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20mm CUTMASTER™ Service Manual

1. 5 4 PRI2 PRI 1 PRI Ll BIAS Al D SUPPLY ps 12VDC lo oi 1 1 2 3 at ois 9 x P 4 59 zo 2 4 L UNITS ONLY EMI FILTER wi L1 1 1 1 8 L2 2 2 02 172 9 L3 Eo a GND 4 4 t pm Q2 380 400 415V Si OR 600V A f 3 PH AC INPUT pM PRIMARY POWER CONNECTIONS USE L1 L2 L3 amp GND EN X CD MTH7 MTHS 2 INPUT CAPACITOR 5 CM52 12mm 20mm A40 C3 amp may not be installed TEST POINTS ub 2 24 VAC RETURN GOVMON GND2 COMMON GND3 COMMON 6 H2V1 12 VDC SUPPLY avt 48 VDC SUPPLY LDMD 1 CURRENT DEMAND D59 PCR SEN TIP DRAG SENSE 1 SERIAL PORT 2 P 4 D78CSR 12vDC 5 PCB1 MAIN assy SOLENOID 2 40 CIRCUIT RIBBON CABLE n 40 PIN RIBBON CABLE SIGNALS P 1 V OUT SIGNAL ML 2 VOLTS ML ERRORIND FAULT MAX 3 SENSE ML AC H 4 460V_IN LM MAX OVER PRESSURE 2 5 230V IN LM 90 INTERNAL ERROR 6 CUR SET LM 85 SHORTED TORCH 90 7 JRAR RAPID AUTO RESTART L M 4 OVERTEMP 80
2. 12V1 WORK 1 GND2 PRI 1 AC1 AC2 5 PRI 2 TP6 SEC1 48V2 12V2 48V1 Manual 0 5079 J4 1 33VDC CUTMASTER 20mm B LED INDICATORS 059 PCRIndicates Pilot IGBT gate signal is ON RXD D78 CSRindicates cutting arc has been established J4 4 Common J4 5 D C MAIN PCB TEST POINTS GNDI Common pa ave Eo J5 2 Not used 12V1 12VDC 5 3 SOLENOID 48V1 48VDC I DMD10 4VDC Current Demand Signal J6 1 24VAC Supply for W1 J6 2 24VAC Return 7 1 12VDC J7 2 FAN J8 1 12VDC J8 2 FAN 19 1 PIP J9 2 Common J9 3 TORCH SWITCH Start J9 4 Common J9 5 Torch solenoid 24VAC supply 9 6 Not Used J9 7 Torch solenoid 24VAC return 110 1 OK TO MOVE J10 2 Not used J10 3 OK TO MOVE 110 4 Not used J10 5 Common J10 6 Common J10 7 Not used J10 8 START Torch Switch 111 1 Jumper installed 111 2 Jumper installed 12 1 12VDC J12 2 460VAC J12 3 230VAC Manual 0 5079 5 29 SERVICE CUTMASTER 20mm 5 16 Main PCB Wiring Diagram JA J3 J2 V A To SW2 To Logic Pcb J12 To PCB2 J1 To SW1
3. 4 7 sa e os ea 75 sz 2 ns news samo 1s ost oss ea 52 9 os nn nA fun msi eso 1s eo 18 ous oss ea rs 52 oo 2 u on NOTES Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads refer to section 4 02 Operating Pressure Total flow rate includes plasma and secondary gas flow OPERATION 4T 12 Manual 0 5079 CUTMASTER 20mm 4T 09Recommended Cutting Speeds for SL60 Torch With Shielded Tip fooss 40 as or ro ss ooo 54 oos sese 120 40 220 vo ss vo o2 or om re ssme 121 40 208 ss vo or 12 40 7s orfas 7o ss 170 54 esae 123 40 vo ss 170 oe 54 9575 95 1 40 11 or fae vo 55 vo NR NR 12 7 e200 1e 40 7 018 om faa ss vo NA Nn Nh 15e 40 s oo orlas ss vro NA NR NR Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Inches Volts VDC Amps Meters 036 0 9 9 8208 109 Inches mm o D
4. se vo 02 Ts efes os 70 se vo oz 54 olsen sos ome o e vo os NN NN ala 5 gt CD ce 172 EE ojojo ak vo 254 oss as ss vo Fw 24 ner as ro as Cie oat 4s ss ro wa NR NR OPERATION 4T 10 Manual 0 5079 CUTMASTER 20mm mw sna Ame mens veers mes m ru twr Get Ser metes us e m om acm sr e ss wm Toe fer Lus m sm rer ose e r foo um sr vs oo 15 ss oro faa 5 52 o0 2 on roxas e ws s18 ois aa 75 52 o0 ze 020 ar samo 122 eo 22 oxo aa 5 sz 9 020 9020 05 sa ssno 120 e es 155 oxo aa 5 sz eo m5 090 020 51 roars ss esno 1 e or vois faa 75 52 2 os 5 oz esno i e oss ois fae 75 sz oo 2 ovs ar Ens 541 130 eo is oss oxo aa 75 sz wm NR oro ue 12 os ozs oa rs 52 2 ne wm nA Type Torch SL60 With Exposed Tip Type Plasma Gas
5. 2 R25 R27 R24 R28 R26 R42 R49 C29 us R58 R60 J2 c33 R72 R74 c35 R77 R76 R59 o g Lj R68 C34 l A 59 reas vii o 2 D10 LOGIC PCB LAYOUT D13 J1 Pinout Same for MAIN PCB J2 OUTPUT VOLTAGE Active high when tip is installed 5 24 Approx 100VDC while cutting with tip not in contact w work piece Active low when tip contact work during cut Drag Mode Active low with 400VAC primary input voltage TP3 TP4 TP1 J1 TP2 D2 D3 D4 D5 D6 D7 D8 D9 J3 Art 08504 Signal Source Destination M L M L M L L M Manual 0 5079 11 5 71 6 1 7 11 8 1 9 1 10 71 11 11212 1 13 71 14 1 15 1 16 71 17 71 18 71 19 71 20 71 21 71 22 71 23 1 24 71 25 1 26 71 27 71 28 71 29 71 30 71 31 71 32 J1 33 J1 34 11 35 71 36 7037 71 38 71 39 1 40 CUR SET
6. 5 6 5 07 CilcuitlFault ISolatiOl ees 5 8 5 08 Main Input and Internal Power 5 11 5 09 5 16 5 10 Main Arc and Controls Problems 5 17 5 11 CNC Interface Problems 5 18 5 12 TOSLPrOCEdU O ns LEES 5 18 5 13 Capacitor PCB Layout amp 5 22 5 14 Logic PCB Layout amp Signals cotra etienne tridente dts 5 24 5 15 Main PCB Layout amp Signals xe devi eet cite dain 5 28 5 16 Main PCB Wiring 5 30 SECTION 5 TORCH SERVICE sotoen ea oa ANE aTa EEEE N 5T 1 5T 01 eee 5T 1 5T 02 Inspection and Replacement of Consumable Torch Parts 5T 2 SECTION 6 PARTS EIS ES iih es oes der re etre eines 6 1 6 01 re DS 6 1 6 02 Ordering Information diam ren ie manne 6 1 6 03 Power Supply Replacement 6 1 6 04 Major External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement Parts 6 4 6 07 Right Side Replacement Parts 6 5 6 08 Options and Accessories 6 6 6 09 Replacement Parts for Hand Torch
7. 3 z 5 1TORCH PIP SWITCH ow gt SEC2 CHOKE1 N7 PARE TORCH SWITCH TEMP circum OVERTEMP CONNECTOR E AUTOMATION 2 2 TORCH SOLENOID 5 5 5 5 7 7 8 8 VOUT1 77 5 E64 ELECTRODE1 D3 5 o5 4 PILOT IGBT N WORK cum E 17 80 ISTART 3 24 RETURN 5 8 83 24VAC SUPPLY il 7 INTERFACE STANDARD 40 amp A60 UNITS INTERFACE OPTIONAL ON 52 amp 82 UNITS 42 P10 IH 13 okToMove 1 1 12 250VAC 30VDC OK TO MOVE I 2 2 11 ih PINOUT 3 3 10 4 4 9 5 5 8 12VDC A H H 7 7 6 8 8 5 2 start stop 3 77 Sink Soma 12 00 1 FULL FEATURED AUTOMATION INTERFACE OPTION 12VDC 12vDC To configure DIVIDED ARC VOLTS signal output TAN No jumper installed for ARC VOLTS 16 67 Jumper pins 1 amp 2 for ARC VOLTS 30 _ Jumper pins 2 amp 3 for ARC VOLTS 50 s s VOUT 1 gam on 1 N ET 2 2 Ji voc E STOP 1 1 5 40 2 2 aL te DIVIDED ARC VOLTS 3 3 ARC VOLTS MOT2 s H 100K IN SERIES 2 6 10 7 7 11 8 8 r 2 H Kt 13 OK TO MOVE ur AUTOMATION INTERFACE 09133 Rev Revisions By Date No AA INTRO ECO B1357 RWE 03 3109 JHERMAL DYNAMIC 16052 Suingley Ride Road ASSY No
8. Vos TT Ene Um m In M Ka 4 4 L au th e L i dil eo eo a aur s LJ s Css j amp D mune 1 301 El qi d 97 EL 6 B o we PA mof RIBS ro m RI m 184 ra Art A 08902 To Automation Interface Pcb MAIN PCB WIRING DIAGRAM SERVICE 5 30 Manual 0 5079 CUTMASTER 20mm SECTION 5 TORCH SERVICE 5T 01General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE Refer to Previous Section 5 System for common and fault indicator descriptions Upper O Ring in Correct Groove Threads Cleaning Torch Lower O Ring Art A 03725 Even if precautions are taken to use only clean air Torch Head O Ring with a torch eventually the inside of the torch be comes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch A WARNING BE Disconnect primary power to the system be
9. Art A 07990 8 Install the new or cleaned assembly by reversing these procedures 9 Turn ON theair supply and check for leaks before reinstalling the cover 10 Reinstall the power supply cover PARTS REPLACEMENT B Optional Single Stage Filter Element Replacement These instructions apply to power supplies where the optional Single Stage Filter has been installed The Power Supply shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele ment 3 Disconnect gas supply hose Turn the Filter Housing Cover counter clockwise and remove it The Filter Element is located inside the Housing Housing Filter Element Cat No 9 7741 e O ring Cat No 9 9743 Assembled Filter Cover p DE Fitting Art A 02476 Optional Single Stage Filter Element Replacement 5 Remove the Filter Element from the Housing and set Element aside to dry Wipe inside of housing clean then insert the replacement Filter Element open side first Replace Housing on Cover 8 Reattach gas supply 9 Reinstall the power supply cover NOTE If
10. m M PM OV Or Or Or ids B BRBIBIB AB o 8 o 2 2 A Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Pierce Height 3 mm Inches psi bar Plasma Total Inches m 55 170 ooo 030 4 0 ojo N O1 O1 MyM MI Mh 210 1 o o j o ak ALATA TAT is ofo 0125 32 08208 130 ose 132 k E 4 2 DINJIN 2 D A Manual 0 5079 4T 13 OPERATION CUTMASTER 20mm Type Torch SL60 With Shielded Tip Type Material Mild Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch psi bar Plasma Inches mm 257 245 230 4 245 9820 i 1 2 1 2 3 4 2 1 2 1 2 1 1 DIET ras semo vs e 02 o2 s oeo vs e 203 fois 0 726 oss 1 o oso zs os 2 s sa een ws 4 036 or EN ws eo 14 for Tooo fasal same 15 s a 010 os Type Plasma Gas Air Thickness Amperage Speed Per Minute Standoff Flow CFH Pierce Pierce Height s
11. Wh fo endant 8 2 lt 2 3 Switch Connector 3 eZ 2 SiN 2n ge 2 I A 6 Open el 2 77 2 PIP SS 5 5 Open SA 1 PIP Art A 08576 C Automation Machine Torch Pin Out Diagram ATC Male Connector ATC Female Receptacle Front View Front Vi nt View Negative Plasma Negative Plasma o AY 4 LON ile MIA geen NE CA El ik 7 Gree 7 Torch 8 Torch Solenoid Solenoid Wien 1 E 7 6 Open 6 Open We 1 Black SSE IP Circuit PIP Pilot Solenoid Pilot 4 Manual 0 5079 A 3 APPENDIX CUTMASTER 20mm APPENDIX 4 TORCH CONNECTION DIAGRAM A Hand Torch Connection Diagram Torch SL60 SL100 Hand Torch Leads Torch Leads with ATC Connector Power Supply with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power __ Torch Supply Head Leads PIP TT Black O Orange Switch To Power Supply Circuitry Torch O PM Green Switch To Power Supply OMM white Circuitry 0 BR O1 Negative Plasma Negative Plasma Pilot Pilot Art A 03797 B Mechanized Torch Connection Diagram Torch Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector
12. H H UM M HH H xi There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Problem Symptom Possible Cause Recommended Action ON OFF Switch 1 Primary power disconnect is in 1 Turn primary power disconnect switch to ON position is ON but the A C OFF position Indicator does not 2 Primary fuses breakers are blown or tripped 3 Faulty components in unit 2 a Have qualified person check primary fuses breakers b Connect unit to known good primary power receptacle 3 Return to authorized service center for repair or replacement FAULT indicator lashing 65 PSI 1 Incorrect Primary line Voltage 2 Primary input voltage problem 1 Check that appropriate line voltage is connected to unit 2 Have qualified person check primary voltage to insure it meets unit requirements see section 2 04 3 Faulty components in unit 3 Return to authorized service center for repair or replacement indicators flashing 1 Air flow through or around the unit is obstructed 2 Duty cycle of the unit has been exceeded 3 Failed components in unit 1 Gas supply not connected to unit 2 Gas supply not turned ON 3 Gas supply pressure too low 4 AIR PRESSURE CONTROL regulator set too low 5 Failed components in unit 1 Shield
13. 3 On torches with a shield cup body and a shield dins ad cap or deflector ensure that the cap or deflector Electrode Wear is threaded snugly against the shield cup body In shielded drag cutting operations only there may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring 8 Reinstall the desired starter cartridge and tip into Drag Shield Cap the torch head 7 Reinstall the Electrode by pushing it straight into the torch head until it clicks 9 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 Shield Cup Body This completes the parts replacement procedures Art A 03878 SERVICE 5T 2 Manual 0 5079 CUTMASTER 20mm SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Power Supply Replacement Section 6 04 Major External Replacement Parts Section 6 05 Front Panel Replacement Parts Section 6 06 Left Side Replacement Parts Section 6 07 Right Side Replacement Parts Section 6 08 Options and Accessories Section 6 09 Replacement Parts for Hand Torch Section 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Section 6 11 Torch Consumable Parts Manual and Mechanized Torches NOTE Parts listed without i
14. 6 7 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads 6 8 6 11 Torch Consumable Parts Manual and Mechanized Torches 6 10 SECTION 7 REPLACEMENT PROCEDURES iii 7 1 7 01 SCODE siste ttis ette cure riesce ees 7 1 7 02 Anti Static Handling 2 44420 0 7 1 7 03 Parts Replacement General Information 7 1 7 04 Major External Parts 7 2 7 05 Front Panel Parts Replacement 7 3 7 06 Left Side Internal Parts Replacement 7 4 7 07 Rear Panel Parts Replacement 7 5 7 08 Right Side Internal Parts 7 7 APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4 APPENDIX 5 APPENDIX 6 TABLE OF CONTENTS SEQUENCE OF OPERATION BLOCK DIAGRAM eene A 1 DATA TAG INFORMATION oc eei rene made ttu ds A 2 TORCH PIN OUT A 3 TORCH CONNECTION DIAGRAMS ii 4 SYSTEM SCHEMATIC 380 400 415V UNITS A 6 Publication te 8 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Rear Cover This Page Intentionally Blank SECTION 1 GENERAL INFORMATION 1 01 Notes
15. o e a o N o o oj oj B N 10 130 ojo I co N ajo olo c 5 N o o N o rw 48 70 48 55 58 58 ao 025 secos 111 5 Par oss ore 7 os id gt gt RISA SATA z mmj o o c 8 a a M N B 2 2 o Type Torch 8160 With Exposed Tip ie Pas Gas A OL xs a sss 902 fows s2 4s ss 10 ooo sr a eazoe 4o rer ows sz 48 ss vo 51 ow s osme e wo Tas m for as ssoos 124 46 ost 70 s ss vo 9 2 sn es ose 122 7o se vo 02 sa sese 128 40 10 025 oterjae as 55 170 nn NR ne D Type Torch 5160 With Exposed Tip Type Material Aluminum LP Plasma Gas Air Type Secondary Gas Single Gas Torch DES nce fao Tee ss 060 2 4o sso sse
16. 4 Install the starter cartridge and desired tip for the operation into the torch head 5 Hand tighten the shield cup assembly until it is seated on the torch head If resistance is felt when installing the cup check the threads before proceeding OPERATION CUTMASTER 20mm 4T 02Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Cut quality requirements differ depending on application For instance nitride build up and bevel angle may be major factors when the sur face will be welded after cutting Dross free cut ting 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 m 98 Dross Build Up Cut Surface Bevel Angle Rounding A 00007 Cut Surface 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 perpendicul
17. England PR6 7BX CE GENERAL INFORMATION 6 Manual 0 5079 CUTMASTER 20mm 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER 1Series 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 Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics 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 merchantahility or fitness for a particular purpose Thermal Dynamics 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 Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the pr
18. In Place Circuit Diagram for Hand Torch When the torch is started a pilot arc is established between the electrode and cutting tip This pilot Remote Pendant arc creates a path for the main arc to transfer to the work ft D Main Cutting Arc DC power is also used for the main cutting arc The To ATC a Shield Cup negative output is connected to the torch electrode through the torch lead The positive output is con lt nected to the workpiece via the work cable and to the torch through a pilot wire CNC Start To ATC PIP Switch Shield Cup 4 i Art A 08168 Automation Torch PIP Switch Shield Cup P Parts In Place Circuit Diagram for Machine Torch Manual 0 5079 2T 3 INTRODUCTION CUTMASTER 20mm This Page Intentionally Blank INTRODUCTION 2T 4 Manual 0 5079 SECTION 3 SYSTEM INSTALLATION 3 01 Unpacking 1 Use the packing lists to identify and ac count for each item 2 Inspect each item for possible shipping damage If damage is evident contact your distributor and or shipping company before proceeding with the installation 3 Record Power Supply and Torch model and serial numbers purchase date and ven dor 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 Do not touch live elect
19. MISSING INRUSH LM 75 4 9 Wl ON LM Za 70 PARTS IN PLACE d 10 SHDN LM 65 INPUT POWER 85 11 TORCH SOLENOID LM GAS MIN UNDER PRESSURE 12 SOLENOID ON LM 2 13 OK TO MOVE LM 2 14 ON LM ui TEST POINTS 80 15 ACTIVE LM aN 18 TORCH SWITCH ML p 2 2VDC Ls 17 ML d ta AC ON TP3 5 VDC 75 GAS CONTROL 18 age ERROR 3 3 VDC 20 TORCH_SOLENOID_DETECT ML us AT NE ee La REGULATOR 21 OVERTEMP ML 5 SOLENOID 22 VIN Mai TP7 POT DEMAND VALVE 23 ML X p E 24 12VDC ML 4 25 COMMON ML Current Control 65 FILTER 26 COMMON ML 12VDC AIR 29 MAIN ID ML T 2 INLET 34 460 IN ML X Bon LATCH m MN PRESSURE D ME ues E TRANSDUCER 38 COMMON LM lt 39 D ML RUN svoc 43 1 eo RAR 0 100PSI 0 4 5VDC 2 5 3 o LOGIC PCB lt 5 4 APPENDIX A 6 Manual 0 5079 CUTMASTER 20mm
20. SENTER DES RISQUES ET DES DANGERS DE SANTE 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 Il faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possi bles 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 603 298 5711 ou votre distributeur local si vous avez des questions amp 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 Manual 0 5079 CUTMASTER 20mm 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 Utilisez 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 pen dent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff
21. ing its wires through from the right side of the unit Install replacement Output Inductor by reversing the above steps Reinstall the power supply cover Manual 0 5079 CUTMASTER 20mm 7 07 Rear Panel Parts Replacement A Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Subsection 5 02 and either cleaned or replaced 1 Remove power from the power supply turn OFF the gas supply and bleed down the system Remove the system cover See A Cover Re moval in this section Locate the internal air line and the fitting from the filter assembly Number 1 in the following illustration Hold a wrench or similar tool against the locking ring on the filter assembly fitting then pull on the hose to release it Numbers 2 and 3 in the following illustration Art A 07989 Remove the fitting from the filter element as sembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration PARTS REPLACEMENT CUTMASTER 20mm 6 Disconnect the input line from the filter element assembly Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly
22. Air Type Secondary Gas 15 98210 200 757 un oors 120 eo 724 ou n vm e iof asr forfa 2 2 gt A e are gt to PO Amp A AID roxas eo oso 4o ose ss emo 2s ore eal zs 2_ mesa semp ns m pum m os ss Te 52 es seno va w 17 o fas 7s 52 ve 60 26 oe ore 52 0625 127 o 19 o4 orfas 7s 52 missmo 14 1 o3 orfas 75 52 Fam o 6 os or 52 245 245 os fo pu co A pp D gt n A Manual 0 5079 47 11 OPERATION CUTMASTER 20mm Ceres ense erra pss mmn pecene no e so oss ea 52 o oo ox 64 oeo no e ao os ea 75 52 eo ms eo 25 635 0 ea 75 sz 2 on nzs 4 834 16 eo 170 a32 oss ea rs 52 9 5 020 nzs 4 sa 12 eo 216 0 ea rs 52 oo 2 sao e ss 114 ea 75 sz
23. 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 is helpful in ef ficient operation of the system A 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 operating area A WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box such as this 1 02 Important Safety Precautions WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN 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 understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions A GASES AND FUMES Gases and fumes produced during the pl
24. LUN 2 PIP V QN WS 1 PIP Pilot Lead Art A 08124 b For machine torches using a remote pendant check continuity of Pendant switch circuit c For CNC input see section 5 07 H Tip Missing Fault 2 Defective Logic PCB a Jumper on Main PCB between J2 16 and test point GND1 If gas does not flow replace Logic PCB b With Torch Switch closed measure voltage on Main PCB between test points GND1 to 1 for 1 4VDC Replace Logic PCB if voltage is not present 3 Defective Main PCB 1 a With Torch Switch closed measure voltage on Main PCB between test points GND1 to I_DMD1 for 1 4 VDC Replace Main PCB 1 if voltage is present B SHORTED TORCH FAULT After torch switch is closed gas flows for two 2 seconds then momentarily shuts OFF then back ON FAULT INDICATOR flashes and 85 PSI LED flashes 1 Upper O Ring on torch head is in the wrong posi tion a Remove shield cup from torch check position of the upper o ring and correct if needed SERVICE Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art 03725 2 Torch start cartridge is stuck a Turn OFF power supply Bleed down the sys tem Remove the shield cup tip start cartridge and electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not move freely Spring Lo
25. 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 rensei gnements 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 phosg ne 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 de 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 A CHO
26. tip start cartridge and electrode must be installed for the type of operation Refer to Section 4T 07 Torch Parts Selection for details INSTALLATION 3T 2 Manual 0 5079 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering Identification 1 Output Current Control Sets the desired output current Output settings up to 60 Amps may be used for drag cutting with the torch tip contacting the workpiece or standoff cutting Function Control Function Control Knob Used to select between the different operating modes SET ra Used to purge the air through the unit and torch and leads and to adjust gas pressure RUN c t Used for general cutting operations RAPID AUTO RESTART o o Allows for faster restarting of the Pilot Arc for uninterrupted cutting LATCH Used for longer hand held cuts Once a cutting arc is established the torch switch can be released The cutting arc will remain ON until the torch is lifted away from the work piece the torch leaves the edge of the work piece the torch switch is activated again or if one of the system interlocks is activated ON OFF Power Switch ON OFF Switch controls input power to the power supply Up is ON down is OFF Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock NY AC Indicator Steady l
27. with the Output Current Control Knob Cutting Operation When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position there is a brief delay in restarting the pilot arc With the knob in the RAPID AUTO RESTART position when the torch leaves the work piece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded metal or gratings or in gouging or trimming operations when an uninter rupted restart is desired And with the knob in the LATCH position the main cutting arc will be main tained after the torch switch is released Manual 0 5079 CUTMASTER 20mm Typical Cutting Speeds Cutting speeds vary according to torch output am perage the type of material being cut and operator skill Refer to Section 4T 08 and following for greater details Output current setting or cutting speeds may be reduced to allow slower cutting when following a line or using a template or cutting guide while still producing cuts of excellent quality Postflow Release the trigger to stop the cutting arc Gas con tinues to flow for approximately 20 seconds During post flow if the user moves the trigger release to the rear and presses the trigger the pilot arc starts The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece Sh
28. 10 Set the FUNCTION CONTROL SWITCH to LATCH mode 11 Start a cut and release the torch switch Maincutting arc will remain ON until the torch is lifted away from the plate approximately 34 19 mm or until the torch is brought OFF the edge of the metal Once the arc has extinguished DCLED turns OFF After 20 second post flow time solenoid closes e Gas flow stops This completes the Main Arc and Controls Test If the above are all correct then proceed to the next section H CNC Interface Test If the unit does not function as stated above then note the symptom and proceed to Section 5 09 Main Arc and Controls Problems 5 10 Manual 0 5079 CNC INTERFACE TEST If theunithas one of the two factory supplied options for CNC interface installed proceed with this section otherwise the tests are complete 1 Connect an ohmmeter between J2 12 to J2 14 START signal Position the torch to pilot Check the OK TO MOVE signal by connecting a jumper between J2 3 and J2 4 START signal e Pilot arc is established Bring the torch to the work piece and transfer to cutting arc OK TO MOVE signalis present Meter shows continuity Remove jumper from J2 Arc shuts OFF OK TO MOVE signal OFF Meter shows no continuity e Gas continues to flow DC LED goes OFF After 20 second Post flow time Gas solenoid closes Gas flow stops If the unit has the Basic CNC Interface harness the test is c
29. 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele ment 3 Disconnect gas supply hose Manual 0 5079 CUTMASTER 20mm 4 Turnthe Filter Housing Cover counter clockwise and remove it The Filter Element is located inside the Housing Housing Filter Element Cat No 9 7741 Cat No 9 97743 Assembled Filter Cover o Barbed a5 Fitting g Art A 02476 Optional Single Stage Filter Element Replacement 5 Removethe Filter Element from the Housing and set Element aside to dry 6 Wipe inside of housing clean then insert the replacement Filter Element open side first 7 Replace Housing on Cover 8 Reattach gas supply NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage SERVICE CUTMASTER 20mm Optional Two Stage Filter Element Replacement The Two Stage Air Filter has two Filter Elements When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unac ceptable Refer to Section 6 Parts List for replacement filter element catalog number 1 Shut OFF primary input power 2 Shut OFF air supply and bleed down system WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could
30. 80 PSI XA 75 PSI X 3 70 PSI X 2 65 PSI X 1 MIN PRESSURE X 0 AC 1 X OVERTEMP 2 X GAS 3 X DC 4 X ERROR 5 X C LOGIC PCB TEST POINTS TP1 TP2 TP3 TP4 TP5 TP6 TP7 SERVICE Common 12VDC 5VDC 3 3DCV 0 5 to 5 VDC 0 100 psi 1 8VDC Potentiometer Current Demand 0 3 3VDC FIRMWARE VERSI 5 26 ERROR MESSAGE Over Pressure Internal Error Shorted torch Tip Missing Start Signal active during power up Parts In Place Fault PIP Input Power Fault Low Pressure Manual 0 5079 CUTMASTER 20mm This Page Intentionally Blank Manual 0 5079 5 27 SERVICE CUTMASTER 20mm 5 15 Main PCB Layout amp Signals PRI 3 D59 TIP1 ELECTRODE1 V_OUT1 Art 08518 AB J2 PINOUT DAL wer x MAIN PCB LAYOUT A MAIN PCB SIGNALS 71 2 71 3 11 4 J1 5 J2 J3 1 J3 2 SERVICE L1 Primary AC Line Not used Not used Not used L2 Primary AC Line Signal info is the same as Logic PCB 3 connector J1 230VAC Common 5 28 CHOKE1 SEC2
31. 9 0115 but the logic PCB as well Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting If there is a transducer and wire harness instead of the tube the kit is not needed Art A 08828 NOTE Illustration may vary slightly from unit Manual 0 5079 6 5 PARTS LIST CUTMASTER 20mm 6 08 Options and Accessories PNR RR jd fd Hi PARTS LIST Description Single Stage Filter Kit includes Filter amp Hose Replacement Filter Body Replacement Filter Hose not shown Replacement Filter Element Two Stage Filter Kit includes Hose amp Mounting Screws Bracket Filter Mounting not shown Two Stage Air Filter Assembly First Stage Cartridge Second Stage Cartridge Extended Work Cable 50 ft 15 2 m with Clamp Multi Purpose Cart Automation Interface Kit 25 7 6 m CNC Cable for Automation Interface Kit 35 10 7 m CNC Cable for Automation Interface Kit 50 15 2 m CNC Cable for Automation Interface Kit Nylon Dust Cover Filter Element Cat No 9 7741 sm E Cat No 9 95743 Assembled Filter Cover S Barbed Fitting Jg Art A 02476 Optional Single Stage Filter Kit log 7 7507 9 7740 9 7742 9 7741 9 9387 9 7527 9 1021 First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Kit Manual 0 5079 CUTM
32. AB B1399 RWH 05 05 09 Sute 300 Scale upersedes A THERMADYNE Company St Louis MO 63017 USA Date information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent Thursday March 27 2008 Drawn References NOTE UNLESS OTHERWISE SPECIFIED RWH 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk Sheet 1 of 1 TITLE SCHEMATIC Size DWG No Past Modified Wednesday May 08 2009 191829 CM52 82 12mm 20mm 25mm A40 A60 380 400 415 600Y 42X1329 3 z I 3 Manual 0 5079 A 7 APPENDIX CUTMASTER 20mm APPENDIX 6 Publication Histor Cover Date Rev Change s Jan 9 2009 AA Manual released May 29 2009 AB Updated 400V 600V schematic in appendix per ECOB1399 Feb 25 2010 AC Updated CNC cable part numbers in section 6 per ECOB1637 Aug 31 2010 AD Delete Logic PCB NOTE information in section 6 per ECOB1800 Feb 8 2011 AE Per ECOB1859 corrected Schematics with art number A 09131 and A 09133 to show proper Volts for Automation Interface PCB Mar 20 2012 AF Changed COO text per ECOB2149 Mar 26 2012 AG Updated CAP PCB catalog number page 6 5 per ECOB1502 April 25 2012 AH Updated ART A 07994 per ECOB2136 APPENDIX A 8 Manual 0 5079 This Page Intentionally Blank Denton TX USA U S Customer Care Ph 1 800 426 1888 Fax 1 800 535 055
33. Cap Drag CUTTING 40A 9 8244 40A CUTTING Tip Shield Cap Deflector 2 Y 9 8243 9 40A 9 8208 Standoff Guide 9 8251 STANDOFF CUTTING 50 60A Shield Cap Deflector TTIN f M 9 8243 Start Cartridge 50 55 9 8209 9 8213 60A 9 8210 d s STANDOFF CUTTING C DRAG SHIELD AT 2 Shield Cap Drag Electrode CUTTING i m Ci 70 100A 9 8236 9 8215 70 120A A ASE CUTTING ES Shield Cap Deflector 9 8243 Tips 70A 9 8231 80A 9 8211 Standoff Guide 90 100A 9 8212 9 8281 120A 9 8253 STANDOFF CUTTING 40 120A GOUGING Shield Cap Gouging 9 8241 Tip Gouging 9 8225 40 Amps Max Tip Gouging E 978226 100 Amps CutMaster 12mm uses 40A and less CutMaster 20mm uses 60A and less d Tip Gouging 9 8227 60 120 Amps CutMaster 25mm uses 80A and less CutMaster 35mm uses 100A and less Tip Gouging D 9 8228 60 120 Amps CutMaster 40mm uses 120A and less Tip Gouging E 9 8254 60 120 Amps Manual 0 5079 4T 9 OPERATION CUTMASTER 20mm 4T 08Recommended Cutting Speeds for SL60 Torch With Exposed Tip Im Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Standoff Pierce Height afee sese roles 1 5 9 8208 108 40 250 019 48 70 55 170 1 108 4o 19 55 wejes seme 70 55 40 40 40 40 3 ols Co y
34. Cup loose 2 Torch not properly connected to Refer to clearance information section 2 04 Allow unit to cool Return to authorized service center for repair or replacement Connect gas supply to unit Turn gas supply ON Set air supply inlet pressure to unit to 120 psi Adjust regulator to set air pressure see section 4 02 Return to authorized service center for repair or replacement Hand tighten the shield cup until it is snug Insure torch ATC is securely fastened to unit power supply 3 Problem in torch and leads PIP circuit 4 Failed components in unit Replace torch and leads or return to authorized service center or repair or replacement 4 Return to authorized service center for repair or replacement FAULT and 75 PSI indicators flashing 1 Start signal is active when ON OFF SWITCH is turned to ON position 1 Start can be active for one of the following Hand torch switch held closed Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Replace torch and leads or return to authorized service center or repair or replacement 3 Return to authorized service center for repair or replacement 2 Problem in the torch and leads switch circuit 3 Failed components in unit SERVICE 5 4 Manual 0 5079 CUTMASTER 20mm Problem Symptom Possible Cause Recommended Action is closed Or CNC START signal is active No gas f
35. 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 ricaine 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 ASSOCIES disponible aupr s de la National Fire Protection Asso ciation 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 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOU DAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES 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 SOUD
36. Manual 0 5079 CUTMASTER 20mm SECTION 5 SYSTEM SERVICE 5 01 General Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of torch tip and electrode NS Weekly AD TM mmm 7 gt Visually inspect the torch body tip Replace as needed electrode start cartridge and shield cup LZ 3 Months Replace all Clean broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 07938_AB Manual 0 5079 5 1 SERVICE CUTMASTER 20mm 5 02 Maintenance Schedule 5 03 Common Faults Problem Symptom Cause NOTE The actual frequency of maintenance may need to be adjusted according to the operating environ ment Daily Operational Checks or Every Six Cutting Hours 1 Check torch consumable parts replace if dam aged worn or when cut performance has dimin ished Insufficient Penetration Main Arc Extinguishes 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics parts used 7 Incorrect gas pressure 1 Cutting speed too slow 2 Torch standoff too high from Workpiece 2 Check pl d d ly and P pod EL 3 Cutting current too high 4 Work cable disconnected 3 Purge plasma gas line to remove any mois
37. RAR INRUSH W1 ON SHDN SOL SOL ON OK TO MOVE FAN ON LATCH ACTIVE SW PIP AC ON CSR TORCH SOL DETECTED OVERTEMP V IN 12VDC 12VDC GND GND Not Used Not Used MAIN BD ID Not Used Not Used Not Used Not Used For Factory Use For Factory Use For Factory Use For Factory Use GND For Factory Use Not Used Manual 0 5079 CUTMASTER 20mm Signal Source Destination Current demand signal Variable 1 4VDC Active low when in Rapid Auto Restart mode Active low after inrush time expires Active low to enable W1 contactor Active low enables PWM circuit Active low to enable Torch Solenoid Active low to enable Power Supply solenoid Active low to enable TO MOVE CNC Active low to enable fans Active low when Latch mode is active during cut Active low START is active Torch switch Active low PARTS IN PLACE satisfied Pulse signal Active high during main transfer Active low for torch with remote solenoid Active low when over temperature Input Voltage signal 2 6VDC 400 VAC Voltage level to identify Main PCB 1 7VDC 5 25 L M L M L M L M L M L M L M L M L M M L M L M L M L M L M L M L M L M L M L M L M L M L M L M L SERVICE CUTMASTER 20mm B LOGIC PCB LED INDICATORS RMAL INDICATI D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 12VDC MAX PRESSURE X 7 90 PSI X 6 85 PSI X 5
38. START signal is active low Release the START signal source 2 Problem in the torch and leads switch circuit a Check continuity of torch switch circuit at pins 3 amp 4 See previous illustration 3 Shortin CNC cable a Check continuity 4 Defective Logic PCB PCB 3 a Measure voltage at Main PCB between J2 16 to test point GND1 for 12VDC If voltage is present replace Logic PCB 5 Defective Main PCB a Replace Main PCB SERVICE CUTMASTER 20mm J TIP MISSING FAULT The FAULT Indicator and 80 PSI LED is flashing Gas solenoid cycles ON and OFF 1 TorchShield Cup is loose a Tighten shield cup by hand Do not over tighten 2 Torch tip electrode or starter cartridge missing a Turn OFF power supply Replace missing part s 3 Starter Cartridge is stuck a Turn OFF power supply Bleed down the sys tem Remove the shield cup tip start cartridge and electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not move freely Spring Loaded Lower End Fitting Full Compression Spring Loaded Lower End Fitting at Reset Full Extension Art A 08064 AC 4 Open conductor in torch leads a Check continuity 5 Defective Main PCB b Measure voltage at Main PCB between J2 2 to test point GND1 for 12VDC If voltage is present replace Main PCB 6 Defective Logic PCB a Replace Logic PCB K AC LED ON yellow TEMP LED is ON
39. avoid excessive pilot arc time to improve parts life 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 significantly affect the bevel angle Reducing standoff will generally result in a more square cut Manual 0 5079 Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not 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 cut ting 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 be ing 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 TM cue Angie Right Side Cut Angle A 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 dr
40. dee 3T 1 31 01 Torch ne AMAR EMA RAA a 3T 1 3T 02 Setting Up Mechanical Torch 3T 1 SECTION 4 SYSTEM OPERATION iiir eie betes elec 4 1 4 01 Front Panel Controls Features 4 1 4 02 Preparations for Operation oce rn e ore deter eR RE ede een 4 2 SECTION 4 Enea e a ant AT 1 4T 01 Torch Parts Selection AT 1 43 02 C t QUAY ttc estet eer rb ee does 4T 2 4T 03 General Cutting Information AT 2 4T 04 Torch Operation si AT 3 4105 GOUJO TI TO DTI ILLUM AT 7 4T 06 Mechanized Torch Operation 4T 8 4T 07 Parts Selection for SL60 Torch Cutting 4 9 4T 08 Recommended Cutting Speeds for SL60 Torch With Exposed Tip 4T 10 4T 09 Recommended Cutting Speeds for SL60 Torch With Shielded Tip 4T 13 PATENT INFORMATION tues nt eec peret ge hn genda 4T 15 TABLE OF CONTENTS SECTION 5 SYSTEM SERVICE iii 5 1 5 01 General Maintenance 2 5 1 5 02 Maintenance Schedule 5 2 5 03 ComM FAUS ascia 3 nt 5 2 5 04 Fault IndiGator so etn b e Ec une con Fe 5 3 5 05 Basic Troubleshooting Guide 5 4 5 06 Power Supply Basic Parts
41. from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard 249 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from Ameri can Welding Society 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPAStandard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards As sociation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4
42. it will not pull out 5 Reinstall the power supply cover Manual 0 5079 CUTMASTER 20mm D Air Regulator Replacement Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Remove the three 3 air hoses from the regulator per subsection 7 05 C 3 Pull the Air Regulator adjusting knob from the shaft 4 Loosenand remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 5 Install replacement Air Regulator by reversing the above steps 6 Reinstall the power supply cover E Gas Solenoid Replacement Tools required T20 Torx Driver Flat Screw Driver 1 Remove the cover per subsection 7 04 A 2 Disconnect J5 connector from the Main PCB 3 Remove the air hose from Gas Solenoid per sub section 7 05 C 4 The Solenoid utilizes the same type locking fit ting as the gas hoses Using a flat blade screw driver push the locking ring towards the Sole noid while pulling the Solenoid away from the ATC 5 Install the replacement Gas Solenoid by reversing the above steps 6 Reinstall the power supply cover F Logic PCB PCB 3 Replacement Tools required T20 Torx Driver Flat Screw Driver wrench 1 Remove the cover per subsection 7 04 A 2 Remove the two large and one small gas hoses from the pressure regulator per subsection 7 05 3 Unplug the connector J2 from the Main 4 Remove the Current Control Potentiometer Knob and
43. long For 50 15 2 m leads refer to section 4 02 Operating Pressure Total flow rate includes plasma and secondary gas flow 50 OPERATION 4T 14 Manual 0 5079 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U S and Foreign Patents as follows Patent s Catalog 9 8215 9 8213 9 8205 9 8206 9 8207 9 8252 9 8208 9 8209 9 8210 9 8231 9 8211 9 8212 9 8253 9 8225 9 8226 9 8227 9 8228 9 8241 9 8243 9 8235 9 8236 9 8237 9 8238 9 8239 9 8244 Catalog Manual 0 5079 Description Electrode Cartridge Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Shield Cap Shield Cap Shield Cap Shield Cap Shield Cup Shield Cap Shield Cap Shield Cap Description Other Pa 6703581 D504142 Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa t s Pending CUTMASTER 20mm US Pat No s 6163008 6987238 US Pat No s 6903301 6717096 6936786 D496842 D511280 D492709 D499620 Other Pat s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pe
44. red FAULT Indicator is flashing 1 Air flow through unit is restricted a Provide adequate airflow See Ventilation Clearance Requirements section 2 04 2 Exceeded duty cycle of the power supply a Allow unit to remain ON but at idle with fan running to cool power supply See Power Supply Specifications section 2 04 for duty cycle information SERVICE NOTE When the unit is turned ON the cooling fans MOT 1 amp 2 will remain OFF In earlier units MOT 1 will turn ON for one 1 second and then turns OFF The fans will turn ON when a START signal Torch Switch Remote Pendant switch or CNC START is active and will remain ON for ten 10 minutes after the START signal is removed If an over tem perature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condition is cleared 3 Fan s not turning a Measure voltage at plug between J7 1 to J7 2 and between J81 to J8 2 on Main PCB for 12VDC If voltage is present replace fan 4 Defective Main PCB a Measure voltage at plug between J7 1 to J7 2 and between J8 1 to J8 2 on Main PCB for 12VDC If voltage is missing at either recep tacle replace Main PCB 5 Defective Logic PCB a Replace Logic PCB L AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing Gas is not flowing 1 Gas supply not connected to unit a Connect gas supply to unit 2 Gas
45. remov ing the replacement PC board from its protective enclosure Disconnect primary power to the system before disassembling the torch torch leads or power supply enclosure Where these instructions include specific torquing instructions failure to torque properly will cause component damage Do not operate the equipment or test equipment un der power while wearing the grounding wrist strap Manual 0 5079 CUTMASTER 20mm Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Unroll the rest of the band and peel the liner from the copper foil at the opposite end Attach the copper foil to a convenient and ex posed electrical ground Connect the equipment primary cable ground to the same electrical ground as the wrist strap Open the equipment enclosure and remove the failed PC board Carefully open the ESD protective bag and re move the replacement PC Board Install the replacement PC Board in the equip ment and make all necessary connections Place the failed PC Board in the ESD protective bag and seal for return shipping Replace the power supply cover 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equip ment 7 03 Parts Replacement General Information The parts replacement procedures described in this manual except fo
46. reves R4 R3 R1 R2 Lx e C1 c2 y UM MTHS MTH8 MTH7 MTHS MTH6 MTH1 MTH3 4 MTH2 Art A 08841 J3 CONNECTOR PINOUT T 2 3 CAPACITOR PCB 2 LAYOUT A CAPACITOR PCB SIGNALS J1 1 Capacitor bank A J1 5 Capacitor bank A J2 1 Capacitor Bank J2 5 Capacitor Bank B Signal Source Destination J3 1 12 VDC M C J3 2 460 Active low for 460VAC input M C J3 3 230 Active low for 230VAC input M C SERVICE 5 22 Manual 0 5079 CUTMASTER 20mm B CAPACITOR PCB TEST POINTS MTH 1 2 Capacitor bank A MTH 3 4 Capacitor bank A MTH 6 8 Capacitor Bank MTH 5 7 Capacitor Bank B Manual 0 5079 5 23 SERVICE CUTMASTER 20mm 5 14 Logic PCB Layout amp Signals D1 TP6 A LOGIC PCB SIGNALS J1 1 OUT 11 2 TIP VOLTS J1 3 TIP_SEN J1 4 400V IN SERVICE R5 R32 R38 C16 c17 c18 R41 R51 R44 R39 R52 R46 ces R53 res R18 cs
47. rough cut will be produced as the arc moves from side to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle or around a corner slowing down the travel speed will result in a squarer cut The power source output should be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required Piercing With Machine Torch 4T 8 To pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the front end of the torch When operating with a cutting machine a pierce or dwell time is required Torch travel should not be enabled until the arc penetrates the bottom of the plate As motion begins torch standoff should be reduced to the recommended 1 8 1 4 inch 3 6 mm distance for optimum speed and cut quality Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Manual 0 5079 CUTMASTER 20mm 4T 07Parts Selection for SL60 Torch Cutting Tips DRAG TIP A Shield Cap Deflector CUTTING ant 9 8243 14 20 9 8205 30A 9 8206 40A 9 8207 mL o eee RE NOR CNN DRAG SHIELD 1 Shield
48. show a charging action Initially a low resistance will be shown and then the resistance will start to increase If the meter probes are reversed the reading will decrease to zero then start charging in the opposite polarity 2 Ifa short is found replace Capacitor PCB assem bly 3 Check continuity between the following points me Open wma Omm wma wms Open 4 Ifa shortis found replace Capacitor PCB assem bly D IGBT Modules Test 1 Disconnect transformer wires from Main PCB 1 terminals PRI 1 A and PRI 4 D 2 Using anohmmeter perform the following checks IGBT A Meter Meter Indication PRI 1 A MTH2 Forward Bias PRI 1 A MTH4 Reverse Bias MTH 2 PRI 1 A MTH 4 PRI 1 A PRI 2 B MTH 2 PRI 2 B 4 MTH 2 PRI 2 B MTH 4 PRI 2 B Reverse Bias Forward Bias Forward Bias Reverse Bias Reverse Bias Forward Bias Manual 0 5079 CUTMASTER 20mm IGBT B Meter PRI 3 C PRI 3 C MTH 6 Meter MTH 6 MTH 5 PRI 3 C PRI 3 C MTH 6 MTH 5 Indication Forward Bias Reverse Bias Reverse Bias MTH 5 PRI 4 D PRI 4 D MTH 6 PRI 4 D MTH 5 PRI 4 D 3 If the test reveals a failed component replace Main PCB and perform main contactor test Sec tion 5 11 A If no problem is found reconnect the transformer wires to Main PCB 1 Forward Bias Forward Bias Reverse Bias Reverse Bias Forward Bias E Output Diode Modul
49. supply not turned ON a Turn gas supply ON 3 Gas supply pressure too low a Set gas supply pressure to 95 120 psi 4 Air Pressure Control Regulator set too low a Adjust AIR PRESSURE CONTROL to set pressure as specified in section 4 02 Setting Operational Pressure M INTERNAL ERROR FAULT Indicator and 90 PSI Indicator flashing 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error Manual 0 5079 MAX PRESSURE ERROR MAX Pressure LED is lit 1 Gas pressure set too high a Reduce gas pressure 2 Defective Logic PCB a Replace Logic PCB O AC LED ON TEMP LED OFF GAS LED ON Gas does not flow in SET mode using a hand torch or a machine torch without remote solenoid 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage is present change SOL 1 2 Defective Logic PCB a Measure on Main PCB between J2 12 to test point GND1 for 12 If voltage is present replace Main PCB 3 Defective Main PCB a Replace Main PCB P AC LED ON TEMP LED OFF GAS LED ON Gas does not flow in SET mode using a machine torch with remote solenoid Disconnect the gas solenoid SOL1 from the back of the ATC connector If Gas DOES NOT flow out of SOL1 when the unit is in SET mode 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage is pres
50. unit leaks between housing and cover inspect the O ring for cuts or other damage Manual 0 5079 7 08 Right Side Internal Parts Replacement A Capacitor PCB PCB 2 Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Remove the eight screws securing PCB 2 to the Main PCB Install the replacement PCB by reversing the above steps B Main PCB PCB 1 Replacement Tools required T20 Torx Driver 1 2 9 Remove the Cover per subsection 7 04 A Remove the two large gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 5 05 E Remove Capacitor PCB per subsection 7 08 A Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector Remove the four 4 mounting screws securing the PCB to the center chassis Carefully guide the PCB assembly up and out of the unit Install the replacement PCB by reversing the above steps Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Remove all wires from W1 noting the location and orientation of each wire Loosen the two 2 Torx head screws securing the Main Contactor to the base Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mount ing screws Lift Main Contactor up and out of the unit Insta
51. you feel the threads line up then begin to turn the screw clockwise to tighten Do not over tighten PARTS REPLACEMENT C Tube Handle Replacement Tools required T20 Torx Driver 1 2 3 6 Disconnect the Torch and Leads from the unit Remove the cover per subsection 7 04 A Remove the screws securing the tube handles to the base of the unit NOTE Some of the earliest manufactured units have Tube Handles that are joined together under the base of the unit Later versions are not joined together 4 Remove the power supply from the Tube Han dles Replace the Tube Handles by reversing the above steps Reinstall the power supply cover D Disconnecting Front and Rear Panels from the base In many of the replacement procedures it may be help ful to disconnect the front or rear panel from the base in order to allow more room to access the parts Tools required T20 Torx Driver 1 2 Remove the cover per subsection 7 04 A For earlier models remove the Tube Handles per subsection 7 04 C The earlier model Tube Handles join together under the base Later mod els do not and there is enough room to perform this procedure without removing them While grasping the panel close to the base pull the panel directly from the base to release the locking tabs Tore engage the panel position the panel so that the locking tabs are above the base then push the panel back onto the base until the lockin
52. 01 Notes Cautions and Warnings 1 1 02 Important Safety 1 1 03 PUDIICAUIONS HR nn eles ate 2 1 04 Note Attention et Avertissement 3 1 05 Precautions De Securite Importantes 3 1 06 Documents De Reference is 5 1 07 Declaration of Conformity ss 6 1 08 Statement of Warranty si 7 SECTION 2 SYSTEM INTRODUCTION ini 2 1 2 01 How To Use This Manual rentre cement 2 1 2 02 Equipment Ideritification iuit era etae tte ouv t Federer pee arn de 2 1 2 03 Receipt OF Equipment rooien n o ci etn Po 2 1 2 04 Power Supply Specifications entree 2 2 2 05 Input Wiring Specifications 0 22 1 0 2 3 2 06 Power Supply FeatUres terit create erecti bus kate 2 4 SECTION 2 TORCH INTRODUCTION iii 2T 1 2T 01 Scope of Manual 2T 1 2T 02 General Description 2T 1 21 03 Specifications ere 2T 1 2T 04 Options And Accessories 2T 2 21 05 Introduction to Plasma tenaient A 2T 2 SECTION SYSTEM INSTALLATION iii 3 1 3 01 WIA PACKING 3 1 3 02 Lifting Options e HR 3 1 3 03 Primary Input Power Connections 3 1 3 04 Gas Connections iii 3 2 SECTION S TORCH INSTALLATION astra di t n ede
53. 1 RECOM MENDED 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 15 ANSI Standard 288 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 5079 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me A ATTENTION Toute proc dure pouvant r sulter l eandommagement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute 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 A AVERTISSEMENT Fournit l information concernant des dommages possibles de choc lectrique Des avertissements seront enferm s dans une bo te de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE A L ARC AU JET DE PLASMA PEUVENT PRE
54. 7 tollfree 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 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 THERMADYNE A Global Cutting amp Welding Market Leader U S Customer Care 800 426 1888 rax 800 535 0557 Canada Customer Care 905 827 4515 rax 800 588 1714 www thermal dynamics com International Customer Care 940 381 1212 rax 940 483 8178 Form No 63 12xx 01 25 12 2012 Thermadyne Industries Inc www thermadyne com Printed in Mexico
55. AGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Manual 0 5079 14 15 CUTMASTER 20mm Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM MANDATIONS 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 INFORMATIONS G N RALES CUTMASTER 20mm 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive 2006 95 EC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC 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 a unit and date of manufacture National Standard and Technical Specificati
56. ASTER 20mm 6 09 Replacement Parts for Hand Torch Item Description Catalog 1 1 Torch Handle Replacement Kit includes items No 2 amp 3 9 7030 2 1 Trigger Assembly Replacement Kit 9 7034 3 Handle Screw Kit 5 each 6 32 x 1 2 cap screw and wrench 9 8062 4 1 Torch Head Assembly Replacement Kit includes items No 5 amp 6 9 8219 5 1 Large O Ring 8 3487 6 1 Small O Ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 SL60 20 foot Leads Assembly with ATC connector 4 7834 1 51 60 50 foot Leads Assembly with ATC connector 4 7835 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 9 7031 10 1 Torch Control Cable Adapter includes item 11 7 3447 11 1 Through Hole Protector 9 8103 Art 07993 Manual 0 5079 6 7 PARTS LIST CUTMASTER 20mm 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Item No Oty Description Catalog No 1 1 Torch Head Assembly without leads includes items 2 3 and 14 9 8220 2 1 Large O Ring 8 3487 3 1 Small O Ring 8 3486 4 1 PIP Switch Kit 9 7036 5 Unshielded Automated Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7850 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7851 1 25 foot 7 6 m Leads Assembly with ATC connector 4 7852 1 50 foot 15 2 m Leads Assembly
57. C 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 lectrique 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 INFORMATIONS G N RALES CUTMASTER 20mm A INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d a l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre 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
58. IHERMAL DYNAMICS 20m In CUTMASTER PLASMA CUTTING SYSTEM IHERMAL DYNAMICS 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 agency call 1 800 426 1888 or visit us on the web at www thermal dynamics com This Operating 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 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 Thermadyne Industries 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 a
59. Shield Cap Drag NX 70 100A 9 8236 Shield Cap Deflector 1 9 8243 90 100 9 8212 120 9 8253 STANDOFF CUTTING 40 120A GOUGING Tip Gouging 9 8225 40 Amps Max Tip Gouging 9 8226 50 100 Amps Tip Gouging 9 8227 60 120 Amps Tip Gouging 9 8228 60 120 Amps Tip Gouging 9 8254 60 120 Amps Standoff Guide 9 8281 Shield Cap Gouging 9 8241 CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less Manual 0 5079 SECTION 7 REPLACEMENT PROCEDURES 7 01 Scope This section describes parts replacement procedures which may be performed on the CutMaster 20mm Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 7 02 Anti Static Handling Procedures A CAUTION PC Boards can be irreparably damaged by improper handling due to electrostatic discharge ESD A General Replacement PC Boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping A ground strap is included with each replacement board to prevent static damage during installation WARNING Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or
60. To Remote Control Power Supply with ATC Female Receptacle Remote Pendant Connector ATC Female Receptacle Male ATC Leads Connector EN _ _ _ _ Power NEN Torch Supply Head Leads PIP O Black Switch To Power Supply O Orange Circuitry 0 White Not MEN Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry gt BB O1 Pilot Art A 08577 APPENDIX 4 Manual 0 5079 CUTMASTER 20mm C Automation Torch Connection Diagram Automated CutMaster Power Supply with ATC Torch Receptacle Automated SL100SV Torch w Solenoid on Positioning Tube Torch Lead with ATC Connector ATC Male ATC Female Torch Leads Connector Torch Receptacle 1 Torch Head 1 Torch Leads D Power Supply j Pin No s PIP Black 1 401 21 Main PC Board White pee 5 Main PC Board Green 7 Main PC Board Not Connected Negative Plasma Lead Pilot Lead i Not Connected Art A 07115 Manual 0 5079 A 5 APPENDIX CUTMASTER 20mm APPENDIX 5 SYSTEM SCHEMATI 400 415V UNIT
61. aded Lower End Fitting Full Compression Spring Loaded Lower End Fitting at Reset Full Extension Art A 08064 AC 3 Worn or faulty torch parts a Inspect torch consumables parts Replace if necessary 4 Shorted Torch a Disconnect torch from unit With consumables removed from the torch check continuity of torch at ATC between negative plasma lead connection to pilot lead connection Negative Plasma Lead Torch Switch owltc 2 5 1 PIP Pilot Lead Art A 08124 Manual 0 5079 C ACLED ON TEMP LED OFF GAS LED ON gas flowing DC LED OFF Fault Indicators OFF No arc in torch l Defective Logic PCB 3 a Measure voltage at Main PCB between test point GNDI to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after torch switch is de pressed If voltage does not drop replace Logic PCB b While pilot arc is established measure voltage on Main PCB 1 between test points GND1 to I_DMD1 for 1 4 VDC If voltage is low or not present replace Logic PCB 2 Defective Main PCB 1 a Measure voltage at Main PCB 1 between test point GND1 to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after torch switch is depressed If voltage does not drop to less than 2VDC for approximately one 1 second then replace Main PCB D AC LED ON TEMP LED OFF GAS LED ON gas
62. ale receptacle Push the male connector into the female receptacle The connectors should push together with a small amount of pressure 2 Secure the connection by turning the lock ing nut clockwise until it clicks DO NOT use the locking nut to pull the connection together Do not use tools to secure the connection Om Art A 07885 f Connecting the Torch to the Power Supply 3 The system is ready for operation Manual 0 5079 To test the quality of air 1 Put the OFF O switch in the up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn on the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02Setting Up Mechanical Torch NOTE An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine torch A WARNING Disconnect primary power at the source before disassembling the torch or torch leads The mechanical torch includes a positioning tube with rack and pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the sur face of the workpiece 3T 1 INSTALLATION CUTMASTER 20mm Pinch Block Assembly Workpiece A 02585 Mechanical Torch Set Up 3 The proper torch parts shield cup
63. ar 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 OPERATION 4T 2 Bottom Dross Buildup Molten material which 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 4T 03General Cutting Information WARNING Disconnect primary power at the source be fore 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 operator s 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 Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible
64. asma cutting process can be dangerous and hazardous to your health Manual 0 5079 CUTMASTER 20mm 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 on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the 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 explosive 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 ch
65. atic File Number Rated Supply Voltage Note 2 Degree of Protection NOTES 1 2 APPENDIX Symbol shown indicates single or three phase AC input static frequency converter transformer rectifier DC output Indicates input voltages for this power supply Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built Top row Duty cycle values IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission TDC duty cycle value is determined under the power supply manufacturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values Sections of the Data Tag may be applied to separate areas of the power supply A 2 and Revision Level Standard Symbols AC DC 0 Art 03288 Manual 0 5079 CUTMASTER 20mm APPENDIX 3 TORCH PIN QUT DIAGRAM A Hand Torch Pin Out Diagram ATC Male Connector Green EN 8 Open 8 Ground Bun ESN M 4 Switch T B wet 3 White n e 7 Open p IAN J Swich TEE 2 o oven T 22 e 2 PIP AN c Metre 4 5 Open 5 Open SZ lot A 03701 ATC Female Receptacle Front View Negative Plasma lt
66. 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 Le 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 RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc 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 ne 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 perso
67. dividual wires 4 Pass the cable being used through the input cable opening strain relief in the back panel of the power supply Refer to Sec tion 2 for power cable specifications A CAUTION The primary power source and power cable must conform to local electrical code and the recom mended circuit protection and wiring require ments refer to table in Section 2 3 1 INSTALLATION CUTMASTER 20mm 5 Connect the wires as follows For non CE units wn TA f Art A 08753 Terminal d e Three phase wires to L1 L2 and L3 on the W1 contactor It does not matter what order these wires are attached See previous illustration and on label in the power supply e Green Yellow wire to Ground Termi nal For CE units EMC Input Power Filter Art A 08752_AA e Three phase wires to L1 L2 and L3 on the CE Input Power Filter It does not matter what order these wires are at tached See previous illustration and on label in the power supply e Green Yellow wire to Ground 6 With a little slack in the wires tighten the strain relief to secure the power cable 7 Reinstall the Power Supply cover per in structions found in section 5 8 Connect the opposite end of individual wires to a customer supplied plug and plug into an appropriate input power receptacle or connect directly to main disconnect 9 Close the main disconnect switch to supply power to the unit INSTALLATION 3 04 Gas Connec
68. e Test 1 Disconnect transformer wires from Main PCB terminal SEC 1 2 Using ohmmeter perform the tests in the chart Output Diode Module Meter Meter Indication SEC 1 WORK 1 Forward Bias SEC 1 CHOKE 1 WORK 1 SEC 1 SEC 1 WORK 1 CHOKE 1 SEC2 SEC 2 3 If the test reveals a failed component replace Main PCB If no problem is found reconnect the transformer wires to Main PCB Reverse Bias Reverse Bias Forward Bias Forward Bias CHOKE 1 SEC 2 SEC2 WORK 1 CHOKE 1 Reverse Bias Reverse Bias Forward Bias SERVICE CUTMASTER 20mm F Pilot IGBT Test 1 Disconnect wire from Main PCB terminal TIP1 2 Measure continuity on Main PCB between test point GND1 to terminal 3 If the test reveals a failed component replace Main PCB If no problem is found reconnect wire to Main PCB Signal Information Many of the signal listed will be low voltage signals that will be in one of two states 12VDC High or OVDC Low with respect to PCB common When a signal name is preceded by the mark it denotes that the signal is an active low For example OVERTEMP This signal is normally High but when an over temperature fault exists this line will change state to a Low SERVICE 5 20 Manual 0 5079 CUTMASTER 20mm This Page Intentionally Blank Manual 0 5079 5 21 SERVICE CUTMASTER 20mm 5 13 Capacitor PCB Layout amp Signals J3 FT 02 PLI 4 33 HNR
69. e torch perpen dicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start b For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiece as shown below OPERATION CUTMASTER 20mm Torch Shield Cup Standoff Distance 1 8 3 8 3 9mm Standoff Distance 3 Hold the torch away from your body 4 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start Trigger Release A 02986 5 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch OPERATION Trigger 4 P 6 Cut as usual Simply release the trigger assembly to stop cutting 7 Follow normal recommended cutting practices as provided in the power supply operator s manual NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components 8 Fora consistent standoff height from the workpiece install the standoff guide by sliding it onto the torch s
70. eed depends on material thickness and the operator s ability to accurately follow the desired cut line The following factors may have an impact on system performance 4T 6 Torch parts wear Air quality Line voltage fluctuations Torch standoff height Proper work cable connection Manual 0 5079 4T 05Gouging WARNING Be sure the operator is equipped with proper gloves clothing eye and ear protection and that all safety precautions at the front of this manual have been followed Make sure no part of the operator s body comes in con tact with the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power Supply A CAUTION Sparks from plasma gouging can cause damage to coated painted or other surfaces such as glass plastic and metal Check torch parts The torch parts must correspond with the type of operation Refer to Section 4T 07 Torch Parts Selection Gouging Parameters Gouging performance depends on parameters such as torch travel speed current level lead angle the angle between the torch and workpiece and the distance between the torch tip and workpiece standoff A CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear Torch Travel Speed NOTE Refer to Appendix Pages for additional infor mation as related to the Power Supply used Optimum torch travel speed is d
71. eleased after main arc transfer RESULT Gas flow stops ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts PILOT ARC ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfers Pilot arc off ACTION ACTION Unplug input power cord or open external disconnect ON OFF switch to OFF O RESULT RESULT All indicators off No power to system Power supply fans shut off Art 08793 A 1 APPENDIX CUTMASTER 20mm APPENDIX 2 DATA TA INFORMATION IHERMAL Dy NAMICS West Lebanon NH USA 03784 Manufacturer s Name and or re ee Logo Location Model and Model S N Revision Level Serial Number Date of Mr Made in USA and Production Code Type of Power 43 Regulatory Standard Covering Supply Note 1 He This Type of Power Supply Output Duty Cycle Factor Output Range Amperage 2 Voltage Plasma Cutting Symbol TT X Duty Cycle Data Note 3 U2 Rated No a Conventional Load Voltage Load Voltage Rated Maximum Supply Current Input Power Symbol U1 4g max 30 19 gg Maximum Effective jx Supply Current Input Power Specifications Phase AC or DC Hertz Rating 1 Manufacturer s Electrical Schem
72. emicals 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 A 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 A 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 material in the workplace Any material that cannot be removed must be protected GENERAL INFORMATION CUTMASTER 20mm e Ventilate all flammable or explosive vapors from the workplace e Do not cut or weld on containers that may have held combus tibles Provide a fire watch when working in an area where fire hazards may exist e Hydrogen gas may be formed and trapped under aluminum workpieces when t
73. en transfers to the workpiece through the column of plasma gas in Zone C Power Supply A le i B Workpiece A 00002 Typical Torch Head Detail By forcing the plasma gas and electric arc through a smallorifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arcis 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 Manual 0 5079 CUTMASTER 20mm B Gas Distribution E Parts In Place PIP The single gas used is internally split into plasma The torch includes Parts In Place PIP circuit and secondary gases When the shield cup is properly installed it closes a switch The torch will not operate if this switch The plasma gas flows into the torch through the is open negative lead through the starter cartridge around P c the electrode and out through the tip orifice Torch Switch Torch Trigger t The secondary gas flows down around the outside C a e Wiring 9 6 of the torch starter cartridge and out between the bre tip and shield cup around the plasma arc PIP Switch Shield Cup O Pilot Arc Parts
74. ens as suggested in the following per ANSI ASC 749 1 Minimum Protective Suggested Arc Current hade No hade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece Pb LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq GENERAL INFORMATION 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 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 Government Printing Office Washington D C 20402 4 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 5 ANSI Standard 241 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable
75. ent change SOL 1 2 Defective Logic PCB a Measure on Main PCB between J2 12 to test point GND1 for 12 If voltage is present replace Main PCB 3 Defective Main PCB a Replace Main PCB If gas DOES flow out of SOL1 when the unit is in SET mode reconnect SOL1 to the ATC connector 4 Defective torch solenoid a Measure the coil terminals of the torch mount ed gas solenoid SOL2 for 24VAC If present replace SOL2 Manual 0 5079 CUTMASTER 20mm 5 Defective Main PCB a Measure on Main PCB between J2 20 to GND1 for less than 2VDC If voltage is 12VDC replace Main PCB b Measure on Main PCB between J2 11 to GND1 for less than 2VDC If voltage is less than 2VDC replace Main PCB 6 Defective Logic PCB a Measure on Main PCB between 2 11 to GND1 for less than 2VDC If voltage is 12VDC re place Logic PCB Q Cannot adjust gas pressure in the SET mode 1 Inlet gas pressure is too low a Increase inlet gas pressure to 95 120 psi 2 Faulty regulator a Replace Regulator SERVICE CUTMASTER 20mm 5 09 Pilot Arc Problems A AC LED ON TEMP LED OFF GAS LED ON Nothing happens when torch switch or remote switch is closed Or CNC START signal is active No gas flow DC LED OFF 1 Problem in the torch and leads switch circuit or remote pendant or CNC signal missing a For hand torches check continuity of torch switch circuit at ATC pins 3 amp 4 Negative Plasma Lead 3 Torch Switch uns
76. ent Control and Function Control Knobs 9 8527 2 1 Toggle On Off Switch SW1 9 0109 3 1 Work Cable with Clamp 20 Ft 6 1 m 9 0184 Not Shown 1 Wire harness from SW1 w EMI Choke CE Power Supplies Only 9 0247 Art A 08123 Illustration may vary slightly from unit Manual 0 5079 6 3 PARTS LIST CUTMASTER 20mm 6 06 Left Side Replacement Parts Item Description 1 1 Main PCB Assembly 2 1 Logic PCB 3 1 Center Chassis Molded Plastic 4 1 Fan 5 1 Transformer Main 6 1 Inductor Output Not Shown 1 1 T gl MI Illustration may vary slightly from unit PARTS LIST Power Cable Strain Relief for all units Input Power Cord for 380 400 415V Power Supply Ref log PCB1 9 0108 PCB3 9 0107 9 0102 1 2 9 0104 JT 9 0106 L1 9 0105 9 0111 9 0218 Art A 08122 Manual 0 5079 CUTMASTER 20mm 6 07 Right Side Replacement Parts Item Description Ref log 1 1 Contactor 4 Pole W1 9 8587 2 1 Solenoid 12V SOL1 9 0114 3 1 Spare Parts Box 7 3267 4 1 Spare Parts Box Cover 7 3266 5 1 Console Quick Disconnect 9 0161 6 1 Regulator with knob and mounting nut 9 0115 7 1 Assembly PCB Input Capacitors PCB2 9 0475 8 1 Filter Auto Drain 9 0116 NOTE 9 0115 regulator If the serial number of the power supply is prior to 205078755 then kit number 9 0201 will be needed to replace not only the regulator
77. ependent on current setting lead angle and mode of operation hand or machine torch Current Setting Current settings depend on torch travel speed mode of operation hand or machine torch and the amount of material to be removed Manual 0 5079 CUTMASTER 20mm Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed The recommended lead angle is 35 Ata lead angle greater than 45 the molten metal will not be blown out of the gouge and may be blown back onto the torch If the lead angle is too small less than 35 less material may be removed requiring more pass es Insome applications such as removing welds or working with light metal this may be desirable 35 Torch Head Standoff Height Workpiece A 00941 AB Gouging Angle and Standoff Distance Standoff Distance The tip to work distance affects gouge quality and depth Standoff distance of 1 8 1 4 inch 3 6 mm allows for smooth consistent metal removal Smaller standoff distances may result in a severance cut rather than a gouge Standoff distances greater than 1 4 inch 6 mm may result in minimal metal removal or loss of transferred main arc Slag Buildup 4T 7 Slag generated by gouging on materials such as car bon and stainless steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to
78. erruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 Thermal Dynamics 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 Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 5079 7 GENERAL INFORMATION CUTMASTER 20mm This Page Intentionally Blank GENERAL INFORMATION 8 Manual 0 5079 SECTION 2 SYSTEM INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page 1 To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows NOTE An operation procedure or background infor mat
79. est Procedures A Main Contactor W1 Test 1 Check continuity between L1 to T1 L2 to T2 L3 to T3 L4 to T4 The contacts should be open no continuity SERVICE Cover Screws Actuator Button Side Art A 08794 Retest continuity between terminals while engag ing the contacts manually This can be done by pushing down on the recessed actuator button on the top of W1 or pushing down on the actuator arm on the side of W1 L1 to T1 L2 to T2 L3 to T3 L4to T4 The contacts should be closed Continuity 3 2 Visually check W1 contact points To take the cover OFF remove the two cover screws shown in the previous illustration Replace if contacts are stuck together or show excessive arcing B Input Diode Module Test 1 Using an ohmmeter perform the tests in the chart Input Diode Module Meter Meter Indication AC1 Forward Bias 2 Forward Bias AC3 Forward Bias MTH 2 Reverse Bias MTH 2 Reverse Bias MTH 2 Reverse Bias MTH 5 Forward Bias MTH 5 Forward Bias MTH 5 Forward Bias AC1 Reverse Bias AC2 Reverse Bias AC3 Reverse Bias If the test reveals a failed component replace Main PCB and perform main contactor test Sec tion 5 11 A Manual 0 5079 C Input Capacitor PCB Test 1 Using an ohmmeter check continuity between the following points Input Capacitors Meter Meter Indication MTH4 Charging MTH 5 Open MTH5 Charging MTH 2 MTH4 MTH 6 Most meters will
80. f the unit Remove the two screws securing the Main Trans former to the base Manual 0 5079 14 15 16 Remove the Main Transformer carefully guiding all its wires through from the right side of the unit Install replacement Transformer by reversing the above steps Reinstall the power supply cover C Output Inductor L1 Tools required T20 Torx Driver gt Nut Driver 1 2 9 10 11 12 13 14 15 16 17 Remove the Cover per subsection 7 04 Remove the Tube Handle per subsection 7 04 C Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 E Disconnect J2 amp J3 connectors from Main PCB Disconnect Output Inductor wire from terminal Chokel on the Main PCB Disconnect Output inductor wire from ATC con nector Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief Disengage the Rear panel from the base per sec tion 7 04 D Guide the rear panel back six 6 inches away from the base Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit Remove the two screws securing the Output Inductor to the base Remove the Output Inductor carefully guid
81. flowing DC LED ON Fault Indicators OFF No arc in torch 1 Defective Main PCB 1 a Install jumper on Main PCB 1 between test point GND1 to terminal b Close torch switch If Pilot starts replace Main PCB E AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicators OFF Pilot Arc is intermittent 1 Defective Logic PCB a Measure for 12VDC on Main PCB between test Point GND1 to J2 8 If 12VDC is present replace Logic PCB 3 2 Defective Main PCB 1 a Replace Main PCB 1 F INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error Manual 0 5079 5 17 CUTMASTER 20mm 5 10 Main Arc and Controls Problems A Main arc will not establish LED D59 on Main PCB remains ON while pilot arc is striking the work piece 1 Work Cable not connected a Connect cable to work piece 2 Work cable open broken a Check continuity of work cable Insure con nection of cable to clamp is secure B Main arc transfers but current cannot be adjusted 1 Defective Logic PCB 3 a While main arc is transferred measure volt age on Main PCB between test points GND1 toI DMDI S Adjust CURRENT CONTROL POTENTIOM ETER from maximum to minimum Voltage should vary from 4VDC at max to 1 VDC at min If voltage does not vary with CURRENT CONTROL POTENTIOMETER
82. fore disassembling the torch or torch leads ATC Male Connector DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air A CAUTION Art 03791 E O Ring Dry the torch thoroughly before reinstalling ATC O Ring O Ring Lubrication NOTE DO NOT use other lubricants or grease they may not be designed to operate within high tempera tures or may contain unknown elements that may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life An o ring on the Torch Head and ATC Male Connec tor requires lubrication on a scheduled basis This will allow the o rings to remain pliable and provide a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to potential performance problems It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o rings on a weekly basis Manual 0 5079 5T 1 SERVICE CUTMASTER 20mm 5T 02Inspection and Replacement 4 Remove the tip Check for excessive wear i
83. from torch check upper O Ring wrong position 2 Torch start cartridge is stuck 3 Worn or faulty torch parts 4 Shorted Torch position correct if necessary 2 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 3 Inspect torch consumable parts Replace if necessary 4 Replace torch and leads or return to an authorized service center for repair 1 Low output voltage during pilot 1 Low output voltage during pilot 2 Low output voltage during cut 2 Low output voltage during cut 3 For Automation Torch only Tip 5 For Automation Torch only Tip contacted work piece during contacted work piece during cut with output correct set above 45 amps 1 Internal Error 1 Work cable not connected to Work piece 2 Work cable connector broken 3 Failed components in unit 1 Incorrect current setting 2 Worn torch consumables 3 Poor work cable connection to Work piece 4 Torch being moved too fast 5 Excessive oil or water in torch 6 Failed components in unit cut with output correct set above 45 amps 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized service center 1 Connect work cable 2 Replace work cable 3 Return to an authorized service center for repair 1 Check and adjust t
84. fully pull the Cover up and away from the unit 5 8 Manual 0 5079 B Cover Installation 1 Reverse previous procedures for cover installa tion NOTE When installing the upper screws attempt to reuse the original threads The easiest way to do this is by turning the screw counter clockwise until you feel the threads line up then begin to turn the screw clockwise to tighten to 15 18 in lbs Do not over tighten C Pre Power Up Tests Prior to applying primary line power to the unit perform the following checks to prevent component failure or blowing primary fuses The troubleshoot ing guide will assume these tests were done and no failure was found or that any failures found were corrected Main Contactor W1 Check Section 5 1 A Input Diode Module Test Section 5 12 B Input Capacitor PCB Test Section 5 12 C Output Diode Module Test Section 5 12 E 1 2 3 4 IGBT Modules Test Section 5 12 D 5 6 Pilot IGBT Test Section 5 12 F If all of the Pre Power Up Tests are OK proceed with the trouble shooting guide A CAUTION Due to the close proximity of the Main PCB to the Capacitor PCB It is recommended to use an insu lated meter probe when making measurements on the J2 connector on the Main PCB Do not short between the pins Do not short to the Capacitor PCB connections D Initial Set up Conditions This section is to help isolate the defective circuit before troubleshooting identify s
85. g tabs engage the mating holes in the base For complete removal of panel disconnect any other item still attached to the panel and another component of the power supply Manual 0 5079 7 05 Front Panel Parts Replacement Refer to section 6 05 for Front Panel Replacement Parts and overall detailed drawing A Current Control Potentiometer A Knob Replacement Tools required Flat Screw Driver 1 Turn the potentiometer fully clockwise and note the location of the pointer mark on the knob 2 Loosen the screw securing the Current Control Knob to the potentiometer shaft and remove the knob 3 Replacethe knob on the potentiometer shaft with the pointer in the same position as noted in step 1 B Function Control Switch Knob Replacement Tools required Flat Screw Driver 1 Turn the Function Control Switch until the pointer on the knob is in the LATCH position 2 Loosen the screw securing the knob to the switch shaft and remove the knob 3 Replace the knob on the switch shaft with the pointer in the position noted in step 1 C Replacing Gas Hoses Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Push the gas fitting locking ring back A small open end wrench works well for this 1 2 3 3 Pull the hose from the fitting Art A 08150 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pull ing on the hose If done correctly
86. hey 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 e Noise levels should be measured to be sure the decibels sound do not exceed safe levels e Forinformation on how to test for noise see item 1 in Subsec tion 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red 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 e Wear welding gloves and suitable clothing to protect 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 l
87. hield cup Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc During operation posi tion the legs of the standoff guide against the workpiece E Shield Cup e Standoff Guide 7 Torch N 7 Workpiece Art A 04034 4 4 Manual 0 5079 Shield Cup With Straight Edge The drag shield cup can be used with a non conduc tive straight edge to make straight cuts by hand A WARNING The straight edge must be non conductive Non Conductive Straight Edge Cutting Guide A 03539 Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less NOTE For best parts performance and life always use the correct parts for the type of opera tion 1 Install the drag cutting tip and set the out put current 2 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 holding technique that feels most comfort able and allows good control and move ment 4 Keep the torch in contact with the work
88. ight indicates power supply is ready for operation Blinking light indicates unit is in pro tective interlock mode Shut unit OFF shut OFF or disconnect input power correct the fault and restart the unit Refer to Section 5 for details Manual 0 5079 CUTMASTER 20mm Art A 07886 5 6 7 8 9 10 Temp Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Let the unit cool before continuing operation Gas Indicator Indicator is ON when minimum input gas pressure for power supply operation is present Minimum pressure for power supply operation is not sufficient for torch operation DC Indicator Indicator is ON when DC output circuit is active b Fault Error Indicator Indicator is ON when Fault circuit is active See sec tion 5 for explanations of fault lights 10 Pressure Indicators Art A 08170 The Indicators will illuminate according to the pressure set by the Pressure Control Knob number 4 OPERATION CUTMASTER 20mm 4 02 Preparations for Operation At the start of each operating session A WARNING E Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies Torch Parts Selection Check the torch for proper assembly and appropri ate torch parts The torch parts must correspond with the type of operation and
89. ion which requires additional emphasis or is helpful in efficient operation of the system A 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 op erating area A WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box such as this Additional copies of this manual may be purchased by contacting Thermadyne at the address and phone number in your area listed in the inside back cover of this manual Include the Service Manual number and equipment identification numbers Manual 0 5079 CUTMASTER 20mm Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link http www thermal dynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a data tag attached to the rear panel Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely attached card or the shipping container Record these numbers on the bottom of page i for future reference 2 03 Receipt Of Equipment When you recei
90. ions operating instructions and maintenance procedures for the I Torch Models SL60 Manual and SL100 Mecha nized Plasma Cutting Torches Service ofthis equip ment is restricted to properly trained personnel unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual at the risk of voiding the Warranty Read this manual thoroughly A complete under standing ofthe characteristics and capabilities of this equipment will assure the dependable operation for which it was designed 2T 02General Description Plasma torches are similar in design to the automo tive spark plug They consist of negative and posi tive sections separated by a center insulator Inside the torch the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip Once the pilot arc has ionized the plasma gas the superheated column of gas flows through the small orifice in the torch tip which is focused on the metal to be cut A single torch lead provides gas from a single source to be used as both the plasma and secondary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 2 2T 05 Introduction to Plasma on page 2T 2 for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional speci fications as related to the Power Supply u
91. ll we are committed to developing technologically ad vanced products to achieve a safer working environment within the welding industry WARNING 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 20mm SL60 1Torch Service Manual Number 0 5079 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2009 2010 2011 2012 by Thermadyne Corporation 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 negli gence accident or any other cause Original Publication Date January 9 2009 Revision Date April 25 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial This Page Intentionally Blank TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 1
92. ll the replacement Contactor by reversing the above steps Reinstall the power supply cover Manual 0 5079 CUTMASTER 20mm PARTS REPLACEMENT CUTMASTER 20mm This Page Intentionally Blank PARTS REPLACEMENT 7 8 Manual 0 5079 CUTMASTER 20mm APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ON OFF switch to ON Close external disconnect switch RESULT Power to system RESULT AC indicator ON GAS indicator 29 ON when inp pressure is adequate for power supply operation Power circuit ready ACTION Connect work cable to workpiece Set output amperage RESULT System is ready for operation ACTION Protect eyes and activate Torch switch START RESULT Fans turn on Gas flows briefly then stops Gas restarts DC indicator Pilot arc established ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will continue to run for 10 minutes after the Torch switch START is removed Manual 0 5079 ACTION ACTION RUN Rapid Auto Restart RUN SET LATCH Rapid Auto Restart switch to RUN 6 SET LATCH switch os to SET for most applications a or to Rapid Auto Restart 62 RESULT 222 for gouging trimming Gas flows to set or expanded metal pressure applications or to LATCH is used for specific applications torch switch can be r
93. low indicators flashing at 1 cycle per second indicators flashing at 5 cycles per second FAULT and 90 PSI indicators flashing Pilot arc is ON but cutting arc will not establish orch cutting is diminished Manual 0 5079 1 Torch shield cup is loose 2 Torch tip electrode or starter cartridge missing 3 Torch start cartridge is stuck 4 Open conductor in torch leads 5 Problem in the torch and leads switch circuit 6 Failed components in unit 1 Problem in the torch and leads switch circuit Remote pendant switch circuit 2 CNC Contoller device not providing Start signal 3 Failed components in unit 1 Tighten shield cup by hand Do not overtighten 2 Turn OFF power supply Remove shield cup Install missing parts 3 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 4 Replace torch and leads or return to authorized service center for repair or replacement 5 Replace torch and leads or return to authorized service center for repair or replacement 6 Return to authorized service center for repair or replacement 1 Take Torch and Leads Remote Pendant to Authorized Repair Facility 2 Contact Controller manufacturer 3 Return to authorized service center for repair or replacement 1 Upper O Ring on torch head is in Remove shield cup
94. ndi cated by an elongated or oversized orifice Clean of Consumable Torch Parts or replace the tip if necessary Good Tip Worn Tip A WARNING gt gt a 0 Disconnect primary power to the system before 9 disassembling the torch or torch leads SZ SZ DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Example of Tip Wear 5 Remove the starter cartridge Check for excessive wear plugged gas holes or discoloration Check the lower end fitting for free motion Replace if Remove the consumable torch parts as follows NOTE necessary The shield cup holds the tip and starter cartridge Spring Loaded Spring Loaded in place Position the torch with the shield cup Lower End Fitting Lower End Fitting at Reset Full Compression Full Extension facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the torch NOTE Art A 08064_AC Slag built up on the shield cup that cannot be re moved may effect the performance Of the system 6 Pull the Electrode straight out of the Torch Head Check the face of the electrode for excessive wear 2 Inspect the cup for damage Wipe it clean or Refer to the following figure replace if damaged t en New Electrode Art A 08067 e c p Ex Shield Cups Worn Electrode
95. nding t s Pending Other Pa t s Pending t s Pending Patent s 4T 15 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6914211 D505309 US Pat No s 6914211 D493183 US Pat No s 6914211 D505309 US Pat No s 6914211 D505309 US Pat No s 6914211 D501632 D511633 US Pat No s 6914211 D496951 US Pat No s 6914211 D496951 US Pat No s 6914211 D505309 OPERATION CUTMASTER 20mm 9 8245 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237 Shield Cup 9 8238 Shield Cap 9 8239 Shield Cap 9 8244 Shield Cap 9 8245 Shield Cap OPERATION 4T 16 Manual 0 5079 CUTMASTER 20mm This Page Intentionally Blank Manual 0 5079 4T 17 OPERATION CUTMASTER 20mm This Page Intentionally Blank OPERATION 4T 18
96. nnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommen dation qui suivent ANSI ASC 249 1 Nuance Minimum Nuance Sugger e urant Arc Protective Num r Num r Moins de 300 8 9 300 400 9 12 400 800 10 14 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 cach par moiceau de travail INFORMATIONS G N RALES BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d ez 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 tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e Il faut mesurer les niveaux sonores 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 page 5 PLOMB AVERTISSEMENT Ce produit contient des produits chimiques comme le plomb ou engendre des produits chimiques reconnus par l tat de Californie comme pouvan
97. nut securing the potentiometer shaft to the front panel per subsection 7 05 A 5 Remove the Function Control Switch Knob and the nut securing the switch shaft to the front panel per subsection 7 05 B 6 Pull the top of the front panel forward slightly and carefully remove the Logic PCB from the unit 7 Install the replacement Logic PCB by reversing the above steps 8 Reinstall the power supply cover 7 3 PARTS REPLACEMENT CUTMASTER 20mm G ON OFF Switch SW1 Replacement Tools required T20 Torx Driver 1 2 5 Remove the cover per subsection 7 04 A Disconnect the wires on the rear of the switch noting the location and orientation of each wire as shown below Art A 08169 Squeeze together the clips on the back of the switch then remove the switch through the front panel Install the replacement switch by reversing the above steps Reinstall the power supply cover H Work Cable Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Disconnect the work cable from the WORK1 terminal on the Main PCB Squeeze the top and bottom of the Work Cable Strain Relief and remove from the front panel Install the replacement Work Cable by reversing the above steps Reinstall the power supply cover PARTS REPLACEMENT 7 06 Left Side Internal Parts Replacement A Fan Replacement Tools required T20 Torx Driver 1 2 3 7 Remove the Cover
98. o proper setting 2 Check torch consumables and replace as needed 3 Check the connection of the Work Lead to the work piece 4 Reduce cutting speed 5 Refer to Check air quality in section 3 Torch 6 Return to an authorized service center for repair 5 5 SERVICE CUTMASTER 20mm 5 06 Power Supply Basic Parts Replacement A WARNING Disconnect primary power to the system before disassembling the torch leads or power supply This section describes procedures for basic parts replace ment For more detailed parts replacement procedures refer to the Power Supply Service Manual A Cover Removal 1 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover Lower Screws Art A 07947 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reconnect the ground wire if necessary 2 Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws SERVICE C Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Subsection 5 02 and either cleaned or replaced 1 Remove power from the power supply turn OFF the gas s
99. oduct to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Product Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 12mm 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 Thermal Dynamics Corporation Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermal Dynamics Corporation 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 int
100. oltage Temperature 40 Voltage 500V Arc Striking Voltage G Gas Requirements Manual and Mechanized Torch Gas Specifications Gas Plasma and Secondary Compressed Air Operating Pressure 60 95 psi Refer to NOTE 4 1 6 5 bar Maximum Input Pressure 125 E ae Gas Flow Cutting and 300 500 scfh Gouging 142 235 Ipm A WARNING This torch is not to be used with oxygen 0 NOTE Operating pressure varies with torch model op erating amperage and torch leads length Refer to gas pressure settings charts for each model H Direct Contact Hazard For standoff tip the recommended standoff is 3 16 inches 4 7 mm 2T 04Options And Accessories For options and accessories see section 6 INTRODUCTION 2T 2 2T 05Introduction to Plasma A Plasma Gas Flow Plasma is a gas which has been heated to an ex tremely 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 pilot arc between the electrode and the torch tip heats and ionizes the gas The main cutting arc th
101. omplete If the unit does not function as stated above then note the symptom and proceed to Section 5 10 CNC Interface Problems the unit has the Automation Interface PCB installed continue with this section 4 There are three 3 ARC VOLTs signals available from the J2 connector a J2 9 to J2 7 b J2 5 to J2 6 Auto Interface PCB J3 con nector with jumper installed between pins 1 and 2 ARC VOLTS divided by 50 J2 5 to J2 6 Auto Interface PCB J3 con nector with jumper installed between pins 2 and 3 ARC VOLTS divided by 16 Manual 0 5079 CUTMASTER 20mm Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximately as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 6 VDC 2 VDC c 19 VDC 6 VDC This completes the CNC Interface Test If the above are all correct then the unit is functioning correctly If the unit does not function as stated then note the symptom and proceed to Section 5 10 CNC Interface Problems 5 08 Main Input and Internal Power Problems A Primary input line fuse blows as soon as primary disconnect is closed 1 Primary input cable installed incorrectly a For Non EMC units Check wiring of primary power cable to the W1 contactor Input Power Cable Connections 380 415 VAC Three Phase 39 12 b L4 Art A 08795 GND b For EMC
102. ons The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 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 For environments with increased hazard of electrical shock Power Supplies bearing the S 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 Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire
103. ontrol and movement NOTE The tip should never come in contact with the workpiece except during drag cutting operations 2 Angle the torch slightly to direct blowback particles away from the torch tip and op erator rather than directly back into it until the pierce is complete In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line Hold the torch per pendicular to the workpiece after the pierce is complete Hold the torch away from your body Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start OPERATION Trigger Release A 02986 6 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTES The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components 7 Clean spatter and scale from the shield cup and the tip as soon as possible Spraying the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Cutting sp
104. or Filter Assembly Hose Clamp Gas Supply 1 4 NPT to 1 4 Hose 6mm Fitting Optional Single Stage Filter Installation Manual 0 5079 inlet Port Art A 07944 CUTMASTER 20mm Installing Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5 microns Connect the air supply as follows 1 Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly NOTE For a secure seal apply thread sealant to the fit ting threads according to manufacturer s instruc tions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch 2 Connect the two stage filter outlet hose to the inlet port of the Regulator Filter As sembly 3 Use customer supplied fittings to connect the air line to the Filter A 1 4 NPT to 1 4 hose barbed fitting is shown as an example Regulator Filter Assembly 2 Stage Filter Inlet Port IN Regulator Input Outlet Port OUT 2 0 Two Stage Filter Hose Clamp e Assembly Gas Supply Hose 1 4 NPT to 1 4 6mm Fitting Art A 07945 AC Optional Two Stage Filter Installation 3 3 INSTALLATION CUTMASTER 20mm Using High Pressure Air Cylinders When using high pressure air c
105. osno 165 2 9 245 om 92015 19 6 s 013 3 o1 oz 1301 eso 15 60 125 ots 321 9 25 020 15 sso 013 32 7 285 os 120 c 5 191 ots s 771726 fea 121 eo 15 os a2 52 90 es ear ve or os 2 52 020 27 9210 19 17 043 oi 48 75 52 o0 2 ors 02015 19 1 3 cc k k 6 sol oso 135 oo 4 os on aa rs 52 ss w Ws o 10 025 oi 48 76 52 aus wm nm Type Torch SL60 With Shielded Tip Type Material Aluminum Type Plasma Gas Air so 1 ase ois a2 7 52 s 2 51 go so sm as ois a2 7 52 e zs 020 51 eo 275 6 32 7s 52 s eas 90 020 52 a oz 020 amp 203 sz 00 245 2 fus 75 sz s zs oso os os e 52 245 51 NM 0 750 9 8210 150 60 oas 7s 52 eo 25 wn WR 15 oss or 75 52 o wr or Wh NOTES Gas pressure shown is for torches with leads up to 25 7 6 m
106. oss Dross present on top of the plate is normally caused by too great a torch to plate dis tance 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 bot tom 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 edge and is very difficultto 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 Manual 0 5079 AT 3 CUTMASTER 20mm 4T 04Hand Torch Operation Standoff Cutting With Hand Torch NOTE For best performance and parts life always use the correct parts for the type of opera tion 1 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 holding technique that feels most comfort able and allows good control and move ment NOTE The tip should never come in contact with the workpiece except during drag cutting operations 2 Depending on the cutting operation do one of the following a For edge starts hold th
107. per subsection 7 04 A Unplug J7 and J8 connectors from Main PCB Carefully feed the fan wires through the center chassis wire slot Remove the fan by pushing the fan retaining clips apart and pulling the fan out of the center chassis On the replacement fan s note the direction of air flow as labeled on the fan housing and orient so fan will blow air into the unit Install replacement fan by reversing the above steps Reinstall the power supply cover B Main Transformer T1 Replacement Tools required T20 Torx Driver gt Nut Driver 1 2 3 10 11 12 13 Remove the Cover per subsection 7 04 A Remove the Tube Handle per subsection 7 04 C Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 E Disconnect the transformer wires from terminals PRI 1 A PRI 2 B PRI 3 C PRI 4 D SEC2 on the Main PCB Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief Disengage the Rear panel from the base per sec tion 7 04 D Guide the rear panel back six 6 inches away from the base Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down to the right side o
108. piece Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 3 9mm of the work piece to establish main cutting arc Main Cutting Arc Establishes e On Main 059 turns OFF and 078 turns ON 1 Clamp DC ammeter around the work cable Out put will be 60 amps 2 While cutting adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to minimum setting Current adjusts from 60 amps down to 20 amps 3 Set the CURRENT CONTROL POTENTIOM ETER to maximum position Current adjusts from 20 amps up to 60 amps SERVICE 4 Whilecutting keep the torch switch closed bring the torch OFF the edge of the material e Cutting arc extinguishes Gas solenoid closes Gas flow stops momentarily then restarts when solenoid opens Pilot arc ignites 5 Open the torch switch DCLED turns OFF After 20 second post flow time Gas solenoid closes e Gas flow stops 6 Set the FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode 7 Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc 8 While cutting keep the torch switch closed and bring the torch OFF the edge of the material Pilot Arc re ignites immediately 9 Open the torch switch DC LED turns OFF After 20 second post flow time Gas solenoid closes e Gas flow stops
109. piece during the cutting cycle Manual 0 5079 4T 5 CUTMASTER 20mm Hold the torch away from your body 6 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start Trigger Release A 02986 7 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch Trigger 4 U 8 Cutas usual Simply release the trigger assembly to stop cutting 9 Follow normal recommended cutting practices as provided in the power supply operator s manual OPERATION CUTMASTER 20mm NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components Piercing With Hand Torch 1 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 technique that feels most comfortable and allows good c
110. r connect unit to a wall receptacle to see if problem is cor rected 2 Defective Main PCB 1 a Measure voltage on Main PCB 1 between test point GND1 to J2 22 400 VAC input approximately 2 6 VDC If voltage is less than 2VDC replace Main PCB 1 3 Defective Ribbon cable a Check continuity of the ribbon cable connect ing between the Main PCB 1 and the Logic PCB 3 4 Defective Logic PCB 3 a Replace Logic PCB 3 H PARTS IN PLACE PIP FAULT The FAULT Indicator and 70 PSI LED is flashing 1 Shield Cup loose a Hand tighten the shield cup to close the PIP switch 2 Torch not properly connected to power supply a Insure torch ATC is securely fastened to unit 3 Problem with torch and leads PIP circuit a Check continuity of torch PIP circuit at ATC pins 1 2 Negative Plasma Lead 3 Torch Switch Lim 2 PIP NS TT KEE 1 PIP Art A 08124 Pilot Lead 4 Defective Logic PCB a Measure the voltage on Main PCB between J2 17 to test point GND1 for 12VDC If the voltage is less than 2VDC replace Logic PCB 5 Defective Main PCB a Replace Main PCB Manual 0 5079 CUTMASTER 20mm l START ERROR FAULT The FAULT Indicator and 75 PSI LED is flashing 1 Start signal is active when SW1 is turned to ON position a Start can be active for one of the following Hand torch switch held closed Hand pendant switch held closed
111. r filter replacement require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled Before removing any connection mark each wire with the connection designation When reassembling make sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when re assembling the unit Each subsection is referenced to Section 6 for parts lists and overall detailed drawings A WARNING Disconnect primary power from the source before opening or disassembling the power Supply PARTS REPLACEMENT CUTMASTER 20mm 7 04 Major External Parts A Cover Removal Tools required T20 Torx Driver 1 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower Screws Art A 07947 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover installa tion NOTE When installing the upper screws attempt to reuse the original threads The easiest way to do this is by turning the screw counter clockwise until
112. rch Up to 25 80 psi 75 psi 7 6 m 5 5 bar 5 2 bar Each additional Add 5 psi Add 5 psi 25 7 6 0 4 bar 0 4 bar 4 Turn FUNCTION CONTROL SWITCH to RUN position Solenoid turns OFF gas stops flowing pres sure display may increase slightly when gas is not flowing This completes the Main Input and Internal Power Test If the above are all correct then proceed to the next section Pilot Arc Test If the unit does not function as stated above then note the symptom and proceed to Section 5 07 Main Input and Internal Power Problems 5 9 SERVICE CUTMASTER 20mm F Pilot Arc Test 1 Activate or depress the torch switch Activate START signal to establish a pilot arc and note the following e Gas solenoid opens e Gas flows e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing DC LED comes e Pilot arc is established 2 Open the torch switch Remote Pendant switch or remove CNC start signal Gas continues to flow e DC LED goes OFF After 20 second post flow time Gas solenoid closes Gas flow stops This completes the Pilot Arc Test If the above are all correct then proceed to the next section G Main Arc and Controls Test If the unit does not function as stated above then note the symptom and proceed to Section 5 08 Pilot Arc Problems G Main Arc and Controls Test Connect work Cable to the work
113. replace Logic PCB 2 Defective Main PCB 1 a Replace Main PCB 1 C In LATCH mode when the torch switch is released the arc shuts OFF immediately 1 Defective Logic PCB 3 a Replace Logic PCB 3 F In RAPID AUTO RESTART mode with torch switch closed the pilot does not start immediately when the cutting arc extinguishes 1 Defective Logic PCB a Replace Logic PCB G INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error SERVICE CUTMASTER 20mm 5 11 CNC Interface Problems A Nothing happens when jumper is installed between J2 3 to J2 4 1 Defective Automation Interface PCB 4 a Measure voltage on PCB 4 between J1 6 to J1 8 for 12VDC If 12VDC is present replace PCB 4 2 Defective Main PCB 1 a Measure voltage on MAIN PCB between J1 6 to J1 8 for less than 2 If voltage is less than 2VDC replace PCB 1 B No OK TO MOVE signal while cutting 1 Defective MAIN PCB 1 a Measure voltage on PCB 4 between J1 1 to J1 3 for 12VDC while cutting If 12VDC is present replace MAIN PCB 1 2 Defective Automation Interface PCB 4 a Measure voltage on PCB 4 between J1 1 to J1 3 for less than 2VDC while cutting If voltage is less than 2VDC replace PCB 4 C ARC VOLTS signals are low or not present 1 Defective Automation Interface PCB PCB 4 a Replace PCB 4 5 12 T
114. result 3 Loosen the two bolts on the top of the Filter As sembly enough to allow the Filter Elements to move freely 4 Notethelocation and orientation of the old Filter Elements 5 Slideout the old Filter Elements First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 7 Hand tighten the two bolts evenly then torque each bolt to 20 30 in Ibs 2 3 3 4 Nm Improper torque may damage the gasket 8 Slowly apply air pressure to the assembly check ing for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures SERVICE 5 07 Circuit Fault Isolation A WARNING The following procedures should not be attempted by anyone who has not had proper training or authorized to do so A Cover Removal 1 Removethe upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower Screws Art A 07947 2 Care
115. rical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate physical strength should lift the unit Liftunit by the handles using two hands Do not use straps for lifting Use optional cart or similar device of ad equate 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 5079 CUTMASTER 20mm 3 03 Primary Input Power Connections A CAUTION Check your power source for correct voltage before plugging in or connecting the unit The primary power source fuse and any extension cords used must conform to local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 Connections for Three Phase Input Power A WARNING Disconnect input power from the power supply and input cable before attempting this procedure These instructions are for installing the input power cable to the power supply and connecting to 380 400 415VAC three phase Primary Input Power 1 Remove the Power Supply cover per in structions found in section 5 2 Loosen the strain relief on the back panel of the power supply 3 Using a customer supplied four conductor input power cable for rated voltage strip back the insulation on the in
116. s will come back ON as soon as the torch switch Start Signal is activated or if the unit is turned OFF then turned ON again If an over temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period once the condition is cleared Set Operating Pressure 1 Place the Power Supply Function Control knob to the SET position Gas will flow 2 For Standoff cutting adjust gas pressure from 70 85 psi 4 8 5 9 bar LED s in center of control panel Refer to the Standoff chart for pressure setting details Art A 07946 Manual 0 5079 STANDOFF CutMaster 20mm Gas Pressure Settings Leads SL60 SL100 Length Hand Torch Mechanized Torch Up to 25 75 psi 75 psi 7 6 m 5 2 bar 5 2 bar Each additional Add 5 psi Add 5 psi 25 7 6 m 0 4 bar 0 4 bar 3 For Drag cutting adjust gas pressure from 75 95 psi 5 2 6 5 bar LED s in center of control panel Refer to the Drag Cutting chart for pressure setting details CutMaster 20mm Gas Pressure Settings Leads SL60 Length Hand Torch Up to 25 80 psi 7 6 m 5 5 bar Each additional Add 5 psi 25 7 6 m 0 4 bar Select Current Output Level 1 Place the Function Control Knob in one of the three operating positions available RUN gt RAPID AUTO RESTART o gt ET 7 or LATCH Gas flow stops 2 Set the output current to desired amperage
117. se 1 Primary power not connected a Check that cable is connected to primary power 2 Primary line fuse breaker is blown tripped a Replace fuse or reset breaker 3 Defective ON OFF SWITCH a Check continuity 4 Defective Main PCB a Measure Main PCB power supply voltages at the following test points GND1 to 12V 12VDC GND1 to 48V 48 VDC Replace Main PCB if not correct 5 Defective Ribbon Cable a Check continuity 6 Defective Logic a Replace Logic PCB SERVICE a Inspect connection and check continuity Re place if open 4 Defective Main PCB 1 a Replace Main PCB 1 F UNDER PRESSURE FAULT AC LED ON FAULT Indicator and 60 PSI LED flashing 1 Air pressure source to unit is too low a Set input pressure source to 90 100 PSI 2 Regulator set too low a Adjust unit regulator to increase pressure 3 Defective Logic PCB3 a Measure for 5VDC on the Logic PCB 3 be tween J3 3 to J3 1 Replace Logic PCB 3 if voltage is not present or low b Measure for voltage on the Logic PCB 3 be tween J3 2 to J3 1 If the voltage is between 3 4 5VDC replace the Logic PCB 3 4 Defective Pressure Transducer a Replace Pressure Transducer Manual 0 5079 INPUT POWER FAULT AC LED ON FAULT Indicator and 65 PSI LED flashing 1 Primary line voltage out of tolerance range a Connect unit to voltage with unit specifica tions See section 2 04 Power supply speci fications If using a generato
118. sed Manual 0 5079 2T 1 CUTMASTER 20mm 2T 03Specifications A Torch Configurations 1 Hand Manual Torch Models The hand torch head is at 75 to the torch handle The hand torches include a torch handle and torch trigger assembly Le 10 125 257 mm Art A 03322_AB 7 1 17 29 mm 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly Le 15 875 403 mm e 9 285 236 mm nd F i Y 1 875 35 mm 1795 0 625 44 5 mm 16mm v B Torch Leads Lengths Hand Torches are available as follows 20 ft 6 1 m with ATC connectors 50 ft 15 2 m with ATC connectors Machine Torches are available as follows 5 foot 1 5 m with ATC connectors 10 foot 3 05 m with ATC connectors 25 foot 7 6 m with ATC connectors 50 foot 15 2 m with ATC connectors C Torch Parts Starter Cartridge Electrode Tip Shield Cup D Parts In Place PIP Torch Head has built in switch 1 175 30 inis 4 95 126 mm Art A 02998 12 VDC circuit rating E Type Cooling Combination of ambient air and gas stream through torch INTRODUCTION CUTMASTER 20mm F Torch Ratings Manual Torch Ratings Ambient 104 F Temperature 40 Duty Cycle 100 60 Amps 400 scfh Voltage V oa 500V Arc Striking V
119. t tre l origine de cancer de mal formations f tales ou d autres probl mes de reproduction Il faut se laver les mains apr s toute manipulation Code de Californie de la s curit et sant paragraphe 25249 5 et suivants Manual 0 5079 1 06 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 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 249 1 LA S CURIT DES OPERATIONS 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 PRO TECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI 249 2 PREVENTION DES INCENDIES LORS DE
120. t voltage based upon power supply rated current To facilitate comparison between power supplies all manufacturers use this output voltage to determine duty cycle Power Supply Dimensions amp Weight Ventilation Clearance Requirements 10 75 A Art A 07941 16 375 416 mm TC 77 2 Tii LLL 43 Ib 19 5 kg INTRODUCTION 2 2 Manual 0 5079 CUTMASTER 20mm 2 05 Input Wiring Specifications CutMaster 20mm Power Supply Input Cable Wiring Requirements Input voltage pe Suggested Sizes Flexible Volts Hz Cord Min 3 380 Phase Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE Refer 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 Manual 0 5079 2 3 INTRODUCTION CUTMASTER 20mm 2 06 Power Supply Features Handle and Leads Wrap c c Torch Leads Receptacle Work Cable lt lt 2 e QE wi W Q X mall Art A 07942 and Clamp Art A 08544 Port for Optional Automation Interface Cable Input Power Cord Filter Assembly Gas Inlet Port 2 4 Manual 0 5079 INTRODUCTION SECTION 2 TORCH INTRODUCTION 2T 01Scope of Manual This manual contains descript
121. tem numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authoriza tion will not be accepted 6 02 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 power supply Address all inquiries to your authorized distributor 6 03 Power Supply Replacement The following items are included with the replacement power supply work cable amp clamp input power cable gas pressure regulator filter and operating manual Q Dao 1 CutMaster 20mm Non CE Power Supply With 380 400 415VAC 3 phase 50 60 Hz input power cable 3 1130 3 1 CutMaster 20mm CE Power Supply with 380 400 415VAC 3 phase 50 60 Hz input power cable 3 1130 4 Manual 0 5079 6 1 PARTS LIST CUTMASTER 20mm 6 04 Major External Replacement Parts Item Description log 1 1 Cover with labels 9 0221 2 1 Base Enclosure Assembly 9 0118 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0227 5 1 Rear Panel 9 0101 TAN qe 7 NAM 00001 dodga Art A 08120 NOTE Illustration may vary slightly from unit PARTS LIST 6 2 Manual 0 5079 CUTMASTER 20mm 6 05 Front Panel Replacement Parts Item Description Ref log 1 1 Output Curr
122. that the START SIGNAL was active ie Torch Trigger depressed hand held pendant switch ON or CNC signal for torch ON during one of three conditions 1 During initial power up when ON OFF switch is turned to ON position 2 When fault which had been disabling the system is cleared 3 When the FUNCTION CONTROL SWITCH Mode is moved from SET position to any of the other three 3 modes of operation CONSUMABLES MISSING Indicates that the elec trode start cartridge or tip is missing or exces sively worn SHORTED TORCH Indicates the torch or lead has a shorted condition between positive and nega tive leads INTERNAL ERROR Indicates a microprocessor er ror OVER PRESSURE Indicates that operating pressure is set too high The Error Indicator will not flash when the pressure is above 95 PSI This LED will remain ON and the system will operate but pilot starting and cut performance may be affected NOTE The cooling fans will turn ON as soon as the unit is turned ON After the unit is idle for ten 10 minutes the fans will turn OFF The fans will come back ON as soon as the torch switch Start Signal is activated or if the unit is turned OFF then turned ON again If an over temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period once the condition is cleared SERVICE CUTMASTER 20mm 5 05 Basic Troubleshooting Guide A WARNING jpu H
123. the side of the gouge path However slag build up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc The build up is most often a result of improper travel speed lead angle or standoff height OPERATION CUTMASTER 20mm 4T 06Mechanized Torch Operation Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC 1 To start a cut at the plate edge position the center of the torch along the edge of the plate Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate The arc can be one of the following 1 Straight Arc A straight arc is perpendicular to the workpiece surface This arc is generally recommended for the best cut using air plasma on stainless or aluminum 2 Leading Arc The leading arc is directed in the same direction as torch travel A five degree leading arc is generally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direc tion as torch travel Standoff Distance A 02586 Trailing Arc M Leading Arc Mechanized Torch Operation OPERATION For optimum smooth surface quality the travel speed should be adjusted so that only the leading edge of the arc column produces the cut Ifthe travel speed is too slow a
124. tial power up two lights will temporarily illumi nate for 2 3 seconds to show the version of software used To determine the first digit countthe function indicators left to right 1 through 5 To determine the second digit count the pressure indicators reading from bottom to top 0 through 7 In the example below the Temp indica tor and 75 psi indicators are ON indicating the version would be 2 3 NW BOD Art 07988 1234 5 When the D Fault indicator is ON or blinking it will be accompanied by one of the pressure indica tor lights depending on what the Fault is Only one of these faults will be displayed at one time If more than one fault exists when the first fault is corrected and cleared the next fault will then be displayed It is possible to have a fault indicated in the function indicators and another fault indicated in the pres sure indicators The following table shows each of the Faults possible Pressure Fault Indicator Max 90 Internal Error Shorted Torch 80 Consumables Missing Min NOTE Fault explanations are covered in the following tables Manual 0 5079 CUTMASTER 20mm Explanation of Faults UNDER PRESSURE Indicates that operating pres sure is set too low and power supply output power will be disabled PART IN PLACE Indicates that the shield cup is not properly installed or tightened START ERROR Indicates
125. tions Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders Refer to the following two subsections if an optional air line filter is to be installed 1 Connect the air line to the inlet port The illustration shows typical fittings as an example NOTE 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 air passages in the torch Regulator Filter Assembly N a Inlet Port ee he A 1 4 NPT or ISO R Gas Supply li amp Hose Art A 07943 Air Connection to Inlet Port 3 2 Manual 0 5079 Installing Optional Single Stage Air Filter An optional filter kit is recommended for im proved filtering with compressed air to keep moisture and debris out of the torch 1 Attach the Single Stage Filter Hose to the Inlet Port 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instruc tions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Con nect as follows Regulat
126. ture 5 Worn torch parts build up Weekly or Every 30 Cutting Hours Excessive Dross 6 Non Genuine Thermal Dynamics parts used 1 Cutting speed too slow 2 fan for proper operation and adequate air Formation 2 Torch standoff too high from workpiece 2 Inspect torch for any cracks or exposed wires 3 Worn torch parts replace if necessary 4 Improper cutting current 5 Non Genuine Thermal Dynamics 3 Inspect input power cable for damage or exposed parts used wires replace if necessary Six Months or Every 720 Cutting Hours 6 Incorrect gas pressure Short Torch Parts Life Oil or moisture in air source 2 Exceeding system capability 1 Check the in line air filter s clean or replace as i required material too thick 3 Excessive pilot arc time 2 Checkcables and hoses for leaks or cracks replace 4 Gas pressure too low if necessary 5 Improperly assembled torch 3 Check all contactor points for severe arcing or dh i al pits replace if necessary Difficult Starting 1 Worn torch parts 4 Vacuum dust and dirt out of the entire machine A CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical com ponents and cause damage to the unit SERVICE 2 Non Genuine Thermal Dynamics parts used 3 Incorrect gas pressure Manual 0 5079 5 04 Fault Indicator At ini
127. units Check wiring of primary pow er cable to the EMC Filter terminal block EMC Input Power Filter Three Phase Input Power Wiring 2 W1 contactor points are stuck closed a Check per section 5 11 A 3 Primary plug not wired correctly a Check manufacturer s plug installation in structions 4 Primary input cable is defective a Check cable for shorts SERVICE CUTMASTER 20mm B Primary line fuses blow immediately after ON OFF SWITCH SW1 is turned to ON position 1 Shorted Input Diode Module a Check per section 5 11 B 2 Shorted Input Capacitor PCB a Check per section 5 11 C C Gas flows with ON OFF SWITCH in OFF position 1 Foreign debris has lodged in gas solenoid E AC LED ON W1 contactor does not energize In earlier revision units the fan MOT 1 will come ON after approximately 20 seconds 1 Defective contactor a Measure for 24VAC between wires 5 amp 6 If voltage is present replace W1 2 Defective Logic PCB3 a Measure W1 ON signal on Logic PCB 3 be tween J1 9 to TP1 Voltage should be 12VDC then drop to less than 1VDC 2 seconds after turning SW1 to ON a Replace gas solenoid This is a problem caused by improperly filtered air supply Customer needs to add filtration to air supply prior to Open or improperly connected ribbon cable to J2 connector on Main PCB 1 unit inlet D All front panel indicators are OFF fans do not run Main Contactor W1 does not clo
128. upply and bleed down the system 2 Remove the system cover See Cover Re moval in this section 3 Locate the internal air line and the fitting from the filter assembly Number 1 in the following illustration 4 Hold a wrench or similar tool against the lock ing ring on the filter assembly fitting then pull on the hose to release it Numbers 2 and 3 in the following illustration Art A 07989 5 Remove the fitting from the filter element as sembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration 5 6 Manual 0 5079 6 Disconnect the input line from the filter element assembly 7 Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly Art A 07990 8 Install the new or cleaned assembly by reversing these procedures 9 TurnON the air supply and check for leaks before reinstalling the cover Optional Single Stage Filter Element Replacement These instructions apply to power supplies where the optional Single Stage Filter has been installed The Power Supply shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section
129. utdown Turn the OFF switch to OFF down Power Supply indicators shut OFF Unplug the input power cord or disconnect input power Power is removed from the system OPERATION CUTMASTER 20mm This Page Intentionally Blank OPERATION 4 4 Manual 0 5079 SECTION 4 TORCH OPERATION 4T 01Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used Type of operation Drag cutting standoff cutting or gouging Torch parts Shield Cup Cutting Tip Electrode and Starter Cartridge NOTE Refer to Section 4T 07 and following for ad ditional information on torch parts Change the torch parts for a different operation as follows A WARNING Disconnect primary power at the source before assembling or disassembling torch parts or torch and leads assemblies NOTE The shield cup holds the tip and starter car tridge in place Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup assem bly from the torch head Manual 0 5079 4T 1 CUTMASTER 20mm 2 Remove the Electrode by pulling it straight out of the Torch Head Torch Head Electrode Start Cartridge n Tip Shield Cup A 03510 Torch Parts Drag Shield Cap amp Shield Cup Body Shown 3 Install the replacement Electrode by push ing it straight into the torch head until it clicks
130. ve the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to ship ping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or ship ping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 1 INTRODUCTION CUTMASTER 20mm 2 04 Power Supply Specifications CutMaster 20mm Power Supply Specifications 380 VAC 360 440 VAC Three Phase 50 60 Hz 400 415 VAC 360 440 VAC Three Phase 50 60 Hz Power Supply includes input cable Cable for 380 400 415V 3 Phase 20 60 Amps Continuously Adjustable Particulates to 5 Microns CutMaster 20mm Power Supply Duty Cycle Ambient Tempera Duty Cycle Ratings 40 C 104 F ture Operating Range 0 50 C Rating Rating Rating All Units NOTE The duty cycle will be reduced if the primary input power AC is low or the output voltage DC is higher than shown in this chart NOTE IEC Rating is determined as specified by the International Electro Technical Commission These specifications include calculating an outpu
131. with ATC connector 4 7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7843 1 25 foot 7 6 m Leads Assembly with ATC connector 4 7844 1 50 foot 15 2 m Leads Assembly with ATC connector 4 7845 7 1 11 279 mm Rack 9 7041 8 1 11 279 mm Mounting Tube 9 7043 9 1 End Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 7 2896 13 1 PIP Plunger and Return Spring Kit 9 7045 1 Pinion Assembly Not shown 7 2827 1 5 126 mm Positioning Tube Not shown 9 7042 NOTE Does not include Control Cable Adapter or Through Hole Protector PARTS LIST 6 8 Manual 0 5079 CUTMASTER 20mm Manual 0 5079 6 9 PARTS LIST CUTMASTER 20mm 6 11 Torch Consumable Parts Manual and Mechanized Torches Start Cartridge 9 8213 Electrode 9 8215 Art A 08065 AE PARTS LIST DRAG TIP CUTTING A 60A 9 8252 DRAG SHIELD CUTTING 40A CUTTING Shield Cap Deflector 9 8243 Shield Cap Deflector 9 8243 e 40A 9 8208 STANDOFF CUTTING DRAG SHIELD CUTTING 50 60A CUTTING Standoff Guide 9 8251 Shield Cap Deflector U 9 8243 ut 50 55A 9 8209 60A 9 8210 STANDOFF CUTTING 70 120A CUTTING Standoff Guide 9 8281 G
132. with the amperage output of this Power Supply 60 amps maximum Refer to Section 4T 07 and following for torch parts selection Torch Connection Check that the torch is properly connected Only Thermal Dynamics model SL60 Manual or SL100 Mechanical Torches may be connected to this Power Supply See Section 3T of this manual 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 supply power to the system Air Source Ensure source meets requirements refer to Section 2 Check connections and turn air supply ON Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 04509 OPERATION Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator w turns ON Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cool ing fans turn ON NOTE Minimum pressure for power supply opera tion is lower than minimum for torch opera tion The cooling fans will turn ON as soon as the unit is turned ON After the unit is idle for ten 10 minutes the fans will turn OFF The fan
133. ylinders as the air supply 1 Refer to the manufacturer s specifications for installation and maintenance proce dures for high pressure regulators 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign material Briefly open each cylin der valve to blow out any dust which may be present 3 The 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 300 scfh 141 5 Ipm 4 Connect supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure cylinder regulator Supply hose must be at least 1 4 inch 6 mm 1 0 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 air passages in the torch INSTALLATION Manual 0 5079 CUTMASTER 20mm Check Air Quality SECTION 3 TORCH INSTALLATION 3T 01Torch Connections If necessary connect the torch to the Power Sup ply Connect only the Thermal Dynamics model SL60 Manual or SL100 Mechanical Torch to this power supply Maximum torch leads length is 100 feet 30 5 m including extensions A WARNING Disconnect primary power at the source before connecting the torch 1 Align the male connector on the torch lead with the fem
134. ymptoms and test the unit for proper operation Follow the instructions as given to identify the possible symptom s and the defective circuit After repairs are complete run the following tests again to verify that the unit is fully operational 1 Connect gas supply to rear of Power Supply 2 Turn ON gas supply and set operating pressure per pressure setting label on power supply Manual 0 5079 CUTMASTER 20mm 3 Set the Power Supply controls as follows e ON OFF SWITCH to OFF position Turn FUNCTION CONTROLSWITCH to SET position CURRENT CONTROL POTENTIOMETER to MAXIMUM position fully clockwise E Main Input and Internal Power Test 1 Connect Primary Line power to the unit 2 Turn the ON OFF SWITCH SW1 to ON position and observe the following e Software version is displayed See section 5 04 Fault Indicators After approximately three 3 seconds Inrush relay on PCB 1 energizes starting pre charging of working capacitors e W1 energizes e AC and GAS Indicators come ON e Gas flows e Fans turn ON 3 Adjust the pressure regulator to set the gas pres sure as specified in charts STANDOFF CutMaster 20mm Gas Pressure Settings Leads 5160 51100 Length Hand Torch Mechanized Torch Up to 25 75 psi 70 psi 5 2 bar 4 8 bar Add 5 psi Add 5 psi 0 4 bar Each additional 7 6 m 25 7 6 m 0 4 bar CutMaster 20mm Gas Pressure Settings Leads SL60 51100 Length Hand Torch Mechanized To

20mm CUTMASTER™ Service Manual

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20mm CUTMASTER&trade; Service Manual

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20mm CUTMASTER™ Service Manual