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102 CUTMASTER™ Service Manual

1. SEC1 CHOKE1 mz iL E OUT 1 E SEC2 mm Eu m 4 TE PMTH3 PRI3 N J9 AC2 PRI4 OUT AC3 GND1 DMD1 T PRI2 PRI1 PMTH2 PMTH1 Art A 08506 40AMP PCB 5 LAYOUT 5 32 Manual 0 4998 SERVICE CUTMASTER 102 40AMP PCB 5 SIGNALS J1 1 12VDC Supply for Fan MOT2 J1 2 FAN Active Low to enable Fan MOT2 J2 1 12VDC Supply for Fan MOT3 J2 2 FAN Active Low to enable Fan MOT3 Signal Source Destination J3 1 12VDC 12VDC Supply C 40A J3 2 Common 12VDC Return C 40A J4 4 OVERTEMP Active Low signal when OVERTEMP 40A M 4 5 FAN ON Active Low to enable Fans M 40A J4 6 CSR Active low to Enable PWM M 40A J4 7 CUR SET 1 2 4VDC Cut Current Demand M 40A J4 8 MAIN PCB ID 825 Ohms to common 40 J4 9 Not Used J4 10 Common 40A M TEST POINTS 80A_AC1 AC Input Phase 1 80A AC2 AC Input Phase 2 80A_AC3 AC Input Phase 3 40A_AC1 AC Input Phase 1 40A AC2 AC Input Phase 2 40A_AC3 AC Input Phase 3 1 Capacitor Bank MTH2 Capacitor Bank MTH4 Capacitor Bank A MTH6 Capacitor Bank B MTH7 Capacitor Bank B MTH8 Capacitor Bank B 1 Capacitor Bank PMTH2 Capacitor BankA PMTH3 Capacitor Bank PMTH4 Capacitor Bank B 1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV TP5 0 5 to 5 VDC 0 100 psi TP6 1 8VDC TP7 1 5 VDC Pilot Curre
2. Art A 07886 5678 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 rauit 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 102 4 02 Preparations for Operation At the start of each operating session Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads as semblies 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 with the amperage output of this Power Supply 100 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 SL100 Manual or SL100 Mechanical Torches may be con
3. 3 4 SECTION 3 TORCH INSTALLATION iii 3T 1 31 01 Torch Connections tereti iii 3T 1 8T 02 Setting Up Mechanical Torch 4 000000000000 3T 1 SECTION 4 SYSTEM OPERATION intro sic recu raa ter ipa EBENE v pu RAS 4 1 4 01 Front Panel Controls Features 4 1 4 02 Preparations for Operation 4 2 SECTION 4 TORCH OPERATION aaaea eaaa e ana 4T 1 4701 Torch Parts Selection 4T 1 47 02 eqeU i am 4T 2 4T 08 General Cutting Information ss 4T 2 41 04 Operations ke 4T 3 ATO5 47 7 47 06 Mechanized Torch Operation 4T 8 4T 07 Parts Selection for Manual and Mechanized Torch Cutting 4T 9 4T 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip4T 10 4T 09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip4T 13 PATENT INFORMATION ntt tenete bade 47 16 TABLE OF CONTENTS SECTION 5 SYSTEM SERVIGOE s aa sor pu ae Rue SEES 5 1 5 01 General 5 1 5 02 Maintenance Schedule 5 2 5 03 Common Fausse tentant tee IHE ISO ELA ho 5 2 5 04 glo c
4. GND2 PRI 1 1 2 5 PRI 2 TP6 SEC1 48 2 12V2 48V1 Manual 0 4998 4 ja 2 3 4 J2 5 2 6 p J2 8 2 9 2 10 J2 11 2 12 2 13 2 14 2 15 2 16 jou 2 18 2 19 2 20 2 21 J2 22 72 23 72 24 2 25 72 26 72 27 72 28 72 29 72 30 72 31 72 32 72 33 72 34 72 35 72 36 72 37 72 38 72 39 72 40 3 1 73 2 VOUT TIP VOLTS SEN 460V IN 230V IN CUR SET RAR INRUSH W1 ON SHDN TRCH SOL SOL ON OK TO MOVE FAN ON ACTIVE TRCH SW PIP AC ON CSR 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 3 3VDC TXD RXD Common D Not Used 230VAC Common Manual 0 4998 OUTPUT VOLTAGE Active high when tip is installed Approx 100VDC while cutting w tip off work Active low in Drag Mode Active low with 460vac primary input voltage Active low with 230vac primary input voltage 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 OK TO MOVE CNC Active low to enable fans Active low when Latch mode is active during cut Active low S
5. 5 3 5 05 Basic Troubleshooting Guide 5 6 5 06 Circuit Fault 5 8 5 07 Main Input and Internal Power 5 12 5 08 Pilot Are ProDIEMS 5 16 5 09 Main Arc and Controls 5 19 5 10 CNC Interface Problems 5 20 5 11 Test PrOCOdU 68 ort robe 5 20 SECTION 5 TORCH SERVICE issia ctia etes ee rax bu geo ex da ERE YR 5T 1 51 01 G n ral Maintenance uen nes 5T 1 5 02 Inspection and Replacement of Consumable Torch Parts 51 2 SECTION 6 LISTS 6 1 6 01 6 1 6 02 Ordering Information 6 1 6 03 Power Supply Replacement 6 1 6 04 Major External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement Parts 2 0 6 4 6 07 Right Side Replacement Parts 0 24 6 5 6 08 Replacement Power Supply 6 6 6 09 Options and Accessories 6 6 6 10 Replacement Parts for Hand Torch 6 7 6 11 Replacement Parts for Machine Torches with Unshielded Leads 6 8 6 12 Torch Consumable Parts SL100 5 6 10 SECTION 7 REPLACEMENT PROCEDURES 7
6. 9 2 ws Foz x eo is oss 48 9 w ws ES EIE 48 48 48 48 sm 9 48 7 9 48 9 48 48 48 48 Manual 0 4998 4T 13 OPERATION CUTMASTER 102 ooo is sas eo rn o 4s ws 9 oo 02 st vas ao m s oi ae as ws s 02 si 04 eam va ao s foisfas as ws amo ov oz si sam 128 eo var ois as 4s ws 90 oz 02 51 eem ti eo 100 251 oxo mo 4s ws 90 02 51 5 oan xw m 0 1m omae 7o as ws s 080 oz asm eam as as ow ois as ws s oe 02 si 0589 eam ws w os onus 4s ws 90 ors uz 51 tu eo ie oae oxo aa 4s ws wa Ws WR 22 eam ws m o2 omae as ws s ws Ws WR we s s oz o aa ws so ws Ws Ww eo 20 sso 0 oo 02 51 ns m 200 oso ws sw 02 osla osn s a0 625 1 2 ws 02 51 oslas sse eo 170 425 1 2 ws se 02 02 saan we eo s zm ws se 02 ss ss es vs
7. 5 Input Diode D1 Test 1 Using an ohmmeter perform the tests in the chart Input Diode Module D1 on PCB5 Test points are located on PCB2 Meter Meter Indication 40A AC1 PMTH 1 Forward Biased Diode 40A AC2 PMTH 1 Forward Biased Diode 40A PMTH 1 Forward Biased Diode PMTH 1 40A AC1 Reverse Biase Diode PMTH 1 40A AC2 Reverse Biase Diode PMTH 1 40A Reverse Biase Diode 4 40 1 Forward Biased Diode 4 40 _ 2 Forward Biased Diode 4 40 _ Forward Biased Diode 40A AC1 PMTH 4 Reverse Biase Diode 40A AC2 PMTH 4 Reverse Biase Diode 40A PMTH 4 Reverse Biase Diode PMTH 4 PMTH 1 2 Forward Biased Diodes Manual 0 4998 5 21 CUTMASTER 102 D PCB 2 Capacitor Relay Test 1 Using an ohmmeter perform the tests in the chart INPUT CAPACITORS PCB 2 Meter Meter Indication MTH 2 MTH4 Charging MTH 8 MTH7 Charging Most meters will show a charging action Initially a low resistance will be shown and then the reststance will start to increase If the meter probews are re versed the reading will decrease to zero then start charging in the opposite polarity 2 Using an ohmmeter perform the tests in the chart INPUT VOLTAGE SELECTION RELAYS PCB 2 Meter Meter X Indication MTH 7 MTH 4 Charging MTH 8 MTH 2 Charging MTH 8 MTH 4 Charging E PCB 1 IGBT Test 1 Disconnect transformer wire from PCB 2 Terminal A 2 Using an ohmmeter check c
8. gt oc Art A 07988 1234 5 When the 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 indictated in the pres sure indicators The following table shows each of the Faults possible Pressure Fault Indicator Max 90 IntemalError Shorted Torch 80 Consumables Missing Min NOTE Fault explantions are covered in the basic trouble shooting guide later in this chapter Manual 0 4998 CUTMASTER 102 Explanation of Faults UNDER PRESSURE Indicates that operating pres sure is set too low and power supply output power will be disabled INPUT POWER Indicates primary line voltage is outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit Low is 208 230 VAC and high is 460 VAC PART IN PLACE Indicates that the shield cup is not properly installed or tightened START ERROR Indicates 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 3 conditions 1
9. Full Extension Art 08064 3 Worn or faulty torch parts a Inspect torch consumables parts Replace if necessary Manual 0 4998 CUTMASTER 102 4 Shorted Torch leads 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 p 4 Torch Switch LUE 3 Torch Switch 2 PIP 1 PIP m 4 TE TSN ES i W a NL Pilot Lead Art A 08124 If a short is found the problem is in the torch and leads assembly Remove the torch head from the leads and check the leads and head to determine which is defective 5 Defective 40Amp 5 a Disconnect and isolate the wire from the CHOKE connection on the 40Amp 5 Supply a START signal If the FAULT is not present replace the 40 AMP PCB 5 6 Defective Main 1 a Replace Main PCB 1 C SHORTED TORCH FAULT Fault indicator and 85 PSI Indicators are flashing at 5 cycles per second This mode is a non latched mode 1 While using an Automation Torch at current set tings above 45 amps the tip has contacted the work piece a Check standoff height 2 Air restriction in torch resulting in low voltage during pilot a Check torch consumables for wear or debris 3 Low voltage during cutting due to torch or con sumable problem a Check torch consumables for wear or debris In a
10. oro 48 ases seno xa eo so 127 orlas o ss oso 0948 oso per seno xs s 26 ose ms 075 09 as 06 ax xz m oa orlas p ss ws WR NR orofo xx s os orlas m 6 ww NR NR Fem osen wo eo s os oras o ss nn NR Type Secondary Gas Single Gas Torch Speed Per Minute Standoff Flow Pierce Pierce Height nches Meters Inches mm psi bar Plasma Fo 15 19 3 om as e om ox Rs ne 471978710614 70 48 ews 010 oz s so seno ws 150 38 25 a Cas 90 fus o1 fox orelas loso 12 22 orfas 2 2 3 per lw EN sisisisisisls k sso 120 c es 1 019 roars as seno 15 e 049 asm 27 e8210 19 o 2 oss ois as w 2 07 020 5 mo e 1s oss oie oo s wn mi ssno we o oat vo as o s wn wn 60 a oz as oo 3e oo ea no o a ne oztea 245 010 025
11. This Page Intentionally Blank OPERATION 4 4 Manual 0 4998 SECTION 4 TORCH OPERATION 4T 01 Torch 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 Start Cartridge NOTE Refer to Section 4T 07 and following for additional information on torch parts Change the torch parts for a different operation as follows A G Disconnect primary power at the source be fore assembling or disassembling torch parts or torch and leads assemblies NOTE The shield cup holds the tip and start cartridge 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 4998 4T 1 CUTMASTER 102 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 Install the replacement Electrode by push ing it straight into the torch head until it clicks Install the start cartridge and desired tip for the operation into the torch head Hand tighten the shield cup assembly until it is seated on the torch head If resistance is felt when installing the cup check
12. Trigger Release A 02986 OPERATION Line voltage fluctuations Torch standoff height Proper work cable connection 4 6 Manual 0 4998 4T 05 Gouging AN s 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 contact with the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power supply OD UTION 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 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 information as related to the Power Supply used Optimum torch travel speed is dependent on current setting lead angle and mode of operation hand or machine torch Current Setting Current settings depend on torch travel spee
13. 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 PARTS REPLACEMENT CUTMASTER 102 This Page Intentionally Blank PARTS REPLACEMENT 7 10 Manual 0 4998 CUTMASTER 102 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION Close external ON OFF switch to ON RUN RUN a disconnect switch SH Rapid Auto Restart NET ciet RESULT SET LATCH switch 0 AC indicator to SET for most applications Power to system Fan s ON or to Rapid Auto Restart 62 GAS indicator ON RESULT 0080 when input Cast for gouging trimming pressure is adequate as flows to set or expanded metal ressure ins for power supply operation P or to Power circuit ready LATCH is used for specific applications torch switch can be released after main arc transfer ACTION RESULT Gas flow stops Connect work cable to workpiece Set output amperage RESULT ACTION Torch moved away from work while System is ready still activated for operation RESULT Main arc stops Pilot arc automatically ACTION restarts Protect eyes and activate torch PILOT ARC RESULT Gas flows briefly then stops Gas restarts ACTION Torch moved within transfer distance of workpiece RESULT
14. 4 Manual 0 4997 CUTMASTER 102 This Page Intentionally Blank Manual 0 4997 A 5 APPENDIX CUTMASTER 102 APPENDIX 5 SYSTEM SCHEMATI 460V UNIT PRI PRA i D INRUSH 3 resistors ac 5 2 INRUSH a pt cM 102 c10 J not installed 4 Act fo cpm ace primary L2 8 ACINPUT uin 1 L3 9 pe GND ix a ire sw Buss earsuumpers 9 0 1 NA INPUT VOLTAGE SELECTOR primary power Closed for 230VAC input CONNECTIONS Mort nape For a PH REMOVE BUSS BARSLIUMPERS 1 4 BETWEEN LI TOLA amp LZ TOLS 2 a CONNECT PRIMARY INPUT CABLE L11213 GND FoR a INSTALL BUSS BARSIJUMPERS BETWEEN L1 TO L4 amp L2 TO LS T CONNECT PRIMARY INPUT CABLE 1 TO BUSS BARS 114 203 2 SOLENOID 5 zayac 1 2 24VAC RET E swe SERIAL PORT 2 Um 3 89 1 ver
15. AC LED on 5 Defective Ribbon cable FAULT INDICATOR and 60 PSI Indicator a Check continuity of the ribbon cable connect flashing ing between the Main PCB 1 and the Logic l Air pressure source to unit is too low PCB3 a Set input pressure source to 90 100PSI 6 Defective Logic PCB 3 2 Regulator set too low a Replace Logic PCB 3 a Adjust unit regulator to increase pressure G PARTS IN PLACE PIP FAULT The FAULT Indicator and 70 PSI LED flashing After 20 seconds fan MOT1 turns on 1 Shield Cup loose 3 Defective Logic PCB 1 a Measure for 5S VDC on the Logic PCB 3 between 18 3 to J3 1 Replace Logic PCB 3 if voltage is not present or low a Hand tighten the shield cup to close the PIP b Measure for voltage on the Logic PCB 3 be switch tween J3 2 to J3 1 If the voltage is between 2 Torch not properly connected to power supply 3 4 5VDC replace the Logic PCB 3 a Insure torch ATC is securely fastened to unit 4 Defective Pressure Transducer 3 Problem with torch and leads PIP circuit a Replace Pressure Transducer a Disconnect the Torch from the unit and check F INPUT POWER FAULT AC LED on FAULT continuity of torch PIP circuit at ATC pins 1 Indicator and 65 PSI LED flashing amp 2 If open check torch and leads for open lead or PIP switch 1 INPUT VOLTAGE SELECTOR SWITCH SW2 Negative Plasma Lead set for incorrect voltage Set SW2 to correspond to the primary
16. N 4 Switc 3 White Pendant Te Connector RE 2 Orange PIP SIN Not Used 964 7 2 5 White Not Used 66 XXE 5 5 1 Black PIP Manual 0 4997 A 3 APPENDIX CUTMASTER 102 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 m Head Leads PIP 4 Black To Power Supply Switch Orange Circuitry Torch LIT Green Switch White To Power Supply Circuitry gt oan D 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 4 Remote Pendant Connector To Remote Control Power Supply with ATC Female Receptacle Male 5 Female Leads f v IN Receptacle Connector _ _ _ _ Power NEN Torch L Supply Head Leads T Switch o Orange MEN Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry White To Power Supply Circuitry BB OO Pilot Art A 08577 APPENDIX
17. NOTES 1 2 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 APPENDIX A 2 Standard Symbols EEG Phase Art A 03288 Manual 0 4997 CUTMASTER 102 APPENDIX 3 TORCH PIN OUT DIAGRAM A Hand Torch Pin Out Diagram ATC Male Connector ATC Female Receptacle Negative Front View Front View Negative Plasma 2 7 7 9 S je i n Mrd range NS 29 70 7 2 PIP Black Se P Pilot SSE 1 lot EE A 03701 B Mechanized Machine Torch Pin Out Diagram ATC Male Connector Front View MACHINE TORCH ATC Female Receptacle Front View Negative Plasma Black 8 Green Plasma Connect 8 Ground
18. PCB 1 Output Diode D3 Test Disconnect transformer wires from Main PCB 1 terminal SEC1 Using an ohmmeter perform the following checks PCB 1 D3 Test points located on PCB 1 amp PCB 2 Meter Meter CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 Forward Bias SEC1 CHOKE1 Reversed Bias SEC2 WORK1 SEC1 WORK1 SEC2 SEC1 WORK1 SEC2 WORK1 Reversed Bias Reversed Bias Reversed Bias Forward Bias Forward Bias H PCB 5 Output Diode D2 Test Disconnect transformer wires from Main PCB 5 terminal SEC1 Using an ohmmeter perform the following checks PCB 5 02 Test points located on PCB 5 Meter Meter CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 SEC1 CHOKE1 SEC2 CHOKE1 OUT 1 SEC1 OUT 1 SEC2 SEC1 OUT 1 SEC2 OUT 1 Forward Bias Reversed Bias Reversed Bias Reversed Bias Reversed Bias Forward Bias Forward Bias PCB 1 Pilot IGBT Test Disconnect wire E35 from Main PCB 1 terminal Using mutlimeter with a diode test scale place the positive probe on PCB 1 terminal TIP1 and the negative probe on PCB 1 terminal WORKI and check for a forward biased diode reading If the test reveals a failed component replace Main PCB 1 If no problem is found reconnect wire to Main PCB Manual 0 4998 J PCB 2 Capacitor Relay Test with PCB2 removed from the unit 1 Using an ohmmeter perform the following checks PCB 2 Capacitor amp Relay Test MTH 4 MTH 7 Charging MTH 4
19. 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 1 for future reference 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and in spect the equipment for possible damage due to shipping If there is any damage notify the car rier 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 INTRODUCTION CUTMASTER 102 2 04 Power Supply Specifications Input Power Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster 102 Power Supply Duty Cycle Ambient Temperature Duty Cycle Ratings 40 C 104 Opperating Range 0 50 C Duty Cycle T 5 DC Voltage 120 120 118 NOTE The duty c
20. m 1 2 ws 025 64 os s 18 o nsa ws su 0 025 64 oss esa 135 eo 16 1 32 48 ws s 10 025 64 eo e 02 4s nm 2221 es ur 0 e oz ss ws sw nA we Roma ss 10 s s oz 2 70 ss nus se Ws m OPERATION 4T 14 Manual 0 4998 CUTMASTER 102 Type Torch Mechanized With Shielded Tip Type Plasma Gas Air Type Secondary Gas Single Gas Torch ts eemi 1s so sm s ors 2 70 48 ns 40 025 8 2 ons 32 48 16 419 08 a2 70 48 020 10 24 32 70 48 48 48 48 48 k mec m ES k 4e 79 Cas os fore 70 i s om os faa 48 s ow faa 48 vs so 4 A 3 j NOTES Gaspressureshown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads set gas pressure to 70 psi 4 8 bar Total flow rate includes plasma and secondary gas flow Manual 0 4998 41 15 CUTMASTER 102 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U S
21. maximum heat protection Choose the When the shield cup is properly installed there technique that feels most comfortable and is a slight gap between the shield cup and the allows good control and movement torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield to close this gap Forcing the shield The tip should never come in contact with cup against the torch head or torch handle can the workpiece except during drag cutting damage components operations 7 Clean spatter and scale from the shield cup 2 Angle the torch slightly to direct blowback and the tip as soon as possible Spraying particles away from the torch tip and op the shield cup in anti spatter compound erator rather than directly back into it until will minimize the amount of scale which the pierce is complete adheres to it 3 In a portion of the unwanted metal start the Cutting speed depends on material thickness pierce off the cutting line and then continue the operator s ability to accurately follow the the cut onto the line Hold the torch per desired cut line The following factors may have pendicular to the workpiece after the pierce impact on system performance is complete Torch parts wear 4 Hold the torch away from your body 5 Slide the trigger release toward the back 88 of the torch handle while simultaneously squeezing the trigger The pilot arc will start
22. so too as foal vo s ns 2 84 2 a 64 2 EI i e 10 Cao ns Cao 4s ns oa 1500 27 Cao as ns 3 os 025 oe 12 s 26 oss as ws 0 025 oa 15 9 oer ozs sa as nus o ws ws wn 2221 so io oss ozs sa us o nn Ws WR 102 6 ous ozsa m 48 us 0 nn W NOTES Gaspressureshown is for torches with leads up to 25 7 6 mlong For 50 15 2 m leads set gas pressure to 70 psi 4 8 bar Total flow rate includes plasma and secondary gas flow OPERATION 4T 12 Manual 0 4998 CUTMASTER 102 4T 09Recommended Cutting Speeds for Mechanized Torch With Shielded Tip Type Torch Mechanized With Shielded Tip Type Material Mild Steel Type Secondary Gas Sa Gas Toro ris 14 555 1 60 es 60 049 1 e 20 5 019 e ws os ws m E 02 EN ms o2 Faas ow o2 Em ms ow a Cas E 025959420 Fs pos p ss s os os o2 far sw sso 17 z oss ois ae 70 99 os eis sso 15 eo os ou vo as oo ws Ws AR 0761611 oser ws e
23. 0191 1 Hi Lo voltage selection switch SW2 9 0110 ESS A I I Y W Art A 08560 PARTS LIST 6 4 Manual 0 4997 CUTMASTER 102 6 07 Right Side Replacement Parts Item Description Ref log 1 1 Contactor 4 Pole W1 9 8587 2 1 Solenoid 12V SOLI 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 0192 8 1 Filter Auto Drain 9 0116 NOTE 9 0115 regulator If the serial number of the power supply is prior to 805078755 then kit number 9 0201 will be needed to replace not only the regulator 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 Illustration may vary slightly from unit Manual 0 4997 6 5 PARTS LIST CUTMASTER 102 6 08 Replacement Power Supply Parts Description Ref log 1 Regulator 9 0115 1 Filter Assembly Replacement Element 9 0116 1 Input Power Cord for 208 230 V Power Supply 9 0191 6 09 Options and Accessories Descsinti Ref 1 Single Stage Filter Kit includes Filter amp Hose 7 7507 1 Replacement Filter Body 9 7740
24. 35 LM 37 RO ML COMMON LM D n Sec CHOKE 4 4 ERRORIND FAULT Ww Ac OVER PRESSURE 0 INTERNAL ERROR 47 85 SHORTED TORCH 4 overtemp 80 CONSUMABLES MISSING E 75 START ERROR 5 PARTS IN PLACE INPUT POWER cas UNDER PRESSURE 2 2 d TEST POINTS Yy 2 stzvoc a lx ERROR GAS CONTROL TPs Qu 80 VDC 0 I00PSI T 1 LA LA CURRENT DEMAND kr SOLENOID Current Control Pres VALVE ATC TEMP ET OVERTEMP AIR INLET LATCH 54 PRESSURE ser TRANSDUCER 2 0 RUN 8 wae OUT 1 RAR 3 0 100651 0 5VDC H 1 Logic pcs I PCB3 19X2369 9 0107 Rev Das FOB No THERMAL DYNAMICS WEAS an INTRO aszuos PARK a 2 5 AB IPDAIE PER 1116 09 11 08 ATHERMADYME Compamy 285711 Information Prostar THERMAL DYNAMICS CORPORATION Not For Release Reproduion or Distribution without Writen Consent Unless Otherwise Specified Resistors are in Ohms 1 4W 5 Capacitors are in Mlrofreds UF Su tot SCHEMATIC DWG No Last Thareday 11 200 230 460 VAC CUTMASTER 102 amp 152 D 42X1315 T Manual 0 4997 APPENDIX CUTMASTER 102 APPENDIX 6 Publication Histor Cover Da
25. ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 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 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington 22202 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 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 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 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institu
26. Ifthe test reveals a failed component replace 40Amp 5 IILL Many of the signals listed in the PCB information to follow will be low voltage signals that will be in one of two states 12 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 24 Manual 0 4998 CUTMASTER 102 This Page Intentionally Blank Manual 0 4998 5 25 SERVICE CUTMASTER 102 PRI 4 Jii J9 J8 J7 J6 J5 Art A 08518 CHOKE1 SEC2 MAIN PCB 1 LAYOUT MAIN PCB 1 SIGNALS Jii 12 11 3 71 4 71 5 L1 Primary AC Line Not used Not used Not used L2 Primary AC Line SERVICE 5 26 12 1 WORK 1
27. Open MTH 2 Open MTH 4 Open Charging Most meters will show a charging action Initially a low resistance will be shown and then the reststance will start to increase If the meter probews are re versed the reading will decrease to zero then start charging in the opposite polarity 2 Iftest reveals a failed component replace Capaci tor PCB 2 K PCB 1 Input Diode Test With PCB 2 removed form unit 1 Using an ohmmeter perform the following checks Input Diode Module D1 on PCB1 Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biase Diode Reverse Biase Diode Reverse Biase Diode Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biase Diode Reverse Biase Diode Reverse Biase Diode 2 Forward Biased Diodes 2 Ifthe test reveals a failed component replace Main 1 Manual 0 4998 5 23 CUTMASTER 102 5 Input Diode Test With 2 removed form unit 1 Using an ohmmeter perform the following checks Input Diode Module D1 on PCB5 Test points are located on PCB5 PMTH 1 Forward Biased Diode PMTH 1 Forward Biased Diode PMTH 1 AC1 Reverse Biase Diode AC2 Reverse Biase Diode Forward Biased Diode AC3 Reverse Biase Diode AC1 Forward Biased Diode AC2 Forward Biased Diode AC3 Forward Biased Diode PMTH 4 PMTH 4 PMTH 4 PMTH 1 Reverse Biase Diode Reverse Biase Diode Reverse Biase Diode 2 Forward Biased Diodes 2 If the
28. This LED will remain on and the system will operate but pilot starting and cut performance may be affected NOTE When the unit is turned on the cooling fans 1 amp will remain off In earlier units MOT 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 temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condi tion is cleared SERVICE Manual 0 4998 CUTMASTER 102 This Page Intentionally Blank Manual 0 4998 5 5 SERVICE CUTMASTER 102 5 05 Basic Troubleshooting Guide WARNING 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 is onj1 Primary power disconnect is 1 Turn primary power disconnect switch to ON position FAULT indicator lashing 65 PSI indicator flashing Fan is on After 20 seconds fan MOT1 turns on FAULT and 75 PSI indicators flashing SE
29. and then turn to ON position to clear the error 2 Defective Logic PCB 3 a Replace Logic PCB 3 SERVICE G Fans MOT1 3 do not not turn on after a START signal is activated 1 Defective Logic PCB 3 a Measure voltage at J1 14 to J1 25 on Logic PCB 3 for 12VDC The voltage should drop to less than 2vdc after a START signal is active If the voltage remains at 12VDC replace the Logic 3 When the unit is turned the cooling fans MOT1 3 will remain off In earlier units 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 temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condition is cleared 2 Measure for 12VDC on the Logic PCB 3 between J7 1 to J7 1 after the START signal is activated If voltage is not present replace Main 1 H Fan MOT1 does not turn on after START signal is activated MOT2 amp do turn on 1 Defective Main 1 a Turn SW1 to off position Turn SW1 back to ON position and measure for 12VDC between J7 1 to J7 2 before START signal is activated If no voltage is present Replace Main PCB 1 2 Defective MOT1 a Check to be sure there is no physical obstruc tions preventing
30. and Foreign Patents as follows 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 OPERATION 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 4T 16 Patent s US Pat No s 6163008 6987238 Other Pat s Pending US Pat No s 6903301 6717096 6936786 D504142 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pa
31. and a shield cap or deflector ensure that the cap or deflector 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 Drag Shield Cap Shield Cup Body Art A 03878 SERVICE 4 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip Co 2 NZ A 03406 Example of Tip Wear 5 Remove the start cartridge Check for excessive wear plugged gas holes or discoloration Check the lower end fitting for free motion Replace if necessary Spring Loaded Spring Loaded Lower End Fitting Lower End Fitting at Rest Full Compression 1 8 Full Extension Art A 08064 6 Pull the Electrode straight out of the Torch Head Check the face of the electrode for excessive wear Refer to the following figure lt New Electrode cce Cem Worn Electrode Art A 03284 Electrode Wear 7 Reinstall the Electrode by pushing it straight into the torch head until it clicks 8 Reinstall the desired start cartridge and tip into the torch head 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 This completes the
32. before reconnecting primary power to the equip ment 7 03 Parts Replacement General Information The parts replacement procedures described in this manual except for 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 Disconnect primary power from the source before opening or disassembling the power supply PARTS REPLACEMENT CUTMASTER 102 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 N E 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 08429 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover instal
33. installations refer to local or national codes Iqmax is taken at TDC rated minimum duty cycle is taken at TDC 100 rated duty cycle Manual 0 4998 2 3 INTRODUCTION Handle and Leads Wrap 2 06 Power Supply Features CUTMASTER 102 Work Cable and Clamp Art A 08360 Torch Leads Receptacle TA LA X ST AED Control Panel Port for Optional Automation Interface Cable Input Power Cord Input Power Selection Filter Assembly Art A 08359 Gas Inlet Port 2 4 Manual 0 4998 INTRODUCTION SECTION 2 TORCH INTRODUCTION 2T 01Scope of Manual This manual contains descriptions operating instructions and maintenance procedures for the I Torch Models SL100 Manual and SL100 Mech anized Plasma Cutting Torches Service of this equipment is restricted to properly trained person nel 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 of the characteristics and capabilities of this equipment will assure the dependable opera tion for which it was designed 2T 02General Description Plasma torches are similar in design to the auto motive spark plug They consist of negative and positive sections separated by a center insulator Inside the torch the pilot arc
34. 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 Shutoffair supply and bleed down system before disassembling Filter to change Filter Element 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 gt Cat No 9 9743 Assembled Filter Cover 5 Barbed e Fitting Art 02476 Optional Single Stage Filter Element Replacement PARTS REPLACEMENT CUTMASTER 102 5 Optional Two Stage Filter Element 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 Reattach gas supply Reinstall the power supply cover NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage 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 1 2 element catalog number Shut off primary input power Shut off air supply and bleed down system G Always turn off the ai
35. one small gas hoses per subsection 7 05C Remove the Gas Solenoid per subsection 7 05F Disconnect the transformer wires from terminals PRI 1 A PRI2 B from the Capacitor PCB and PRI 3 D PRI 4 C SEC1 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 securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Disengage the Front and Rear panels from the base per section 7 04D 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 of the unit Remove the two screws securing the Main Trans former to the base 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 Main Transformer T2 Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04A Remove the two large and one small gas hoses per subsection 7 05C Remove the Gas Solenoid per subsection 7 05F Disconnect the transformer wires from terminals PRI 1 A PRI 2 B PRI 3 D PRI 4 C SEC2 on the 40A Power PCB Disconnect J2 amp J3 connectors fro
36. 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 LA 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 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 Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure e Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommenda tion qui suivent ANSI ASC 749 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
37. parts replacement procedures 5T 2 Manual 0 4998 CUTMASTER 102 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 08 Complete 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 Replacement Power Supply Parts Section 6 09 Options and Accessories Section 6 10 Replacement Parts for Hand Torch Section 6 11 Replacement Parts for Machine Torches with Unshielded Leads Section 6 12 Replacement Shielded Machine Torch Leads Assemblies Section 6 13 Torch Consumable Parts SL100 NOTE Parts listed without item 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 ca
38. 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 4998 CUTMASTER 102 Typical Cutting Speeds Cutting speeds vary according to torch output am perage the type of material being cut and opera tor 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 Shutdown Turn the ON 0 OFF switch to OFF down All Power Supply indicators shut off Unplug the input power cord or disconnect input power Power is removed from the system OPERATION CUTMASTER 102
39. 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 102 4T 06 Mechanized 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 15 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 If the travel speed is too slow a rou
40. 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 second ary 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 2T 05 Introduction To Plasma for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional specifi cations as related to the Power Supply used Manual 0 4998 2T4 CUTMASTER 102 2T 03 Specifications 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 lt 10 125 257 gt 3 75 95 mm Art A 03322_AB 7 1477 29 mm 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly fe 15 875 403 mm 9 285 ee 1 JD 1 375 35 mm 4 95 126 mm 1479 0 625 44 5 mm 16mm W 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 connec
41. test reveals a failed component replace Main PCB 5 M PCB 1 IGBT Test With PCB 2 removed from unit 1 Using an ohmmeter perform the following checks PCB 1 Q1 Test points located on PCB 1 Wert Forward Biased Diode Meter Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode PCB 1 Q2 Test points located on PCB 1 vero Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode 3 If the test reveals a failed component replace Main PCB 1 SERVICE CUTMASTER 102 N PCB 5 IGBT Test With PCB 2 removed from unit 1 Using an ohmmeter perform the following checks PCB 5 Q1 Test points located on PCB 5 vaut 1 2 PRI 1 PRI 1 PMTH 1 PMTH 2 PRI 2 PRI 2 Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode PCB5 Q2 Test points located on PCB 5 Meter Meter PMTH 3 4 PRI 4 PRI 4 4 PMTH 3 PRI 3 PRI 3 Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode 2
42. the Front and Rear panel from the base per section 7 04D Carefully guide the Center Chassis towards the center of the base to disengage the bottom lock ing 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 ing its wires through from the right side of the unit PARTS REPLACEMENT CUTMASTER 102 13 Install replacement Output Inductor by reversing the above steps 14 Reinstall the power supply cover E Output Inductor L2 Tools required T20 Torx Driver 1 2 e 7 Remove the Cover per subsection 7 04A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05F Disconnect Output Inductor wires from Choke1 terminal on the 40A Power PCB and from the Disconnect J2 amp J3 connectors from Main Remove the two screws securing the Center Chassis to the base Loosen the two screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Disengage the Front and Rear panel from the base per section 7 04D Carefully guide the Center Chassis towards the center of the base to disengage the bottom lock ing tabs securing the Chassis to the base 10 Carefully guide the Center Cha
43. this Lower Screws N S S 4 Art A 07947 2 Carefully pull the Cover up and away from the unit SERVICE B Cover Installation 1 Reverse previous procedures for cover installa tion NOTE When installing the upper screws attempt to reuse the original threads The easaiest way to do this is by turning the screw counter clockwise until you feel the threads lign 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 11 A PCB 1 Input Diode D1 Test Section 5 11 B PCB 5 Input Diode D1 Test Section 5 11 C PCB 2 Capacitor Relay Test Section 5 11 D PCB 1 IGBT Test Section 5 11E PCB 5 IGBT Test Section 5 11 F PCB 1 Output Diode Test Section 5 11G PCB 5 Output Diode Test Section 5 11H PCB 1 Pilot IGBT Test Section 5 111 PF SP tr If no fault is found in Pre Power Up Tests 2 6 skip steps 10 14 If a fault is found in Pre Power Up Tests 2 6 remove PCB2 and perform the following Pre Power Up Tests to determine which PCBs have failed 10 2 Capacitor Relay Test Section 5 11 11 PCB1 Input Diode D1 T
44. 1 7 01 COG S 7 1 7 02 Anti Static Handling Procedures 7 1 7 03 Parts Replacement General Information 7 1 7 04 Major External Parts npe bunt epe ter tese e iege 7 2 7 05 Front Panel Parts Replacement 7 3 7 06 Left Side Internal Parts 7 4 7 07 Rear Panel Parts Replacement 7 6 7 08 Right Side Internal Parts 7 9 TABLE OF CONTENTS APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 DATA TAG INFORMATION 1 1 1 02000 0060 00000 00 nennt nennen A 2 APPENDIX 3 TORCH PIN OUT 5 A 3 APPENDIX 4 TORCH CONNECTION 4 APPENDIX 5 SYSTEM SCHEMATIC 208 460V A 6 APPENDIX 6 Publication 8 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 01 Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows Notes Cautions and Warnings NOTE An operation procedure or backgrou
45. 1 Replacement Filter Hose not shown 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose Bracket amp Mounting Screws 9 0233 1 Bracket Filter Mounting not shown 9 9386 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 Automation Interface Kit 9 8311 1 Automation Harness 9 9385 T 25 7 6 m CNC Cable for Automation Interface Kit 9 8312 1 50 15 2 m CNC Cable for Automation Interface Kit 9 8313 1 Nylon Dust Cover 9 7071 Filter Element Cat No 9 7741 pring 5 O ring d Cat No 9 7743 Assemb Cover ed Filter First amp Second Stage Cartridges as marked Barbed amp Fitting Art A 02476 Art 02942 Optional Single Stage Filter Kit Optional Two Stage Filter Kit PARTS LIST 6 6 Manual 0 4997 CUTMASTER 102 6 10 Replacement Parts for Hand Torch Item Description log 1 1 Torch Handle Replacement Kit includes items No 2 amp 3 9 7030 2 1 Trigger Assembly Replacement Kit 9 7034 3 1 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 SL100 20 foot Leads Assembly with
46. 2 B PRI 3 D PRI 4 C SECI SEC2 1 2 TP3 TP4 TP5 TP6 TP7 8 TIP1 V_OUT1 WORK1 5 28 12VDC 12VDC 48VDC 48VDC AC Input AC Input AC Input Negative DC output to L1 Negative DC output to torch Common Common Current Demand Signal 1 5VDC during Pilot 1 2 4 VDC During Cut IGBT Bank A Output to T1 IGBT Bank A Output to T1 IGBT Bank B Output to T1 IGBT Bank B Output to T1 T1 Secondary T1 Secondary Capacitor Bank A Capacitor Bank A Capacitor Bank B Capacitor Bank B Capacitor Bank A Capacitor Bank A Capacitor Bank B Capacitor Bank B Positive Tip DC Output Negative DC output Positive DC output Manual 0 4998 MTH8 MTH6 MTH1 MTH2 BLACK ACL ORANGE CUTMASTER 102 PMTHA PMTH3 o Mc IT MTHS 15 PRI2 AN I R9 TD E P o MTH7 PRI2 MTH4 80 _ 1 80 _ Q 80A AC2 PMTH1 Art A 08505AB 40A AC1 40A AC3 40A AC2 CAPACITOR PCB 2 LAYOUT CAPACITOR PCB 2 SIGNALS MTH7 CAP BANK B 12 MTHS CAP BANK B 11 2 460VAC PMTH1 CAP BANK A 11 3 230VAC PMTH2 CAP BANK A PMTH3 CAP BA
47. 98 CUTMASTER 102 B Gas Distribution E Parts In Place PIP The single gas used is internally split into plasma The torch includes a 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 start cartridge around c the electrode and out through the tip orifice Torch Switch Torch Trigger The secondary gas flows down around the outside CODI Cable Wiring of the torch start cartridge and out between the tip X O and shield cup around the plasma arc PIP Switch Shield Cup A 02997 xm O 5s PIGDATE Parts 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 WOIK i Main Cutting Arc DC power is also used for the main cutting arc The To ATC PIP Switch Shield Cup negative output is connected to the torch electrode through the torch lead The positive output is con nected to the workpiece via the work cable and to th h through a pilot wire e torc rough a pilot wire CNC Start To ATC PIP Switch Shield Cup lt Art A 08168 Automation Torch PIPSwitch Shield Cup PI Par
48. ARNING 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 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAIN
49. ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 2 total _ 9 7031 07993 Manual 0 4997 6 7 PARTS LIST CUTMASTER 102 6 11 Replacement Parts for Machine 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 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 6 1 11 279 mm Rack 9 7041 7 1 11 279 mm Mounting Tube 9 7043 8 1 End Cap Assembly 9 7044 9 2 Body Mounting Pinch Block 9 4513 10 1 Pin Mounting Pinch Block 9 4521 11 1 Torch Holder Sleeve 7 2896 12 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 PARTS LIST 6 8 Manual 0 4997 CUTMASTER 102 Manual 0 4997 6 9 PARTS LIST CUTMASTER 102 6 12 Torch Consumable Parts SL100 SV Ohmic Clip 20 40A Tip 9 8224 Dc Shield Cap Machine STANDOFF CUTTING 40 9 8245 6 20 9 8205 Shield Cap Deflector 50 60A STANDOFF
50. And Accessories For options and accessories see section 6 INTRODUCTION 21 2 2T 05 Introduction 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 then transfers to the workpiece through the column of plasma gas in Zone C Power Supply A le e 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 49
51. B2 to the Main PCB and 40AMP PCB 5 Install the replacement PCB by reversing the above steps B Main PCB PCB1 Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04A 2 Remove Capacitor PCB per subsection 7 08A 3 Remove the two large gas hoses per subsection 7 05 C 4 Remove the Gas Solenoid per subsection 5 05F 5 Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector 6 Remove the four 4 mounting screws securing the PCB to the center chassis 7 Carefully guide the PCB assembly up and out of the unit 8 Install the replacement PCB by reversing the above steps 9 Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04A 2 Remove all wires from W1 noting the location and orientation of each wire 3 Loosen the two 2 Torx head screws securing the Main Contactor to the base 4 Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mount ing screws 5 Lift Main Contactor up and out of the unit Manual 0 4998 7 9 1 2 3 Remove the Cover per subsection 7 04A Remove Capacitor PCB per subsection 7 08A Remove the two large gas hoses per subsection 7 05 C Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector Remove the four
52. C 3 Disconnect cable from the Pressure Transducer 4 Pull the Air Regulator adjusting knob from the shaft 5 Loosenand remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 6 Remove the Pressure Transducer from the regu lator and install on new regulator using liquid pipe thread sealant 6 Install replacement Air Regulator by reversing the above steps 2 5 7 Reinstall the power supply cover E Pressure Transducer Replacement Tools required T20 Torx Driver 11 16 Open End Wrench 1 Remove Air Regulator per subsection 7 05D 2 Remove the defective Pressure Transducer from the regulator and install the new Transducer onto the Air Regulator 3 Install the regulator assembly per subsection 7 05D 4 Reinstall the power supply cover F Gas Solenoid Replacement Tools required T20 Torx Driver Flat Screw Driver 1 Remove the cover per subsection 7 04A 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 7 3 PARTS REPLACEMENT CUTMASTER 102 G Logic PCB PCB3 Replacement Tools required T20 Torx Drive
53. CUTTING p 30A 9 8206 40A 9 8208 9 8243 50 55A 9 8209 60A 9 8210 Shield Cap Machine 50 60A 9 8238 Shield Cap Deflector 9 8243 Cem M Shield Cap Machine 70 100 9 8239 Electrode Starter an B 98215 Cartridge 70 120A 70A 9 8231 9 8213 STANDOFF Shield Cap Deflector CUTTING c 9 8243 90 100 9 8212 6 120A 9 8253 PARTS LIST GOUGING 9 8225 40 9 8226 50 120 Amps 9 8241 Shield Cup Gouging Tip 9 8227 60 120 Amps Art 08066 AB Tip D 9 8228 60 120 Amps 6 10 Manual 0 4997 SECTION 7 REPLACEMENT PROCEDURES 7 01 Scope This section describes parts replacement procedures which may be performed on the CutMaster 52 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 PC Boards can be irreparably damaged by im proper 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 AN s Read and understa
54. Cap Deflector i 9 8243 Standoff Guide 9 8251 40 9 8208 STANDOFF CUTTING 20 60 Tips Shield Cap Deflector D 9 8243 Start Cartridge 50 55A 9 8209 Standoff Guide 9 8213 60A 9 8210 9 8281 STANDOFF CUTTING Shield Cap Drag Elecirode 70 100 9 8236 9 8215 70 120 41555 05 CUTTING Shield Cap Deflector 9 8243 7OA 9 8231 80A 9 8211 _ Standoff Guide 90 100A 9 8212 9 8281 120A 9 8253 STANDOFF CUTTING 40 120A GOUGING i N Shield Cap Gouging C _ Jy 9 8241 Tips Tip Gouging 9 8225 40 Amps Max Tip Gouging 9 8226 50 100 Amps CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less Art 08065 AB Tip Gouging 9 8227 60 120 Amps CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less Tip Gouging D 9 8228 60 120 Amps Tip Gouging 9 8254 60 120 Amps Manual 0 4998 4T 9 OPERATION CUTMASTER 102 4T 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip Fue s ze 757 orlas o 4a o ms om us as roars is seno xo so ss 7 orlas a ow us as umo 120 eo 180 497 orlas vo ss ow us wo 4s orlas m0 as Fores 11 eo 1 zs ss om usw as umo ns s 20 orlas ss o
55. DC indicator Pilot arc established Main arc transfers Pilot arc off ACTION Release torch trigger RESULT ACTION ACTION Main arc stops Gas flow stops after post flow Unplug input ON OFF switch power cord or to OFF O open external disconnect RESULT SU RESULT All indicators off No power to syste ower supply fan s shuts off Art 07979 Manual 0 4997 A 1 APPENDIX CUTMASTER 102 APPENDIX 2 DATA TAG INFORMATION Type of Power IHERMAL DYNAMICS West Lebanon NH USA 03784 A THERMADYNE Company Date of Mfr Made in USA Manufacturer s Name and or Logo Location Model and Revision Level Serial Number and Production Code Supply Note 1 ses n sp EST Regulatory Standard Covering This Type of Power Supply Output Current Type Duty Cycle Factor Output Range Amperage e p ge Amperag Plasma Cutting s Voltage Symbol F 2 X Duty Cycle Data Note 3 Uo U2 Rated No Pad als Load Voltage Load Voltage Rated Maximum Supply Current Input Power Symbol E 19 1max 45 leff 3g Maximum Effective jx Supply Current Input Power Specifications Phase AC or DC Hertz Rating Manufacturer s Electrical Schematic File Number and Revision Level Degree of Protection Rated Supply Voltage Note 2
56. DE PROTECTION DE LA SANTE 29CFR 1910 disponible du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible 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 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 Ameri can 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 749 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROCEDES 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 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 Incendi
57. 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 OUTPUT FAULT This indicator has two modes of operation Firstis the latched Fault mode The 85 PSI LED blinks at 1 cycle per second indicating that one of two fault conditions exist 1 A shorted condition in the torch leads or consumables 2 Low or no output voltage from the inverter circuits In both cases to reset the machine turn the unit OFF indentify and clear the problem and turn back ON SERVICE CUTMASTER 102 The second mode is a non latched mode The 85 PSI LED blinks at 5 cycles per second indicating one of three fault modes exists 1 While using an Automation Torch at current settings above 45 amps the tip has contacted the work piece 2 Air restriction in torch resulting in low voltage during pilot 3 Low voltage during cutting due to torch or consumable problem In all three cases to reset the machine remove the START signal 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
58. ED 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 connec tion of cable to clamp is secure Manual 0 4998 CUTMASTER 102 B Main arc transfers but current cannot be adjusted 1 Defective Logic PCB 3 a While main arc is transferred measure voltage on Main between test points GND1 to I DMDI b 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 Replace Logic PCB 3 2 Defective Main PCB 1 a Replace Main 1 C In LATCH mode when the torch switch is released the arc shuts off immediately 1 Defective Logic 3 a Replace Logic D With CURRENT CONTROL POTENTIOMETER set at maximum output current is only 60 amps 1 Tipis touching the work piece Drag mode a Lift tip off work piece 2 Defective Pilot IGBT on Main PCB 1 a Check per section 4 10I 3 Open Sync cable between 14 on Main PCB 1 and 40Amp PCB 5 a Check continuity and replace if open 4 Open ribbon cable between Main 1 and logic 3 a Check continuity 5 Defective 40Amp 5 a Replace 40Amp 5 E In RAPID AUTO RESTART mode with torch switch closed the pilot does not start immediately when the cu
59. IHERMAL DYNAMICS 2 CUTMASTER PLASMA CUTTING SYSTEM IHERMAL DYNAMICS A Read and understand this entire Manual and your employer s safety practices before installing operat ing 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 102 SL100 1TorchTM Service Manual Number 0 4998 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2008 by Thermadyne Corporation rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date September 25 2008 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial ff Torch Serial This Page Intentionally Blank TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION nennen nennen nnns enne nnne nns 1 1 1 01 Notes Cautions and Warnings ss 1 1 1 02 Import
60. LENOID H EE 5 5 wre oH 4 _ ELECTRODES y 5 5 a PILOT IGBT 1 ons WORK L Ex ER quat 1 1 ISTART 3 80 4 24VAC RETURN 5 24VAC SUPPLY 4 1 TT T BASIC CNC INTERFACE OPTION n LT m Pio 5 1 1 2 2 42 PINOUT 250046 3 3 5 5 tj 5 7 7 H START STOP 40 PIN RIBBON CABLE SIGNALS D FULL FEATURED AUTOMATION INTERFACE PCB OPTION TEST POINTS SIGNAL 69 PCR 2 IP vous To configure DIVIDED ARC VOLTS signal output GND 3 MP SENSE ML Jumper pins 1 amp 2 for ARC VOLTS 50 GND2 COMMON 4 MSN LM Jumper pins 2 amp 3 for ARG VOLTS 16 22 Savi M2VDC SUPPLY 5 RAIN Lu P 148 VDC SUPPLY CUR SET LM EI LDMD1 CURRENT DEMAND 7 IRAR RAPIDAUTORESTART LM s TiPSEN TIP DRAG SENSE E ANRUSH LM 9 LM Et 10 SHDN LM o 1 11 SOLENOID Lu 2 12 SOLENOID ON Lu Pio 3 H HE ET sape 1 menie 14 FAN ON LM x 1 5 19 EM i i 8 7 MO anc vous 18 TORCH SWITCH ML 3 3 i ARC VOLTS 17 ML 100K IN SERIES 2 18 ML 5 5 iJ 8 cok ML 20 SOLENOID DETECT M L 1 1 4 21 OVERTEMP AUTOMATION 2 12 2 VN ME EMEN eL joeowoe 23 ML Taara CAT east ML 25 COMMON ML 26 COMMON ML 29 MAIN ID ML ER ML
61. MOT fan blades from turn ing Replace MOTI 1 Either MOT2 or MOT3 do not turn on after START signal is activated 1 Fan wires not connected to 40A PCB a Check and reconnect to 40A PCB 5 2 Defective fan a Check to be sure there is no physical obstruc tions preventing fan blades from turning Replace respective fan J Fans MOT2 amp do not turn on after START signal is activated 1 Defective Capacitor PCB 2 Manual 0 4998 a Measure for 12VDC between J2 1 to J2 2 on PCB 2 If no voltage is present replace Capaci tor PCB 2 2 Open connection between Capacitor PCB 2 J2 and 40A PCB 5 J3 a Verify connectors are plugged in Check continuity 3 Open connection between Main 1 J13 to 40A PCB 5 a Verify connectors are plugged in Check tinuity b Measure voltage at J4 2 to J4 10 on 40AMP 5 for 12VDC The voltage should drop to less than 2vdc after a START signal is active If the 12VDC is not present or does not drop to less than 2VDC after a START signal is activated then replace the ribbon cable 4 Defective 40AMP PCB 5 a Measure the voltage between J1 1 to J1 2 on the 40AMP PCB 5 for 12VDC after the START signalis activated If 12VDC is present replace 40AMP PCB 5 5 Defective Fans MOT2 and 3 a If 12VDC is resent J1 and J2 connectors on 40A PCB 5 replace fans MOT2 amp MOT3 5 09 Main Arc and Controls Problems A Main arc will not establish L
62. NK B 12 1 412VDC PMTH4 CAP BANK B 80A ACI AC line 1 j2 2 Common 80A AC2 AC line 2 CAPACITOR PCB 2 TEST POINTS BAHIA penes 40A ACI1 AC line 1 1 40A AC2 AC line 2 MTH2 CAP BANK A 40A AC3 AC line 3 MTH4 CAP BANK A MTH6 CAP BANK B Manual 0 4998 5 29 SERVICE CUTMASTER 102 TP7 TP6 TP2 TP5 d D R55 Di mm mm OE R6 RT RB C3 R9 Ul R10 R11 a R12 R13 C6 aa R15 R16 R17 um wm C10 emm m Wu EET se ms Bo n E a s TP3 TP4 U4 d L Farm E 161 Tig e e WWMM m mr mo em mom C37 8 e e e M X jj X X E X 5 D2 D3 D4 D5 D6 D7 D8 D9 J3 Art A 08504 D10 D12 D14 011 013 LOGIC 3 LAYOUT SERVICE 5 30 Manual 0 4998 CUTMASTER 102 LOGIC PCB 3 SIGNALS JA Signal i
63. 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 8 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 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 l arc de plasma 1 3 GENERAL INFORMATION CUTMASTER 102 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 bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et soudez pas les conteneurs ayant 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
64. RVICE 2 Primary fuses breakers are blown or tripped 3 Faulty components in unit 1 INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage 2 Primary input voltage problem 3 Faulty components in unit 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 Cup loose 2 Torch not properly connected to power supply 3 Problem in torch and leads PIP circuit 4 Failed components in unit 1 Start signal is active when ON OFF SWITCH is turned to ON position 2 Problem in the torch and leads switch circuit 3 Failed 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 1 Turn off power to unit then set INPUT VOLTAGE SELECTION SWITCH to match primary input voltage 2 Have qualified person check primary voltage to insure it meets unit requirements see section 2 04 3 Return to authorized service center for repair or replacement Refer to clearance information section 2 04 Allow unit to cool Return to authorized service center for repair or replacement Connect gas supply to uni
65. TART is active Torch switch Active low PARIS 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 3VDC 460 VAC 1 5VDC 230VAC Voltage level to identify Main Pcb 1 7VDC 5 27 CUTMASTER 102 Signal Source Destination M L M L M L L M L M M L M L M L L M M L M L SERVICE CUTMASTER 102 J4 1 J4 2 J4 4 J4 5 J5 1 5 2 5 3 16 1 16 2 ja 7 2 J8 9 1 9 2 J9 3 9 4 9 5 19 6 19 7 710 1 10 2 710 3 10 4 710 5 710 6 10 7 710 8 yi 712 1 712 2 12 3 3 3VDc TXD RXD Common D 12VDC Not used SOLENOID 24VAC Supply for W1 24VAC Return 12VDC FAN Not Used PIP Common TORCH SWITCH START Common Automation Torch solenoid 24VAC supply Not Used Automation Torch solenoid 24VAC return Not used OK TO MOVE Not used Common Common 12VDC START Remote Pendant CNC Signal N A 12VDC 460VAC 230VAC SERVICE J13 1 713 2 713 3 713 4 713 5 713 6 OVERTEMP FAN ON CSR CUR SET MAIN ID Common MAIN PCB 1 LED INDICATORS D59 PCR Indicates Pilot IGBT gate signal is on D78 CSR Indicates cutting arc has been established MAIN PCB 1 TEST POINTS 12V1 12V2 48V1 48V2 AC1 AC2 AC3 1 ELECTRODE1 GND1 GND2 I DMD1 PRI 1 A PRI
66. TE For a secure seal apply Permatex 56521 or equivalent thread sealant to the fitting threads according to the 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 Inlet Port to 1 4 6mm Fi Hose Clamp AG f E EAE 1 4 NPT or 150 Art A 07943 Air Connection to Inlet Port INSTALLATION Manual 0 4998 CUTMASTER 102 Installing Optional Single Stage Air Filter An optional filter kit is recommended for improved 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 Permatex PX56521 or equivalent thread sealant to the fitting threads according to the 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 Inlet Port Y An ao7oas L ET 2 Hose Clamp 1 1 4 NPT to 1 4 Hose 6mm Fitting Optional Single Stage Filter Installation Manual 0 4998 3 5 INSTALLATION CUTMASTER 102 Installing Optional Two S
67. Torch start cartridge is stuck 1 cycle per second FAULT indicator Manual 0 4998 3 Worn or faulty torch parts 4 Shorted Torch 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 reely 4 Replace torch and leads or return to authorized service center or repair or replacement 5 Replace torch and leads or return to authorized service center or 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 Remove shield cup from torch check upper O Ring 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 reely 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 Check torch consumable parts for wear or foreign debris 1 Work cable not connected to ork piece 2 Wo
68. a pere c un c 018 10 25 oean 132 s0 9 023 049 Type Secondary Gas Single Gas Torch Inches mm Plasma Total Inches m vm s se uos Lue i DEEE wu 5 7 CHERS s zm sn oss ss vm w wo ss us s CEE m 3 2s o5 S 7 seat we sm s s os oso pez sem vs 28 on oss s AI BR BR DR e gt BI B EB BRIS 25 5 D T 2 15 osr vos s orofo sem us s 10 os oos 22 oem s so o 029 oz fe eo e 020 0218 ajajaja ts 5 oeololoj oj o o o oj o o o T gt sa Manual 0 4998 4T 11 OPERATION CUTMASTER 102 Type Torch Mechanized With Exposed Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Standoff Plasma Gas Press Flow CFH Pierce Height Inches Cat No Volts VDC Amps Inches psi Plasma Total Delay Sec mm 4 4 1 so ss es ozs fea m as vs oss 14 ao um oz 64 ns 340 sso i
69. able for the voltage desired and strip back the insulation on the individual wires 5 Pass the cable being used through the access opening in the back panel of the power supply Re fer to Section 2 for power cable specifications UTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 INSTALLATION 3 2 Manual 0 4998 CUTMASTER 102 6 Connect the wires as follows Connect Bus Bar Jumpers on the contactor as shown in prior illustration and on label in the power supply e Green Yellow wire to Ground 7 With a little slack in the wires tighten the through hole protector to secure the power cable 8 Reinstall the Power Supply cover 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power cable or close the main disconnect switch to supply power B Connections to Three Phase Input Power Disconnect input power from the power supply and input cable before attempting this procedure These instructions are for changing the input power and or cable on the 208 230 400 460 VAC Power Supply to Three Phase input power 1 Remove the Power Supply cover per instructions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chassis ground connection 3 Loosen the through hole protecto
70. anel Install the replacement Work Cable by reversing the above steps Reinstall the power supply cover 7 06 Left Side Internal Parts Replacement A Fan Replacement Tools required T20 Torx Driver Fan 1 1 2 3 7 Remove the Cover per subsection 7 04A Unplug J7 connector 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 heatsink Install replacement fan by reversing the above steps Reinstall the power supply cover Fans MOT2 or MOT3 7 2 Remove the Cover per subsection 7 04 Unplug corresponding 1 or J2 connector from the 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 heatsink Install replacement fan by reversing the above steps Reinstall the power supply cover Manual 0 4998 B Main Transformer T1 Replacement Tools required T20 Torx Driver 1 2 10 11 12 13 14 Remove the Cover per subsection 7 04A Remove the two large and
71. ant Safety Precautions 2 22 40 1 1 1 03 PUDICATONS 2555 EE 1 2 1 04 Note Attention et Avertissement 1 3 1 05 Precautions De Securite 1 3 1 06 Documents De Reference 1 5 1 07 Declaration of Conformity eene 1 6 1 08 Statement of Warranty 5 itte a iibri bee ER 1 7 SECTION 2 SYSTEM INTRODUCTION 2 1 2 01 How Use This 2 1 2 02 Equipment 2 1 2 03 Receipt Of Equipment hautement ute 2 1 2 04 Power Supply Specifications 2 2 2 05 Input Wiring Specifications sisstin ient rennen e dea a 2 3 2 06 Power Supply Features 2 4 SECTION 2 TORC HINTRODUC MON curo t dot teet Entrar ott ne Fete rude 2T 1 2101 lt nn o e Ren 2T 1 2102 G n ral Description iecit rsen eR etui 2T 1 271 03 Specifications iii 27 1 27 04 Options And Accessories 2 2 21 05 Introduction to Plasma ea tanen un 2 2 SECTION SYSTEM INSTALLATION 2 2 2244 40440 40 nnn nnne 3 1 3 01 Biaereuomrtem Et 3 1 3 02 le NO 3 1 3 03 Primary Input Power Connections 3 2 3 04
72. ant switch B CNC cable interfaced to cotroller 1 Provide a START signal to establish a pilot arc and note the following e Cooling fans MOT1 3 turn on e Gas solenoid opens Gas flows e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing DCLED comes on Pilot arc is established 2 Remove the START signal and not the follow ing Gascontinues to flow DCLED goes off After 20 second post flow time e Gas solenoid closes e 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 piece provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc Main Cutting Arc Establishes e On PCB 1 D59 turns off and D78 turns 1 Clamp DC ammeter around the work cable Out put will be 100 amps 2 While cutting adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to minimum setting SERVICE 5 10 Current adjusts from 100 amps down to 20 amps 3 Set the CURRENT CONTROL POTENTIOM ETER to maximum position Current adjusts from 20 amps up to 100 amps 4 While cutting touch the tip of th
73. arranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 4998 1 7 GENERAL INFORMATION CUTMASTER 102 GENERAL INFORMATION 1 8 Manual 0 4998 SECTION 2 SYSTEM INTRODUCTION 2 01 How To Use This Manual This Owner s 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 WARNING gives information regarding possible personal injury UTION A CAUTION refers to possible equipment dam age NOTE A NOTE offers helpful information concerning certain operating procedures 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 Owner s Manual number and equipment identification numbers 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 Manual 0 4998 2 1 CUTMASTER 102 2 02 Equipment Identification
74. ble gas pressure regulator filter and operating manual Description log 1 CutMaster 102 Power Supply 208 230 460VAC Single or 3 Phase 60Hz with 208 230 single phase input power cable and plug 3 1330 1 with 460V single phase input power cable 3 1330 2 Manual 0 4997 6 1 PARTS LIST CUTMASTER 102 6 04 Major External Replacement Parts Item Description log 1 1 Cover with labels 9 0128 2 1 Base Enclosure Assembly 9 0186 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0187 5 1 Rear Panel 9 0101 Art A 08564 Illustration may vary slightly from unit PARTS LIST 6 2 Manual 0 4997 CUTMASTER 102 6 05 Front Panel Replacement Parts Item Description Ref log 1 1 Output Current 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 0189 Illustration may vary slightly from unit Manual 0 4997 PARTS LIST CUTMASTER 102 6 06 Left Side Replacement Parts Item Description Ref log 1 1 Main PCB Assembly 1 9 0108 1b 1 Main PCB Assembly 40 Amp PCB5 9 0194 2 1 Logic PCB PCB3 9 0107 3 1 Center Chassis Molded Plastic 9 0190 4 1 Fan 3 total MOTI1 3 9 0104 5 1 Transformer Main T1 9 0106 5b 1 Transformer Main 60 Amp T2 9 0196 6 1 Inductor Output 11 9 0105 6b 1 Inductor Output 40 Amp L2 9 0195 Not Shown 1 Power Cable Strain Relief for all units 9 0111 1 Input Power Cable 230 V with plug 9
75. bove then note the symptom and proceed to Section 5 10 CNC Interface Problems If the unit has the Automation Interface PCB installed continue with this section 4 There are three 3 ARC VOLTS signals available from the J6 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 VOLIS divided by 50 J2 5 to J2 6 Auto Interface pcb J3 con nector with jumper installed between pins 2 and 3 ARC VOLIS divided by 16 Measure the voltage between these points while pi loting Open Circuit Voltage and while cutting The voltages should approx as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 6 VDC 2 VDC c 19 DVC 6 VDC SERVICE CUTMASTER 102 This completes the CNC Interface Test If the above areall Gas flows with ON OFF SWITCH in OFF correct then the unit is functioning correctly If the unit position does not function as stated then note the symptom and proceed to Section 5 10 Interface Problems 1 Foreign debris has lodged in gas solenoid a Replace gas solenoid This is a problem caused 5 07 Main Input and Internal Power by improperly filtered air supply Customer Problems needs to add filtration to air supply prior to unit inlet m idis 2 D All front panel indicators are off Fan 1 y never turns on Contactor W1 does 1 Primary input cabl
76. d mode of operation hand or machine torch and the amount of material to be removed Manual 0 4998 CUTMASTER 102 Pressure Setting Even though the setting is within the specified range if the torch does not pilot well the pressure may need to be reduced Lead Angle Theangle 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 In some applications such as removing welds or working with light metal this may be desirable AN 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 4 7 Slag generated 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 the
77. dentification 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 higher for standoff cutting 2 Function Control Function Control Knob Used to select between the different operating modes SET 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 no 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 3 On Off Power Switch ON OFF Switch controls input power to the power supply Up is ON down is OFF 4 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 5 N AC Indicator Steady light indicates power supply is ready for op eration Blinking light indicates unit is in protective 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 4998 CUTMASTER 102
78. ding 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 GENERAL INFORMATION CUTMASTER 102 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA age Directive European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC 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 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 Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification
79. dition exists and for a ten 10 minute period after the condition is cleared Set Operating Pressure 1 Place the Power Function Control knob to the SET flow position Gas will 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 4998 STANDOFF CutMaster 102 Gas Pressure Settings Leads SL100 SL100 Length Hand Torch Mechanized Torch Up to 25 80 psi 80 psi 7 6 m 5 5 bar 5 5 bar Each additional Add 5 psi Add 5 psi 25 0 4 bar 0 4 bar 7 6 m 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 STANDOFF CutMaster 102 Gas Pressure Settings Leads SL100 Length Mechanized Torch Up to 25 70 psi 7 6 m 4 8 bar Each additional 25 7 6 m Select Current Output Level 1 Place the Function Control Knob in one of the three operating positions available RUN RAPID AUTO RESTART re or LATCH Gas flow stops 2 Set the output current to desired amperage with the Output Current Control Knob Cutting Operation When thetorch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position there is a brief delay in restarting the
80. e installed incorrectly not close a Check wiring of primary power cable to the 1 Primary power not connected contactor See illustration below a Check that cable is connected to primary 2 W1 jumpers installed incorrectly power a Check jumper installation for correct phase 2 Primary line fuse breaker is blown tripped being used a Replace fuse or reset breaker Input Power Cable Connections 3 Defective ON OFF SWITCH Single Phase 10 and Jumper Settings Three Phase 39 Store copper jumpers on base plate a Check continuity 4 Defective Main PCB 1 L2 a Measure Main Pcb power supply voltages at the following test points GND1 to 12V 12VDC GNDI to 48V 48 VDC Art A 08493 GND Single and Three Phase Input Power Wiring Replace Main Pcb if not correct 3 contactor points are stuck closed 5 Defective Ribbon Cable a Check per section 5 11A a Check continuity 4 Primary plug not wired correctly 6 Defective Logic a Check manufacturer s plug installation instruc a Replace Logic PCB 3 tions 5 Primary input cable is defective a Check cable for shorts 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 11B and 5 11C 2 Shorted Input Capacitor PCB 2 a Check per section 5 11D SERVICE 5 12 Manual 0 4998 CUTMASTER 102 E UNDER PRESSURE FAULT
81. e torch to the work piece This is called Drag Mode For Hand and Machine Torches Tip Saver circuit will activate current drops to 60 amps For Automation Torches The Arc will shut off the FAULT indicator and the 85 PSI LED will flash at 5 cycles per second To reset lift tip off the work piece remove and re apply the START signal and go to step 6 5 Lifttip off the plate approx 1 4 e Tip Saver circuit deactivates current goes back to 100 amps 6 While cutting 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 e Pilot arc ignites 7 Open the torch switch DC LED turns off After 20 second post flow time Gas solenoid closes Gas flow stops 8 Set the FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode 9 Provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc 10 While cutting keep the torch switch closed and bring the torch off the edge of the material Manual 0 4998 Pilot Arc re ignites immediately 11 Open the torch switch e DCLED turns off After 20 second post flow time Gas solenoid closes Gas flow stops For Automation Torches Skip steps 12 amp 13 12 Set the FUNCTION CONTROL SWITCH to LATCH mode 13 Start a cut and remove the START signal Maincutting a
82. elding 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 difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding 4T 04 Hand Torch Operation Standoff Cutting With Hand Torch 4 3 NOTE For best performance and parts life always use the correct parts for the type of operation 1 The torch be comfortably held 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 OPERATION CUTMASTER 102 2 Depending on the cutting operation do one of the following a For edge starts hold the 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 torc
83. es NFPA LES SYSTEMES A GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection As sociation 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 SOUD AGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Manual 0 4998 14 15 CUTMASTER 102 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 RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Wel
84. es can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in 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 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 lens as suggested in the following per ANSI ASC 749 1 Minimum Protective Suggested 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 W
85. est Section 5 11K 12 5 Input Diode D1 Test Section 5 11L 13 PCB 1 IGBT Test Section 5 11M 14 PCB 5 IGBT Test Section 5 11N 5 8 Manual 0 4998 If all of the Pre Power Up Tests are ok proceed with the trouble shooting guide 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 2 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 symptoms and test the unitfor 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 3 Setthe Power Supply controls as follows e ON OFF SWITCH to OFF position Turn FUNCTION CONTROLSWITCH to SET position CUTMASTER 102 3 Adjustthe pressure regulator to set the gas pres sure as specified in charts STANDOFF CutMaster 102 Gas Pressure Settings Leads SL100 SL100 Length 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 ps
86. gh 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 4998 CUTMASTER 102 4T 07 Parts Selection for Manual and Mechanized Torch Cutting Shield Cap Deflector 9 8243 DRAG TIP A CUTTING CD 20A 9 8205 30A 9 8206 40A 9 8207 60A 9 8252 P Shield Cap Drag 40A 9 8244 Shield
87. h 1 8 3 8 in 3 9 mm from the workpiece as shown below 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 characteristic of the power supply and not a function of the torch OPERATION 4T 4 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 For a consistent standoff height from the workpiece install the standoff guide by sliding it onto the torch shield 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 w
88. i 25 0 4 bar 0 4 bar 7 6 m CutMaster 102 Gas Pressure Settings Leads SL100 Length Mechanized Torch Up to 25 80 psi 7 6 m 5 5 bar Each Adds psi J 0 4 bar 7 6 m 4 Turn FUNCTION CONTROL SWITCH to RUN position Solenoid turns off gas stops flowing pressure display may increase slightly when gas is not flowing CURRENT CONTROL POTENTIOMETER to MAXIMUM position fully clockwise This completes the Main Input and Internal Power Test If the above are all correct then proceed to the next section E Main Input and Internal Power Test F Pilot Arc Test If the unit does not function as stated 1 Connect Primary Line power to the unit above then note the symptom and proceed to Section 5 07 Main Input and Internal Power Problems 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 approx three 3 seconds Inrush relay on energizes starting pre charging of working capacitors W1 energizes e AC and GAS Indicators come on e Gas flows e For earlier units Fan MOT1 turns on for one 1 second then shuts off Manual 0 4998 5 9 SERVICE CUTMASTER 102 F Pilot Arc Test There are three types of START signals which can be used to begin system operation 1 Hand Torch Operator switch mounted on the torch handle 2 Machine torch or Automation torch A Hand heled pend
89. ing the unit Check the Voltage Selector at the rear of the unit for correct setting 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 wiring requirements as specified in Section 2 The following illustration and directions are for changing phase of the power supply Input Power Cable Connections Single Phase 19 and Jumper Settings Three Phase 39 Store copper jumpers on base plate mmm 2 m 2 Art 08493 GND Single and Three Phase Input Power Wiring NOTE There are two jumpers used for the single phase 230V setting and none for three phase A Connections to Single Phase Input Power G Disconnect input power from the power supply and input cable before attempting this procedure These instructions are for changing the input power and or cable on the 208 230 400 460 VAC Power Supply to Single Phase input power 1 Remove the Power Supply cover per instructions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chassis ground connection 3 Loosen the through hole protector on the back panel of the power supply Pull the original power cable out of the power supply 4 If the power cable being used is not the factory supplied cable use a three conductor input power c
90. 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 England PR6 7BX GENERAL INFORMATION 1 6 Manual 0 4998 CUTMASTER 102 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 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 re
91. la tion NOTE When installing the upper screws attempt to reuse the original threads The easaiest way to do this is by turning the screw counter clockwise until you feel the threads lign 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 Remove the cover per subsection 7 04 A 2 Remove the screws securing the tube handles to the base of the unit 3 Remove the Tube Handles 4 Replace the Tube Handles by reversing the above steps 5 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 Remove the cover per subsection 7 04 A 2 While grasping the panel close to the base pull the panel directly from the base to release the locking tabs 3 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 locking tabs engage the mating holes in the base 4 For complete removal of panel disconnect any other item still attached to the panel and another component of the power supply 7 2 Manual 0 4998 7 05 Front Panel Parts Replacement Refer to section 6 05 for Front Panel Replacement Parts and overall de
92. life Standoff may also signifi cantly affect the bevel angle Reducing standoff will generally result in a more square cut 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 T GU Angle a 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 Manual 0 4998 CUTMASTER 102 Dross When dross is present on carbon steel it is com monly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate dis tance Top dross is normally very easy to remove and can often be wiped off with a w
93. line voltage Turn SW1 to OFF position then back to ON position to clear the error 4 Torch Switch 2 Defective SW2 3 Torch Switch a Check continuity 2 PIP i 1 PIP 3 Primary line voltage out of tolerance range a Connect unit to voltage with unit specifica tions See section 2 04 Power supply speci A 08124 I qu Pilot Lead fications If using a generator connect unit to a wall receptacle to see if problem is cor 4 Defective Logic Pcb rected a Measure the voltage on Main Pcb between J2 17 4 Defective Main PCB 1 to test point GND1 for 12VDC If the voltage is less than 2VDC Replace Logic Pcb a Measure voltage on Main PCB 1 between test point GND1 to J2 22 5 Defective Main PCB 1 460 VAC input approx 3 VDC a Replace Main PCB 1 230 VAC input approx 1 5 VDC m With all power removed from the unit dis connect the ribbon cable from J2 connector on Main PCB 1 Check continuity on PCB 1 between 2 34 to test point GND 1 With SW2 in LOW position continuity should be present with SW2 in the HIGH position It should read open If not correct replace Main PCB 1 Manual 0 4998 5 13 SERVICE CUTMASTER 102 H START ERROR FAULT The FAULT Indicator and 75 PSI LED 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 START signal is active
94. ll three cases to reset the machine remove the START signal SERVICE CUTMASTER 102 D AC LED on TEMP LED off GAS LED on gas flowing DC LED amp Fault Indicator off No arc in torch 1 Defective Main Pcb a On Main PCB 1 LED D59 should be on and LED D78 should be off If LEDs are incorrect Replace Main 1 2 Defective Logic PCB 3 a Measure voltage at Main PCB 1 between test point GND1 or GND2 to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after START signal is acti vated If voltage does not drop replace Logic PCB 3 3 Defective Main PCB 1 a Replace Main PCB 1 AC LED on TEMP LED off GAS LED on gas flowing DC LED on Fault Indicator off No arc in torch 1 Defective Main 1 a Install jumper on Main PCB 1 between test point GND1 to terminal b Apply START signal If Pilot starts replace Main 1 AC LED on TEMP LED off GAS LED on gas flowing DC LED on Fault Indicator off Pilot Arc is intermittent 1 Defective Main contactor W1 a Check W1 per Pre Power UP checks 2 Defective Logic PCB 3 a Measure for 12VDC on Main PCB between test Point GNDI to J2 8 If 12VDC is present replace Logic PCB 3 3 Defective Main PCB 1 a Replace Main 1 F INTERNAL ERROR Fault Indicator and 90 PSI Indicators are flashing 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position
95. low Release the START signal source 2 Problem in the torch and leads switch circuit a Check continuity of torch switch circuit at ATC pins 3 amp 4 See previous illustration 3 Shortin CNC cable a Check continuity 4 Defective Logic Pcb PCB3 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 1 a Replace Main PCB 1 l 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 start cartridge missing a Turn off power supply Replace missing part s 3 Start Cartridge is stuck a Turn off power supply Bleed down the system 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 1 8 Spring Loaded Lower End Fitting at Rest Full Extension Art A 08064 SERVICE 4 Open conductor in torch leads a Check continuity 5 Defective Main PCB 1 b Measure voltage at Main Pcb between J2 2 to test point GND1 for 12VDC If voltage is present replace Main PCB 1 6 Defective Logic PCB3 a Replace Logic PCB 3 J AC LED on yellow TEMP LED is on red FAULT Indicator is flashi
96. ltage is 12VDC Replace the Logic PCB 3 3 Defective Main PCB 1 a Replace Main PCB 3 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 1 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 12VDC 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 present change SOL 1 2 Defective Logic PCB 3 a Measure on Main PCB between J2 12 to test point GND1 12VDC If voltage is present replace Main PCB 1 SERVICE CUTMASTER 102 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 connector 4 Defective torch solenoid a Measure the coil terminals of the torch mounted gas solenoid SOL2 for 24vac If present re place SOL2 5 Defective Main 1 a Measure on Main PCB between J2 20 t
97. m Main PCB Remove the two screws securing the Center Chassis to the base Manual 0 4998 10 11 12 13 14 CUTMASTER 102 Loosen the two screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Disengage the Front and Rear panel from the base per section 7 04D 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 of the unit Remove the two screws securing the Main Trans former to the base 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 D Output Inductor L1 Tools required T20 Torx Driver 1 2 10 11 12 Remove the Cover per subsection 7 04A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05F Disconnect Output Inductor wires from Chokel terminal on the Main PCB and from the ATC Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the two screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Disengage
98. moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail GENERAL INFORMATION 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 40467 vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de 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 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 pouvant 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 1 4 Manual 0 4998 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
99. nd information which requires additional emphasis or is helpful in ef ficient operation of the system procedure which if not properly followed may cause damage to the equipment WARNING zx cp c ox c c ac A procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02 Important Safety Precautions WARNINGS a 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 ET GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Manual 0 4998 CUTMASTER 102 The kinds of f
100. nd these instructions and the instructions on the grounding wrist strap package before opening the equipment enclo sure or removing 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 prop erly will cause component damage Do not operate the equipment or test equip ment under power while wearing the ground ing wrist strap pecu M Manual 0 4998 CUTMASTER 102 Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unrolltherest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and ex posed electrical ground 4 Connectthe equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure and remove the failed PC board 6 Carefully open the ESD protective bag and re move the replacement PC Board 7 Install the replacement PC Board in the equip ment and make all necessary connections 8 Place the failed PC Board in the ESD protective bag and seal for return shipping 9 Replace the power supply cover 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection
101. nected 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 ZW turns on Gas indicator turns on if there is sufficient gas pres sure for power supply operation and the cooling fans turn on NOTE Minimum pressure for power supply operation is lower than minimum for torch operation When the unit is turned on the cooling fans MOT will remain off In earlier units 1 will turn on for one 1 second and then turn 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 temperature condition occurs the fans will continue to run while the con
102. nfo is the same as MAIN PCB 1 J2 connector jJ3 1 5VDC 13 2 Pressure Transducer output 0 5 to 5 VDC 0 100 psi J3 3 Common LOGIC PCB 3 LED INDICATORS RMAL INDICATI FIRMWARE VERSI ERROR MESSAGE D1 12VDC D2 MAX PRESSURE 7 Over Pressure D3 90 PSI X 6 Internal Error D4 85 PSI X 5 Shorted torch Output Fault D5 80 PSI XA Tip Missing D6 75 PSI X 3 Start Signal active during power up D7 70 PSI X 2 Parts In Place Fault PIP D8 65 PSI X 1 Input Power Fault D9 MIN PRESSURE X 0 Low Pressure D10 AC 1 X 2 X D12 GAS 3 X D13 DC 4 X D14 ERROR 5 X LOGIC 3 TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV TP5 0 5 to 5 VDC 0 100 psi TP6 1 8VDC TP7 Potentiometer Current Demand 0 3 3VDC Manual 0 4998 5 31 SERVICE CUTMASTER 102 Ji J2 J3 J4 J5
103. ng all three fans turn on 1 flow through unit is restricted a Provide adequate airflow See Ventillation 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 Sup ply Specifications section 2 04 for duty cylcle information NOTE When the unit is turned on the cooling fans MOT will remain off In earlier units MOT will turn on for one 1 second and then turns off The fans will turn on when 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 temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condi tion is cleared gt Defective 40A 5 Measure for 12VDC on the 40A PCB 5 between 4 4 to J4 10 Replace 40A PCB 5 if voltage is not present 4 Defective Main PCB 1 a Measure for 12VDC on Main PCB 1 between J2 21 to TP GND1 Replace Main PCB 1 if volt age is not present 5 Defective Logic PCB3 a Change Logic 3 Manual 0 4998 K ACLED on TEMP GAS DC LED s are off FAULT Indicator is flashing MIN PRESSURE LED is flashing 1 Gassupply not connected to unit a Connect gas supply to unit 2 Gas supply not turned on a Turn gas supply on 3 Gassupply pressure
104. nt Demand M 40A 1 2 4VDC Cut Current Demand Manual 0 4998 5 33 SERVICE CUTMASTER 102 This Page Intentionally Blank SERVICE 5 34 Manual 0 4998 CUTMASTER 102 SECTION 5 TO RCH It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o rings on a E RVI E weekly basis 5T 01 General Maintenance F Refer to Previous Section 5 System for common and fault indicator descriptions Upper Groove with Vent Holes Must Remain Open Upper O Ring Cleaning Torch in Correct Groove Even if precautions are taken to use only clean air with a torch eventually the inside of the torch be comes coated with residue This buildup can affect Lower O Ring Art A 03725 the pilot arc initiation and the overall cut quality of Torch Head O Ring the torch Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is 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 JN Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head and ATC Male Connec tor requi
105. o os vo as oo os ws nn WM 1 000 254 98210 1 60 4 019 48 70 48 90 245 NR NR NR Fon is semo s is ais ois vo ae o os oz st roars e is so os sa vo 9 os nw 020 sr so ns so fus or ae 9 us nw st Fuss e zo or sz oo as nw st emo vm e 7s i9 or s2 vo ae 9 os nz st seno vn e is os sz vo 9 os no 020 51 ams ve on o sz o 9 us 020 st oso pez e v o ou ae ae 9o os 075 020 st 06 ss emo ms e nas ou e ae 9o os NA NA use eeo we e 10 025 as o0 W NR Foo rs sso ios eo as am 9o ne ooo 020 51 Foo no eo ss 9o ns 020 51 os ao eseo eo zs 6s se 70 4s 020 51 122 eo s56 sz v ae 9o ns 020 020 51 sexo va eo so 203 vo ae 9o ns 030 020 51 Fosm as ssno wo e as iw orfas vo ae 9o ns os 020 5 oso farl 34 eo 2 oss ois e vo 4s oo 25 020 51 oss se sso ws eo 19 os
106. o GND1 for less than 2VDC If voltage is 12VDC replace Main PCB 1 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 3 a Measure on Main PCB 1 between 2 11 to GND1 for less than 2VDC If voltage is 12vdc replace Logic PCB 3 Q Cannot adjust gas pressure 1 Inlet gas pressure is too low a Increase inlet gas pressure to 95 120 psi 2 Faulty regulator a Replace Regulator 3 Faulty Pressure transducer Air flow changes but display does not a Measure on Main PCB between J2 11 to GND1 while adjusting thePressure regulator from Min to Max VOltage should adjust from 0 4 5VDC If voltage does not change Replace the Pressure Transducer 4 Faulty Logic PCB 3 a Replace PCB 3 SERVICE 5 08 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 pers 3 Torch Switch Uns 1 is 1 PIP SS Art A 08124 Pilot Lead b For machine torches using a remote pendant Check continuity of Pendant switch circuit c Check CNC START signal 2 Defective Logic PCB a Jumper on Main PCB bet
107. oa o 260 ess ozs s4 o a8 245 oa Fse sa semo o wo o as oo se 020 025 ea naso 12 o as oo 28 ooo oss ea Foss ss semo 10 o as 114 oztea o 4s zs 025 oa oso us o 076 ze ozs oa os pss ws 60 20 ost o as oo ss w wm NR oropei esmo ws o w os o as oo w ue ne OPERATION 47 10 Manual 0 4998 CUTMASTER 102 Type Torch Mechanized With Exposed Tip Type Material Mild Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Standoff Flow CFH Pierce Height Inches Cat No Amps nches psi Plasma Total nches Lim a 340 1 o EE gt 3 TETE vs so eo asr oro 4 ris s ox va so 340 3 020 m sm jose rea oan ra 9 1 zm s ui 4 o ux een olo e zx ZEN Er co gt e aan co Ap za A co os 25 sean j 1 ww 040 5 o9 049 05 fo ME of sean 5 os om fo e foa forf
108. om the Main PCB 1 and recheck If continuity still exists replace W1 If disconnecting J1 from Main PCB 1 removes the short replace the Main PCB 1 CutMaster 52 amp 82 W1 contactor wired for 1PH Cover Screws Actuator Jumper Main Contactor input Aa Art 08157 AR 2 Retestcontinuity 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 L4 to T4 The contacts should be closed Continuity 3 Visually check W1 contact points To take the cover off remove the two cover screws shown in the previous illustration If contacts are stuck together or show excessive arcing or pitting re place W1 Manual 0 4998 B PCB 1 Input Diode D1Test 1 Using an ohmmeter perform the tests in the chart Input Diode Module D1 on PCB1 Test points located on PCB 2 Meter Meter Indication 80A 1 MTH 1 Forward Biased Diode 80A AC2 MTH 1 Forward Biased Diode 80A AC3 MTH 1 Forward Biased Diode MTH 1 80A AC1 Reverse Biase Diode MTH 1 80A AC2 Reverse Biase Diode MTH 1 80A AC3 Reverse Biase Diode MTH 7 80A AC1 Forward Biased Diode MTH 7 80A AC2 Forward Biased Diode MTH 7 80A AC3 Forward Biased Diode 80A AC1 MTH 7 Reverse Biase Diode 80A AC2 MTH 7 Reverse Biase Diode 80A AC3 MTH 7 Reverse Biase Diode MTH 7 MTH 1 2 Forward Biased Diodes C
109. onths Replace all Clean broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 07938_AB Manual 0 4998 5 1 SERVICE CUTMASTER 102 5 02 Maintenance Schedule NOTE 5 03 Common Faults Problem Symptom The actual frequency of maintenance may need to be adjusted according to the operating envi ronment Daily Operational Checks or Every Six Cutting Insufficient Penetration 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low Hours 6 Non Genuine Thermal Dynamics parts used 1 Check torch consumable parts replace if dam 7 Incorrect gas pressure aged worn or when cut performance has demi nished Main Arc 1 Cutting speed too slow Extinguishes 2 Torch standoff too high from 2 Check plasma and secondary supply and pres workpiece sure 3 Cutting current too high 3 Purge plasma gas line to remove any moisture Work cable disconnected build up Weekly or Every 30 Cutting Hours 5 Worn torch parts 6 Non Genuine Thermal Dynamics parts used 1 Check fan for proper operation and adequate air Excessive Dross 1 Cutting speed too slow flow Formation 2 Torch standoff too high from 2 Inspect torch for any cracks or exposed wires Rp AR parts replace if necessary 4 Improper cutting current 3 Inspectinput power cable for damage or ex
110. ontinuity between the following points PCB 1 Q1 Test points located on PCB 2 Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias SERVICE CUTMASTER 102 3 Using an ohmmeter check continuity between the following points PCB 1 Q2 Test points located on PCB 1 amp PCB 2 wee meert F PCB 5 IGBT Test 1 Disconnect transformer wires from 40 Amp 5 terminal PRI 1 A 2 Using an ohmmeter perform the following checks Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias PCB 5 Q1 Test points located on PCB 2 AND PCB 5 Meter Meter PRI 1 PMTH 1 PRI 1 PMTH 2 PMTH 1 PRI 1 PMTH 2 PRI 1 PRI 2 PMTH 1 PRI 2 PMTH 2 PMTH 1 PRI 2 PMTH 2 PRI 2 3 Disconnect transformer wire from 40 Amp PCB 5 terminal PRIA C 4 Using an ohmmeter perform the following checks Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias PCB5 Q2 Test points located on PCB 2 AND PCB 5 PMTH 3 PMTH 4 PRI 4 PRI 4 PMTH 3 PMTH 4 PRI 3 PRI 3 SERVICE Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias G
111. orkpiece 1 Shield Cup Standoff Guide Torch Tip Workpiece Art A 04034 Manual 0 4998 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 The straight must be conduc tive 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 3 16 4 7 mm thick or less NOTE Drag cutting can only be performed at 60 amps or less For best parts performance and life always use the correct parts for the type of operation 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 Manual 0 4998 4T 5 CUTMASTER 102 piece during the cutting cycle Hold the torch away from your body 6 Slide the trigger release towa
112. pair or replacement This warranty is exclusive and in lieu of any warranty of merchantability 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 product 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 M and Labor EE ON and Labor CUTMASTER 39 39 4 AYears 1 1 CUTMASTER 52 CUTMASTER 62 CUTMASTER 102 CUTMASTER 152 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 1 Repair of the defective p
113. posed 5 Non Genuine Thermal Dynamics wires replace if necessary Six Months or Every 720 Cutting Hours parts used 6 Incorrect gas pressure Short Torch Parts Life Oil or moisture in air source 1 Check the in line air filter s clean or replace as 2 Exceeding system capability required material too thick 2 Checkcables and hoses for leaks or cracks replace 8 Excessive pilot arc time 4 Gas pressure too low if necessary 5 Improperly assembled torch 3 Check all contactor points for severe arcing or 6 Non Genuine Thermal Dynamics pits replace if necessary parts used 4 Vacuum dust and dirt out of the entire machine Difficult Starting 1 Worn torch parts _ Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit SERVICE 2 Non Genuine Thermal Dynamics parts used 3 ncorrect gas pressure Manual 0 4998 5 04 Fault Indicator At initial power up two lights will temporarily illu minate 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
114. 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 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 CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une 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
115. r Flat Screw Driver wrench 1 2 Remove the cover per subsection 7 04A Remove the two large and one small gas hoses from the pressure regulator per subsection 7 5C Unplug the connector J2 from the Main 4 Disconnect cable from the Pressure Transducer 5 Disconnect front panel from base per subsection 9 7 04D Remove the Current Control Potentiometer Knob and nut securing the potentiometer shaft to the front panel per subsection 7 05A Remove the Function Control Switch Knob and the nut securing the switch shaft to the front panel per subsection 7 05B Install the replacement Logic PCB by reversing the above steps Reinstall the power supply cover H ON OFF Switch SW1 Replacement Tools required T20 Torx Driver 1 2 PARTS Remove the cover per subsection 7 04A Disconnect the wires on the rear of the switch noting the location and orientation of each wire as shown below Switch 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 REPLACEMENT Work Cable Replacement Tools required T20 Torx Driver 1 2 5 Remove the Cover per subsection 7 04 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 p
116. r on the back panel of the power supply Pull the original power cable out of the power supply 4 Using a customer supplied four conductor input power cable for the voltage desired strip back the insulation on the individual wires 5 Pass the cable being used through the access opening in the back panel of the power supply Re fer to Section 2 for power cable specifications UTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 6 Connect the wires as follows Wires to L1 L2 and L3 input 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 7 With a little slack in the wires tighten the through hole protector to secure the power cable 8 Reinstall the Power Supply cover 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power cable or close the main disconnect switch to supply power Manual 0 4998 3 3 INSTALLATION CUTMASTER 102 3 04 Gas Connections 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 NO
117. r supply and bleed the system before disassembling the Filter As sembly as injury could result Loosen the two bolts on the top of the Filter As sembly enough to allow the Filter Elements to move freely Notethe location and orientation of the old Filter Elements Slide out the old Filter Elements First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement PARTS REPLACEMENT 7 8 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 Manual 0 4998 7 08 Right Side Internal Parts Replacement A Capacitor PCB PCB2 Replacement Tools required T20 Torx Driver 2 Phillips Head 6 7 CUTMASTER 102 Install the replacement Contactor by reversing the above steps Reinstall the power supply cover D 40 AMP PCB PCB5 Replacement Driver Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04A 2 Disconnect J1 amp J2 from PCB2 3 Notethe location and remove all wires connected to PCB2 4 Remove the fifteen 15 screws securing PC
118. rc will remain on until the torch is lifted away from the plate approx 4 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 e Gas solenoid closes Gas flow stops Ten 10 minutes after the Start signal is re moved the cooling fans turn off This completes the Main Arc and Controls Test If the above are all correct then proceed to the next section 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 H CNC INTERFACE TEST If the unit has 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 Manual 0 4998 CUTMASTER 102 2 Bring the torch to the work piece and transfer to cutting arc OK TO MOVE signal is present Meter shows continuity 3 Remove jumper from J6 e OK TO MOVE signal off Meter shows no continuity Gas continues to flow DCLED goes off After 20 second Post flow time e Gas solenoid closes Gas flow stops If the unit has the Basic CNC Interface harness the test is complete If the unit does not function as stated a
119. rd the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start Trigger Release A 02986 LJ 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 characteristic of the power supply and not a function of the torch Trigger Art A 03383 8 Cut as usual Simply release the trigger assembly to stop cutting 9 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 OPERATION CUTMASTER 102 Piercing With Hand Torch 6 Bring the torch within transfer distance to the work The main arc will transfer to the 1 The torch can be comfortably held in one hand or steadied with two hands Position work and the pilot arc will shut off the hand to press the Trigger on the torch NOTES LLLI handle With the hand torch the hand may The gas preflow and postflow are a characteristic be positioned close to the torch head for of the power supply and not a function of the maximum control or near the back end for torch
120. res lubrication on a scheduled basis This will allow the o rings to remain pliable and provide ATC O Ring 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 DO NOT use other lubricants or grease they may problems 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 per formance or poor parts life Art 03791 7 O Ring Manual 0 4998 5T 1 SERVICE CUTMASTER 102 5T 02Inspection and Replacement of Consumable Torch Parts GS Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts as follows The shield cup holds the tip and start cartridge in place Position the torch with the shield cup 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 Slag built up on the shield cup that cannot be re moved may effect the performance of the system 2 Inspect the cup for damage Wipe it clean or replace if damaged CO m Art A 08067 Shield Cups 3 Ontorches with a shield cup body
121. rk cable connector broken 3 Failed components in unit 1 Incorrect current setting 2 Worn torch consumables 3 Poor work cable connection to piece 4 Torch being moved too fast 5 Excessive oil or water in torch 6 Failed components in unit For these modes to reset the machine remove the START signal 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized service center for repair 1 Connect work cable 2 Replace work cable 3 Return to an authorized service center for repair 1 Check and adjust to 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 7 SERVICE CUTMASTER 102 5 06 Circuit Fault Isolation A NG The following procedures should not be attempted by anyone who has not had proper training or authorized to do so 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 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
122. roduct 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 interruption 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 w
123. ssis up far enough to lay the Chassis down towards the right side of the unit 11 Remove the two screws securing the Output Inductor to the base 12 Remove the Output Inductor carefully guid ing its wires through from the right side of the unit 13 Install replacement Output Inductor by reversing the above steps 14 Reinstall the power supply cover PARTS REPLACEMENT 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 7 04 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 Manual 0 4998 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 Disconnect the input line from the filter element assembly Remove the filter elemen
124. t 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 is securely fastened to 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 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 Manual 0 4998 CUTMASTER 102 Problem Symptom Possible Cause Recommended Action Nothing happens when torch switch or remote switch Or CNC START signal is active No gas flow 1 Torch shield cup is loose 2 Torch tip electrode or 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 Upper O Ring on torch head is in wrong position indicators flashing at 2
125. t 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 B Voltage Selection Switch Replacement Tools required T20 Torx Driver 9 16 wrench 1 Remove the Cover per subsection 7 04A 2 Disconnect J3 from the Logic PCB 3 Remove retaining nut securing the switch to the rear panel 4 Feed the wires and connectors out of the panel 5 Install replacement filter by reversing above steps Manual 0 4998 CUTMASTER 102 C Input Power Cable Replacement Tools required T20 Torx Driver Phillips Head Screw driver Flathead Screwdriver 1 Remove the Cover per subsection 7 04A 2 Disconnect the input cable wires from the W1 contactor terminals and ground lug Loosen the two screws in the cable strain relief Remove cable through the rear panel Install replacement Input Power Cable by revers ing above steps 6 Reinstall the power supply cover D 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
126. t s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6914211 D505309 Other Pat s Pending US Pat No s 6914211 D493183 Other Pat s Pending US Pat No s 6914211 D505309 Other Pat s Pending US Pat No s 6914211 D505309 Other Pat s Pending US Pat No s 6914211 D501632 D511633 Other Pat s Pending US Pat No s 6914211 D496951 Other Pat s Pending US Pat No s 6914211 D496951 Other Pat s Pending US Pat No s 6914211 D505309 Other Pat s Pending Manual 0 4998 6703581 D496842 D511280 D492709 D499620 CUTMASTER 102 Catalog Description Patent s 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 Manual 0 4998 4T 17 OPERATION CUTMASTER 102 This Page Intentionally Blank OPERATION 47 18 Manual 0 4998 CUTMASTER 102 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 1 Weekly 42 DM mmm 7 AS Visually inspect the torch body tip Replace as needed electrode start cartridge and shield cup f 3 M
127. tage Air Filter Kit This optional two stage air line filter 15 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 Permatex PX56521 or equivalent thread sealant to the fitting threads according to the 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 2 Connect the two stage filter outlet hose to the inlet port of the Regulator Filter Assembly 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 Regulator Inlet Port IN Input Outlet Port 2 OUT Two Stage Filter En Assembly Gas Supply gt Hose Art A 07945 AB 6mm Fitting Optional Two Stage Filter Installation Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply 1 Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure regulators 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign mate rial Briefly open each c
128. tailed 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 04A 2 Push the gas fitting locking ring back A small open end wrench works well for this 1 2 3 v 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 it will not pull out 5 Reinstall the power supply cover Manual 0 4998 CUTMASTER 102 D Air Regulator Replacement Tools required T20 Torx Driver 11 16 Open End Wrench 1 Remove the cover per subsection 7 04A 2 Remove the two 2 air hoses from the regulator per subsection 7 05
129. te 22272727 Sept 25 2008 AA Manual released APPENDIX A 8 Manual 0 4997 IHERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com 16062 Swingley Ridge Road IHERMAL DYNAMICS
130. te 1430 Broadway New York NY 10018 Manual 0 4998 1 04 Note Attention et Avertissement Dans ce manuel les mots note 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 TTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question VERTISSEMENT 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 1 05 Precautions De Securite Importantes VERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre pro fessionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d vi
131. ter E 5 Es 2 ON Eye 4 CUR ser 57 5 MAN PCB ID 88 PCB4 MAIN Pcs 8 COMMON 8 CM 102 19X2971 CAT 9 0108 CM 152 18x2416 CAT 9 0125 m m enawoonses E PRIT PRIZ 1 PRIA PRIS a cy D 1 swe OA Aot 42 at x M H 2 Aci Puit Fa PCB2 CAPACITOR PCR 1 CM 102 teX2478 CATI 9 0192 152 18X2548 CATH 9 0202 AAA rural 102 40 AMP Pca PCBS 19X2417 CAT 9 0194 CM 152 50 AMP PCB un TOX2417 6 0208 z APPENDIX A 6 Manual 0 4997 CUTMASTER 102 CMISEORLY 1TORCH PiP SWITCH c 5 TORCH SWITCH D 5 5 ss a sete m CONNECTOR 1 1 AUTOMATION Teme 2 E 2 TORCH SO
132. ter les blessures possibles lisez comprenez et suivez tous les avertisse ments 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 E 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 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 Manual 0 4998 attention et avertissement sont utilis s pour mettre en relief des informations caract re important CUTMASTER 102 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 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 505 celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseigne ments
133. the threads before proceeding OPERATION CUTMASTER 102 4T 02 Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff alignment 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 Cut Surface Bevel Angle q Spatter 7 NE Top Edge 7 7 Rounding 22 Dross Cut Surface A 00007 Drag Lines Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece OPERATION 4 2 Bot
134. tom 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 03 General Cutting Information Ai Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review the Important Safety Pre cautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated UTION Sparks from the cutting process can cause damage to coated painted and other surfaces 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 avoid excessive pilot arc time to improve parts life Manual 0 4998 Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup
135. too low a Set gas supply pressure to 95 120psi 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 5 Faulty Pressure Transducer a a Adjust pressure Regulator to maximum Measure voltage on Logic PCB 1 beween J3 1 to J3 2 If voltage is more than 2VDC Replace Pressure Transducer 6 Faulty Logic PCB 3 a Replace Logic PCB 3 L 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 1 Faulty Logic PCB 3 a Replace Logic PCB 3 M MAX PRESSURE ERROR MAX Pressure LED is lit 1 Gas pressure set too high a Reduce gas pressure 2 Pressure Regulator set too high a Adjust Pressure Reulator 2 Defective Pressure Transducer a Adjust pressure Regulator to minimum Mea sure voltage on Logic PCB 1 beween J3 1 to 3 2 If voltage is more than 4 VDC Replace Pressure Transducer 3 Defective Logic PCB a Replace Logic PCB Manual 0 4998 CUTMASTER 102 N AC LED on TEMP LED off GAS LED on Gas flows DC LED amp FAULT indictor off W1 contactor does not energize 1 Defective W1 Contactor a Measure for 24VAC between wire 5 to wire 6 on W1 If voltage is present replace W1 2 Defective Logic PCB 3 a Measure voltage on Main PCB 3 between J2 9 to GND1 If vo
136. tors Machine Torches are available as follows 5 foot 1 5 m with connectors 10 foot 3 05 m with ATC connectors 25 foot 7 6 m with connectors 50 foot 15 2 m with ATC connectors C Torch Parts Start Cartridge Electrode Tip Shield Cup D Parts In Place PIP Torch Head has built in switch Art A 02998 12 vdc circuit rating E Type Cooling Combination of ambient air and gas stream through torch INTRODUCTION CUTMASTER 102 F Torch Ratings Manual Torch Ratings Ambient 104 F Temperature 40 100 100 Amps 400 scfh Voltage V oa 500V Arc Striking Voltage Temperature 40 100 100 Amps 400 scfh Voltage V 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 psi 8 6 bar 300 500 scfh Gas Flow Cutting Gouging 142 235 G This torch is not to be used with oxygen 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 04 Options
137. ts In Place Circuit Diagram for Machine Torch Manual 0 4998 2 3 INTRODUCTION CUTMASTER 102 This Page Intentionally Blank INTRODUCTION 2 4 Manual 0 4998 CUTMASTER 102 SECTION 3 SYSTEM INSTALLATION 3 01 Unpacking 1 Use the packing lists to identify and account for each item 2 Inspect each item for possible shipping damage If damage 1 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 vendor name in the information block at the front of this manual 3 02 Lifting Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely Disconnect input power cord before moving unit Do not touch live electrical parts 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 adequate capacity to move unit e Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle Manual 0 4998 3 1 INSTALLATION CUTMASTER 102 3 03 Primary Input Power Connections UTION Check your power source for correct voltage before plugging in or connect
138. tting arc extinguishes 1 Defective Logic PCB 3 a Replace Logic PCB 3 SERVICE CUTMASTER 102 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 2 Defective Logic PCB 3 a Replace Logic PCB 3 5 10 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 PCB4 between J1 6 to J1 8 for 12VDC If 12VDC is present replace Automation Interface 4 2 Defective Main PCB 1 a Measure voltage on Main 1 between J1 6 to J1 8 for less than 2VDC If voltage is less than 2VDC replace Main PCB 1 B No OK TO MOVE signal while cutting 1 Defective Main 1 a Measure voltage on PCB4 between J1 1 to J1 3 for 12VDC while cutting If 12VDC is present replace PCB 1 2 Defective Automation Interface PCB 4 a Measure voltage on 4 between 1 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 4 a Replace 4 SERVICE 5 20 5 11 Test 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 If con tinuity is found disconnect J1 fr
139. ull the connection together Do not use tools to secure the connection Art A 07885 Connecting the Torch to the Power Supply 3 The system is ready for operation Manual 0 4998 To test the quality of air 1 Putthe ONU switch in the ON 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 oper ate a machine torch Disconnect primary power at the source be fore 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 obtain a clean vertical cut use a square to align the torch perpendicular to the sur face of the workpiece 3T1 INSTALLATION CUTMASTER 102 Pinch Block Assembly Workpiece 02585 Mechanical Torch Set Up 3 The proper torch parts shield cup tip start cartridge and electrode must be installed for the type of operation Refer to Section 4T 07 Torch Parts Selection for details INSTALLATION 2 Manual 0 4998 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering I
140. umes 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 an area where combustible or explosive gases or materials are located e Phosgene a toxic gas is generated from the vapors of chlo rinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq A ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energ
141. ween J2 16 and test point GND1 If gas does not flow replace Logic PCB b With START signal active measure voltage on Main between test points GND1 to DMDI for 1 4VDC Replace Logic PCB if voltage is not present 3 Defective Main PCB a With START Signal active measure voltage on Main between test points GND1 to I DMDI for 1 4 VDC Replace Main PCB if voltage is present Manual 0 4998 B SHORTED TORCH OUTPUT FAULT Fault indicator and 85 PSI Indicators are flashing at 1 cycle per second This is a Latched Failure Mode After START signalis activated gas flows for two 2 seconds then momen tarily shuts off then back on FAULT INDICATOR flashes and 85 PSI LED flashes To reset the machine turn the unit OFF indentify and clear the problem and turn back ON 1 UpperO 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 Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art A 03725 2 Torch start cartridge is stuck a Turn off power supply Bleed down the system 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 1 8 Spring Loaded Lower End Fitting at Rest
142. y can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot e 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 e Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications e Disconnect power source before performing any service or repairs e 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 e Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected e Ventilate all flammable or explosive vapors from the work place GENERAL INFORMATION CUTMASTER 102 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 Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Plasma arc process
143. ycle 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 output 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 273 mm 16 375 416 mm Art A 07925 Zt 63 Ib 28 6 kg INTRODUCTION 2 2 Manual 0 4998 CUTMASTER 102 2 05 Input Wiring Specifications CutMaster 102 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Suggested Sizes Flexible Cord Volts Hz Imax Fuse amps AD 9 80 1Phase 20 60 2 78 460 60 9 50 60 208 230 60 8 43 40 9 7 RIRE Un 3 Phase ae e T 4 230 o o EE EN Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements The suggested sizes are based on flexible power cable with power plug installations For hard wired
144. ylinder 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 regulator 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 For a secure seal apply Permatex PX56521 or equivalent thread sealant to the fitting threads according to man ufacturer 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 3 6 Manual 0 4998 CUTMASTER 102 Check Air Quality SECTION 3 TORCH INSTALLATION 3T 01 Torch Connections If necessary connect the torch to the Power Sup ply Connect only the Thermal Dynamics model SL100 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 female 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 p

102 CUTMASTER™ Service Manual

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102 CUTMASTER&trade; Service Manual

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102 CUTMASTER™ Service Manual