead to testpoint 30 Negative meter lead testpoint 29 0 VDE Positive meter lead to testpoint 32 EEE Ca pA ORAE Negative meter lead to testpoint 31 Table 6 1 DC BUS Multimeter set to measure DC volts Manual 0 5198 6 7 Troubleshooting TROUBLESHOOTING CUTMASTER 12 6 09 Preliminary Check of the Main Inverter Board vvcO0L V HV A Read and follow safety information in Section 6 03 before proceeding 02 Z SSIST4 3 e e e e ee 561614 42 ee 93d5 t 011 990 1 011 Yo 66 66 0 CIC ANO NI 114X Oc6l 8 1 eu 0 5198 6 8 Troubleshooting TROUBLESHOOTING CUTMASTER 12 IGBT Testing Multimeter Lead Placement Diode Voltage GBT 4 Positive meter lead to test point 3 0 2000 to 0 8000 VDC Negative meter lead to test point 2 IGBT 2 Positive meter lead to test point 5 0 2000 to 0 8000 VDC Negative meter lead to test point 4 IGBT 3 Positive meter lead to test point 9 0 2000 to 0 8000 VDC Negative meter lead to test point 7 VIGBT 4 Positive meter lead to test point 10 0 2000 to 0 8000 VDC Negative meter lead to test point 9 IGBT 1 Positive meter lead to test point 14 0 2000 to 0 8000 VDC Negative meter lead to test point 13 PFC IGBT Positive meter lead to test point 12 0 2000 to 0 8000 VDC Negative meter lead to test point 11 orice 0 2000 to 0 8000 VDC Negative meter lead to test point 25 Table
23. TR IHERMAL DYNAMICS Manual No 0 5198 EEE AMP VAC pam hun Y IL ll LO 3 LED 285 I service Manual Issue Date September 3 2012 CUTMASTER PLASMA CUTTING SYSTEM Revision AC Operating Features VW THERMAL DYNA MICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service provider visit us on the web at www thermal dynamics com Americas and Europe This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product We have made every effort to provide you with accurate instructions drawings and photographs of the product s we used when writing this manual However errors do occur and we apologize if there are any contained in this manual Due to our constant effort to bring you the best products we may make an improveme
24. To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using a Cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep cutting power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as pos sible About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recommended General information CUTMASTER 12 1 06 Note Attention et Avertissement JJ 66 Dans ce manuel les mots note Ces mises en relief sont classifi es comme suit NOTE op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui con tribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT a OS ES loute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 07 Precautions D
25. afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs e Pour des renseignements sur la mani re de tester le bruit consultez l article 1 Manual 0 5198 CUTMASTER 12 B RAYONS D ARC DE PLASMA Les rayons provenant de de plasma peuvent blesser vos yeux et br ler votre peau Le proc d larc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous vous prot gez pas correctement e Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire e Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc e Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure e Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection e Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent tableau NOTE Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cac
26. anual 0 5198 1 1 Disassembly Procedure CUTMASTER 12 DISASSEMBLY PROCEDURE 7 02 Control Board Removal Read and follow safety information in Section 6 03 before proceeding with disassembly Remove case refer to 6 05 before remove control board Refer to graphics on page 7 3 1 M4 Screw Remove 4 screws from Control panel Disconnect HF QF harness from HF QF connector Disconnect MB harness from MB connector Disconnect SOURCE amp TIP harness from SOURCE amp TIP connector Disconnect DRIVE harness from DRIVE connector Disconnect U D harness from U D connector Disconnect WA harness from WA connector Disconnect FAN harness from FAN connector Disconnect TRANF IFB harness from TRANF IFB connector 0 Disconnect WV harness from WV connector Z2 O pD pm Ra A Disconnect D PORT harness from D PORT connector 12 Disconnect OT harness from OT connector 13 Disconnect PRESSURE harness from PRESSURE connector 14 Disconnect GUN amp TEST harness from GUN amp TEST connector 5 1 cn n 4 J 10 11 Disassembly Procedure 7 2 Manual 0 5198 CUTMASTER 12 DISASSEMBLY PROCEDURE Disassembly Procedure LAAs cine ea Cdi 4 p i Li Olz Lr p ae eat 3 553 4 1 i HE 4 _ ee ee 5 rm 183 SR TL js eat a nia
27. ar gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit A WARNING MOVING PARTS can cause injury Keep away from moving parts such as fans Keep away from pinch points such as drive rolls Have only qualified persons remove panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Manual 0 5198 GENERAL INFORMATION Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power SN WARNING MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away from servicing areas until consulting their doctor and the device manufacturer WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to cut again Do not block or filter airflow to unit N gt WARNING RADIATION can cause interference High frequency H F can interfere with radio navigation Safety services computers and communications equipment Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified el
28. coloration Check the lower end fitting for free motion Replace if necessary Art A 09792 5 Pull the electrode straight out of the torch head Check the face of the electrode for excessive wear Refer to the following figure New Electrode CUT ire Worn Electrode Art 09346 Electrode Wear 6 Reinstall the electrode by pushing it straight into the torch head until it clicks 7 Reinstall the desired starter cartridge and tip into the torch head 8 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the cup check the threads before proceeding 5140 Replacement Parts Item Description Cat No A 09817 1 Electrode 9 0096 Torch E 2 Start Cartridge 9 0097 3 Tip 20A Drag 9 0091 Electrode 1 Tip 40 Drag 9 0093 2 Tip 40 Standoff 9 0094 4 Shield Cup 9 0098 3 5 5140 Torch w 15ft 4 6m leads 7 0040 Manual 0 5198 6 5 Troubleshooting CUTMASTER 12 TROUBLESHOOTING Turn SW1 to OFF position and disconnect unit from primary line voltage before working unit significant DC voltage can remain on capacitors after unit is Wait until all front panel LED s are off before removing case Check DC bus voltage according to Section 6 08 after removing case Before troubleshooting or applying power to unit complete the following checks to avoid causing further damage 6 04 Tools Needed for Troubleshooting and Serv
29. de back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error 2 04 Transportation Methods Ap Disconnect input power con ductors from de energized supply line before moving the cutting power source Lift unit with handle on top of case Use handcart or Similar device of adequate capacity If using a fork lift vehicle secure the unit on a proper skid before trans porting Compressed air Reduce pressure filter Gas valve Cutting torch Workpiece Manual 0 5198 21 Art 09204 Introduction CUTMASTER 12 INTRODUCTION 2 06 Power Supply Features Torch Lead nel Y d On Off Switch Air Inlet Power Cord A 09335 Introduction 2 2 Manual 0 5198 INTRODUCTION SECTION 2TORCH INTRODUCTION 2T 01 Scope of Manual This manual contains descriptions operating instruc tions and maintenance procedures for the SL40 Plasma Cutting Torch Service of this equipment is restricted to properly trained personnel unqualified personnel are Strictly cautioned against attempting repairs or adjust ments not covered in this manual at the ris
30. e Securite Importantes AVERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer S Il existe des risques de sant II faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les bles sures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 4 603 298 5711 ou votre distributeur local si vous avez des questions FUM E et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant e Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau General information attention et avertissement sont utilis s pour mettre en relief des informations caract re important GENERAL INFORMATION Utilis
31. e du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 General information 1 8 10 11 12 13 14 19 GENERAL INFORMATION Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply A
32. e soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq 7 CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le mat riel conform ment au Code lec trique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes Manual 0 5198 GENERAL INFORMATION NCENDIE EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant me
33. ectrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and Shielding to minimize the possibility of interference WARNING READ INSTRUCTIONS Use Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for cutting safety precautions Use only genuine replacement parts from the manufacturer Manual 0 5198 CUTMASTER 12 1 05 EMF Information Considerations About Cutting And The Effects Of Low Frequency Electric And Magnetic Fields Cutting current as it flows through cutting cables will cause elec tromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies span ning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence contin ues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting
34. ee International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA Sales Office Latin America Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 VICTOR TECHNOLOGIES INNOVATION TO SHAPE THE WORLD U S Customer Care 800 426 1888 e Canada Customer Care 905 827 4515 International Customer Care 940 381 1212 Form No 0 5198 09 03 12 2012 Victor Technologies International Inc www victortechnologies com Printed in USA
35. egative meter lead testpoint AC1 Positive meter lead to testpoint DC Negative meter lead to testpoint 2 Table 6 4 IGBT s Multimeter set to measure Diode Voltage Measurements may be made directly onto the main input rectifier AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position 6 14 DC Bus Voltage Measurement Apply voltage to the Power Source c 7 There are extremely dangerous voltage and power levels present inside these Power Sources Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts Manual 0 5198 6 11 Troubleshooting TROUBLESHOOTING CUTMASTER 12 vvoOL V HV 066L 8111 ze ps Que so 9 O i 141 zin eeu 81 x ed ZN 143 215153 m p e 216155 14 on Manual 0 5198 6 12 Troubleshooting TROUBLESHOOTING CUTMASTER 12 Positive meter lead to testpoint 30 FT eP OEA AO ep Negative meter lead to testpoint 29 Positive meter lead testpoint 31 Power capaci Negative meter lead to testpoint 32 Positive meter lead to test
36. er to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested sizes are based on flexible power cable with power plug installations Cable conductor temperature used is 167 F 75 C Installation 3 4 Manual 0 5198 OPERATION CUTMASTER 12 SECTION 4 SYSTEM OPERATION 4 01 Control Panel Front Panel The Hear Panel 1 ON OFF Switch Power Switch Lamp Controls input power to the power supply is ON Red Lamp O is OFF 2 A Output Current Control sets the desired output current If the overload protection fuse or circuit breaker on the input power circuit opens frequently either reduce cutting output reduce the cutting time or connect the unit to more adequate input power Note For 120V input power the unit will automatically limit the output current to a maximum of 27A For 230V input power the maximum output is 40 Amps Refer to Section 2 for input power requirements 3 N AC Indicator oteady light indicates power supply is ready for operation 4 OVERHEAT Indicator TEMP Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Allow the unit to run with the fan on until the temp indicator turns off 5 AIR Indicator AIR light should be ON when there is sufficient gas pressure 6 READY DC Indicator Indicator is ON when DC outpu
37. ez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents Cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosgene un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ce produit dans le proc der d
38. ge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding Operation CUTMASTER 12 OPERATION Notes Operation 4 8 Manual 0 5198 THEORY OF OPERATION CUTMASTER 12 SECTION 5 THEORY OF OPERATION 5 01 Inverter Design What does the word inverter mean The term inverter refers to the ability to change DC power into AC Inverter power supplies immediately rectify the incoming AC to and then the transistors create a higher frequency AC The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Technology Summary Rectifier Filter IGBT Transformer Rectifier Inductor AC 50 60Hz DC Rippled DC Smooth AC 23KHz AC 23KHz DC Rippled DC Smooth High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage Art A 09846 Manual 0 5198 5 1 Theory of operation CUTMASTER 12 Notes Theory of operation 5 2 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 SECTION 6 TROUBLESHOOTING 6 01 Basic Troubleshooting Power So
39. h par moiceau de travail General information CUTMASTER 12 1 08 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements b OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National otandards Institute 1430 Broadway New York NY 10018 Norme ANSI 749 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 de l Association Am ricain
40. hermal overload indicator LED on the front panel is illuminated The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current and also detect transformer saturation The Hall effect current sensor is powered from regulated amp 15VDC supplies and provides a voltage signal proportional to the output DC cutting current to allow the control circuit to regulate cutting current Manual 0 5198 6 19 Troubleshooting TROUBLESHOOTING 6 18 Circuit Diagram CUTMASTER 12 AbT EET 11 LNdLNO AM HAL 1 1 WHOLV3IHdIAHLL Mund m ah ANS 5 s ANS HOUOL ISAL PEPPE LALLA EM CN INOAH Ld V N 3IOV8GOHHA D S ASTASI ASNVAL Od IVNDIS dilL 4H94NOS Ce Vg ee Quam Tce vg 2 1 a gt X JO2LLNOO INTIAN Od LO IHANOd ENSNSNNNNNS Art A 09396 AE 2 09 0 lt LOdNI 7X e I AOCTI AO C OV I 0 5198 6 20 Troubleshooting DISASSEMBLY PROCEDURE CUTMASTER 12 SECTION 7 DISASSEMBLY PROCEDURE 7 01 Safety Precautions for Disassembly A Read and follow safety information in Section 6 03 before proceeding Unplug unit before beginning Disassembly procedure M
41. icing Aap jl KES Art 09849 6 05 Case Removal Read and follow safety information in Section 6 03 before proceeding Remove the ten screws from the cover and remove the cover panel Art 10242 Troubleshooting 6 6 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 6 06 Clear Cover Sheet Removal Read and follow safety information in Section 6 03 before proceeding 1 Clear protective sheet Take out clear protective sheet Art A 10243 6 07 Visually Inspect Visually inspect the inside of the Power Source The levels of current present in these units can cause burning or arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the following a Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of arcing Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of components used in the Power Source Locate the faulty component s then replace where necessary 6 08 Preliminary DC Bus Measurement of the Main Inverter Board Read and follow safety information in Section 6 03 before proceeding DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF
42. ing section before touching any parts b LD WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards WARNING FIRE OR EXPLOSION hazard Do not place unit on over or near combustible surfaces Do not service unit near flammables General information 1 4 GENERAL INFORMATION ah WARNING FLYING METAL or DIRT can injure eyes W Wear safety glasses with side shields or face shield during servicing Be careful not to short metal tools parts or wires together during testing and servicing 77 WARNING HOT PARTS can cause sever burns Do not touch hot parts bare handed Allow cooling period before working on equipment To handle not parts use proper tools and or wear heavy WARNING EXPLODING PARTS can cause injury Failed parts can explode or cause other parts to explode when power Is applied to inverters Always wear a face shield and long sleeves when servicing inverters amp gt WARNING SHOCK HAZARD from testing Turn Off cutting power source or stop engine before making or changing meter lead connections Use at least one meter lead that has self retaining spring clip such as an alligator clip Read instructions for test equipment WARNING FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running ge
43. k of voiding the Warranty Read this manual thoroughly A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed 21 02 Specifications A Torch Configurations 1 Hand Torch Model 5140 The hand torch head is at 5 to the torch handle The hand torches include a torch handle and torch trigger assembly 96 24 38mm Torch Leads Lengths Hand Torches are available as follows e 15ft 4 6m Torch Parts otarter Cartridge Electrode Tip Shield Cup Parts In Place PIP Torch has built in switch 12 vdc circuit rating Type Cooling Combination of ambient air and gas stream through torch Manual 0 5198 2141 CUTMASTER 12 F Torch Ratings SL40 Torch Ratings Ambient 104 F Temperature 40 C Duty Cycle 100 40 Amps 250 scfh 40 Amps Voltage 900V Arc Striking Voltage 500V G Current Ratings SL40 Current Ratings Up to 40 Amps DC SL40 Torch amp Leads Straight Polarity NOTE Power Supply characteristics will determine material thickness range H Gas Requirements SL40 Torch Gas Specifications Gas Plasma and Secondary Compressed Air 85 psi 5 9 bar 125 psi 8 6 bar 193 scfh 91 Minimum Input Pressure Maximum Input Pressure Gas Flow WARNING This torch is not to be used with oxygen 0 This torch is not to be use with high frequency starting
44. leshooting 6 18 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 The mains supply voltage is connected via double pole switch to the input rectifier UT through an filter Overvoltage protection is provided by varistor The rectifier circuit converts the input AC voltage to DC voltage The input current is controlled by comparing with a reference waveform which is a pure sine wave derived from the source voltage The PFC control chip will be used to generate suitable gate signal to drive V8 V8 1 ensuring the current is sinusoidal The boostdiode output charges the main capacitor bank C16 C17 C18 C19 C20 and C21 to high voltage Inrush current limiting is provided by a high power resistor which is then bypassed by relay J1 after a few seconds The primary igbt transistors T1 T2 T4 and T5 switch the transformer primary at high frequency and varying duty cycle The transformer return wire is taken from the junction of the capacitors C20 and C21 the voltage at this point is approximately half the DC bus voltage Secondary output voltage from the transformer is rectified by the output diodes T14 1 amp T16 1 to DC This DC is controlled by the PWM of the primary side igbt transistors and is filtered by an inductor before connecting to the output terminals Athermal overload device thermistor is fixed to the rectifier heatsink When an over temperature occurs the control circuit inhibits the trigger and the output The t
45. n Ger AIST CUTMASTER 12 DISASSEMBLY PROCEDURE 7 03 Front Panel Assembly Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Case removal Remove the ten screws from the cover panel and remove the cover panel 2 Remove the screws on front panel 3 Unplug the three harnesses from control PCB as shown in photo on following page 4 Remove the two screws Disassembly Procedure 7 4 Manual 0 5198 DISASSEMBLY PROCEDURE CUTMASTER 12 7 04 Front Panel Operator Interface Circuit Board PCB3 Removal A Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Remove the screw on the potentiometer knob 2 Remove the nut 3 Remove the front panel PCB pp a a E Ari f 18252 Manual 0 5198 1 5 Disassembly Procedure CUTMASTER 12 DISASSEMBLY PROCEDURE 7 05 Back Panel Removal Read and follow safety information in Section 6 03 before proceeding with disassembly 1 Remove screws on back panel 2 Remove the three screws 3 Terminals from supply cable Disconnect two terminals from switch 4 Wires from main 1 Disconnect the two terminals from switch 5 Goung wire terminal Remove the nut En E PE Paro anotan n n mou mom mou mu mou mom mom jm HIS mom HONOR NORD HIN
46. ndicator ON 1 Unit air flow obstructed a Check for blocked air flow around the unit and correct condition 2 Fan blocked a Check for blocked status and correct condition 3 Unit is overheated a Keep the machine plugged in and turned on for five minutes This will allow the fan to run and cool the machine Manual 0 5198 6 1 Troubleshooting CUTMASTER 12 TROUBLESHOOTING 4 Faulty components in unit a Return for repair or have qualified technician repair per service manual Torch will not pilot when torch trigger is activated 1 Faulty parts in torch a Check torch parts per section 4 02 replace as needed 2 Gas pressure too low a Adjust supply pressure to proper setting value NOTE The pressure should be set at 100 PSI 3 Faulty components in unit a Return for repair or have qualified technician repair per service manual No cutting output when torch is activated AC indicator ON gas flows fan turns 1 Torch is not connected properly to power supply a Check torch connection to power supply 2 Working cable not connected to work piece or connection is poor Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit Return for repair or have qualified technician repair per service manual 4 Faulty torch Return for repair or have qualified technician repair G Torch cuts but not adequately 1 Incorrect setting of output curre
47. nt control a Check and adjust to proper setting 2 Working cable connection to work piece is poor Make sure that work cable has proper connection to a clean dry area of the work piece 3 Faulty components in unit Return for repair or have qualified technician repair H Output is restricted and can not be controlled 1 Input or output connection is poor Check all input and output connection leads 2 Working cable connection to work piece is poor Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit Return for repair or have qualified technician repair per service manual Cutting output is unstable or inadequate at 120V operation 1 Low or fluctuating input voltage a Turn output current to minimum 20 amps and suggest using 20A Drag tip b Connect to a dedicated input line voltage c Have electrician check input line voltage under load Troubleshooting 6 2 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 Check all input and output connection leads 3 Working cable connection is poor Make sure that work cable has a proper connection to clean dry area of the work piece J Hard to startup 1 Torch parts worn consumables a Turn off input power remove shield cup tip start cartridge and electrode and check them all If the electrode or cutting tip is worn out replace them If the start cartridge does not move freely replace it
48. nt that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry WARNINGS Read and understand this entire Manual and your employer s safety practices before installing operating 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 Plasma Cutting Power Supply CutMaster 12 5140 Torch Service Manual Number 0 5198 Published by Thermal Dynamics Corporation 02 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copy
49. onal filters provide increased filtering capabilities NOTE Rating is determined as specified by the International Electro Technical Commission These specifications include calculating an output voltage based upon power supply rated current To facilitate comparison between power supplies all manufacturers use this output voltage to determine duty cycle Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch This voltage may be more or less than IEC voltage depending upon choice of torch consumables and actual cutting operation Manual 0 5198 3 3 Installation CUTMASTER 12 INSTALLATION Li eee Arts 09933 RU n 7T7mrmi rd Figure 2 1 Power Supply Dimensions amp Weight NOTE Weight includes torch amp leads input power cord and work cable with clamp A CAUTION Provide clearance for proper air flow through the power supply Operation without proper air flow will inhibit proper cooling and reduce duty cycle 3 06 Input Wiring Specifications input Power Input Current Input Current input Suggested Sizes Voltage Volts AC 115 15 9 3 230 50 60 40 5 0 2 50 60 50 208 58 ine Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard NOTE Ref
50. ong them are CSA Canadian Standards Association standard 622 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories 2002 95 EC RoHS directive A 60974 1 Arc Welding Equipment Welding Power Sources For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications WARNING This equipment does not comply with IEC 61000 3 12 If it is connected to a public low voltage system it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment may be connected Victo
51. or 5 Plug harness into DRIVE connector 6 7 8 9 Plug harness into U D connector Plug harness into WA connector Plug harness into FAN connector Plug harness into TRANF IFB connector 10 Plug harness into WV connector 11 Plug harness into D PORT connector 12 Plug harness into OT connector 13 Plug harness into PRESSURE connector 14 Plug harness into GUN amp TEST connector 15 Install clear protective sheet Manual 0 5198 0 5 CUTMASTER 12 Assembly Procedures CUTMASTER 12 ASSEMBLY PROCEDURES 2 Fa PAE 152 Art A 10250 10 11 Art A 10260 Assembly Procedures 8 6 Manual 0 5198 CUTMASTER 12 aNd uod q LI ANJOLP TL Nv3 er VW Zf 9 201 LV DORE XH NNN ne _ 59 4 9 6SE 990 6 1n9 93d 0 orsu 10596054 053 107017 18653840617 R317C309 02030 L T HFOUT ze p 40 4H LP gn er noder 811930409 1 0 9 ASSEMBLY PROCEDURE Assembly Procedures 8 Manual 0 5198 ASSEMBLY PROCEDURES CUTMASTER 12 8 05 Installing Case Install Case 1 2 Install Screws Tighten screws CS AUC EN OHS i e S Art A 10261 Manual 0 5198 8 8 Assembly Procedures REPLACEMENT PARTS CUTMASTER 12 SECTION 9 REPLACEMENT PARTS 9 01 Introduction
52. ot touch ing the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutting arc as quickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Left Side Cut Angle Right Side Cut Angle 00512 Side Characteristics Of Cut To make a square edged cut along an inside diameter of a circle the torch should move coun terclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Dross When dross is present on carbon steel it is com monly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut ed
53. otect 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 protec tive booths screens or shields Use the shade of lens as suggested in the following chart NOTE These values apply where the actual arc 15 clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece AWS F2 2 2001 R2010 Adapted with permission of the American Welding Society AWS Miami Florida Guide for Shade Numbers From AWS F2 2 Lens Shade Selector Shade numbers are mu as a guide only and may be varied b suit individual needs Shielded Metal Arc Welding SMAW 3 32 5 32 2 4 5 32 1 4 4 0 More 1 Gas Metal Arc Welding GMAW Flux Cored Arc Welding FCAW Gas Tungsten arc Welding GTAW Plasma Arc Welding PAW Plasma Arc Cutting PAC ir Carbon Arc Cutting CAC A Suggested Shade No Comfort 0 160 250 250 550 Less than 50 8 50 150 8 150 500 10 10 11 Es than 20 20 100 100 400 400 800 Less than 20 20 40 40 60 60 80 80 300 300 400 400 800 As a rule of thumb start with a shade that is too dark to see the weld zone Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum In oxyfuel gas welding cutting or brazing where the torch and or
54. ould never come in contact with the workpiece except during drag cutting operations B Depending on the cutting operation do one of the following a For drag cutting place the tip on the Trigger 4 mii plate holding the torch at a angle to the plate so that only one edge of the tip is When the shield cup is properly installed in contact with the plate This prevents there is a slight gap between the shield cup damage to the tip during the piercing and the torch handle Gas vents through process this gap as part of normal operation Do b For standoff cutting hold the torch tip not attempt to force the shield cup to close on the work piece pull the trigger After this gap Forcing the shield cup against the arc is initiated lift the tip to 1 8 the torch head or torch handle can damage 3 8 3 4mm off the work components e Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less Torch NOTE For best parts performance and life always use the correct parts for the type of opera tion A Install the drag cutting tip and set the output current The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch Shield Cup Standoff Distance B 1 8 3 8 3 9mm handle With the hand torch the hand may be positioned close to the torch head for maximum control or near
55. point 29 Overall bank addo aD 384 VDC 10 Table 6 5 DC BUS Multimeter set to measure DC volts Note These DC voltages are at nominal mains supply voltage of 240VAC Manual 0 5198 6 13 Troubleshooting A 88 ec E e ao ul 5 c duo Read and follow safety information in Section 6 03 before proceeding 107017 181593849617 CUEL E ue uod LIP Manual 0 5198 AW OLP 9 1 50 6 Nv4 8r VM f uv 9 6GE 9906 119 334 090 6 14 9 m 28 fes y Less HFOUT res Lno4H en 918394105 JAN SP Troubleshooting TROUBLESHOOTING CUTMASTER 12 2 Control circuit power source 2000 3 Negative of solenoid control signal OVDC when solenoid is 4 of solenoid control 27 VDO o 4 1 Current control potentiometer 0 4VDC 0 NN 3 Fault indicator signal 2vdc when indication lights up 5 Control circuit power supply 7 signal 20250 o 8 9 Work indication signal 205 44 c2 c uc 5VDC when the machine dose no work 0VDC when the machine is woking 4 GND OV 5 Control circuit power source 2AVDO Drive circuit powe
56. r 2 IGBT 1 pwm drive signal 15Vp psqarewave 6 Overcurrent signal gt 7VDC when over primary current protection 23VDC input 115vac 3 Output current feedback B NO Manual 0 5198 6 15 Troubleshooting CUTMASTER 12 TROUBLESHOOTING VDC OVDC fan negative when fan is on OVDC 1 Pilot ARC current feedback signal 0 8VDC 5VDC main cutting arc is established 2 Pilot ARC IGBT drive signal PO 42 Thermostat OVDC when thermostat closed 3 592 8 5 Troubleshooting 6 16 Manual 0 5198 TROUBLESHOOTING CUTMASTER 12 6 16 Waveforms 1 Vds of inverter IGBT at no load Test point C1 4 and 5 C2 9 and 10 Testpoints refer to inverter PCB diagram in Sec 6 13 R Measure 1 1 Pafreqieti 2 P4dreqiucz P 5 max c 2 27 value 416 40 384460 kHz 410 v 40 375655 kHz status Timebase 19 6 HS 10 0 Stop Edge Positive 200 Vidi 0 0 offset 0 0 offset 500 k5 5 0 65 5 Art A 10247 2 Vds of inverter IGBT at full load Test point C1 4 and 5 C2 9 and 10 Testpoints refer to inverter PCB diagram in Sec 6 13 aee e aas WB e e E AM nde axem m E Measure F1 maxic1 Perm stl 1
57. r Technologies has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative in Europe Steve Ward Operations Director Victor Technologies Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PRG 7 Manual 0 5198 1 9 General information CUTMASTER 12 GENERAL INFORMATION 1 10 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Victor Technologies warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Victor Technologies Shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Victor Technologies s specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Victor Technologies will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Victor Technologies must be notified
58. r this power supply 1 Place the ON OFF switch on the power supply to ON up position Red indicator lamp is illuminated AC indicator w turns on fan turns on NOTE During initial power up there will be a delay of about 2 seconds before the AC Indicator light will illumi nate and the pre flow gas and fan starts The gas will automatically flow from torch for approximately 10 seconds only after the AC Indicator lamp is illuminated The AC Indicator lamp and fan turns on approximately 2 seconds after the ON OFF switch is enabled this is a process that makes sure all inputs gas input power torch connection and torch parts are acknowledged for proper operation 2 Wear protective clothing including welding gloves and appropriate eye protection see table 1 1 Place tip on work piece and pull trigger Arc will initiate and start cutting material e Standoff Cutting With Hand Torch NOTE For best performance and parts life always use the correct parts for the type of operation Operation 4 4 Manual 0 5198 OPERATION CUTMASTER 12 A The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement NOTE The tip sh
59. rch 15ft 4 6m w consumables Carry case 40A Tip Drag 20A Tip Drag 40A Tip Standoff Electrode Gloves Cutting Glasses 2 Inspect each item for possible shipping damage If damage is evident contact your distributor and or ship ping company before proceeding with the installation NNN ok 3 Record Power Supply and Torch model and serial numbers purchase date and vendor name in the information block at the front of this manual 3 02 Lifting Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNING Disconnect input power cord before moving unit WARNING FALLING EQUIPMENT can cause serious personal injury and can damage equipment Do not touch live electrical parts HANDLE is not for mechanical lifting e Only persons of adequate physical strength should lift the unit Lift unit by the handle using two hands Do not use straps for lifting Use optional cart or similar device of adequate capacity to move unit Place unit on a proper skid and secure in place before transporting With a fork lift or other vehicle Manual 0 5198 3 1 Installation CUTMASTER 12 INSTALLATION 3 03 Primary Input Power Connections Power Cord and Plug This power supply comes installed with a input power cable with no plug single phase input power CAUTION Check your power source for correct voltage before
60. re they are clean and free of oil grease or any foreign material Briefly open each cylinder valve to blow out any dust which may be present 3 he cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 250 scfh 120 Ipm 4 Connect gas supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure gas cylinder regulator Supply hose must be at least 1 4 inch 6 I D For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch 3 05 Power Supply Specifications CUTMASTER 12 Power Supply Specifications Input Power 115 VAC 10 1Phase 50 60Hz 230 VAC 10 1Phase 50 60Hz Output Current 20 27 Amps Q 115VAC 20 40 Amps 230VAC 104 F 40 C 30 115VAC 40 230VAC 202 1 Duty Cycle is the percentage of time the system can be operated without overheating Duty cycle is reduced if primary input voltage AC is low or the DC voltage is higher than shown in this chart 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear Opti
61. right 2011 2012 by Victor Technologies All rights reserved Reproduction of this work in whole or in part without written permission 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 October 31 2011 Revision AC Date September 3 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION uis 2 ces ces die 1 1 1 01 Notes Cautions Warnings nne 1 1 1 02 Important Safety Precautions is 1 1 1 03 DOS IPIE 1 3 2057 1 4 1 05 EMF MEN Vd 1 5 1 06 Note Attention et Avertissement 1 6 1 07 Precautions De Securite 1 6 1 08 Documents De Reference iii 1 8 1 09 Declaration of 1 9 1 10 Statement of 1 10 SECTION 2 SYSTEM RCE TR 2 1 2 01 How to Use This Manual 2 1 2 02 Equipment Identification tuo nest 2 1 2 03 Receipt of 2 2 4 2 1 2 04
62. rk NY 10018 General information CUTMASTER 12 1 04 Servicing Hazards WARNING The symbols shown below are used throughout this manual to call attention to and identify possible haz ards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should test maintain and repair this unit Only qualified persons should test maintain and repair this unit WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off cutting power source and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from receptacle or stop engine before Servicing unless the procedure specifically requires an ener gized unit Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground Do not leave live unit unattended If this procedure requires and energized unit have only per sonnel familiar with and following standard safety practices do the job When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free Disconnect input power conductors from de energized supply line BEFORE moving a cutting power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instructions in Troubleshoot
63. sive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlo rinated 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 defects and in some cases cancer California Health amp 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 operator or others in the workplace Never touch any parts that are electrically live or hot 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 Publications Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the work place Do no
64. ssociation 1900 Arch Street Philadelphia PA 19103 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 5198 GENERAL INFORMATION CUTMASTER 12 1 09 Declaration of Conformity Manufacturer Victor Technologies West Lebanon New Hampshire 03784 USA RoHS The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 2006 95 EC and to the National legislation for the enforcement of this Directive Address 82 Benning Street The equipment described in this manual conforms to all applicable aspects and regulations of the Directive European Council Directive 2004 108 EC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to number of standards and technical requirements Am
65. t circuit is active NOTE All consumables must be correctly installed and maintained to ensure correct operation Manual 0 5198 4 1 Operation CUTMASTER 12 OPERATION 4 02 Preparations For Operating At the start of each operating session Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies A Torch Parts Selection Check the torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this power supply 40 amps maximum Use only genuine Thermal Dynamics parts with this torch Art A 09340 AG gt A Start Cartridge 2 No 9 0097 40 Amp 40 Amp Drag Tip Cat No 9 0093 Standoff Tip Cat No 9 0094 Shield Cup Cat No 9 0098 Worn Electrode Worn Tip NOTE When operating the torch in normal condition some gas vents through the gap between the shield cup and torch handle Do not attempt to over tighten the shield cup as irreparable damage to internal components may result B Torch Connection Check that the torch is properly connected C Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power requirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to suppl
66. t cut or weld on containers that may have held com bustibles General information CUTMASTER 12 Provide fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater 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 dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in Sub section 1 03 Publications in this manual GENERAL INFORMATION PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infrared light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pr
67. ttre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables e Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles e Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie e gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es 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 moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm Q BRUIT Le bruit peut provoquer une perte permanente de Les d s de soudage de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous du4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie e Pour prot ger votre ou e contre les bruits forts portez des tam pons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e faut mesurer les niveaux sonores
68. understand and fol low all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health GASES AND FUMES e Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Manual 0 5198 1 1 CUTMASTER 12 The kinds of fumes and gases from the plasma arc depend the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more ofthe following 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 information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explo
69. urce Faults A WARNING e eS There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair it unless you are an accredited service provider and you have had training in power electronics measurement and troubleshooting techniques Common Faults symptom LED Indicators A AC indicator OFF 1 Main input power cord does not connect to power distribution net a Connect the power cord 2 Power ON OFF switch in OFF down position a switch to ON up position 3 Actual input voltage does not correspond to voltage of unit a Verify that the input line voltage is correct 4 Faulty components in unit a Return for repair or have qualified technician repair per service manual B AC indicator blinking 1 Indicator blinking 1 sec ON 1 Sec OFF Gas may also pulse 3 times a J Check for missing torch parts or not properly installed Turn ON OFF switch to OFF position and restart the machine by turning the power switch to ON 2 Indicator blinking 1 sec ON 3 Sec OFF a J Check for worn or sticking torch parts Replace if necessary 3 Indicator blinking 3 sec ON 3 Sec OFF a Torch switch was depressed before machine was completely powered up Turn ON OFF switch to OFF position and the restart the machine by turning the power switch to ON C Air indicator OFF 1 Gas pressure too low Check supply pressure D indicator ON AC i
70. y power to the system Operation 4 2 Manual 0 5198 OPERATION CUTMASTER 12 D Gas Selection Ensure gas source meets requirements listed in section 2T Check connections and turn gas supply on E Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Con nect only to the main part of the workpiece do not connect to the part to be cut off Art A 03387 F Power On Place the power supply ON OFF switch to the ON I position Power indicator turns on pm On Off Switch Air Inlet Power Cord 120V 15 120V 20 4 230V 20 Art A 09339_AD Nd LUE art A 09335 Rear Panel with ON OFF Switch Front Panel With Power ON OFF Indicator Manual 0 5198 4 3 Operation CUTMASTER 12 OPERATION G Select Current Output Level Set the desired current output level 115V 16 115V 32 ll 230V 16 E A 09937 a 7 vo 115V 16A 115V 32A 230V 16A 4 03 Sequence of Operation The following is a typical sequence of operation fo

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