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Service Manual CUTMASTER™ 10mm 12mm

Contents

1. Overheat m ie m j lt gt lt gt lt gt lt gt lt gt lt gt lt gt S IS WZ SET Art A 10218 Figure 4 1 Front Control Panel Figure 4 2 Rear Controls 1 ON OFF Switch Power Switch Controls input power to the Power Source is ON O is OFF 2 Output Current Control Sets the desired output current If the overload protection fuse or circuit breaker on the input power circuit opens frequently either reduce cutting output reduce the cutting time or connect the unit to more adequate input power For 240V input power the maximum output is 40 Amps Refer to Section 2 for input power requirements 3 ny AC Indicator Steady light indicates Power Source is ready for operation 4 OVERHEAT Indicator TEMP Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Allow the unit to run with the fan ON until the temp indicator turns OFF 5 AIR Indic
2. Assembly Procedures 8 8 Manual 0 5230 5 CUTMASTER 10MM 12MM SECTION 9 REPLACEMENT PARTS 9 01 Introduction A Parts List Breakdown C Ordering Information The parts list provides a breakdown of all replace Order replacement parts by part number and able components complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch If a product must be returned for service contact Address all inquiries to your authorized distributor your distributor Materials returned without proper authorization will not be accepted 9 02 Power Source Replacement Parts B Returns Item Qty Description Catalog 1 1 Logic PCB assembly 10mm amp 12mm 9 0076 2 1 Control PCB assembly 10mm 9 7555 2 1 Control PCB assembly 12mm 9 0077 3 1 Main PCB assembly 10mm 9 7556 3 1 Main PCB assembly 12mm 9 0079 4 1 Air Regulator 10mm amp 12mm 9 0081 5 1 Solenoid assembly 10mm amp 12mm 9 0082 6 1 Pressure Switch 10mm amp 12mm 9 0075 7 1 Hall Current Sensor 10mm amp 12mm 9 0088 8 1 ON OFF Switch 10mm amp 12mm 9 0074 9 1 Cooling Fan 10mm amp 12mm 9 0042 10 1 Input Rectifier 10mm amp 12mm 9 0049 Art A 10400 Parts 9 1 Power Source Manual 0 5230 9 1 Replacement Parts CUTMASTER 10MM 12MM 9 03 SL60 Replacement Parts Item Qty 1 1 2 1 3 1 1
3. Manual 0 5230 2 H 2 d AANI s 9 N c I hr lt 7 E D SASLASTI al AM ep 5 4 ae O PASAST 2 09 05 OVAOPC le 5 1 TI 7 IVNDIS JARI TTE PSI ize vg 9 INO NI AIAX 1 1 rt 129 I L 1ndlnO AM APCOQ TVNDISOIOVEGHHA lt DL 2 7 2 Ar 1 2 AUALVAAWAL 1 P d MS 5639 Pd Ana an MONINOD _ AI Isa 2 c 1 IVNDIS I LITT 9 ag Y VIN 4 GIONATOS svoj vx 10 Figure 6 11 Circuit Diagram 6 20 Troubleshooting CUTMASTER 10MM 12MM SECTION 6 TORCH SERVICE 6T 01General Maintenance Cleaning Torch Even if precautions are taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affect the
4. 6 3 TABLE OF CONTENTS 604 AGNO aa AA 6 4 6 05 Visually aaa ra n edt rud add 6 5 6 06 X Preliminary Check of the Main Inverter Board 6 6 6 07 Check Main ON OFF Switch ul essen 6 8 6 08 Check Pressure Switch aasaran 6 9 6 09 Check Regulator sees nennen nennen nennt tens 6 10 6 10 Check Main Input Rectifier esee ener nnns 6 11 6 11 DC Bus Voltage 6 12 6 12 Checkof Control PCB 6 13 613 6 16 5 14 Main Circuit Description 6 17 BB 6 20 SECTION 6 TORCH ERVI CE 6T 1 6T 01 General Maintenance csceccccssscsssssssesssessceesssensssenseseesseesesseeenseeanees 6T 1 67 02 Inspection and Replacement of Consumable Torch 67 2 SECTION 7 DISASSEMBLY PROCEDURE 22 2 AnG 7 1 7 01 Safety Precautions for Disassembly 2222 20 7 1 1 02 Control 7 2 703 Front Panel Assembly 7 3 7 04
5. Introduction 2 4 Manual 0 5230 INTRODUCTION SECTION 2TORCH INTRODUCTION 27 01 Scope of Manual This manual contains descriptions operating instructions and main tenance procedures for the SL60 Plasma Cutting Torch Service of this equipment is restricted to properly trained personnel unquali fied 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 understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed 27 02 Specifications A Torch Configurations 1 Hand Torch Model SL60 The hand torch head is at 75 to the torch handle The hand torches include a torch handle and torch trigger assembly 10 125 257 mm gt 3 75 95 Art 03322 1 17 29 Figure 2T 1 5160 Torch B Torch Leads Lengths Hand Torches are available as follows 4 20ft 6 2 C Torch Parts Starter Cartridge Electrode Tip Shield Cup See Figure 4 3 5160 Torch Parts page 4 2 D Parts In Place PIP Torch has built in switch 12 vde circuit rating E Type Cooling Combination of ambient air and gas stream through torch F Torch Ratings Temperature 40 C Duty Cycle Maximum Current 60 Amps Voltage 900V Arc Striking Voltage
6. This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life Manual 0 5230 6T 1 TORCH SERVICE CUTMASTER 10MM 12MM 6T 02Inspection and Replacement of Consumable Torch Parts A WARNING Jisconnectprimary power to the system be fore disassembling the torch or torch leads DO MOT touch any internal torch parts while the AC indicator light of the Power Source is ON Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter cartridge shield cup in place Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be removed may effect the performance of the system 2 Inspect the cup for damage Wipe it clean or replace if damaged Art A 09345 Figure 6T 3 Consumable Parts TORCH SERVICE 3 Remove the tip Check for excessive wear in dicated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 09791 Figure 6T 4 Tip Wear 4 Remove the starter cartridge Check for excessive wear plugged gas holes or discol oration Check the lower end fitting for free motion Replace if necessary Art A 09792 Figure 6T 5 Start Cartridge 5 Pull the electrode straight out o
7. 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PROTEC TION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 General Information GENERAL INFORMATION 1 04 Servicing Hazards AN WARNING The symbols shown below are used throughout this manual to call attention to and identify possible haz ards When you see the symbol watch out and follow the related instructions to avoid the hazard Only qualified persons should test maintain and repair this unit Only qualified persons should test maintain and repair this unit WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Turn Off cutting power source and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from receptacle or stop engine before servicing unless the procedure specifically requires an en ergized unit Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground Do not leave live unit unattended If this procedure requires and energized unit have only per sonnel familiar wi
8. 2000 to 0 VD Neel Negative meter lead to TP 9 UEM EODD MD Positive meter lead to TP 14 VD ae Negative meter lead to TP 13 WEE MODUM VPE Positive meter lead to TP 12 FC IGBT2 2000 to 0 VDC Negative meter lead to TP 11 SUUM Positive meter lead to TP 26 PILOT IGBT1 Negative meter lead to TP 25 0 2000 to 0 8000 VDC Table 6 2 IGBT s Multimeter Set to Measure Diode Voltage Manual 0 5230 6 7 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 07 Check Main ON OFF Switch AN WARNING Read and follow safety information in Section 6 02 before proceeding 1 3 2 4 Art A 10245 Figure 6 5 Main ON OFF Switch View Positive meter lead to TP 1 0to 10 Switch ON Positive meter lead to TP 3 01010 NN Switch OFF Positive meter lead to TP 1 gt 1 0 Switch OFF Positive meter lead to TP 3 gt 1 0 0 Table 6 3 Power Switch Multimeter set to measure ohms 0 Troubleshooting 6 8 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 6 08 Check Pressure Switch Art A 10292 2 Figure 6 6 Pressure Switch View Turn ON the power switch disconnect the contact of the pressure switch and start the test as below 1 Pressure switch open When the pressure is up to 3 5kgf cm 49 78 PSI the pressure switch turns OFF 2 Pressure switch closed When the pressure is less than 2 4kgf cm 34 13
9. Manual 0 5230 2T 1 cutmaster 10MM 12MM G Current Ratings SL60 Current Ratings Up to 60 Amps DC SL60 Torch amp Leads Straight Polarity NOTE Power Supply characteristics will determine material thickness range H Gas Requirements SL60 Torch Gas Specifications Gas Plasma and Secondary Operating Pressure Refer to NOTE Compressed Air 60 75 psi 4 1 5 2 bar Maximum Input Pressure 125 psi 8 6 bar 300 500 scfh Gas Ho 142 235 Ipm WARNING This torch is not to be used with oxygen This torch is not to be use with high frequency starting systems NOTE Operating pressure varies with torch model operating amperage and torch leads length Refer to gas pres sure settings charts for each model Introduction CUTMASTER 10MM 12MM 21 03 Introduction to Plasma A Plasma Gas Flow Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically con ductive 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 INTRODUCTION D Main Cutting Arc DC power is also used for the main cutting arc The negative output is connected to the torch electrode through the torch lead The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire
10. cia pan R169 136 HUB ps cpa 906 3 4 20 HE cx 9 6 i R179 vo p Ly T Rina pi R177 A JR 1 vs gt ja amp A DC RL RAS R38 8 9 190846 RAS R44 R43 RAZ R41 RAO RS3 R49 RAT vis 100 Tita WVOUT Lo 3 21 zevo SPIN Qm 1 bs nga E R62 RE R60 RS9 R58 RISERINTRS R56 R63 RSS R54 R39 R39 1 RG GDN 008 oci 062 R35 4 jour 10NY2 Art A 10249 4 Figure 6 10 Main Circuit Description XHIF 3PIN Troubleshooting 6 18 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM The mains supply voltage is connected via a double pole switch to the input rectifier U1 through an EMC filter Overvoltage protection is provided by varistor CY1 The rectifier circuit converts the inputted AC voltage to DC voltage The input current is controlled through being compared with reference wave The reference point is a pure sine wave which derives from the source voltage The PFC control chip will be used to generate suitable gate signal to drive V8 and V8 1 ensuring the current is sinusoidal The boost diode output charges the main capacitor bank C16 C17 C18 C19 620 and C21 to high voltage In rush current limiting is provided by a high power resistor which is then bypassed by relay J1 after a
11. 12MM Recommended Protective Filters for Electric Welding Description of Process Approximate ume Minimum Shade Number of Filter s Tss an ar equal a100 8 am than Aluminum and tea Gas Meta Arc Welding GMAW ey aes Gas Tungsten Are Woking SAW 16 Flux cored Arc Welding FCAW with or with out Pasma Arc Cutting Plasma Arc Spraying OT oz Co 45 Plasma Arc Welding Submerged ArcWelding 2 Resistance Welding Safety Spectacles or eye shield Refer to standard AS NZS 1338 1 1992 for comprehensive information regarding the above table Table 1 1 Protective Filters Manual 0 5230 1 3 General Information CUTMASTER 10MM 12MM 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING ob tainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broad
12. Front Panel Operator Interface 7 4 7 05 Rear Panel REMOVAL Edda 7 5 7 06 Power Switch 51 and Power Cord 7 6 PGE Bas amp Panel 7 7 SECTION 8 ASSEMBLY PROCEDURES 2 2 8 1 8 01 Installing BOSE Boal 8 1 installing Rear 8 2 OS INS TANG IRON PANG NA 8 4 8 04 Installing Main Control PCB and Clear Cover 8 5 509 Installing GAS cc 8 7 SECTION 9 REPLACEMENT PARTO i otn gcnus aaa a 9 1 9 02 Power Source Replacement Parts esses 9 1 9 01 DWN CLIC TION E C AA 9 1 293 5160 Replacement Parts aaa Gana 9 2 9 04 Options and Accessories 7na aaa 9 2 Slalemehit of eT 1 GLOBAL CUSTOMER SERVICE CONTACT 3 GENERAL INFORMATION CUTMASTER 10MM 12MM SECTION 1 GENERAL INFOR 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follow
13. PSI the pressure switch turns ON and the resistance between 1 and 2 is about 0 10 Manual 0 5230 6 9 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 09 Check Regulator Art 10293 Figure 6 7 Regulator View Turn ON the power switch and start the test as below When solenoid valve is ON adjust the knob 1 If the pressure is continuously adjustable the regulator is OK Troubleshooting 6 10 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 6 10 Check Main Input Rectifier 1 DC AC2 DC Art A 10291 Figure 6 8 Main Input Rectifier Remove the main input rectifier from the heatsink and start the testing Input Rectifier Testing Multimeter Lead Placement Diode Voltage Positive meter lead to AC1 ULIS Negative meter lead to TP DC Positive meter lead to AC2 Negative meter lead to DC Wess ME Positive meter lead to TP DC TUS Negative meter lead to TP AC1 Voc VOR Positive meter lead to TP DC AC2 to DC Negative meter lead to TP AC2 0 2 0 8 VDC Table 6 4 Input Rectifier Multimeter Set to Measure Diode Voltage Measurements may be made directly onto the main input rectifier AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position Manual 0 5230 6 11 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 11 DC Bus Voltage Measurement pam Warning There are extremely dangerous voltage and po
14. Service Manual Number 0 5230 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www victortechnologies com Copyright 2012 2013 by Victor Technologies International Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher 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 Publication Date December 5 2012 Revision AB Date May 27 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION uiui S quiete 1 1 1 01 Notes Cautions and 05 1 1 1 02 Important Safety Precautions u s naasa 1 1 E 1 4 1 04 Servicing HazardS ee Renee ie cibo 1 4 1 05 1 6 1 06 Declaration of Conformity tid 1 7 SECTION 2 SYSTEM INTRODUCTION 2 1 2 01 a OBRA SS t 2 1 202 Egilpnient pe 2 1 2 03 Receip
15. Voltage Low Voltage Low Voltage Low Voltage Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage Art A 09846_AB Figure 5 1 Inverter Technology Manual 0 5230 5 1 Theory of Operation CUTMASTER 10MM 12MM THEORY OF OPERATION Notes Theory of Operation 5 2 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM SECTION 6 TROUBLESHOOTING 6 01 Basic Troubleshooting Power Source Faults WARNING go mc a Ra Re a There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair it un less you are an accredited service provider and you have had training in power electronics measurement and troubleshooting techniques Common Faults Symptom LED Indicators A AC indicator n OFF 1 Main input power cord does not connect to power distribution net a Connect the power cord 2 Power ON OFF switch in OFF down position a Turn switch to ON up position 3 Actual input voltage does not correspond to voltage of unit a Verify that the input line voltage is cor rect 4 Faulty components in unit a Have an Accredited CIGWELD service provider repair or replace as required B AC indicator vo blinking 1 Indicator blinking 1 sec ON 1 Sec OFF Gas may also pulse 3 times a Check for missing torc
16. few seconds The primary igbt transistors T1 T2 T4 and T5 switch the transformer primary at high frequency and varying duty cycle The transformer return wire is taken from the junction of the capacitors C20 and C21 the voltage at this point is approximately half the DC bus voltage Secondary output voltage from the transformer is rectified by the output diodes T14 1 and T16 1 to DC This DC is controlled by the PWM of the primary side igbt transistors and is filtered by an inductor before connecting to the output terminals A thermal overload device thermistor is fixed to the rectifier heatsink When an over temperature occurs the con trol circuit inhibits the trigger and the output The thermal overload indicator LED on the front panel is illuminated The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current and also detect transformer saturation The Hall effect current sensor is powered from regulated amp 15VDC supplies and provides a voltage signal proportional to the output DC cutting current to allow the control circuit to regulate cutting current Manual 0 5230 6 19 Troubleshooting TROUBLESHOOTING CUTMASTER 10MM 12MM 6 15 Circuit Diagram Art 11638 L 7 HON 5 K kn KG N
17. for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 2004 108 EC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture 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 CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94 0 flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories IEC 60974 10 applicable to Industrial Equipment generic emissions and regulations AS 1674 Safety in welding and allied processes 2001 95 EC RoHS directive AS60974 1 Arc Welding Equipment Welding Power Sources For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the
18. 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 Victor Technologies has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manual 0 5230 1 7 General Information CUTMASTER 10MM 12MM GENERAL INFORMATION Notes General Information 1 8 Manual 0 5230 INTRODUCTION CUTMASTER 10MM 12MM SECTION 2 SYSTEM INTRODUCTION 2 01 How to Use This Manual To ensure safe operation read the entire manual including the chap ter on safety instructions and warnings Throughout this manual the word WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows NOTE Offers helpful information concerning certain operat ing procedures Notes will be shown in italics A CAUTION Refers to possible equipment damage Cautions will be shown in bold type AN WARNING Gives information regarding possible personal injury Warnings will be enclosed in a box
19. properly connected C Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power requirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to supply power to the system D Gas Selection 1 Ensure gas source meets requirements listed in Section 2T 2 Check connections and turn gas supply ON E Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 03387 Figure 4 4 Work Cable Connection F Power ON Place the Power Source ON OFF switch to the ON 1 position Power indicator turns ON SI On Off Switch Air Inlet 1 4 NPT Power Cord Power indicator ZA is E 1S az 9 TRH Ur prt A 10225 Art A 10219 Figure 4 5 Rear Panel with ON OFF Switch Figure 4 6 Front Panel with Power ON OFF Indicator Manual 0
20. 4 1 5 1 Description Electrode 30 120 Amp Start Cartridge Tip 40A Drag fitted Tip 40A Standoff Shield Cup 5160 Torch w 20 ft 6 2m leads not shown Art A 09345 Parts 9 2 Electrode Parts 9 04 Options and Accessories Qty Description Part No 1 Single Stage Filter Kit 7 7507 1 Circle cutting guide 0707 3291 1 Roller amp radius cutting guide OTD7 7501 1 ATC 7 6m Torch torch lead extension OTD7 7545 Replacement Parts 9 2 REPLACEMENT PARTS Part No OTD9 8215 OTD9 8213 OTD9 8207 OTD9 8208 OTD9 8218 OTD7 5204 Manual 0 5230 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Victor Technologies warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Victor Technologies shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Victor Technologies s specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Victor Technologies will repair or replace at its disc
21. 5230 4 3 Operation CUTMASTER 10MM 12MM OPERATION 4 03 Sequence of Operation The following is a typical sequence of operation for this Power Source 1 Place the ON OFF switch on the Power Source to ON up position AC indicator w turns ON fan turns ON NOTE During initial power up there will be a delay of about 2 seconds before the AC Indicator light will illumi nate and the pre flow gas and fan starts The gas will automatically flow from torch for approximately 10 seconds only after the AC Indicator lamp is illuminated The AC Indicator lamp and fan turns ON approximately 2 seconds after the ON OFF switch is enabled this is a process that makes sure all inputs gas input power torch connection and torch parts are acknowledged for proper operation 2 Wear protective clothing including welding gloves and appropriate eye protection See Table 1 1 Place tip on workpiece and pull trigger Arc will initiate and start cutting material Standoff Cutting With Hand Torch Torch NOTE For best performance and parts life al Ways use the correct parts for the type of operation A The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end E for maximum heat protection Choose the holding technique that feels most NES comfo
22. 7400 Fax 61 3 9474 7391 Email enquiries cigweld com au Victor Technologies USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermalarc com Victor Technologies Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Victor Technologies Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana Blok AE No 28 Delta Silicon Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www victortechnologies com Victor Technologies China No 100 Lao Hongjing Rd Minhang District Shanghai 200235 China Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jin Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Victor Technologies Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Victor Technologies International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Asia Pacific Regional Headquarters 71 Gower Street VICTOR Preston Victoria Aus
23. N The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlo rinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric
24. OTING HF QF Header Pin Pinfunction 1 0 00 Control circuit power source 27VDC Negative of solenoid control signal OVDC when soleniod is on Positive of solenoid control signal 27VDC Table 6 6 HF QF Header Pin Function MB Header Pin 7 10 Power indication signal Table 6 7 MB Header Pin Function Header Pn J TE Table 6 8 HFOUT Header Pin Function SOURCE amp TIP Header Pin Positive of TIP test signal 2 TIP test signal when machine dose no work OVDC the machine is woking Control circuit power supply 5VDC Control circuit power source 24VDC 4 OVDC Control circuit power source 24VDC Table 6 9 SOURCE amp TIP Header Pin Function DRIVE Header signal Overcurrent signal gt 7VDC when over primary current protection 7 0 06 Table 6 10 DRIVE Header Pin Function U_D Header Pin Pinfunction Signal Feedback of input voltage 41VDC input 240vac 1 0VDC Table 6 11 U_D Header Pin Function Troubleshooting 6 14 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM WA Header Pin Pinfunction OO Signal 15VDC 15VDC Output current feedback __ 0 00 Table 6 12 WA Header Pin Function FAN Header Pin swa 24VDC fan negative when fan is on OVDC Table 6 13 FAN Header Pin Function Trans FB Header Pin Pinfuntion Sigma Pilot ARC current feedba
25. PCB assembly screws Art 11086 Figure 7 6 Removing Base Panel Manual 0 5230 7 7 Disassembly Procedure CUTMASTER 10MM 12MM DISASSEMBLY PROCEDURE Notes Disassembly Procedure 7 8 Manual 0 5230 ASSEMBLY PROCEDURE CUTMASTER 10MM 12MM SECTION 8 ASSEMBLY PROCEDURES 8 01 Installing Base Board 1 Place main power PCB assembly 2 Install main power PCB assembly screws 3 Install central Panel Screws Art A 11087 Figure 8 1 Installing Base Board Manual 0 5230 8 1 Assembly Procedures CUTMASTER 10MM 12MM ASSEMBLY PROCEDURES 8 02 Installing Rear Panel Install gas inlet Install ON OFF switch Install wire cord Reconnect Input Wire on the ON OFF switch Install fan Install ground wire Reconnect AC Input wire on Main Power PCB to power ON OFF switch Reconnect the three screws KO Reconnect Rear Panel screws Art A 11640 Assembly Procedures 8 2 Manual 0 5230 ASSEMBLY PROCEDURE CUTMASTER 10MM 12MM Art 10258 Figure 8 2 Installing Rear Panel Manual 0 5230 8 3 Assembly Procedures CUTMASTER 10MM 12MM ASSEMBLY PROCEDURES 8 03 Installing Front Panel 1 Place front panel PCB assembly into front panel Install the nut and screw 2 Reconnect three harnesses to control PCB 3 4 Install the front
26. Parts In Place PIP The torch includes a Parts In Place PIP circuit When the shield cup is properly installed it closes a switch The torch will not operate if this switch is open While the goal of plasma arc cutting is separation of the material plasma arc gouging is used to remove metals to a controlled Torch Switch Torch Trigger depth and width To Control Cable Wiring Plasma Cutting Torch cool gas enters Zone where a arc between the electrode and the torch tip heats and ionizes PIP Switch Shield Cup the gas The main cutting arc then transfers to the workpiece A 09595 lt through the column of plasma gas Zone Parts In Place Circuit Diagram for Hand Torch By forcing the plasma gas and electric arc through a small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma cut ting 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 Power Supply A i B Workpiece A 00002 Typical Torch Head Detail B Gas Distribution The single gas used is internally split into plasma and second ary gases The pl
27. UBLESHOOTING 2 Working cable connection is poor a Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Low or fluctuating input voltage a Have electrician check input line voltage under load J Hard to startup 1 Torch parts worn consumables a Turn off input power remove shield cup tip start cartridge and electrode and check them all If the electrode or cutting tip is worn out replace them If the start cartridge does not move freely replace it If there is too much spatter on shield cup replace it K Arc goes out while operating Arc can t be re started when torch trigger is activated 1 Power Supply is overheated TEMP indicator Let unit cool down for at least 5 min utes Make sure the unit has not been oper ated beyond duty cycle limit 2 Fan blades blocked TEMP indicator Check and clear blades 3 Air flow blocked a Check for blocked air flow around the unit and correct condition 4 Gas pressure is too low Air indicator ON when torch trigger is activated Check gas source Adjust to proper setting value 5 Torch parts worn a Check torch shield cup cutting tip start cartridge and electrode Replace as needed 6 Faulty component in unit Have an Accredited CIGWELD service provider repair or replace as required L Torch cuts but not well 1 Current control is set too low a Increase th
28. VICTOR THERMAL DYNAMICS 10mm MASTER 6 sil m asi LA Art A 1083 Revision AB ssue Date Onerati E 7 A 9 kl o q 4 i wu Vi Vi Vi y ue Date May 27 2013 Manual No 0 5230 perating Features 40 240 AMP VAC VICTOR THERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service net work To locate your nearest distributor or service provider call 1300 654 674 Asia Pacific 1800 462 2782 Americas or visit us on the web at www cigweld com au Asia Pacific www thermal dynamics com Americas and Europe This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfac tion with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product We have made every effort to provide you with accurate instructions drawings and photographs of the product s we used when writing this manual However errors do occur and we apologize if there are any contained i
29. a E 20 5060 3 58 99 16 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your Situation in this regard CUTMASTER 12mm Input Power Requirements Input Power Input Current Input Current Input dei See kVA Max Amps eff Amps Fuse Amps Vosa E 240 16 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your Situation in this regard NOTE Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested sizes are based on flexible power cable with power plug installations Cable conductor temperature used is 167 F 75 C Manual 0 5230 3 5 Installation CUTMASTER 10MM 12MM INSTALLATION Notes Installation 3 6 Manual 0 5230 OPERATION CUTMASTER 10MM 12MM SECTION 4 SYSTEM OPERATION 4 01 Control Panel On Off Air Inlet MERO AC Indicator Switch 1 4 i DC Indicator Ready Power Cord Air Indicator
30. andcart or similar device of adequate capacity If using a fork lift vehicle secure the unit on a proper skid before transporting 2 1 Introduction CUTMASTER 10MM 12MM INTRODUCTION 2 05 Working Principle Rectifier Inverter Transformer Rectifier Compressed air moms educe pressure filter as valve utting torc j Workpiece Art A 09204_AB Figure 2 1 Working Principle Introduction 2 2 Manual 0 5230 INTRODUCTION CUTMASTER 10MM 12MM 2 06 Power Supply Features To Air Supply clean dry Control Panel Art 10217 Torch Lead Figure 2 2 Power Supply Features On Off Switch Air Inlet 1 4 NPT Power Cord ae 4 gt mal lt gt lt gt c lt gt lt gt c 11 Paa oF Sk IN 3 UU LU Art A 10225 Figure 2 3 Rear with Plug 2 3 Introduction Manual 0 5230 CUTMASTER 10MM 12MM INTRODUCTION Notes
31. arc initiation and the overall cut quality Upper Groove with Vent Holes Must Remain Open of the torch Upper O Ring in Correct Groove A WARNING Threads Disconnectprimary power to the system be Lower O Ring Art 03725 fore disassembling the torch or torch leads Figure 6T 1 Torch Head O Ring DO MOT touch any internal torch parts while the AC indicator light of the Power Source is ON The inside of the torch should be cleaned with elec trical 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 Dry the torch thoroughly before reinstalling O Ring Lubrication An O Ring the Torch Head and ATC Male Con nector requires lubrication on a scheduled basis This will allow the o rings to remain pliable and provide a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to potential performance problems Art A 03791 O Ring Figure 6 2 ATC O Ring It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o rings on a weekly basis CAUTION DO Or use other lubricants or grease they may not be designed to operate within high temperatures or may contain unknown ele ments that may react with the atmosphere
32. asma gas flows into the torch through the negative lead through the starter cartridge around the electrode and out through the tip orifice The secondary gas flows down around the outside of the torch starter cartridge and out between the tip and shield cup around the plasma arc C Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip This pilot arc creates a path for the main arc to transfer to the work Introduction 2T 2 Manual 0 5230 INSTALLATION CUTMASTER 10MM 12MM SECTION 3 INSTALLATION 3 01 Unpacking 1 Use the packing lists to identify and account for each item A Contents List for CutMaster 10mm Plant Part No 1 4730 6 Description Quantity SL60 Torch Including SL60 Torch 20 ft 6 2m w ATC consumables 1 set spare parts kit Shoulder Strap Operating Manual Table 3 1 Contents List for CutMaster 10mm Plant B Contents List for CutMaster 12mm Plant Part No 1 4200 6 5160 Torch Including 5160 Torch 20 ft 6 2m w ATC consumables 1 set spare parts kit Shoulder Strap EE Operating Manual LEEREN Table 3 2 Contents List for CutMaster 12mm Plant 2 Inspect each item for possible shipping damage If damage is evident contact your distributor and or ship ping company before proceeding with the installation 3 Record Power Source and Torch model and serial numbers purchase date and vendor name in the information
33. ator AIR indicator light should be ON when there is sufficient gas pressure 6 READY DC Indicator Indicator is ON when DC output circuit is active Manual 0 5230 4 1 Operation CUTMASTER 10MM 12MM OPERATION 4 02 Preparations for Operating WARNING At the start of each operating session Disconnect primary power at the source before assembling or disassembling Power Source torch parts or torch and leads assemblies NOTE All consumables must be correctly installed and maintained to ensure correct operation A Torch Parts Selection Check the torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Source 40 amps maximum Use only genuine Thermal Dynamics parts with this torch Art A 10224 x Start Cartridge Part No OTD9 8213 a 40 Amp Standoff Part 09 8208 40 Amp Drag Tip Part No OTD9 8207 fitted Shield Cup Part No OTD9 8218 Worn Electrode Figure 4 3 SL60 Torch Parts Worn Tip NOTE When operating the torch in a normal condition some gas vents through the gap between the shield cup and torch handle DO NOT attempt to over tighten the shield cup as irreparable damage to internal components may result Operation 4 2 Manual 0 5230 OPERATION CUTMASTER 10MM 12MM B Torch Connection Check that the torch is
34. block at the front of this manual 3 02 Lifting Options The Power Source includes a handle for hand lifting HANDLE is not for mechanical lifting securely strength should lift the unit A e Lift unit by the handle using two hands Do not for lifting WARNING 0 not use straps for lifting e Use optional cart or similar device of DO NOT touch live electrical parts adequate capacity to move unit Disconnect input power cord before mov e Place unit on a proper skid and secure ing unit in place before transporting with a fork lift or other vehicle WARNING FALLING EQUIPMENT can cause serious personal injury and can damage equipment Manual 0 5230 3 1 Installation CUTMASTER 10MM 12MM 3 03 Air Supply Connections A Connecting Air Supply to Unit The connection is the same for compressed air or in dustrial compressed air in gas cylinders 1 Connect the gas line to the compressed air inlet port at the appropriate pressure On Off Switch Air Inlet 1 4 NPT 1 lt lt gt
35. 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 Forinformation on how to test for noise see item 1 in Sub section 1 03 Publications in this manual General Information 1 2 GENERAL INFORMATION B 15 PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infrared light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to 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 chart NOTE 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 Manual 0 5230 GENERAL INFORMATION CUTMASTER 10MM
36. cing c Any accumulation of metal dust or filings that may have caused shorting or arcing If any parts are damaged they must be replaced Refer to the Spare Parts section for a complete list of components used in the Power Source as well as how to access and remove the failed parts Locate the faulty component s then repair or replace where necessary Manual 0 5230 6 5 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 06 Preliminary Check of the Main Inverter Board AN WARNING Read and follow safety information in Section 6 02 before proceeding jelje i Art A 10244 ES m 2526 8 066 110 R 3CPF C 24 23 36 4 Figure 6 4 Main Inverter Board Troubleshooting 6 6 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage OFF Positive meter lead to TP 30 pper capacitor bank Negative meter lead to TP 29 YANG Positive meter lead to 32 nane Negative meter lead to TP 31 dins Table 6 1 DC BUS Multimeter Set to Measure DC volts IGBT Testing Multimeter Lead Placement Diode Voltage Positive meter lead to TP 3 IGBT 1 Negative meter lead to TP 2 0 2000 to 0 8000 VDC IGBT 2 Positive meter lead to TP 5 0 2000 to 0 8000 VDC Negative meter lead to TP 4 2 Positive meter lead to TP 8 IGBT 3 Negative meter lead to TP 7 0 2000 to 0 8000 VDC Positive meter lead to TP 10
37. ck signal 0 8VDC 5VDC A main cutting arc is established Table zu im IFB Header Pin Function Th Positive of voltage feedback Machine output Negative of voltage feedback Machine output _ Table 6 15 WV Header Pin Function D_port Header Pin Pinfunction Signal 12VDC 12VDC Pilot ARC IGBT drive signal Table 6 16 D_port Header Pin Function OT Header Pin Pin unction 5 2 Thermostat OVDC when thermostat closed O Table 6 17 OT Header Pin Function 104 Hi Pressure switch Odc when switch closed Hala 4VDC 2 _ 6ND Table 6 18 PRESSURE Header Pin Function Nc o 2 Gun switch signal OVDC when switch ON otherwise 27VDC 02002 Cup test signal OVDC Cup test signal OVDC when the cup is fixed otherwise 27VDC Table 6 19 GUN amp TEST Header Pin Function Manual 0 5230 6 15 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 13 Waveforms NOTE All waveforms below are taken with ISOLATED oscilloscope probes These parts being measured are MAINS potential An isolating transformer should be used for the oscilloscope or isolated probes should be used If an isolating transformer is used the frame of the oscilloscope may be live and suitable care should be taken to avoid electric shock 1 Vds of inverter IGBT at no load TP C1 4 and 5 C2 9 and 10 Testpoints refer to main inverter board
38. cles of the tape may break off and block the small gas pas sages the torch Manual 0 5230 INSTALLATION CUTMASTER 10MM 12MM 3 04 Power Source Specifications A CutMaster 10mm Plant Part No 1 4730 6 20 30 Amps 240VAC Ambient Temperature 104 F 40 C Duty Cycle 40 240VAC Rated Current 30 Amps 240VAC SL60 Torch Gas Requirements See Section 2T 02 Note 1 Duty Cycle is the percentage of time the system can be operated without overheating Duty cycle is reduced if primary input voltage AC is low or the DC voltage is higher than shown in this chart Note 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear Optional filters provide increased filtering capabilities Table 3 3 CUTMASTER 10mm Plant Power Source Specifications B CutMaster 12mm Plant Part No 1 4200 6 Input Power 240 VAC 15 1 Phase 50 60Hz Output Curent Ambient Temperature Duy Rated Curren tte SS Note 1 Duty Cycle is the percentage of time the system can be operated without overheating Duty cycle is reduced if primary input voltage AC is low or the DC voltage is higher than shown in this chart Note 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or ev
39. d OV 4 Before troubleshooting or applying power to unit complete the checks through 6 05 and 6 14 to avoid causing further damage 6 03 Tools Needed for Troubleshooting and Servicing ep a e ES cz Art A 09849 Figure 6 1 Tools Needed for Troubleshooting and Servicing Digital Multimeter e DC Clip on ammeter Screwdriver and spanner CRO 20 Mhz bandwidth amp isolating transformer Manual 0 5230 6 3 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHOOTING 6 04 Case Removal AN WARNING Read and follow safety information in Section 6 02 before proceeding Remove the ten screws from the case and remove the case panel a Art A 10242 Figure 6 2 Case Removal View Troubleshooting 6 4 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 6 05 Visually Inspect AN WARNING Read and follow safety information in Section 6 02 before proceeding 1 Take out clear protective sheet over main inverter board Art A 10243 Figure 6 3 Clear Protective Sheet Removal View 2 Visually inspect the inside of the Power Source The levels of current present in these units can cause burning or arcing of PCB transformers switches or rectifier when a failure occurs Carefully inspect all components within these units Look in particular for the following 8 Loose or broken wires or connectors b Burned or scorched parts or wires or evidence of ar
40. e 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 6 OPERATION Bottom Dross Buildup Molten material which is not blown out of the cut area and resolidifies on the plate Excessive dross may require secondary cleanup operations after cutting Kerf Width The width of the cut or the width of material re moved during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has become elongated Manual 0 5230 OPERATION 4 05 General Cutting Information WARNING Disconnect primary power at the source before disassembling the power source 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 15 activated CAUTION Sparks from the cutting process can cause damage to coated painted and other sur faces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also signifi cantl
41. e FOB West Lebanon NH or an authorized Victor Technologies service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Victor Technologies shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Victor Technologies with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of the goods covered by or furnished by Victor Technologies whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor Technologies product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective March 15 2011 OR THERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474
42. e Testing Booklet Part No 150 853 when servicing this unit Consult the Owner s Manual for cutting safety precautions Use only genuine replacement parts from the manufacturer General Information CUTMASTER 10MM 12MM GENERAL INFORMATION 1 05 EMF Information Considerations About Cutting And The Effects Of High Frequency Electric And Magnetic Fields Cutting current as it flows through cutting cables will cause electromagnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Re search Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting WARNING High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment install test and service H F producing units The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about int
43. e comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement C Keep the torch in contact with the workpiece during the cutting cycle D Hold the torch away from your body E Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The arc will start Art A 09342 Figure 4 10 Torch Trigger Release Place the torch tip on the work The main arc will transfer to the work NOTE The gas preflow posttlow are a char acteristic of the Power Source and not a function of the torch Manual 0 5230 4 5 CUTMASTER 10MM 12MM Trigger 9 4 Art A 09341 Figure 4 11 Drag Cutting G Cut as usual Simply release the trigger assembly to stop cutting H Follow normal recommended cutting prac tices as provided herein 3 Complete cutting operation NOTE If the torch is lifted too far from the work piece while cutting the main arc will stop and the pilot arc will automatically restart 4 Release the torch trigger a Main arc stops 5 Set the Power Source ON OFF switch to OFF down position AC indicator w turns OFF 6 Set the ma
44. e current setting Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 2 Torch is being moved too fast across work piece a Reduce cutting speed 3 Excessive oil or moisture in torch a Hold torch 1 8 inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch If there are contaminants in the gas additional filtering may be needed 4 Torch parts worn a Check torch shield cup cutting tip start cartridge and electrode Replace as needed M When torch trigger is activated gas in torch flows and then stops but will not pilot AC indicator light blink ing 1 Torch parts not properly installed in torch There may have been an attempt to remove torch parts without turning off ON OFF power switch to OFF on unit a Turn ON OFF switch to OFF position and then check to make sure torch parts are properly installed b Turn ON OFF switch to OFF and then back to ON 6 02 Checking Unit Before ov Power A The following safety information shall be read before starting troubleshooting and servicing 3 gt 1 Turn SW1 to OFF position and disconnect unit from primary line voltage before working on unit 2 Significant DC voltage can remain on capacitors after unit is OFF Wait until all front panel LED s are OFF before removing case 3 Check DC bus voltage according to Section 6 06 after removing case and make sure the DC bus voltage is close
45. en complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear Optional filters provide increased filtering capabilities Table 3 4 CUTMASTER 12mm Plant Power Source Specifications NOTE IEC Rating is determined as specified by the International Electro Technical Commission These speci fications 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 TDC Rating is determined using an output voltage representative of actual output voltage during cut ting with a TDC torch This voltage may be more or less than IEC voltage depending upon choice of torch consumables and actual cutting operation Manual 0 5230 3 3 Installation CUTMASTER 10MM 12MM INSTALLATION T 18 5 469 9mm Art A 10216 2616 11 8kg Figure 3 3 Power Source Dimensions amp Weight NOTE Weight includes torch amp leads input power cord and work cable with clamp A CAUTION Provide clearance for proper air flow through the Power Source Operation without proper air flow will inhibit proper cooling and reduce duty cycle Installation 3 4 Manual 0 5230 INSTALLATION CUTMASTER 10MM 12MM 3 05 Input Wiring Specifications CUTMASTER 10mm Input Power Requirements Input Power Input Current Input Current Input See kVA Max Amps eff Amps Fuse Amps Wons
46. energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the workpiece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications on page 1 4 Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual General Information CUTMASTER 10MM 12MM Fire and explosion can be caused by hot slag sparks or the plasma arc e Besure 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 Do not cut or weld on containers that may have held com bustibles 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 Q NOISE Noise can cause permanent hearing loss Plasma arc processes
47. erference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference H F RADIATION can cause interference About Implanted Medical Devices SM WARNING MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away from servicing areas until consulting their doctor and the device manufacturer To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them or using cable cover Arrange cables to one side and away from the operator Do not coil or drape cables around your body Keep cutting power source and cables as far away from operator as practical Connect work clamp to workpiece as close to the weld as possible General Information 1 6 Manual 0 5230 GENERAL INFORMATION CUTMASTER 10MM 12MM 1 06 Declaration of Conformity Manufacturer Victor Technologies International Inc Address 82 Benning Street West Lebanon New Hampshire 03784 RoHS USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive European Council Directive 2006 95 EC and to the National legislation
48. f the torch head Check the face of the electrode for excessive wear Refer to Figure 5 6 cu OE New Electrode Worn Electrode o Art 03284 Figure 6T 6 Electrode Wear 6 Reinstall the electrode by pushing it straight into the torch head until it clicks 7 Reinstall the desired starter cartridge and tip into the torch head 8 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the cup check the threads before proceeding 6T 2 Manual 0 5230 DISASSEMBLY PROCEDURE SECTION 7 DISASSEMBLY PROCEDURE 1 01 Safety Precautions for Disassembly CUTMASTER 10MM 12MM A Z ui N A N WARNING Read and follow safety information in Section 6 02 before proceeding Unplug unit before beginning Disassembly procedure Manual 0 5230 7 1 Disassembly Procedure CUTMASTER 10MM 12MM DISASSEMBLY PROCEDURE 7 02 Control PCB Removal AN WARNING Read and follow safety information in Section 6 02 before proceeding the disassembly Remove case refer to 6 04 before removing control PCB Refer to graphics on page 7 3 MA Screw Remove 4 screws from Control panel Disconnect harness from connector Disconnect MB harness from MB connector Disconnect SOURCE amp TIP harnes
49. h parts or not properly installed Turn ON OFF switch to OFF position and restart the machine by turning the power switch to ON 2 Indicator blinking 1 sec ON 3 Sec OFF a Check for worn or sticking torch parts Replace if necessary 3 Indicator blinking 3 sec ON 3 Sec OFF a Torch switch was depressed before machine was completely powered up Turn ON OFF switch to OFF position and restart the machine by turning the power switch to ON C Air indicator OFF 1 Gas pressure too low Check supply pressure a Check and adjust to proper setting Manual 0 5230 D TEMP indicator ON AC indicator ON 1 Unit air flow obstructed a Check for blocked air flow around the unit and correct condition 2 Fan blocked a Check for blocked status and correct condition 3 Unit is overheated a Keep the machine plugged in and turned on for five minutes This will allow the fan to run and cool the machine 4 Faulty components in unit a Have an Accredited CIGWELD service provider repair or replace as required E Torch will not pilot when torch trigger is acti vated 1 Faulty parts in torch a Check torch parts per section 4 02 replace as needed 2 Gas pressure too low a Adjust supply pressure to proper set ting value 3 Faulty components in unit a Have an Accredited CIGWELD service provider repair or replace as required Troubleshooting CUTMASTER 10MM 12MM F No c
50. in Sec 6 06 1 Measure P1 max C1 P2freq C1 P3 max C2 P4cfreq C2 P5 max C2 2 value 416 40 384460 kHz 410 40 375555 kHz status Art A 10247 Troubleshooting 6 16 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 2 Vds of inverter IGBT at full load TP C1 4 and 5 C2 9 and 10 Testpoints refer to main inverter board in Sec 6 06 Measure 1 1 P2 rms C1 P3 mean C1 P4 max C2 P5ims C2 PB mean C2 value 498 V 223 0 182 9 542V 234 0 196 7 V 7 status Art 10248 6 14 Main Circuit Description A WARNING Turn off power and disconnect mains supply plug from receptacle before working on the unit Allow two minutes for capacitors to discharge after disconnection from mains supply voltage Manual 0 5230 Troubleshooting CUTMASTER 10MM 12MM AC 1 TRI ace cp 7 FN LL RX CONS ACI tocon TROUBLESHOOTING ZYOUT 2PIN R2002 R200 06 RISO RISI R157 R168
51. in power disconnect to OFF or unplug input power cord a Input power is removed from the system Operation CUTMASTER 10MM 12MM 4 04 Cut Quality NOTE Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Refer to Appendix pages for additional information as related to the Power Source used Cut quality requirements differ depending on applica tion For instance nitride build up and bevel angle may be major factors when the surface will be welded after cutting Dross free cutting is important when fin ish 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 Top Edge Rounding Dross Build Up Cut Surface A 00007 Drag Lines Figure 4 12 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 angl
52. lt gt lt gt lt gt lt gt lt gt lt gt lt gt ec o2 TO TI ec INJ 3 wg 1 ant A 10223 Figure 3 1 Gas Connection to Compressed Air Input Single Stage Filter Kit No 7 7507 ART A 10675 Hose Fitting Gas Supply Hose Figure 3 2 Optional Single Stage Filter Installation for Compressed Air Input Installation 3 2 INSTALLATION B Using Industrial Compressed Air In Gas Cylinders When using industrial compressed air in gas cylinders as the gas supply 1 Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure gas regulators 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign mate rial Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjust able high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 250 scfh Standard cubic foot per hour 120 Ipm liter per minute 4 Connect gas supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure gas cylinder regulator Supply hose must be at least 1 4 inch Bmm internal diameter For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions DO NOT use Teflon tape as a thread sealer as small parti
53. n this manual Due to our constant effort to bring you the best products we may make an improvement that does not get reflected in the manual If you are ever in doubt about what you see or read in this manual with the product you received then check for a newer version of the manual on our website or contact our customer support for assistance YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies International Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service and technical support together with excellence in sales and marketing expertise Above all we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry A WARNINGS B Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Plasma Cutting Power Source CutMaster 10mm Plant Part Number 1 4730 6 Cutmaster 12mm Plant Part Number 1 4200 6 SL60 Torch
54. panel screws Reconnect two red wires and install the screws Art A 11088 Figure 8 3 Installing Front Panel Assembly Procedures 8 4 Manual 0 5230 ASSEMBLY PROCEDURE CUTMASTER 10MM 12MM 8 04 Installing Main Control PCB and Clear Cover Sheet Install 4 screws Plug harness into HF QF connector Plug harness into MB connector Plug harness into SOURCE amp TIP connector Plug harness into DRIVE connector Plug harness into U D connector Plug harness into WA connector c Plug harness into FAN connector 9 Plug harness into TRANF IFB connector 10 Plug harness into WV connector 11 Plug harness into D PORT connector 12 Plug harness into OT connector 13 Plug harness into PRESSURE connector 14 Plug harness into GUN amp TEST connector 15 Install clear protective sheet Manual 0 5230 8 5 Assembly Procedures CUTMASTER 10MM 12MM ASSEMBLY PROCEDURES NI 1 3 7 8 9 10 11 Art A 10250 15 Art 10260 Figure 8 4 Installing Main Control PCB and Clear Cover Sheet Please refer to Figure 6 9 in Section 6 12 for control PCB Assembly Procedures 8 6 Manual 0 5230 ASSEMBLY PROCEDURE CUTMASTER 10MM 12MM 8 05 Installing Case 1 Install Case 2 Install the ten screws and tighten them 1 9 Art 10261 Figure 8 5 Installing the Case Manual 0 5230 8 7 Assembly Procedures CUTMASTER 10MM 12MM ASSEMBLY PROCEDURES Notes
55. parts can explode or cause other parts to explode when power is applied to inverters Always wear a face shield and long sleeves when servicing inverters 2 WARNING SHOCK HAZARD from testing Turn Off cutting power source or stop engine before making or changing meter lead connections Use at least one meter lead that has a self retaining spring clip such as an alligator clip Read instructions for test equipment EZ 2 WARNING FALLING UNIT can cause injury Use lifting eye to lift unit only NOT running gear gas cylin ders or any other accessories Use equipment of adequate capacity to lift and support unit If using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit Manual 0 5230 1 5 CUTMASTER 10MM 12MM WARNING MOVING PARTS can cause injury Keep away from moving parts such as fans Keep away from pinch points such as drive rolls Have only qualified persons remove panels covers or guards for maintenance as necessary Keep hands hair loose clothing and tools away from moving parts Reinstall panels covers or guards when maintenance is finished and before reconnecting input power WARNING OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to cut again Do not block or filter airflow to unit AN WARNING READ INSTRUCTIONS Us
56. peed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut 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 Operation CUTMASTER 10MM 12MM OPERATION Notes Operation 4 8 Manual 0 5230 THEORY OPERATION CUTMASTER 10MM 12MM SECTION 5 THEORY OF OPERATION 5 01 Inverter Design What does the word inverter mean The term inverter refers to the ability to change DC power into AC Inverter power supplies immediately rectify the incoming AC to DC and then the transistors create a higher frequency AC The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply The AC is then rectified to extremely smooth DC The diagram to the below shows the basic electrical wiring of a DC output inverter power supply Inverter Technology Summary Rectifier Filter IGBT Transformer Rectifier Inductor AC 50 60Hz DC Rippled DC Smooth AC High Frequency AC High Frequency DC Rippled DC Smooth High Voltage High Voltage High Voltage High
57. retion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Victor Technologies must be notified within 30 days of any failure at which time Victor Technologies will provide instructions on the warranty procedures to be implemented Victor Technologies will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Victor Technologies Distributor LIMITED WARRANTY PERIOD Power Source Components Torch and Leads Parts and Labor Parts and Labor Product CUTMASTER 10mm CUTMASTER 12mm This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Victor Technologies 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Victor Technologies 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Victor Technologies and ar
58. rtable and allows good control and _ movement Figure 4 8 Standoff Distance NOTE The tip should never come in contact with the workpiece except during drag cutting operations B Depending on the cutting operation do one of the following a For drag cutting place the tip on the plate holding the torch at an angle to the plate so that only one edge of the tip is in contact with the plate This prevents damage to the tip during the piercing process 4 b For standoff cutting hold the torch E tip on the workpiece pull the trigger Art A 11462 After the arc is initiated lift the tip to 1 8 3 8 3 4mm off the work Figure 4 9 Standoff Cutting Art A 09342 Shield Cup Standoff Distance 1 8 3 8 3 9mm 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 Trigger Release NOT attempt to force the shield cup to close this gap Forcing the shield cup against Figure 4 7 Torch Trigger Release the torch head or torch handle can damage components Operation 4 4 Manual 0 5230 OPERATION e Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6mm thick or less NOTE For best parts performance and life always use the correct parts for the type of opera tion A Install the drag cutting tip and set the output Current B The torch can b
59. s NOTE An operation procedure or background information which requires additional emphasis or is helpful in efficient operation of the system A CAUTION A procedure which if not properly followed may cause damage to the equipment A WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02 Important Safety Precautions A WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and fol low all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Manual 0 5230 1 1 MATIO
60. s from SOURCE amp TIP connector Disconnect DRIVE harness from DRIVE connector Disconnect U D harness from U D connector Disconnect WA harness from WA connector Disconnect FAN harness from FAN connector Disconnect TRANF IFB harness from TRANF IFB connector Disconnect WV harness from WV connector O 309 xo seco opas Disconnect D PORT harness from D PORT connector k NI Disconnect OT harness from OT connector 13 Disconnect PRESSURE harness from PRESSURE connector 14 Disconnect GUN amp TEST harness from GUN amp TEST connector Refer to Figure 6 9 in Section 6 12 for control PCB 1 3 7 8 9 10 11 Art A 10250 Figure 7 1 Removing Control PCB Disassembly Procedure 7 2 Manual 0 5230 DISASSEMBLY PROCEDURE CUTMASTER 10MM 12MM 7 03 Front Panel Assembly Removal AN WARNING Read and follow safety information in Section 6 02 before proceeding the disassembly 1 Unscrew the ten screws from the case panel and remove it 2 Unscrew the two screws on front panel 3 Unplug the three harnesses from control PCB as shown in photo on following page 4 Remove the two screws fixing the harnesses connecting front PCB with main power PCB CUTMASTER Art 11084 Figure 7 2 Removing Front Panel Assembly Manual 0 5230 7 3 Disassembly Procedure CUTMASTER 10MM 12MM DISASSEMBLY PROCEDURE 7 04 Front Panel Operator Interface PCB Removal AN WARNING Read and follow safety informa
61. such as this You will also notice icons from the safety section appearing throughout the manual These are to advise you of specific types of hazards or cautions related to the portion of information that fol lows Some may have multiple hazards that apply and would look something like this PA 0 5230 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a nameplate attached to the machine Equipment which does not have a nameplate at tached to the machine is identified only by the specification or part number printed on the shipping container Record these numbers for future reference 2 03 Receipt of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concern ing damage claims or shipping 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 descrip tion of the parts in error 2 04 Transportation Methods Disconnect input power conduc tors from de energized supply line before moving the cutting power source Lift unit with handle on top of case Use h
62. t of Equipment eese ennt nn nnn raten tns 2 1 2 04 Transportation 8 2 1 205 Working Principle esee terrere pA 2 2 2 06 Power Supply FOatlif aS secessit ab SALA pabasa 2 3 SECTION 2TORCH INTRODUCTION Mese 21 1 18 nd Uh cc 2T 1 202 SPO MN MONS 21 1 ditan DO Plas Ma dena nnd acd npe AA 21 2 SECTION 3 INSTALLATION 3 1 3 01 3 1 SEU EMEN Er DER UTC T PR RAP 3 1 270 Air Supply DOO CHONG AP AN ARAB 3 2 3 04 Power Source Specifications 3 3 305 PRES in AH etas AO 3 5 SECTION 4 SYSTEM OPERATION AA AA AA 4 1 4 01 Control Panel NIRE REINO PS 4 1 4 02 Preparations for OP RF QUIN 4 2 4 03 Sequence of 4 4 VAY CAE aU UPC 4 6 405 General Cutting 4 7 SECTION 5 THEORY OF OPERATION Pee 5 1 5 01 a e P 5 1 SECTION 6 TROUBLESHOOTING m H 6 1 6 01 Basic Troubleshooting Power Source 6 1 6 02 Checking Unit Before Applying 6 3 6 03 Tools Needed for Troubleshooting and
63. th and following standard safety practices do the job When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free Disconnect input power conductors from de energized supply line BEFORE moving a cutting power source SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverters disconnect input power and discharge input capacitors according to instructions in Troubleshooting Section before touching any parts 5 RS WARNING STATIC ESD can damage PC boards Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards WARNING FIRE OR EXPLOSION hazard AN Do not place unit on over or near combustible surfaces Do not service unit near flammables Manual 0 5230 GENERAL INFORMATION gt A WARNING FLYING METAL or DIRT can injure eyes Wear safety glasses with side shields or face shield during servicing Be careful not to short metal tools parts or wires together during testing and servicing z WARNING HOT PARTS can cause sever burns Do not touch hot parts bare handed Allow cooling period before working on equipment To handle not parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns WARNING EXPLODING PARTS can cause injury Failed
64. tion in Section 6 02 before proceeding the disassembly 1 Remove the screw on the potentiometer knob 2 Remove the nut 3 Remove the front PCB Art A 11085 Figure 7 3 Removing Front PCB Disassembly Procedure 7 4 Manual 0 5230 DISASSEMBLY PROCEDURE CUTMASTER 10MM 12MM 7 05 Rear Panel Removal AN WARNING Read and follow safety information in Section 6 02 before proceeding the disassembly 1 Remove screws on rear panel 2 Remove the three screws 3 Terminals from supply cable Disconnect two terminals from switch 4 Wires from main PCB1 Disconnect the two terminals from switch 5 Goung wire terminal Remove the nut Art A 11641 Figure 7 4 Removing Rear Panel Manual 0 5230 7 5 Disassembly Procedure CUTMASTER 10MM 12MM DISASSEMBLY PROCEDURE 7 06 Power Switch 1 and Power Cord Removal WARNING Read and follow safety information in Section 6 02 before proceeding the disassembly 1 Gas inlet Remove gas inlet from rear panel 2 SW locking tabs Squeeze the locking tabs and push SW out from the rear panel 3 Loosen the cable anchorage 4 Remove fan 5 Pull the Input Power Cord out Art 11639 Figure 7 5 Removing Power Switch and Power Cord Disassembly Procedure 7 6 Manual 0 5230 PROCEDURE CUTMASTER 10MM 12MM el Remov AN WARNING Read and follow safety information in Section 6 02 before proceeding the disassembly 1 Remove central panel screws 2 Remove main power
65. tralia 3072 Telephone 61 3 9474 7400 THERMAL DYNAMICS FAX 61 3 9474 7391 Email enquiries victortechnologies com au www victortechnologies com
66. utting output when torch is activated AC indicator ON gas flows fan turns 1 Torch is not connected properly to power supply a Check torch connection to power sup ply 2 Working cable not connected to work piece or connection is poor Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit Have an Accredited CIGWELD service provider repair or replace as required 4 Faulty torch a Return for repair or have qualified technician repair G Torch cuts but not adequately 1 Incorrect setting of output current control Check and adjust to proper setting 2 Working cable connection to work piece is poor a Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit a Return for repair or have qualified technician repair H Output is restricted and can not be controlled 1 Input or output connection is poor a Check all input and output connection leads 2 Working cable connection to work piece is poor a Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit a Havean Accredited CIGWELD service pro vider repair or replace as required 1 Cutting output is unstable or inadequate 1 Input or output connection is poor a Check all input and output connection leads Troubleshooting TRO
67. way New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELD ING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Bat terymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Associa tion 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association
68. wer levels present inside this Power Source Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Apply voltage to the Power Source Once power is applied to the Power Source there are extremely hazardous voltage and power levels present Do not touch any live parts Refer to Figure 6 4 in Section 6 06 for Main Inverter Board DC Bus Testing Multimeter Lead Placement Voltage with Supply voltage ON Positive meter lead to TP 30 pr Upper capacitor bank Negative meter lead to TP 29 192 VDC 10 Positive meter lead to TP 31 Lower capacitor bank Manative meter lead to TP 32 192 VDC 10 Positive meter lead to TP 29 T Overall capacitor bank meter lead to TP 42 384 VDC 10 Table 6 5 DC BUS Multimeter Set to Measure DC volts NOTE These DC voltages are at nominal mains supply voltage of 240VAC Troubleshooting 6 12 Manual 0 5230 TROUBLESHOOTING CUTMASTER 10MM 12MM 6 12 Check of Control PCB AN WARNING Read and follow safety information in Section 6 02 before proceeding J13 PRESSURE J12 0T JT HF QF J11 D port J2 MB R305C301 40 PFC CUT J10 WV 9 066 359 6 R707 R706 J3 HFOUT 2 m S ke c J4 SOURCE amp TIP J5 DRIVE Art A 10246 Figure 6 9 Control PCB Manual 0 5230 6 13 Troubleshooting CUTMASTER 10MM 12MM TROUBLESHO
69. y 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 cutting arc as quickly as possible Manual 0 5230 CUTMASTER 10MM 12MM Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left LeftSide put Angle lt Right Side Cut Angle A 00512 Figure 4 13 Side Characteristics of Cut To make a square edged cut along an inside diameter of a circle the torch should move coun terclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Dross 4 7 When dross is present on carbon steel it is com monly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top dross is normally very easy to remove and can often be wiped off with a welding glove Slow s

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