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Service Manual - Victor Technologies

1. W D4 04 90AMP 5 LAYOUT SERVICE SEC1 CHOKE1 OUT_1 SEC2 PMTH3 PRI3 J9 PRI4 _OUT1 GND1 DMD1 PRI2 1 Art A 08506 Manual 0 4988 N CUTMASTER 152 50AMP PCB 5 SIGNALS J1 1 12VDC Supply for Fan MOT 2 1 2 FAN Active Low to enable Fan MOT 2 J2 1 12VDC Supply for Fan MOT 3 J2 2 FAN Active Low to enable Fan MOT 3 Signal Source Destination J3 1 12VDC 12VDC Supply J3 2 Common 12VDC Return J4 4 OVERTEMP Active Low signal when OVERTEMP J4 5 FAN_ON Active Low to enable Fans J4 6 CSR Active low to Enable PWM J4 7 CUR_SET 1 2 AVDC Cut Current Demand J4 8 MAIN_PCB_ID 0 Ohms to common J4 9 Not Used J4 10 Common TEST POINTS 80A AC1 AC Input Phase 1 80A AC2 AC Input Phase 2 80A AC Input Phase 3 50A AC1 AC Input Phase 1 50A AC2 AC Input Phase 2 50A AC Input Phase 3 MTH 1 Capacitor Bank MTH 2 Capacitor Bank MTH 4 Capacitor Bank A MTH 6 Capacitor Bank MTH 7 Capacitor Bank B MTH 8 Capacitor Bank PMTH 1 Capacitor Bank PMTH 2 Capacitor Bank A PMTH 3 Capacitor Bank PMTH 4 Capacitor Bank B TP1 Common TP2 1
2. 2 io 4 PO E 0 4 7 130 390 gt IIN Speed Per Minute Standoff Flow CFH Pierce Height 100 ss oso as zs 52 10 soo 08 0 200 5 om 0 20 2 22 9 0 so 20 o 98212 144 wo ss 52 10 Torch SL100 With Shielded Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch z 2 en vo so w o2 05 360 N N 9 8212 0 8 0 5 0 8 12 12 13 13 zig N 4T 18 OPERATION Manual 0 4988 N CUTMASTER 152 Type Torch SL100 With Shielded Tip Type Material Mild Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Standoff Plasma Gas Press Flow Pierce Pierce Height Cat No Plasma Total Delay Sec Inches nches Amps Meters 98253 154 1 1 ajo oo
3. 3 5 2 RO PO PO 0 00 2544 0082 160 120 20 176 120 s 020 ojo O1 5 0 0 0 NININININININININIG ojej ojoj ojo joo 5 g 40 42 44 50 54 58 60 70 76 a Type Material Stainless Steel Thickness Speed Per Minute Standoff Flow CFH Pierce Height alata E es ojo ojo 180 360 040 2 2 12 12 2 5 2 n n 15 o 2 Type Plasma Gas ous ws 120 as oa 5 38 75 52 10 wa Fro asap 9353 we 120 zo ost 52 10 wa ws NOTES Gas pressure shown is 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 io ojo Manual 0 4988 OPERATION 4T 19 CUTMASTER 152 s PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U S and Foreign Patents as follows Catalog 7 Description Patent s 9 8215 Electrode US Pat No s 6163008 6987238 Other Pat s Pending 9 8213 Cartridge US Pat No s 6903301 6717096 6936786 6703581 D496842 D511280 D492709 D499620 D50414
4. A 6 APPENDIX 6 SYSTEM SCHEMATIC 600V A 8 APPENDIX 7 PUBLICATION 5 A 10 N CUTMASTER 152 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows NOTE An operation procedure or background information which requires additional emphasis or is helpful in ef ficient operation of the system CAUTION A procedure which if not properly followed may cause damage to the equipment WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area A WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box such as this 1 02 Important Safety Precautions WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipmen
5. s T j d J Y PILOT IGBT CNE 2 1 starr 3 i 2AVAG RETURN 4 CNC INTERFACE STANDARD ON A80 amp A120 UNITS 24VAC SUPPLY it 7 CNC INTERFACE OPTIONAL 102 amp 152 UNITS 2 S m Es 3 TT 8 2 cnc PINOUT 6A 250VAC 1 HE voc 5 5 LE 4 ISTART STOP E 3 1 40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION TEST POINTS 1 OUT SIGNAL ML PCR 2 onoi 5 ENSE ML To configure DIVIDED ARC VOLTS signal output 0 COMMON Hp No hanger stated or ARG VOLTS 1687 Savi Save suPeLy 5 Lit mper pins 1 amp 2 for ARC VOLTS 30 por bns 2 amp for ARE VOLTS 30 D78CSR 1 CURRENT DEMAND 7 IRAR RAPID AUTO RESTART 1 PCB1 1 SEN _ TIP DRAG SENSE ANRUSH n d MON SHON tM r 11 AORCH 12 ISOLENOIDLON 12 SOLENOID ON E 3 14 ON LM 1 1 5 9 15 LATCH EM 1 gt ror 2 E arc vous 18 MORGE SWITCH En 3 TE Davos E ome ME aa H 18 H 5 LH series c ae 20 TORCH SOLENOID DETECT ML 7 7 7 PCB4 ul 21 IOVERTEMP H HH Bh 2 VN
6. Art A 07990 8 Install the new or cleaned assembly by reversing these procedures 9 Turn ON 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 04 A 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 4988 C Input Power Cable Replacement Tools required T20 Torx Driver Phillips Head Screwdriver Flathead Screwdriver 1 Remove the Cover per subsection 7 04 A 2 Disconnectthe input cable wires from the W1 contactor terminals and ground lug 3 Loosen the two screws in the cable strain relief 4 Remove cable through the rear panel 5 Install replacement Input Power Cable by reversing 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 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
7. KE oc Mave 2 COMMON 28 COMMON 2 MAIN PCB D ERN ML En mo 38 COMMON s 5 vt 2 n TROET ERRORIND FAULT OVER PRESSURE ERROR v 85 SHORTED TORCH overteme 55 CONSUMABLES MISSING 5 START ERROR m PARTS IN PLAGE 2 PUT POWER cas UNDER PRESSURE 2 2 d TEST POINTS d A T2 voc gt 5VDC r error a 3 GAS CONTROL Tes dy 10 05 voc 2 Te CORRENT DEMAND amp REGULATOR tn SOLENOID NT 2 AVE TEMP voc 65 FILTER cinco Am MET on SET E can RAR 1 T 6450 i 1 PCB3 I 57 Ey Bue x POBNG NTROECO Bras ee IPT OR Assy AB ECO 81399 RWH 05 05 09 Scale Supersedes AB B1611 RWH 05 05 09 THERMAL DYNAMICS Prope to THERMAL DYNAMICS CORPORATION MARCH 30 2009 Not For Rene Ropodicton or Disirbuton without ton Consent NOTE Unless Otherwise Specified Resistors are in Ohms 1 4W 5 RWH Capacitors are in Microfarads UF he Sheet CES TRE SCHEMATIC ss OWE Ne Last Modillad Friday Decembar T1 CM102 152 35mm 40mmy AB0 A120 380 400 415 6Q0 42 1330 z I I Manual 0 4988 APPENDIX CUTMASTER 152 APPE
8. 1 J10 J9 PCB 1 LAYOUT Art f A 08518_AB CHOKE1 SEC2 12V1 WORK 1 GND2 MAIN PCB 1 SIGNALS J1 1 L1 Primary AC Line J1 2 Not used J1 3 Not used J1 4 Not used J1 5 L2 Primary AC Line Signal Source Destination J2 1 VOUT OUTPUT VOLTAGE M L J2 2 TIP VOLTS Active high when tip is installed M L J2 3 TIP_SEN Approx 100VDC while cutting w tip OFF M L work Active low in Drag Mode J2 4 460V_IN Active low with 460VAC primary input voltage L M J2 5 230V_IN Active low with 230VAC primary input voltage L M J2 6 CUR_SET Current demand signal Variable 1 4VDC L M 5 26 SERVICE Manual 0 4988 CUTMASTER 152 12 7 12 8 12 9 42 10 42 11 42 12 42 13 12 14 42 15 42 16 42 17 42 18 42 19 42 20 12 21 12 22 42 23 42 24 42 25 42 26 42 27 42 28 42 29 42 30 42 31 42 32 42 33 42 34 42 35 12 36 42 37 12 38 12 39 42 50 43 1 43 2 44 1 44 2 44 3 44 4 44 5 45 1 45 2 RAR INRUSH ON SHDN TRCH SOL SOL TO MOVE ON LATCH ACTIVE TRCH SW PIP AC_ON CSR TORCH_SOL_DETECTED OVERTEMP V_IN 12VDC 12VDC GND GND Not Used Not Used MAIN_BD_ID Not Used Not Used Not Used Not Used For Factory Use 3 3VDC TXD RXD Common D Not Used 230VAC Common 3 3VDC TXD RXD Common D 12VDC Not used Manual 0 4988 Active low when in Rapid Auto Restart mode Active low after inrush time expires Active low to enable W1 contactor Active
9. 4o 0125 32 es 4s 55 170 51 9 8208 4o sto 787 o125 32 65 45 55 000 o2 51 oos 155 958208 o 40 240 610 26 2 65 45 55 170 51 5 6208 _120 4o 48 es 4s 55 vo 54 4 9 8208 EM 55 Torch 51100 With Exposed Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch hes mm Cat No Volts VDC Amps Delay Sec Inches mm 65 45 40 0 lt e e zy o o ojo ojo wo zs 019 es as ss ro 51 Los 24 osr as es 4s ss ro 51 ese 123 40 so 127 4s ss o 100 o o m o T o 4 10 OPERATION Manual 0 4988 CUTMASTER 152 Type Material Mild Steel Type Secondary Gas Single Gas Torch Pierce Height CFH Flow m Say na 025 70 ae so 26 025 Type Material Stainless Steel Type Secondary Gas Single Gas Torch Plasma Gas Press Type Secondary Gas Single Gas Torch Type Material Aluminum rise oss ea as oo 246 099 635 70 as oo
10. 9025 ea wo 4s 70 o zs 020 025 oa Cas 21e ossa as s 025 Speed Cas v om eal vo as 00 26 050 025 3o or oz eal vo 4s oo 26 oo 025 os oz sa o as o ss ws un un Pie was oz sa vo as oo un un Syed Per nu Fow FH NEM Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Type Plasma Gas Air Tip x a a H e D 2 i n f cum a et lt Em o gt e 2 c Si EE HET io 93210 3 4 9 8210 132 140 143 145 145 9 8210 127 64 9 8210 9 5 9 8210 9 8210 9 8210 19 1 9 8210 9 8210 0250 64 68210 0 625 15 9 9 8210 9 8210 2210 25 4 Type Torch 51100 With Exposed Tip Type Plasma Gas Air Tip Per Minute 110 120 120 119 21 119 124 9 8210 126 127 19 1 9 8210 134 1 000 9 8210 140 Torch 61100 With Exposed Tip Type Plasma Gas Air 28210 41 11 OPERATION Manual 0 4988 CUTMASTER 152 p 0060 tseem eo sm ara 6 as om 049 48 forza 30 ns eo zx s o 6 as vs 049 ostoa vs eo te as orfas es as 16
11. transfer distance of workpiece Pilot arc established RESULT Main arc transfers Pilot arc off ACTION Release Torch switch RESULT ACTION ACTION Main arc stops Unplug input Gas flow stops after post flow ON OFF switch power cord or to OFF O open external Fans will continue to run for disconnect 10 minutes after the Torch switch RESULT START is removed RESULT All indicators off Power supply fans shut off No power to system Art 07979 0 4988 APPENDIX A3 CUTMASTER 152 of Power Supply Note 1 APPENDIX 2 DATA TA INFORMATI N VICTOR West Lebanon NH USA 03784 THERMAL DYNAMICS Model Date of Mr m Made in USA Manufacturer s Name and or Logo Location Model and Revision Level Serial Number and Production Code BCDB Regulatory Standard Covering This Type of Power Supply Output Duty Cycle Factor Output Range Amperage a Voltage Plasma Cutting ida Duty Cycle D Note 3 ut cle Data Note Uo y Cy Rated No a Conventional Load Voltage Load Voltage Rated Maximum Supply Current Input Power Symbol Ui 1 1MAX agi teff Maximum Effective zi Supply Current Input Power Specifications Phase AC or DC Hertz Rating Manufactu
12. OS Vj 2 5 1 Black 5 Pilot B Mechanized Machine Torch Pin Out Diagram MACHINE TORCH ATC Male Connector ront Vi Front View Negative Plasma N 2 FX Switch ATC Female Receptacle 4 Black Pendant lt e 3 Switch oun Suc ai A Connector 3 White Pendant 4 Connector TMOA A 5 Not Used 70 Bed c open ell eae 52 in By 6 Op d Ll S A 2 PIP SOS 5 Open Pilot Pilot Manual 0 4988 APPENDIX A 3 CUTMASTER 152 APPENDIX 4 TORCH CONNECTION DIAGRAM A Hand Torch Connection Diagram Torch SL60 SL100 Hand Torch Leads Torch Leads with ATC Connector Power Supply with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power __ Torch Supply Head Leads PIP TT Black O Orange Switch To Power Supply Circuitry Torch O PM Green Switch To Power Supply white Circuitry 0 BR Negative Plasma Negative Plasma Pilot Pilot Art A 03797 B Mechanized Torch Connection Diagram Torch Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector To Remote Control Power Supply with ATC Fema
13. OPTIONS to ua 3 1 3 03 Primary Input Power Connections 3 1 3 3 SECTION 3 TORCH 5 0 3T 1 Torch HECHOS seers ast TN 3T 1 3T 02 Setting Up Mechanical Torch 3T 1 SECTION 4 SYSTEM 2 na nona aat mmi 4 1 4 01 Front Pan l Controls 7 gains 4 1 402 Preparations tor dde dnte tes 4 2 TABLE OF CONTENTS SECTION 4 TORCH OPERATION inna iuh uo ru nx epe nona na ope Rit 4T 1 E WU Torch Pans HP NT 4 1 e 4 2 4T 03 General Cutting en 4 2 41 04 Hand Torch 02 2000 4 3 Dm 4T 7 47 06 Mechanized Torch Operation 4 8 4107 Parts Selection for 51100 Torch Cutting sss 4T 9 47 08 Recommended Cutting Speeds for SL100 Torch With Exposed 41 10 4109 Recommended Cutting Speeds for 51100 Torch With Shielded 4T 15 PATER THRO MATION ec 4T 20 SECTION 5 SYSTEM lt lt nr
14. G With CURRENT CONTROL POTENTIOMETER set at maximum output current is only 70 amps 1 Open Sync cable between J14 on Main PCB 1 and 50 5 Check continuity and replace if open 2 Openconnection between J13 on Main PCB 1 to J4 on 50A PCB 5 Check continuity 3 Defective 50 PCB 5 a Replace 50Amp PCB 5 H In RAPID AUTO RESTART mode with torch switch closed the pilot does not start immediately when the cutting arc extinguishes 1 Defective Logic PCB 3 a Replace Logic PCB 3 INTERNAL ERROR FAULT indicator and 90 PSI LED 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 Manual 0 4988 N CUTMASTER 152 5 10 CNC Interface Problems 5 11 Test Procedures A Nothing happens when jumper is installed A Main Contactor W1 Test between J2 3 to J2 4 1 Defective Automation Interface PCB 4 1 Check continuity between L1 to T1 a Measure voltage on PCB 4 between J1 6 to J1 8 for 12VDC L2 to T2 If 12VDC is present replace Automation Interface PCB 4 US L4 to 2 Defective Main PCB 1 a Measure voltage on Main PCB 1 between J1 6 to The contacts should be open no continuity If continuity is 5 found disconnect J1 from the Main 1 and recheck If continuity still exists replace W1 If disconnecting J1 from I
15. VICTOR THERMAL DYNAMICS 208 1 PHASE 3 PHASE 230V Ny UN CUTMASTER 152 PLASMA CUTTING SYSTEM Service Manual Issue Date November 14 2013 Manual No 0 4988 VictorThermalDynamics com VICTOR THERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Victor Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 426 1888 or visit us on the web at www VictorThermalDynamics com This Operating Manual has been designed to instruct you on the correct use and operation of your Victor Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Pre cautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies 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 pr
16. e 2 D D o de a 5t E lt gt 22 o gt ts H IE 0625159 Type Torch SL100 With Shielded Tip Type Material Aluminum Type Secondary Gas Single Gas Torch Type Plasma Gas Air Duy ors 32 65 4s zs 64 15 oras 66 as 15 025 5 on oras 66 as ws 025 64 os oi 66 4s s n 124 138 141 142 Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip Fam 15 oan ns m ors 32 e as 15 oo vo s 610 ui 32 6 as 15 so 0 vo s ui sz 6 as 15 02 0 64 5821 3 eo is os ois 6 4s ns ne wm NR ums 222 m e om as es as us so nn nm we Fama in w 6 oi 66 as wo ww 5 4T 17 OPERATION Manual 0 4988 CUTMASTER 152 Thickness Speed Per Minute Standoff Flow CFH Pierce Heigh Inches Amps Inches Si bar Plasma Inches 130 o5 _ 3 2 aja AIS
17. 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 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 soo El O ring Cat No 9 9743 Assembled Filter Cover 5 Barbed e Fitting Art A 02476 Optional Single Stage Filter Element Replacement PARTS REPLACEMENT 7 7 CUTMASTER 152 p 5 Element aside to dry Remove the Filter Element from the Housing and set 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above Wipe inside of housing clean then insert the replace ment 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 Optional Two Stage Filter Element Replacement 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 checking for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures The Two Stage Air Filter has two Filter Elements When the Filter Elements become dirty the Po
18. 6 09 Replacement Parts for Hand Torch Item t Description talog 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 connectors includes switch assemblies 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 9 7031 Art 07993 Manual 0 4988 PARTS LIST 6 7 CUTMASTER 152 y 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Item No Description talog No 1 1 Torch Head Assembly without leads includes items 2 3 and 14 9 8220 2 1 Large O Ring 8 3487 3 1 Small O Ring 8 3486 4 1 PIP Switch Kit 9 7036 5 Unshielded Automated Leads Assemblies with connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7850 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7851 1 25 foot 7 6 m Leads Assembly with connector 4 7852 1 50 foot 15 2 m Leads Assembly with ATC connector 4 7853 6 Unshielded Mechanized Leads Assemblies with connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with connector 4 7043 1 25 foot
19. 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 For best performance and parts life always Establish the cutting arc as quickly as possible use the correct parts for the type of opera Direction of Cut tion 1 The torch can be comfortably held in one In the torches the plasma gas stream swirls as it leaves 6 ae hand or steadied with two hands Position the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the hand to press the Trigger on the torch the other Viewed along the direction of travel the right handle With the hand torch the hand side of the cut is more square than the left may be positioned close to the torch head Left Side for maximum control or near the back end Cut Angle Right Side for maximum heat protection Choose the Cut Angle holding technique that feels most comfort able and allows good control and move ment NOTE The tip should never come in contact with the workpiece except during drag cutting operations 2 Depending on the cuttin ration n To make a square edged cut along an inside diameter of a epending o e cutting operation do one circle the torch should move counterclockwise around the of the following circle To keep the square edge along an outside diameter a For edge starts hold the torch perpen cut the t
20. hole protector on the back panel of the power supply Pull the original power cable out of the power sup ply 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 ac cess opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION conform to local electrical code and the recom mended circuit protection and wiring require ments refer to table in Section 2 6 Connect the wires as follows e 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 T With a little slack in the wires tighten the through hole protector to secure the power cable 8 Reinstall the Power Supply cover per instruc tions found in section 5 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 4988 N CUTMASTER 152 3 04 Gas Connections 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 Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cyli
21. tibles GENERAL INFORMATION 1 1 CUTMASTER 152 p e 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 processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in Subsec tion 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear e Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep
22. 25 om 020 51 roars 1s ssno 16 1 os s2 ae 9 020 51 uo ns o 126 os faa 9o os 020 51 so zo 10 aa wo 26 on 7s iw 32 70 9 oz 51 amp e 1 32 as 9 2e 51 o 2 on 32 as 9 2 oz 51 7 oa 4a 48 9 ze 025 oz 51 120 121 129 135 110 7 sez D E E H S D i H ded co lt gt a E o gt e E fe 15 58210 CE Type Torch SL100 With Shielded Tip Type Material Aluminum Type Secondary Gas Single Gas Torch Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Type Plasma Gas Air Tip Cat No 29210 8210 MADE 8210 CAE 8210 EE 0 188 0 250 9 8210 9 8210 oso 12 9 8210 9 8210 9 8210 A 9 4 CAE Corso re Manual 0 4988 OPERATION 41 16 CUTMASTER 152 Type Material Mild Steel Type Torch SL100 With Shielded Tip Type Secondary Gas Single Gas Torch Type Plasma Gas Air Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip Type Material Stainless Steel Type Secondary Gas Single
23. 4 CUR PCB1 man pce assy FERRITE 1 i ESLL pom 5 PRI D D PRISD yor D IFAN d B me act Y di 1 AC2 Y 2 Y E PMTHI pi PCB2 INPUT CAPACITOR siad a D PCBS 4050 AMP pce A 09130 AD APPENDIX Manual 0 4988 CUTMASTER 15 z I I 1TORCH eram Oo SWITCH 555 ATC CONNECTOR rf 1 1 Tew overreme 411 AUTOMATION 2 2 TORCH SOLENOID a 4 HSE ug pM 5
24. 7 6 m Leads Assembly with ATC connector 4 7844 1 50 foot 15 2 m Leads Assembly with ATC connector 4 7845 7 1 11 279 mm Rack 9 7041 8 1 11 279 mm Mounting Tube 9 7043 9 1 End Cap Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 1 2896 13 1 PIP Plunger and Return Spring Kit 9 7045 1 Pinion Assembly Not shown 1 2827 1 5 126 mm Positioning Tube Not shown 9 7042 NOTE Does not include Control Cable Adapter or Through Hole Protector 6 8 PARTS LIST Manual 0 4988 CUTMASTER 152 Manual 0 4988 PARTS LIST 6 9 CUTMASTER 152 pl 6 11 Torch Consumable Parts Manual and Mechanized Torches Ohmic Clip Manual Torch STANDOFF CUTTING e 50 60A STANDOFF CUTTING Electrode Auto 9 8232 Manual 9 8215 Starter Heavy Duty Cartridge Starter Cartridge 9 8213 Non HF Only 9 8277 70 120A STANDOFF CUTTING e 40 120A GOUGING Art A 08066 AG 9 8259 Tip D 20A 9 8205 30A 9 8206 40A 9 8208 0 50 55 9 8209 60A 9 8210 Tips 70A 9 8231 80A 9 8211 90 100A 9 8212 120A Auto 9 8233 120A Manual 9 8253 Tips EN Shield 9 8237 Tip A 9 8225 40 Amps Tip 9 8226 50 120 Amps Tip 9 8227 60 120 Amps Tip 9 8228 60 120 Amps Tip E 9 8254 60 120 Amps PARTS L
25. Forward Bias 3 Disconnect transformer wire from 50 Amp PCB 5 terminal PRI 4 C 4 Using an ohmmeter perform the following checks PCB 5 02 Test points located on PCB 2 AND PCB 5 PMTH 3 Forward Bias PMTH 4 Capacitor Charging PRI 4 Capacitor Charging PRI 4 Forward Bias PMTH 3 Forward Bias PMTH 4 Capacitor Charging PRI 3 Capacitor Charging PRI 3 Forward Bias Manual 0 4988 G PCB 1 Output Diode D3 Test 1 Disconnecttransformer wires from Main PCB 1 terminal SEC1 2 Using an ohmmeter perform the following checks PCB 1 D3 Test points located on PCB 1 amp PCB 2 meere meere CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 Forward Bias SEC1 CHOKE1 Reversed Bias SEC2 Reversed Bias WORK1 SEC1 Reversed Bias WORK1 SEC2 Reversed Bias WORK1 Forward Bias SEC2 WORK1 Forward Bias H PCB 5 Output Diode D2 Test 1 Disconnecttransformer wires from Main PCB 5 terminal SEC1 2 Using an ohmmeter perform the following checks PCB5 D2 Test points located on PCB 5 CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 Forward Bias SEC1 CHOKE1 Reversed Bias SEC2 CHOKE1 Reversed Bias OUT 1 SEC1 Reversed Bias OUT 1 SEC2 Reversed Bias SEC1 OUT 1 Forward Bias SEC2 OUT 1 Forward Bias PCB 1 Pilot IGBT Test Disconnect wire E35 from Main PCB 1 terminal TIP1 Using a multimeter with a diode test scale place the positive probe on PCB 1 terminal TIP1 and the negative probe on PCB 1 termin
26. Loosen and remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 6 Remove the Pressure Transducer from the regulator and install on new regulator using liquid pipe thread sealant 7 Install replacement Air Regulator by reversing the above steps 2 5 8 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 05 D 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 05 D 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 04 A 2 Disconnect J5 connector from the Main PCB 3 Remove the air hose from Gas Solenoid per subsection 7 05 4 The Solenoid utilizes the same type locking fitting as the gas hoses Using a flat blade screw driver push the locking ring towards the Solenoid 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 PARTS REPLACEMENT 7 3 CUTMASTER 152 Logic 3 Replacement Tools required T20 Torx Driver Flat Screw Driver 2 wrench 1 2 9 Remove the cover per subsection 7 04 A Remove the two large a
27. Se laver les mains apr s manipulation 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 e Netouchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail des autres parties du circuit de soudage e R parez ou remplacez toute pi ce us e ou endommag e e Prenez des soins particuliers lorsque la zone de travail est humide ou moite e Montez et maintenez le mat riel conform ment au Code lectri que national des Etats Unis Voir la page 5 article 9 e 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 produit du m tal des tincelles des scories chaudes pouvant mettre Manuel 0 4988 INFORMATIONS G N RALES 7 13 CUTMASTER 152 p le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle m
28. 24VAG SUPPLY CNC INTERFACE STANDARD ON amp A120 UNITS CNC INTERFACE OPTIONAL ON 102 amp 152 UNITS ok To move CNC PINOUT N OK TO MOVE 250VAC 30VDC TEST POINTS 068 PCR COMMON GND2 COMMON tavi 12 VDC SUPPLY devi 48 VDC SUPPLY 10 CURRENT DEMAND SEN TIP DRAG SENSE N 2 40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION 1 SIGNAL 2 VOLTS SENSE 5 7 tacente moen anc voute pateat CUR IRAR RAPID AUTO RESTART IINRUSH Wi ON 10 SHDN 11 TORCH SOLENOID 12 SOLENOID ON 13 OK TO MOVE 34 15 ITORCH SWITCH ITORCH SOLENOID DETECT IOVERTEMP COMMON COMMON MAIN 10 460 TD RD COMMON D To VOUT pil on PCB1 an JisranrisToP 343 arc VOLTS te W 100KIN SERIES 2 N NS 22 FERRITE FILTER PCB4 AUTOMATION Kt INTERFACE POB SESEBEUBNEBNNE SUS ERRORIND FAULT OVER PRESSURE INTERNAL ERROR SHORTED TORCH CONSUMABLES MISSING 75 START ERROR 70 PARTS I
29. 7 MTH 7 MTH 7 80A AC1 80A AC2 80A AC3 MTH 7 Meter MTH 1 MTH 1 MTH 1 80A AC1 80A AC2 80A AC3 80A AC1 80A AC2 80A AC3 MTH 7 MTH 7 MTH 7 MTH 1 Indication Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode 2 Forward Biased Diodes C PCB 5 Input Diode 01 Test 1 Using an ohmmeter perform the tests in the chart Input Diode Module D1 on PCB 5 Test points are located on PCB 2 Meter 50A AC1 50A AC2 50A AC3 PMTH 1 PMTH 1 PMTH 1 4 4 4 50A AC1 50A AC2 50A AC3 4 Meter PMTH 1 PMTH 1 PMTH 1 50A AC1 50A AC2 50A AC3 50A AC1 50A AC2 50A AC3 4 4 4 1 Indication Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode 2 Forward Biased Diodes D PCB 2 Capacitor Relay Test 1 Using an ohmmeter perform the tests in the chart INPUT CAPACITORS PCB 2 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 the
30. Chassis Molded Plastic 9 0190 4 1 Fan 3 TOTAL MOT 1 3 9 0232 5 1 Transformer Main Non 600V 1 9 0199 5 1 Transformer 600V Only 1 9 0170 56 1 Transformer 60 Amp Non 600V T2 9 0196 5b 1 Transformer 60 Amp 600V Only T2 9 0171 6 1 Inductor Output L1 9 0105 6b 1 Inductor Output 40 Amp L2 9 0195 Not Shown 1 Power Cable Strain Relief for all units Kit includes both styles 9 0111 1 Input Power Cable 230 VAC single phase with plug 9 0191 1 Input Power Cable 460 600 VAC three phase No Plug 9 0209 1 Hi Lo voltage selection switch SW 9 0213 NOTE 9 0107 Logic PCB 3 If the Logic PCB has a PCB mounted pressure transducer with a small hose connecting the transducer to a fitting on the regulator assembly then kit number 9 0201 which includes both a new Logic PCB and regulator assembly will need to be ordered Art A 08560 6 4 PARTS LIST Manual 0 4988 CUTMASTER 152 6 07 Right Side Replacement Parts ltem Qty Description Ref Catalog 1 1 Contactor 4 Pole W1 9 8587 2 1 Solenoid 12V SOL1 9 0114 3 1 Spare Parts Box 7 3267 4 1 Spare Parts Box Cover 7 3266 5 1 Console Quick Disconnect 9 0161 6 1 Regulator with knob and mounting nut 9 0115 7 1 Assembly PCB Input Capacitors non 600V PCB 2 9 0202 7 1 Assembly PCB Input Capacitors 600V Only PCB 2 9 0164 8 1 Filter Auto Drain 9 0116 NOTE 9 0115 regulator If the Logic PCB has a
31. NY 10018 5 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard 249 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 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 9 NFPAStandard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Bat terymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards As sociation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associati
32. PCB mounted pressure transducer with a small hose connecting the transducer to a fitting on the regulator assembly then kit number 9 0201 which includes both a new Logic PCB and regulator assembly will need to be ordered Art 08558 NOTE Illustration may vary slightly from unit Manual 0 4988 PARTS LIST 6 5 CUTMASTER 152 6 08 Options and Accessories Description Ref talog 1 Single Stage Filter Kit includes Filter amp Hose 7 7507 1 Replacement Filter Body 9 7740 1 Replacement Filter Hose not shown 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose amp Mounting Screws 9 0233 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 Automation Interface Kit PCB 4 9 8311 1 25 7 6 m Cable for Automation Interface Kit 9 1008 1 35 10 7 m CNC Cable for Automation Interface Kit 9 1010 1 50 15 2 CNC Cable for Automation Interface Kit 9 1011 Filter Element Cat No 9 7741 Spring O ring Cat No 9 7743 Assembled Filter First amp Second Stage Cartridges covet as marked 5 Barbed a Fitting Jg Art A 02476 Art 02942 Optional Single Stage Filter Kit Optional Two Stage Filter Kit 6 6 PARTS LIST Manual 0 4988 N CUTMASTER 152
33. Pierce Height 10 889 os 48 14 10 457 025 _18 279 025 6 0375 95 136 s 140 0 0500 127 seit 199 60 38 097 025 64 15 roses s s211 142 26 025 6 45 95 075 025 64 osm 145 24 ost 025 6 45 115 222 98211 1 s 10 025 025 6 45 115 NAT 10 sen 162 6 025 e 45 95 M0 WR NR AT 12 OPERATION Manual 0 4988 N CUTMASTER 152 Speed Per Minute Flow CFH Pierce Height 0250 64 esee wo 05 265 nto ts 75 52 tun 04 02064 wm xe s ia 75 52 0 90 os 020 si esz tes 19 10 ox oreots 7s 52 0 N N 4 gt a Thickness Speed Per Minute Standoff Flow Pierce Pierce Height 0250 64 4202 100 230 00 3 1 82 10 200 orsofso sene 138 we ws 040 0190 2 xm we ws ws 2 xm se ne ws ws Type Torch SL100 with Exposed Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Speed Per Minute Standoff Plasma Gas Press
34. 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 us ing air plasma on stainless or aluminum 2 Leading Arc The leading arc is directed in the same direction as torch travel A five degree leading arc is generally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direction as torch travel 02586 Leading Arc Mechanized Torch Operation 4 8 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 rough cut will be produced as the arc moves from side to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle or around a corner slowing down the travel speed will result in a squarer cut The power source output should be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slow down adjustments that may
35. base Remove the Output Inductor carefully guiding its wires through from the right side of the unit Install replacement Output Inductor by reversing the above steps 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 Cover per subsection 7 04 A 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 illustra tion Koc Art A 07989 Manual 0 4988 N CUTMASTER 152 5 Remove the fitting from the filter element assembly 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 6 Disconnect the input line from the filter element as sembly 7 Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly
36. 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 fora ten 10 minute period after the condition is cleared Defective 50A PCB 5 Measure for 12VDC on the 50A PCB 5 between J4 4 to J4 10 Replace 50A PCB 5 if voltage is not present Defective Main PCB 1 a Measure for 12VDC on Main PCB 1 between J2 21 to TP GND1 Replace Main PCB 1 if voltage is not present Defective Logic PCB 3 a Change Logic PCB 3 5 13 CUTMASTER 152 p AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing 1 Gas supply not connected to unit a Connect gas supply to unit Gas supply not turned ON a Turn gas supply ON Gas supply pressure too low a Set gas supply pressure to 95 120 psi Air Pressure Control Regulator set too low a Adjust AIR PRESSURE CONTROL to set pressure as specified in section 4 02 Setting Operational Pressure Faulty Pressure Transducer a Adjust pressure Regulator to maximum Measure voltage on Logic PCB 3 between J3 1 to J3 2 If voltage is more than 2VDC replace Pressure Transducer Faulty Logic PCB 3 Replace Logic PCB 3 M INTERNAL ERROR FAULT Indicator and 90 PSI LED flashin
37. in center of control panel Refer to the Stand off chart for pressure setting details 1 2 Art A 07946 Manual 0 4988 CUTMASTER 152 CutMaster 152 Gas Pressure Settings Cutting speeds vary according to torch output amperage Leads SL100 SL100 the type of material being cut and operator skill Refer to Mechanized Torch Section 4T 08 and following for greater details 75 psi Output current setting or cutting speeds may be reduced 7 6 m 5 2 bar 5 2 bar to allow slower cutting when following a line or using Each additional Add 5 psi Add 5 psi a template or cutting guide while still producing cuts of 25 7 6 m 0 4 bar 0 4 bar excellent quality Postflow 3 For Drag cutting 60 Amps or below adjust gas pressure from 75 95 psi 5 2 6 5 bar Release the trigger to stop the cutting arc Gas continues LED s in center of control panel Rater i6 to flow for approximately 20 seconds During post flow if the user moves the trigger release to the rear and presses the Drag Cutting chart for pressure setting the trigger the pilot arc starts The main arc transfers to details the workpiece if the torch tip is within transfer distance to DRAG 60 amps or less CutMaster 152 Gas Pressure Shutdown Settings Leads SL100 Turn the ON y OFF switch to OFF down All Length Hand Torch Power Supply indicators shut OFF Unplug the input power Up to 25 80 p
38. 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 As sembly 3 Use customer supplied fittings to connect the air line to the Filter A 1 4 NPT to 1 4 hose barbed fitting is shown as an example Regulator Filter Assembly 2 Stage Filter Regulator Inlet Port IN Input Outlet Port OUT Two Stage Filter Hose Clamp pc Assembly Gas Supply F Hose Art 07945_ Optional Two Stage Filter Installation 3 4 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 material Briefly open each cylinder 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 pr
39. not function as stated above then note the symptom and proceed to Section 5 09 Main Arc and a 300 VDC 100 VDC Controls Problems b 18 VDC 6 VDC H CNC INTERFACE TEST c 10 VDC 3 3 VDC If the unit has one of the two factory supplied options for d 6 VDC 2 VDC CNC interface installed proceed with this section otherwise the tests are complete This completes the CNC Interface Test If the above are all correct then the unit is functioning correctly If the unit does 1 Connect an ohmmeter between CNC connector Pins function as stated then note the symptom and proceed to 12 amp 14 OK TO MOVE signal Position the torch to Section 5 10 CNC Interface Problems pilot Check the OK TO MOVE signal by connecting a jumper between CNC connector pins 3 amp 4 START e Pilot arc is established 2 Bring the torch to the work piece and transfer to cutting arc e OK TO MOVE signal is present Meter shows continuity 3 Remove jumper from the CNC connector OK TO MOVE signal OFF Meter shows no continuity e Gas continues to flow e DC LED goes OFF 5 10 SERVICE Manual 0 4988 N CUTMASTER 152 5 07 Main Input and Internal Power Problems A Primary input line fuse blows as soon as primary disconnect is closed 1 Primary input cable installed incorrectly a Check wiring of primary power cable to the contactor See illustration below 2 W1 jumpers installed incorrectly a Check jumper installation for cor
40. so 049 48 rose eean 1m4 so 340 356 orfas as oz 049 458 0250 54 eea 1a so 100 254 orfas e as 16 049 s orfas 6 as 16 nav 049 os 120 w s ow as 16 s 049 48 0425 v5 s os orfas 66 as so 025 049 48 0750 128 eo 18 046 orfas es as Nn 133 eo 10 oz ou 6 as 16 so 1 ne w o ore as 6 as Type Plasma Gas Air etes mm at Na eea 025 ea 65 15 ou 025 200 2 2 Y 025 64 m es 025 6 s 127 os 120 120 188 48 98211 120 250 64 98211 120 1 129 15 OMS 120 120 120 120 9 5 126 129 135 143 143 46 gt gt 3 159 san es 45 ws s 10 025 oa 750 1 000 25 4 9 8211 gt o os as 15 s ne ne Cas us u 4s ms T ala T 79 Ce oz 025 6 Thickness Speed Per Minute Standoff
41. the FAULT is cleared replace PCB 5 Defective Main PCB 1 a Replace PCB 1 Main Contactor does not close after two seconds of turning the ON OFF switch to ON 1 2 Manual 0 4988 Defective Contactor a Measure for 24VAC on Contactor coil If present replace the Contactor Defective Logic PCB a Measure for W1_ON signal to go low at Main PCB between J2 9 to GND1 3 3 1 SERVICE Ribbon cable from Logic PCB J1 connector to Main PCB J2 not properly connected or open wire a Check the connection Defective Main PCB 1 a Measure for 24VAC supply between J6 1 to J6 2 on Main PCB Fans MOT 1 3 comes ON but plasma gas does not flow after START signal is active 1 Defective solenoid a Measure for 12VDC between J5 1 to J5 2 Ribbon cable from Logic to Main PCB not properly connected or open wire a Check the connection Defective Main PCB Fan MOT 1 turns ON without START signal being activated Rev AB amp earlier Open connection between J2 on Capacitor PCB to J3 on 50A PCB Defective Main PCB a Measure for approximately 325VDC between MTH 1 to MTH 7 Capacitor 12VDC bias supply voltage missing a Disconnect plug from J2 on Capacitor PCB and measure for 12VDC between J2 1 to J2 2 If not correct replace Capacitor PCB Defective 50A PCB See 50A PCB exclusion Fans MOT 2 and MOT 3 do not turn ON when START signal is activated 1 2 Shorted fans MOT 2 or MOT 3 Bad connec
42. 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 contains chemicals including lead known to the State of California to cause birth defects and other reproductive harm Wash hands after handling A ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combus
43. uuu 5 1 5 01 PS EET 5 1 5 02 Maintenance Schedule sce 5 2 303 5 2 5 3 5 05 Basic Troubleshooting Guide 4441 12 5 5 5 06 Circuit Fault Isolation 5 7 5 07 Main Input and Internal Power 5 11 5 08 Pilot Arc Problems ttes 5 15 5 09 Main Arc and Controls 5 20 5 10 GNO Interface PRODIGIING dtu dtes 5 21 5 11 Ng I T M aiaee Sarra 5 21 SECTION 5 TORCH SERVICE hagan ped 5T 1 5T 01 General Maintenance essen eren nnn tnnt nn 5T 1 57 02 Inspection and Replacement of Consumable Torch 5T 2 SECTION 6 PARTS LISTS ne marc 6 1 6 01 men 6 1 6 02 Ordering Information hib 6 1 6 08 Power Supply Replacement sees enne 6 1 6 00 External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement Parts 6 4 6 07 Right
44. we vo 10 ois 45 rs 52 180 025 ws vo 1 sos vis fas 75 52 1 aso oso 025 127 is wo 70 178 aa 75 52 160 025 64 sess 14 vo s ose 025 lea 7s 52 n wn 170 vo 20 osi 025 ea 75 52 10 ww NOTES Gas pressure shown 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 AT 14 OPERATION Manual 0 4988 N CUTMASTER 152 4T 09Recommended Cutting Speeds for SL100 Torch With Shielded Tip 40 432 orlas es 45 55 ooo 51 oos sese 1 40 220 48 6 45 55 vo 02 or om re ssme 121 40 208 oe es 4s 55 vo or esee 1 40 s oe es 45 55 vo oe o2 foi sm ss esme 1 40 11 028 or 48 es 45 55 vo NR NR 8200 1e 40 7 018 or faa 6 45 55 vo NR 15e 40 s oo orfas es 45 55 vro NA Nn WR Type Torch SL100 With Shielded Tip Type Material Stainless Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Standoff Flow CF
45. 02986 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch OPERATION Trigger er g lt u 6 Cut as usual Simply release the trigger as sembly 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 slid ing 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 position the legs of the standoff guide against the work piece Shield Cup Standoff Guide Torch Tip Workpiece Art A 04034 Manual 0 4988 N CUTMASTER 152 Shield Cup With Straight Edge The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand A WARNING The straight edge must be non conductive T
46. 0A PCB J2 40A 50A PCB 40 50 di 40A 50A PCB J3 2 USED Art 08620 AB Manual 0 4988 SERVICE 5 33 CUTMASTER 152 This Page Intentionally Blank 5 34 SERVICE Manual 0 4988 CUTMASTER 152 SECTION 5 TORCH SERVICE 5T 01General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE Refer to Previous Section 5 System for common and fault indicator descriptions Upper O Ring in Correct Groove Threads Cleaning Torch Lower O Ring Art A 03725 Even if precautions are taken to use only clean air with a Torch Head O Ring torch eventually the inside of the torch becomes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch A WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON HIl M M The inside ofthe torch should be cleaned with electrical con tact 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 CAUTION Dry the torch thoroughly before reinstalli
47. 2 Other Pat s Pending 9 8205 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8206 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8207 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8252 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8208 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8209 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8210 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8231 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8226 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8227 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8228 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8241 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8243 Shield Cap US Pat No s 6914211 D493183 Other Pat s Pending 9 8235 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8236 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8237 Shield Cup US Pat No s 6914211 D501632 D511633 Other Pat s Pendi
48. 238 50 55A 9 8209 60A 9 8210 Shield Cap Deflector 9 8243 Drag Shield Cup 70 100A 9 8236 Le Drag Shield Cup 120A 9 8258 to Shield Cap Machine 70A 9 8231 70 100A 9 8239 80A 9 8211 2 Shield Cap Machine 90 100A 9 8212 120A 9 8256 120A Auto 9 8233 Shield Cap Deflector 9 8243 Tips Tip A 9 8225 40 Amps Max Shield Cup Gouging 9 8241 Tip 9 8226 50 120 Amps Tip 9 8227 60 120 Amps Tip D 9 8228 60 120 Amps Tip E 9 8254 60 120 Amps OPERATION 4 9 CUTMASTER 152 4T 08Recommended Cutting Speeds for 51100 Torch With Exposed Type Torch SL100 With Exposed Tip Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow CFH Pierce Pierce Height 36 02 s28 104 ao sea oto fas 65 Cs esz 108 a0 8 34 110 105 267 019 as 65 wa 4o eo 152 049 8 66 3 5 5 5 5 2 5 5 1 5 5 ol IN PN 3 4 1 o o o J ala oa fou AJA ALA 1 65 B B BIBIBIBI IRBR PN 2 2 Type Torch SL100 With Exposed Type Plasma Gas Air
49. 2VDC TP3 5VDC TP4 3 3DCV TP5 0 5 to 5 VDC 0 100 psi TP6 1 8VDC 1 5 VDC Pilot Current Demand 1 2 AVDC Cut Current Demand Manual 0 4988 SERVICE C 50A C 50A 50A M M 50A 50 50 50 90A M M 50A 5 31 CUTMASTER 152 RIGHT SIDE WIRING DIAGRAM NOTUSED TOSW2 TOPCB3 MAIN PCB J4 MAIN PCB J12 MAIN PCB J4 H asm 00 00 ma 099 70 _ 0 9 3 of ESL UD E st De c NOT 2 FR OU io 22 RISO 69 D CHOKE R185 R186 R187 F EL 184 cores mue Oe p uin O3 SRISTRISD 044 m0000000 ge R199 WORK CABLE E 35 me mee TOTS1 CM152 ONLY CNC HARNESS TO MOT1 5011 OPTIONAL Art 08620 AB 5 32 SERVICE Manual 0 4988 CUTMASTER 152 40A 5
50. C connectors e 50 foot 15 2 m with ATC connectors Torch Parts Starter Cartridge Electrode Tip Shield Cup Parts In Place PIP Torch Head has built in switch 12 VDC circuit rating Type Cooling Combination of ambient air and gas stream through torch Manual 0 4988 INTRODUCTION 274 CUTMASTER 152 p F Torch Ratings 2T 05introduction to Plasma Manual Torch Ratings A Plasma Gas Flow Ambient 104 F Temperature 40 C Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electri Duty Cycle 100 120 Amps 400 scfh cally conductive The plasma arc cutting and gouging 120 Amps processes use this plasma to transfer an electrical arc to Voltage 500V the workpiece The metal to be cut or removed is melted the heat of the arc and then blown away Arc Striking Voltage While the goal of plasma arc cutting is separation of the 5 material plasma arc gouging is used to remove metals to Mechanized Torch a controlled depth and width Ambient 104 F Temperature 40 C In a Plasma Cutting Torch a cool gas enters Zone B where a pilot arc between the electrode and the torch tip heats and 1905 120 ionizes the gas The main cutting arc then transfers to the 120 Amps workpiece through the column of plasma gas in Zone C Voltage 500V Arc Striking Voltage G Gas Requiremen
51. CB with Ribbon Cable a Open connection in ribbon cable b Measure Logic PCB for relay configuration signals J1 4 to J1 25 Low for 460V lt 1VDC J1 5 to J1 25 Low for 230V lt 1VDC With START signal active 1 Measure Logic PCB CUR SET signal between J1 6 to J1 25 If missing replace Logic PCB Measure Logic PCB for SHUTDN signal between J2 10 to J2 25 to go low while continuing to activate the start signal 3 4 Defective Main PCB a Measure for approximately 325VDC on a 230V system 650VDC on a 460V system and 850VDC on a 600V system between MTH 1 to MTH 7 under load Readings a lot lower than these will indicate a defective PCB Capacitor 12VDC bias supply voltage missing a Disconnect plug from J2 on Capacitor PCB and measure for 12VDC between J2 1 to J2 2 If not correct replace Capacitor PCB 5 6 4 Defective 50A PCB See 50A PCB exclusion Defective Main PCB Code displayed after START signal is activated during main transfer 1 Ferrite on Ribbon cable between Logic PCB J1 and Main PCB J2 broken or loose Ferrite on harness between J13 on Main PCB to J4 on 50A PCB broken or missing Wires SEC1 and SEC2 routed too close to U2 on 50A PCB 50A PCB needs to be replaced if earlier than rev AD C SHORTED TORCH FAULT FAULT indicator and 85 PSI LED are flashing at 5 cycles per second This mode is a non latched mode 1 While using an Automation Torch at current setti
52. Drag cutting standoff cutting or gouging Torch parts Shield Cup Cutting Tip Electrode and Starter Cartridge Tip NOTE Shield Cup Refer to Section 4T 07 and following for ad m ditional information on torch parts Change the torch parts for different operation as Torch Parts Drag Shield amp Shield Cup Body Shown 3 Install the replacement Electrode by push A ing it straight into the torch head until it WARNING clicks Disconnect primary power at the source before 4 Install the starter cartridge and desired tip assembling or disassembling torch parts or for the operation into the torch head torch and leads assemblies 5 Hand tighten the shield cup assembly until it is seated on the torch head If resistance NOTE is felt when installing the cup check the The shield cup holds the tip and starter car threads before proceeding tridge in place Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup assem bly from the torch head Manual 0 4988 OPERATION 1 CUTMASTER 152 p 4T 02Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Cut quality requirements differ depending on ap plication For instance nitride build up and bevel angle may be major factors when the surface w
53. EM 3 03 Primary Input Power INSTALLATION CAUTION Check your power source for correct voltage 3 01 Unpacking 1 Usethe packing lists to identify and account before plugging in or connecting the unit Check for each item the Voltage Selector at the rear of the unit for 2 Inspect each item for possible shipping before plugging in or d Ar e unit The primary power source fuse an damage damage is evident contact any 4 41 must conform to local your distributor and or shipping company electrical code and the recommended circuit before proceeding with the installation protection and wiring requirements as specified 3 Record Power Supply and Torch model and in Section 2 serial numbers purchase date and vendor following illustration and directions are for name in the information block at the front changing phase of the power supply of this manual Input Power Cable Connections 3 02 Lifting Options Single Phase 10 and Jumper Settings Three Phase 30 Store copper jumpers on base plate EN The Power Supply includes a handle for hand L1 lifting only Be sure unit is lifted and transported 20 2 k safely and securely z 4 z WARNING Single and Three Phase Input Power Wiring Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause seriou
54. ER 152 2 06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 08359 Work Cable and Clamp E Port for Optional Automation Interface Cable Input Power Selection Filter Assembly DES Gas Inlet Port Art A 08360 Input Power Cord Manual 0 4988 INTRODUCTION N CUTMASTER 152 SECTION 2 TORCH INTRODUCTION 2T 01Scope of Manual This manual contains descriptions operating instructions and maintenance procedures for the 1Torch Models SL100 Manual and SL100 Mecha nized 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 starts in the gap between the negatively charged electrode and the positively charged tip Once the pilot arc has ion ized the plasma gas the superheated column of gas flows through the small orifice in the torch tip wh
55. 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 Replace the knob on the potentiometer shaft with the pointer in the same position as noted in step 1 B Function Control Switch Knob Replacement Tools required Flat Screw Driver 1 Turn the Function Control Switch until the pointer on the knob is in the LATCH position 2 Loosen the screw securing the knob to the switch shaft and remove the knob 3 Replace the knob on the switch shaft with the pointer in the position noted in step 1 C Replacing Gas Hoses Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Push the gas fitting locking ring back A small open end wrench works well for this 1 2 3 A 3 Pull the hose from the fitting Art 08150 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pulling on the hose If done correctly it will not pull out 5 Reinstall the power supply cover Manual 0 4988 D Air Regulator Replacement Tools required T20 Torx Driver 11 16 Open End Wrench 1 Remove the cover per subsection 7 04 A 2 Remove the two 2 air hoses from the regulator per subsection 7 05 C 3 Disconnect cable from the Pressure Transducer 4 Pull the Air Regulator adjusting knob from the shaft 5
56. Flow Pierce Height Cat No Volts VDC Amps Inches Meters Inches psi Plasma Total Delay Sec Inches m E 0250 12 360 225 ME 131 40 eo NN en Es 0750 9212 iw 100 25 065 019 2 N Manual 0 4988 OPERATION 41 13 CUTMASTER 152 1 120 wo sev ae 75 52 wo 64 ses 10 120 os 216 nw ae 7s 52 0 oa oscar ses 14 120 wo iz ni s2 uw oso 025 sa 18 120 as uus ae 75 sa oo 070 025 sa 0750 155 120 a0 or nus 7s 52 oc uw oso 025 54 2221 10 120 25 os 025 ea sa seo ne ws un ree 120 os 025 ea 75 s2 we ws Reso wa ees 170 wo 12 025 ea zs 52 v s ws ws ws 5 so wo s 020 ozs 64 5 2 95 ws 0375 95 14 120 wo 250 oie fae 75 52 so 0 025 64 127 255 _ 190 eo as 75 52 1 0 0 oso 64 0750 180 120 2 75 5 eo sso ws nn ww 5 1e 120 18 025 75 52 eo ne we ws aolre oaza vo 120 s wm ors eal 752 oos ww 025
57. G INPUT POWER FAULT AC LED ON FAULT Indicator and 65 PSI LED flashing 1 INPUT VOLTAGE SELECTOR SWITCH SW2 set for incorrect voltage a Set SW2 to correspond to the primary line voltage Turn SW1 to OFF position then back to ON position to clear the error 2 Defective SW2 a Check continuity 3 Primary line voltage out of tolerance range a Connectunitto voltage with unit specifications See section 2 04 Power supply specifications If using a generator connect unit to a wall receptacle to see if problem is corrected 4 Defective Main PCB 1 a Measure voltage on Main PCB 1 between test point GND1 to J2 22 460 VAC input approximately 3 VDC 230 VAC input approximately 1 5 VDC b With all power removed from the unit disconnect the ribbon cable from J2 connector on Main PCB 1 Check continuity on PCB 1 between J2 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 5 12 SERVICE If not correct replace Main PCB 1 5 Defective Ribbon cable a Check continuity of the ribbon cable connecting between the Main PCB 1 and the Logic PCB 3 6 Defective Logic PCB 3 Replace Logic PCB 3 H PARTS IN PLACE PIP FAULT The FAULT Indicator and 70 PSI LED flashing After 20 seconds fan MOT 1 turns ON 1 Shield Cup loose a Handtighten the shield cup to close the PIP switch 2 Torch not properly connected to power supply a I
58. Gas Torch Type Torch SL100 With Shielded Tip Type Plasma Gas Air Dey Se v8 ous sz 66 s vs wo 64 o oussz es as ns wo 0 64 o ou 32 es s ns wo 100 025 5 om 32 es as 15 so Nm un 123 133 135 137 Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip 25 4 0 875 22 2 000 1 tux LO LO LO 1 57 LO LO LO LO ll FITI FTIT YT LC LO LO LO LO LO LO LO ce c ENL ll lle eo 20 lt gt ce ileen m eo o2 oss sz 65 as ns n un m E St E E o
59. H Pierce Height Inches Volts VDC Amps Meters Inches mm psi ba Plasma Total Delay Sec Inches mm O36 09 9 8208 109 alsa ara altaya ajajajaj cue ls ds e 2 2 A Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Output Amperage Speed Per Minute Standoff Plasma Gas Press Pierce Pierce Height mm Inches psi bar Plasma Total Inches mm 220 48 55 170 210 000 5 94208 7 65 ojo O1 REC ai 0 oos wo 0 125 d E eg 0 375 is k 8 2 DININ 2 D A Manual 0 4988 OPERATION 4T 15 CUTMASTER 152 Type Material Mild Steel Type Secondary Gas Single Gas Torch Type Torch SL100 With Shielded Tip Type Plasma Gas Air Pierce Height CFH Flow Standoff Plasma Gas Press Per Minute Speed p m Type Material Stainless Steel Type Secondary Gas Single Gas Torch Output Amperage Speed Per Minute Standoff Gas Press Flow Pierce Height Type Torch SL100 With Shielded Tip Type Plasma Gas Air Tip m _ _ 165 4m 2 70 ae oo
60. IST Ohmic Clip Automation Torch 9 8224 Shield Cap Machine 40A 9 8245 Shield Cap Deflector 9 8243 Drag Shield Cup 9 8235 Shield Cap Machine 50 60A 9 8238 Shield Cap Deflector 9 8243 Drag Shield Cup 70 100A 9 8236 Drag Shield Cup 120A 9 8258 Shield Cap Machine 70 100A 9 8239 Shield Cap Machine 120A 9 8256 Shield Cap Deflector 9 8243 Shield Cup Gouging 9 8241 Manual 0 4988 N CUTMASTER 152 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 CAUTION PC Boards can be irreparably damaged by improper handling due to electrostatic discharge ESD A General Replacement PC Boards are shipped in a protective enclosure to prevent damage from electrostatic discharge ESD during shipping A ground strap is included with each replacement board to prevent static damage during installation WARNING pum H ea Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclosure or remov ing the replacement PC board from its protective enclosure Dis
61. IT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 15 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM MANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Manuel 0 4988 INFORMATIONS G N RALES 5 CUTMASTER 152 1 07 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Victor Thermal Dynamics Corporation warrants to the original retail purchaser that new Victor 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 Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Victor Thermal Dynamics specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warra
62. 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 PCB 3 NOTE When the unit is turned ON the cooling fans MOT 1 3 will remain OFF In earlier units MOT 1 will turn ON for one 1 second and then turns OFF The fans will turn ON when a START signal Torch Switch Remote Pendant switch or 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 Manual 0 4988 2 Measure for 12VDC on the Logic PCB 3 between J7 1 to J7 2 after the START signal is activated If voltage is not present replace Main PCB 1 H Fan MOT 1 does not turn ON after START signal is activated MOT 2 amp MOT 3 do turn ON 1 Defective Main PCB 1 a Turn SW1 ON OFF switch 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 MOT 1 a Check to be sure there is no physical obstructions preventing MOT 1 fan blades from turning Replace MOT 1 l Either MOT 2 or MOT 3 do not turn ON after START signal is activated 1 Fan wires not connected to 50A PCB 5 Check and reconnect to 50A PCB 5 2 Defective fan a Check
63. N PLACE 65 INPUT POWER MN UNDER PRESSURE TEST PoiNTS oND H2VDC 5 VDC 33V0C Ov 5 0 VDC 0 100PS1 18VDC CURRENT DEMAND GAS CONTROL REGULATOR Se as TEMP CIRCUIT our 1 PCB3 Loic pcs A 09132_AC nro Ecoss ICTOR THERMAL DYNAMICS Spaces Resistors ae in Ohms 14w 5 C C Capacitors ara in Miorafarads UF Manual 0 4988 APPENDIX UTMASTER 152 APPENDIX 6 SYSTEM SCHEMATI V UNIT I swi iof oi 1 H aus SUPPLY H oo 5 INRUSH EV RESISTORS INRUSH CE UNS ONLY PEM FILTER act 7 vm ace 12 ay 22 zip l L3 3 3 ks 2 GND 44 occ 80 400 415 OR 600V 3 PH AG INPUT PRIMARY POWER CONNECTIONS USE LT L2 GND 1 2 5 SOLENOID 2avac 24 RET E sync 1 ssvoc seriaLport 2 55 H RAD 1 JOVERTEMP 4 2
64. NDIX 7 Publication History Cover Date Rev A 5 0 0 0 0 0 0 00 00 0000 Sept 25 2008 Nov 12 2008 Jan 27 2009 Apr 24 2009 May 29 2009 Sept 2 2009 Feb 25 2010 Sept 14 2010 Mar 20 2012 April 25 2012 Dec 6 2012 Nov 14 2013 AA AB AC AD AE AF AG AH Al AJ AK AL Manual released Updated system schematic to rev AC Added additional info to troubleshooting section cor rected info in parts list Corrected art sizing in section 3 to show missing information per ECOB1248 Updated power supply specs and input wiring charts in section 2 per ECOB1197 Added 600V system information to sections 2 6 and Appendix per ECOB1346 Updated 400V 600V schematic in appendix per ECOB1399 and updated 230 460V schematic per ECOB1357 Corrected part numbers in section 6 per ECOB1201 Updated section 6 with 600v PCB numbers per ECOB1520 Updated CNC cable part numbers in section 6 per ECOB1637 Updated section 4T and 6 consumables art per ECOB1819 Updated ART A 08066 and changed COO text per ECOB2149 Updated ART A 07994 per ECOB2136 Changed logo on Front Cover and Inside Front Cover from Thermal Dynamics to Victor Thermal Dynamics modified Prop 65 text Section 1 added information to Section 5 09 pg 5 21 per ECOB 2342 Removed Declaration of Conformity Added paragraph at end of p 3 1 Made the following changes per ECO B2527 updated cover to show new Victor Thermal Dynamic
65. Power 600 VAC 540 630 Three Phase 60 Hz Input Power Cable Ambient Temperature Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C All Units 100 NOTE The duty cycle will be reduced if the primary input power is low or the output voltage DC is higher than shown in this chart 60 at 208 230V 1 Phase input ONLY 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 Art A 07925_AB 2 2 INTRODUCTION Manual 0 4988 CUTMASTER 152 2 05 Input Wiring Specifications CutMaster 152 Power Supply Input Cable Wiring Requirements Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements The suggested sizes are based on flexible power cable with power plug installations For hard wired installations refer to local or national codes I1max is taken at TDC rated minimum duty cycle is taken at 100 rated duty cycle Manual 0 4988 INTRODUCTION 2 3 CUTMAST
66. S LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupres de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOU DAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRI MES 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 CUR
67. SMA PEUVENT PRE SENTER DES RISQUES ET DES DANGERS DE SANTE Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possi bles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions amp FUM E et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant attention et avertissement sont utilis s pour mettre en relief des informations caract re important e Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de pla
68. Side Replacement Parts 6 5 6 08 Options and Accessories canaris 6 6 6 09 Replacement Parts for Hand 6 7 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads 6 8 6 11 Torch Consumable Parts Manual and Mechanized Torches 6 10 TABLE OF CONTENTS SECTION 7 REPLACEMENT PROCEDURES T 1 7 01 7 1 7 02 Anti Static Handling PFOUBUINEBS 7 1 7 03 Parts Replacement General Information 7 1 104 Major External dessein 1 2 1 05 Front Panel Parts main 7 3 7 06 Left Side Internal Parts 7 4 7 07 Rear Panel Parts Replacement essere ns 7 6 7 08 Right Side Internal Parts 7 9 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 DATA TAG INFORMATION A 2 APPENDIX 3 TORCH PIN OUT DIAGRAMS A 3 APPENDIX 4 TORCH CONNECTION DIAGRAMS 4 APPENDIX 5 SYSTEM SCHEMATIC 208 460V UNITS
69. VDC J3 2 Pressure Transducer output 0 5 to 5 VDC 0 100 psi J3 3 Common LOGIC PCB 3 LED INDICATORS NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE D1 12VDC D2 MAX PRESSURE 7 Over Pressure D3 90 PSI X 6 Internal Error 04 85 PSI 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 Input Power Fault D9 MIN PRESSURE X 0 Low Pressure D10 AC 1 X D11 OVERTEMP 2 X D12 GAS 3 X D13 DC 4 X D14 ERROR 5 X LOGIC PCB 3 TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV TP5 0 5 to 5 VDC 0 100 psi TP6 1 8VDC Potentiometer Current Demand 0 3 3VDC Manual 0 4988 SERVICE 5 29 CUTMASTER 152 PMTHA AC2 1 2 Ji 3 44 J5 J3 J4 44 mm m R70 R64 017 zi Bal di 422 N gt a T
70. W1 energizes For earlier units Fan 1 turns ON for one 1 second then shuts OFF Adjust the pressure regulator to set the gas pressure as specified in charts STANDOFF CutMaster 152 Gas Pressure Settings Leads SL100 SL100 Length Hand Torch Mechanized Torch Up to 25 75 psi 75 psi 7 6 m 5 2 bar 5 2 bar Each additional 5 psi Add 5 psi 25 0 4 bar 0 4 bar 7 6 m CutMaster 152 Gas Pressure Settings Leads SL100 Length Mechanized Torch Up to 25 80 psi 7 6 m 5 5 bar Each M Add 5 psi 9 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 This completes the Main Input and Internal Power Test If the above are all correct then proceed to the next section F Pilot Arc Test If the unit does not function as stated above then note the symptom and proceed to Section 5 07 Main Input and Internal Power Problems SERVICE Manual 0 4988 N CUTMASTER 152 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 8 Hand held pendant switch b cable interfaced to controller Provide a START signal to establish a pilot arc and note the following e Cooling fans MOT 1 3 turn ON Gas solenoid opens Gas f
71. al WORK1 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 5 23 CUTMASTER 152 p J 2 Capacitor Relay Test with PCB 2 PCB 5 Input Diode Test With PCB 2 removed from the unit removed from unit 1 Using an ohmmeter perform the following checks 1 Using an ohmmeter perform the following checks PCB 2 Capacitor amp Relay Test Input Diode Module D1 on PCB 5 Test points are located on PCB 5 MTH 8 MTH 7 Charging PMTH 1 Forward Biased Diode MTH 7 MTH 4 Open PMTH 1 Forward Biased Diode MTH 8 MTH 2 Open PMTH 1 Forward Biased Diode MTH 8 MTH 4 Open AC1 Reverse Biased Diode Most meters will show a charging action Initially a low AC2 Reverse Biased Diode resistance will be shown and then the resistance will start AC3 Reverse Biased Diode to increase If the meter probes are reversed the reading will ACA Forward Biased Diode decrease to zero then start charging in the opposite polarity AC2 Forward Biased Diode 2 f test reveals a failed component replace Capacitor AC3 Forward Biased Diode PCB 2 PMTH 4 Reverse Biased Diode 4 Reverse Biased Diode 4 Reverse Biased Diode PMTH 1 2 Forward Biased Diodes K PCB 1 Input Diode Test With PCB 2 removed from unit 1 Using an ohmmeter perform the following checks 2 Ifthe test reveals a failed component replace 50A PCB Input Diode Modul
72. all the replacement PCB by reversing the above steps Reinstall the power supply cover PARTS REPLACEMENT 7 9 CUTMASTER 152 This Page Intentionally Blank 7 10 PARTS REPLACEMENT Manual 0 4988 N CUTMASTER 152 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION i RUN Rapid Auto Restart Close external ON OFF switch to ON RUN SET LATCH disconnect switch RESULT Power to system Rapid Auto Restart SET LATCH switch to SET RESULT AC indicator switch to RUN 6 for most applications or to GAS indicator 22 ON Rapid Auto Restart 62 when inp RESULT 22 for gouging trimming or expanded metal applications or to LATCH p is used for specific applications torch switch can be released after main arc transfer pressure is adequate for power supply operation Power circuit ready Gas flows to set pressure RESULT Gas flow stops ACTION Connect work cable to workpiece Set output amperage ACTION RESULT 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 switch START PILOT ARC RESULT Fans turn on Gas flows briefly ACTION then stops Gas restarts Torch moved within DC indicator
73. arc transfers to work piece normally replace 50Amp PCB5 C When Pilot Arc is brought to the work piece the arc goes out immediately or extinguishes while cutting ERROR indicator and 85 PSI indicator flashing a Ferrite filter on ribbon cable between J1 on Logic PCB 3 to J2 on Main PCB 1 is broken loose or missing b Ferrite on wire harness between J13 connector on Main PCB 1 to J4 connector on 50A PCB 5 is broken loose or missing c Wires SEC1 and SEC2 routed too close to component U2 on 50A PCB 5 Re route to space a least 1 inch 25mm away d Older revision 50A PCB 5 Replace if PCB 5 revision is AC or earlier D Main arc transfers but current cannot be adjusted 1 Defective Logic PCB 3 a While main arc is transferred measure voltage on Main PCB between test points GND1 to DMD1 b Adjust CURRENT CONTROL POTENTIOMETER 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 PCB 1 5 20 SERVICE E In LATCH mode when the START signal is released the arc shuts OFF immediately 1 Defective Logic PCB 3 Replace Logic PCB 3 F With CURRENT CONTROL POTENTIOMETER set at maximum output current is only 60 amps 1 Tipis touching the work piece Drag mode a Lifttip off work piece 2 Defective Pilot IGBT on Main PCB 1 a Check per section 4 10 1
74. asiest way to do this is by turning the screw counter clockwise until you feel the threads line up then begin to turn the screw clockwise to tighten Do not over tighten 7 2 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 Replacethe 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 helpful 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 To re 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 Manual 0 4988 CUTMASTER 152 7 05 Front Panel Parts Replacement Refer to section 6 05 for Front Panel Replacement Parts and overall detailed drawing A Current Control Potentiometer A Knob Replacement Tools required
75. ati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables explosives coupez pas et ne soudez pas les conteneurs ayant pu fermer 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 Legas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm LA RAYONS DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement e Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire e Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection e
76. away from your body Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start Trigger Release A 02986 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTES The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components T Clean spatter and scale from the shield cup and the tip as soon as possible Spraying the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Cutting speed depends on material thickness and the operator s ability to accurately follow the desired cut line The following factors may have an impact on system performance Torch parts wear Air quality Line voltage fluctuations Torch standoff height Proper work cable connection OPERATION Manual 0 4988 Manual 0 4988 N CUTMASTER 152 4T 05Gouging WARNING Be sure the operator is equipped with proper gloves clothing eye and ear protection and that all safety precautions at the fron
77. be required Piercing With Machine Torch 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 be gins 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 4988 CUTMASTER 152 4T 07Parts Selection for SL100 Torch Cutting Ohmic Clip Manual Torch 9 8259 20 40A STANDOFF CUTTING 50 60A STANDOFF CUTTING Electrode Auto 9 8232 Manual 9 8215 Starter Heavy Duty Cartridge Starter Cartridge 9 8213 HF Only 9 8277 70 120A STANDOFF CUTTING Ca 40 120A GOUGING Art A 08066_AG Manual 0 4988 120A Manual 9 8253 Ohmic Clip Automation Torch 9 8224 Tip z Shield Cap Machine a 40A 9 8245 o 20A 9 8205 L Shield Cap Deflector 30A 9 8206 9 8243 40A 9 8208 Drag Shield Cup 9 8235 Tips Shield Cap Machine ant 50 60A 9 8
78. changes but display does not 3 Faulty Logic PCB 3 a Measure on Logic PCB 3 for 12 VDC between TP3 to TP1 If voltage is low or not present replace Logic PCB 3 4 Faulty Pressure Transducer a Measure on Logic PCB 3 between J3 2 to TP1 while adjusting the Pressure Regulator from Min to Max Voltage should adjust from 0 4 5VDC If voltage does not change replace the Pressure Transducer 5 Faulty Logic PCB 3 a Measure on Logic PCB 3 between J3 2 to TP1 while adjusting the Pressure Regulator from Min to Max Voltage should adjust from 0 4 5VDC If voltage does change replace the Logic PCB 3 Manual 0 4988 SERVICE AC LED ON TEMP LED is OFF GAS LED is ON Fan MOT 1 turns ON plasma gas not flowing Earlier revision units 1 Open connection between J2 connector on Capacitor PCB 2 to J3 connector on 50A PCB 5 Check continuity 2 Defective Main PCB 1 a Measure for approximately 325VDC on the CAPACITOR PCB 2 between MTH 1 to MTH 7 Replace if no voltage present 3 Defective Capacitor PCB 2 Disconnect plug from J2 connector on Capacitor PCB 2 and measure for 12VDC between J2 1 to J2 2 If low or missing replace PCB 2 4 Defective 50A PCB 5 a Disconnect plug from J4 on 50A PCB 5 If fan MOT 1 turns OFF replace PCB 5 5 Defective Main PCB 1 a Replace PCB 1 5 08 Pilot Arc Problems A AC LED ON TEMP LED OFF GAS LED ON Nothing happens when START signal is active No gas fl
79. connect primary power to the system before disassembling the torch torch leads or power supply enclosure Where these instructions include specific torquing instructions failure to torque properly will cause component damage Do not operate the equipment or test equipment un der power while wearing the grounding wrist strap Uu Manual 0 4988 B Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the 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 remove the replacement PC Board 7 Install the replacement PC Board in the equipment 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 before recon necting primary power to the equipment 7 03 Parts Replacement General Information The parts replacement procedures described in this manual except for filter replacement require that t
80. e following test points GND1 to 12V 12 VDC GND1 to 48V 48 VDC Replace Main PCB 1 if not correct 9 6 E 1 Defective Ribbon Cable Check continuity Defective Logic PCB 3 a Replace Logic PCB 3 AC LED ON W1 contactor does not energize In earlier revision units the fan MOT 1 will come ON after approximately 20 seconds Defective contactor a Measure for 24VAC between wires 5 amp 6 If voltage is present replace W1 Defective Logic PCB 3 a Measure W1 ON signal on Logic PCB between J1 9to TP1 Voltage should be 12VDC then drop to less than 1VDC 2 seconds after turning SW1 torch switch to ON Open or improperly connected ribbon cable to J2 connector on Main PCB 1 a Inspect connection and check continuity Replace if open 4 Defective Main PCB 1 SERVICE Replace Main PCB 1 5 11 CUTMASTER 152 p F UNDER PRESSURE FAULT AC LED ON FAULT Indicator and 60 PSI LED flashing 1 Air pressure source to unit is too low Setinput pressure source to 90 100 PSI 2 Regulator set too low a Adjust unit regulator to increase pressure 3 Defective Logic PCB 3 a Measure for 5VDC on the Logic PCB 3 between J3 3 to J3 1 Replace Logic PCB 3 if voltage is not present or low b Measure for voltage on the Logic PCB 3 between J3 2 to J3 1 If the voltage is between 3 4 5VDC replace the Logic PCB 3 4 Defective Pressure Transducer a Replace Pressure Transducer
81. e 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 parts replacement procedures Manual 0 4988 N CUTMASTER 152 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Power Supply Replacement Section 6 04 Major External Replacement Parts Section 6 05 Front Panel Replacement Parts Section 6 06 Left Side Replacement Parts Section 6 07 Right Side Replacement Parts Section 6 08 Options and Accessories Section 6 09 Replacement Parts for Hand Torch Section 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Section 6 11 Torch Consumable Parts Manual and Mechanized Torches NOTE Parts listed without 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 authorization 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 fo
82. e D1 on PCB 1 5 Test points located on PCB 1 M PCB 1 IGBT Test With PCB 2 removed Forward Biased Diode 1 Using an ohmmeter perform the following checks Forward Biased Diode PCB 1 Q1 Test points located on PCB 1 wer Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Reverse Biased Diode Forward Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode 2 Forward Biased Diodes PCB 1 Q2 2 Ifthe test reveals a failed component replace Main PCB Test points located on PCB 1 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 Ifthe test reveals a failed component replace Main PCB 1 5 24 SERVICE Manual 0 4988 CUTMASTER 152 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 PMTH 1 Forward Biased Diode PMTH 2 Reverse Biased Diode PRI 1 Reverse Biased Diode PRI 1 Forward Biased Diode PMTH 1 Forward Biased Diode PMTH 2 Reverse Biased Diode PRI 2 Reverse Biased Diode PRI 2 Forward Biased Diode PCB5 Q2 Test poi
83. e defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Victor Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Victor Thermal Dynamics and are FOB West Lebanon NH or an authorized Victor Technologies service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Victor 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 Victor 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 Victor 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 Victor Thermal Dy
84. e elongated 4T 03General Cutting Information A WARNING Disconnect primary power at the source be fore disassembling the power supply torch or torch leads Frequently review the Important Safety Pre cautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated A CAUTION Sparks from the cutting process can cause damage to coated painted and other sur faces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff will generally result in a more square cut Manual 0 4988 N CUTMASTER 152 Edge Starting 4T 04Hand Torch Operation For edge starts hold the torch perpendicular to the work tandoff Cuttina With Hand Torch piece with the front of the tip near not touching the edge CURING wi Ana Torg of the workpiece at the point where the cut is to start
85. e negative lead through the starter cartridge around the electrode and out through the tip orifice The secondary gas flows down around the outside of the torch starter cartridge and out between the tip and shield cup around the plasma arc Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip This pilot arc creates a path for the main arc to transfer to the work Main Cutting Arc DC power is also used for the main cutting arc The nega tive 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 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 lt O Torch Switch Torch Trigger To Control 0 gt O Cable Wiring PIP Switch Shield Cup 02997 C O Parts In Place Circuit Diagram for Hand Torch Remote Pendant l PME To ATC PIP Switch Shield Cup x CNC Start To ATC PIP Switch Shield Cup P Art A 08168 Automation Torch 7 PIPSwitch Shield Cup Parts In Place Circuit Diagram for Machine Torch INTRODUCTION 21 3 CUTMASTER 152 This Page Intentionally Blank 214 INTRODUCTION Manual 0 4988 CUTMASTER 152 SECTION 3 SYST
86. e trigger The pilot arc will start OPERATION 8 Cut as usual Simply release the trigger as sembly 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 compo nents 4 5 CUTMASTER 152 p Piercing With Hand Torch 1 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the technique that feels most comfortable and allows good control and movement NOTE The tip should never come in contact with the workpiece except during drag cutting operations 2 Angle the torch slightly to direct blowback particles away from the torch tip and op erator rather than directly back into it until the pierce is complete In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line Hold the torch perpen dicular to the workpiece after the pierce is complete Hold the torch
87. ection 7 05 C 4 5 Remove the Gas Solenoid per subsection 5 05 F Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector Remove the four 4 mounting screws securing the PCB to the center chassis Carefully guide the PCB assembly up and out of the unit Install the replacement PCB by reversing the above steps Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 2 7 Remove the Cover per subsection 7 04 A Remove all wires from W1 noting the location and orientation of each wire Loosen the two 2 Torx head screws securing the Main Contactor to the base Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mounting screws Lift Main Contactor up and out of the unit Install the replacement Contactor by reversing the above steps Reinstall the power supply cover D 40 AMP PCB PCB 5 Replacement Tools required T20 Torx Driver 1 gt 8 Remove the Cover per subsection 7 04 A Remove Capacitor PCB per subsection 7 08 A 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 4 mounting screws securing the PCB to the center chassis Carefully guide the PCB assembly up and out of the unit Inst
88. ective Main PCB 1 a Replace Main PCB Q 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 SERVICE mode 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 Defective Logic PCB 3 a Measure on Main PCB between J2 12 to test point GND1 for 12VDC If voltage is present replace Logic PCB 3 Defective Main PCB 1 Replace Main PCB 1 Manual 0 4988 N CUTMASTER 152 If gas DOES flow out of SOL1 when the unit is in SET mode reconnect SOL1 to the ATC connector 4 Defective torch solenoid a Measure the coil terminals of the torch mounted gas solenoid SOL2 for 24VAC If present replace SOL2 5 Defective Main PCB 1 a Measure on Main PCB 1 between J2 20 to 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 1 6 Defective Logic PCB 3 a Measure on Main PCB 1 between J2 11 to GND1 for less than 2VDC If voltage is 12VDC replace Logic PCB 3 R 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 If air flow
89. ely 34 19 mm or until the torch is brought OFF the edge of the metal Once the arc has extinguished e DC LED turns OFF After 20 second post flow time e Gas solenoid closes e Gas flow stops e 10 minutes after the Start signal is removed the cooling fans turn 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 above 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 Therearethree 3 ARC VOLTAGE signals available from the J1 connector a 1 9 to 42 7 b 2 5 to J2 6 Auto Interface PCB 4 connector P1 with no jumper installed ARC VOLTS divided by 16 67 J2 5 to J2 6 Auto Interface PCB 4 connector P1 with jumper installed between pins 1 and 2 ARC VOLTS divided by 30 d J2 5 4 to J2 6 Auto Interface PCB 4 connector P1 with jumper installed between pins 2 and 3 ARC VOLTS divided by 50 Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximate those listed below This completes the Main Arc and Controls Test If the above are all correct then proceed to the next section Inter Open Circuit Voltage Cutting Voltage face Test If the unit does
90. equency of maintenance may need to be adjusted according to the operating environ ment Daily Operational Checks or Every Six Cutting Hours 1 Check torch consumable parts replace if damaged worn or when cut performance has diminished 2 Check plasma and secondary supply and pressure 3 Purge plasma gas line to remove any moisture build up Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Inspect torch for any cracks or exposed wires replace if necessary Inspect input power cable for damage or exposed wires replace if necessary Six Months or Every 720 Cutting Hours 1 Check the in line air filter s clean or replace as required 2 Check cables and hoses for leaks or cracks replace if necessary 3 Check all contactor points for severe arcing or pits replace if necessary 4 Vacuum dust and dirt out of the entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical com ponents and cause damage to the unit Insufficient Penetration Main Arc Extinguishes Excessive Dross Formation 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics parts used 7 Incorrect gas pressure 1 Cutting speed too slow 2 Torch standoff too hig
91. essures 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 mm LD For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Manual 0 4988 N CUTMASTER 152 SECTION 3 TORCH Check Air Quality INSTALLATION To test the quality of air A 1 Put the switch in the up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn on the air Do not start an 3T 01Torch Connections If necessary connect the torch to the Power Sup ply Connect only the Victor Thermal Dynamics model SL100 Manual SL100 Mechanical Torch to this power supply Maximum torch leads ar length is 100 feet 30 5 m including extensions Any oll Gr inthe air will Oh A the lens WARNING 3T 02Setting Up Mechanical Torch Disconnect primary power at the source before connecting the torch NOTE a 1 Align the ATC male connector on the torch An adapter is required to be installed in the lead with the female receptacle Push the power supply if convertin
92. etween J14 on Main PCB 1 to J9 on 50A PCB 5 a Check continuity Open connection between J12 on Main PCB 1 to J1 on Capacitor PCB 2 Check continuity Manual 0 4988 N CUTMASTER 152 9 10 11 12 13 14 15 Open connection between J2 on Capacitor PCB 2 to J3 on 50A PCB 5 a Check Continuity Open connection between J2 on Main PCB 1 to J1 on Logic PCB 3 Check continuity Defective Logic PCB 3 a Measure Logic PCB 3 CUR SET signal between J1 6 to TP1 If no voltage replace PCB 3 b Measure Logic PCB 3 for SHDN signal between J1 10 to TP1 Normally 12VDC signal should drop to less than 1VDC when START signal is active If voltage does not drop replace PCB 3 c Measure Logic PCB for the corresponding signals to measure less than 2VDC For 230VAC Signal 230 IN between J1 5 to TP1 For 460VAC Signal 460 IN between J1 4 to TP1 If corresponding signal measures 12 VDC replace the Logic PCB 3 Defective Main PCB 1 a Measure for approximately 325VDC on Capacitor PCB 2 between MTH 1 to MTH 7 under load If voltage is not present replace PCB 1 Defective Capacitor PCB 2 a Disconnect plug from J2 on Capacitor PCB 2 and measure between J2 1 to J2 2 for 12VDC If voltage is low or zero replace PCB 2 Defective 50 PCB 5 a Isolate the 50A PCB 5 by disconnecting plug from J4 the Sync Cable from J9 and the wire from terminal CHOKE1 Supply a START signal If
93. f voltage is less than 2VDC replace Main PCB 1 Main PCB 1 removes the short replace the Main PCB 1 CutMaster 52 amp 82 No OK TO MOVE signal while cutting Cover Screws Wi 2 for 1PH 1 Defective Main PCB 1 Actuator Button a Measure voltage on PCB 4 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 PCB 4 between J1 1 to J1 3 for less than 2VDC while cutting Jumpers Main Contactor If voltage is less than 2VDC replace PCB 4 Shi C ARC VOLTS signals are low or not present 2 Retest continuity between terminals while engaging the 1 Defective Automation Interface PCB 4 contacts manually This can be done by pushing down on the recessed actuator button on the top of W1 or a Replace PCB 4 pushing down on the actuator arm on the side of W1 b Check Voltage Divider Jumper L1 to T1 L2 to T2 L3 to T3 L4 to T4 The contacts should be closed Continuity 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 replace W1 Manual 0 4988 SERVICE 551 CUTMASTER 152 p B PCB 1 Input Diode D1 Test 1 Using an ohmmeter perform the tests in the chart Input Diode Module D1 on PCB 1 Test points located on PCB 2 Meter 80A AC1 80A AC2 80A AC3 MTH 1 MTH 1 MTH 1 MTH
94. ft Side Internal Parts Replacement A Fan Replacement Tools required T20 Torx Driver Fan MOT 1 1 2 3 6 T Remove the Cover per subsection 7 04 A 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 MOT 2 or MOT 3 1 2 Remove the Cover per subsection 7 04 A Unplug corresponding J1 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 4988 N CUTMASTER 152 B Main Transformer T1 Replacement Tools required T20 Torx Driver 1 2 14 Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 F Disconnect the transformer wi
95. g 1 2 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error Faulty Logic PCB 3 a Replace Logic PCB 3 N MAX PRESSURE ERROR MAX pressure LED is ON 1 Gas pressure set too high a Reduce gas pressure Pressure Regulator set too high a Adjust Pressure Regulator Defective Pressure Transducer a Adjust pressure Regulator to minimum Measure voltage on Logic PCB 3 between J3 1 to J3 2 If voltage is more than 4 VDC replace Pressure Transducer Defective Logic PCB 3 a Replace Logic PCB O AC LED ON TEMP LED OFF GAS LED ON Gas flows DC LED amp FAULT indicator OFF W1 contactor does not energize 1 Defective W1 Contactor a Measure for 24VAC between wire 5 to wire 7 6 on W1 If voltage is present replace W1 Defective Logic PCB 3 a Measure voltage on Main PCB 3 between J2 9 to GND1 If voltage is 12VDC replace the Logic PCB 3 Defective Main PCB 1 Replace Main PCB 1 P 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 Defective Logic PCB 3 a Measure on Main PCB 1 signal SOL ON between J2 12 to test point GND1 for 12VDC If voltage is present replace Logic PCB 3 Def
96. g a hand torch system male connector into the female receptacle The connectors should push together with a A small amount of pressure WARNING 2 Secure the connection by turning the lock ing nut clockwise until it clicks DO NOT use the locking nut to pull the connection Disconnect primary power at the source before disassembling the torch or torch leads pum pu C c cc c together Do not use tools to secure the The mechanical torch includes a positioning tube connection with rack and pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the sur face of the workpiece Torch to the Power Supply 3 The system is ready for operation Manual 0 4988 INSTALLATION 3T1 CUTMASTER 152 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 4 07 Torch Parts Selection for details 312 INSTALLATION Manual 0 4988 N CUTMASTER 152 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering Identification 1 Output Current Control Sets the desired output current Output settings up to 60 Amps may be used for drag cutting with the torch tip contacting the workpiece or higher for standoff c
97. ge the bottom locking tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit Remove the two screws securing the Output Inductor to the base Remove the Output Inductor carefully guiding its wires through from the right side of the unit Install replacement Output Inductor by reversing the above steps Reinstall the power supply cover CUTMASTER 152 p E Output Inductor L2 Tools required T20 Torx Driver 1 2 10 1 12 13 14 Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 F Disconnect Output Inductor wires from Choke1 termi nal on the 40A Power 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 the Front and Rear panel from the base per section 7 04 D Carefully guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit Remove the two screws securing the Output Inductor to the
98. h from workpiece 3 Cutting current too high 4 Work cable disconnected 5 Worn torch parts 6 Non Genuine Thermal Dynamics parts used 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 Worn torch parts 4 Improper cutting current 5 Non Genuine Thermal Dynamics parts used 6 Incorrect gas pressure Short Torch Parts Life Oil or moisture in air source Difficult Starting 5 2 SERVICE 2 Exceeding system capability material too thick 3 Excessive pilot arc time 4 Gas pressure too low 5 Improperly assembled torch 6 Non Genuine Thermal Dynamics parts used 1 Worn torch parts 2 Non Genuine Thermal Dynamics parts used 3 Incorrect gas pressure Manual 0 4988 N CUTMASTER 152 5 04 Fault Indicator At initial power up two lights will temporarily illuminate for 2 3 seconds to show the version of software used To determine the first digit count the 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 indicator and 75 psi indicators are ON indicating the version would be 2 3 NW gt Art 07988 12345 When the D Fault indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is Only one of t
99. he 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 con nection designation When reassembling make sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when re assembling the unit Each subsection is referenced to Section 6 for parts lists and overall detailed drawings A WARNING Disconnect primary power from the source before opening or disassembling the power supply PARTS REPLACEMENT 7 1 CUTMASTER 152 7 04 Major External Parts A Cover Removal Tools required T20 Torx Driver 1 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower i Screws 7 a ET Slots ee Screws Art 08429 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover installation NOTE When installing the upper screws attempt to reuse the original threads The e
100. helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty e Protect others in the work area from the arc rays Use protective booths screens or shields Usethe 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 WARNING WARNING This product contains chemicals including lead known to the State of California to cause birth defects and other reproductive harm Wash hands after handling 1 2 GENERAL INFORMATION 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard 787 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York
101. hese faults will be displayed at one time If more than one fault exists when the first fault is corrected and cleared the next fault will then be displayed It is possible to have a fault indicated in the function indicators and another fault indicated in the pressure indicators The following table shows each of the Faults possible Pressure Fault Indicator Max Over Pressure 90 internal Error Shorted Torch 80 Consumables Missing Min NOTE Fault explanations are covered in the basic trouble shooting guide later in this chapter Explanation of Faults UNDER PRESSURE Indicates that operating pressure 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 Art A 08316 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 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 operat
102. ices excel lent 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 WARNING 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 152 51100 1Torch Service Manual Number 0 4988 Published by Victor Technologies International Inc 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www victorthermaldynamics com Copyright 2008 2009 2010 2012 2013 by Victor Technologies International Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negli gence accident or any other cause Publication Date September 25 2008 Revision Date November 14 2013 Record the following information for Warranty purposes Where Purchased Purchase Date Power Sup
103. ich 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 on page 2 2 for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional speci fications as related to the Power Supply used 2T 03Specifications A Torch Configurations 1 Hand Manual Torch Models The hand torch head is at 75 to the torch handle The hand torches include a torch handle and torch trigger assembly Le 10 125 257 mm gt 95 mm Art A 03322_AB 7 117 29 mm 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly 15 875 403 mm m 9 285 236 mm F i Y 1 375 35 mm 1 175 30 4 95 126 179 5 0 625 44 5 mm 16mm v Art 4 02998 Torch Leads Lengths Hand Torches are available as follows e 20ft 6 1 m with ATC connectors e 50 ft 15 2 m with ATC connectors Machine Torches are available as follows 5 foot 1 5 m with ATC connectors e 10 foot 3 05 m with ATC connectors e 25 foot 7 6 m with AT
104. if needed Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art 03725 2 Torch start cartridge is stuck a Turn OFF power supply Bleed down the 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 5 16 SERVICE 3 Torch Switch iw 1 is 2 PIP 39 Spring Loaded Spring Loaded Lower End Fitting Lower End Fitting at Reset Full Compression Full Extension Art 08064 AC Worn or faulty torch parts a Inspect torch consumables parts Replace if necessary 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 5 22 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 Low primary input power or missing phase a Measure primary input voltage between L1 L2 amp L3 on W1 contactor under load Defective W1 contactor a Check per section 5 11 C b Check voltage into and out of W1 contactor under load Replace W1 if voltage drop is found Shorted Sync Cable connected b
105. ill be welded after cutting Dross free cutting is im portant when finish cut quality is desired to avoid a secondary cleaning operation The following cut quality characteristics are illustrated in the follow ing figure Kerf Width Cut Surface Bevel Angle Top Edge Rounding Dross Build Up A 00007 Cut Surface Drag Lines Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These build ups 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 per pendicular 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 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 removed 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 becom
106. ion CONSUMABLES MISSING Indicates that the electrode start cartridge or tip is missing or excessively worn SHORTED TORCH OUTPUT FAULT This indicator has two modes of operation First is 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 identify and clear the problem and turn back ON 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 Airrestriction in torch resulting in low voltage during pilot 3 Low voltage during cutting due to torch or consumable problem Manual 0 4988 SERVICE 53 CUTMASTER 152 In all three cases to reset the machine remove the START signal INTERNAL ERROR Indicates a microprocessor error OVER PRESSURE Indicates that operating pressure is set too high The Error Indicator will not flash when the pressure is above 95 PSI This LED will remain ON and the system will operate but pilot starting and cut performance may be affected NOTE When the unit is turned ON the cooling fans MOT 1 3 will remain OFF In earlier units MOT 1 will turn ON for one 1 seco
107. k cable connection to Work piece 4 Torch being moved too fast 5 Excessive oil or water in torch 6 Failed components in unit 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 Connect work cable Replace work cable Return to an authorized service center for repair Check and adjust to proper setting Check torch consumables and replace as needed Check the connection of the Work Lead to the work piece Reduce cutting speed Refer to Check air quality in section 3 Torch Return to an authorized service center for repair SERVICE Manual 0 4988 N CUTMASTER 152 5 06 Circuit Fault Isolation A WARNING EI mo o e o eee 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 NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower Screws Art A 07947 2 Carefully pull the Cover up and away from the unit Manual 0 4988 B Cover Installation 1 Reverse previous procedures for cover ins
108. l can also be downloaded at no charge in Acrobat PDF format by going to the Victor Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link http www victorthermaldynamics com Manual 0 4988 2 02 Equipment Identification The unit s identification number specification part number model and serial number usually appear on a data tag attached to the rear panel Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely attached card or the shipping container Record these numbers on the bottom of page i for future reference 2 03 Receipt Of Equipment When you 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 2 1 CUTMASTER 152 p 2 04 Power Supply Specifications Input
109. ld 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 8 Art A 08067 Shield Cups 3 Ontorches with a shield cup body 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 be tween the shield cup body and drag shield cap Do not lubricate the O ring Shield Cup Body Art 03878 SERVICE 4 Remove the tip Check for excessive wear indicated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip QC SZ A 03406 Example of Tip Wear 5 Remove the starter cartridge Check for excessive wear plugged gas holes or discoloration Check the lower end fitting for free motion Replace if necessary Spring Loaded Lower End Fitting Full Compression Spring Loaded Lower End Fitting at Reset Full Extension Art 08064 AC 6 Pull the Electrode straight out of the Torch Head Check the face of the electrode for excessive wear Refer to the following figure New Electrode CT DTE Worn Electrode Art 4 A 03284 Electrode Wear 1 Reinstall the Electrode by pushing it straight into the torch head until it clicks 8 Reinstall the desired starter cartridge and tip into th
110. le Receptacle Remote Pendant Connector ATC Female Receptacle Male ATC Leads Connector gt ____ Power ___ Torch Supply Head Leads PIP O Black Switch To Power Supply O Orange Circuitry 0 White Not MEN Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry gt Pilot Art A 08577 1 APPENDIX Manual 0 4988 N CUTMASTER 152 This Page Intentionally Blank Manual 0 4988 APPENDIX A 5 CUTMASTER 152 APPENDIX HEMATI INRUSH RESISTORS pc INRUSH voc BIAS SUPPLY CM102 amp A80 C7 amp C10 not installed wt L1 ssi ld L3 a GND xx 2 33 oo 7 uss ennsulurens 1 INPUT VOLTAGE SELECTOR Closed for 230VAC input BETWEEN TO RLZ TOIS O BUSS BARS EA E 2A 1 sen 2 1 oventenp 4 2 FANON 3 4 CUR SET 5 MAIN ID PCB1 6 COMMON FERRITE FILTER vc m sncf q PCB2 INPUT CAPACITOR 5 4050 AMP PCB 09132_ APPENDIX Manual 0 4988 CUTMASTER 15 FIAT ONLY 1TORCH PIP SWITCH CONNECTOR Ki AUTOMATION TORCH SOLENOID ISTART 24VAC RETURN
111. llowing items are included with the replacement power supply work cable amp clamp input power cable gas pressure regula tor filter and operating manual t Description talog 1 CutMaster 152 Power Supply 208 230 460 VAC Single or 3 Phase 60Hz with 208 230 460 VAC input power cable and plug 3 1730 1 with 460 208 230 VAC three phase input power cable 3 1730 2 600VAC 3 Phase 60Hz with 600V 3 phase input power cable and plug 3 1730 5 Manual 0 4988 PARTS LIST 6 1 CUTMASTER 152 6 04 Major External Replacement Parts Item Description talog 1 1 Cover with labels 9 0200 2 1 Base Enclosure Assembly 9 0186 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0188 5 1 Rear Panel 9 0101 Art 08564 NOTE Illustration may vary slightly from unit 6 2 PARTS LIST Manual 0 4988 N CUTMASTER 152 6 05 Front Panel Replacement Parts t Description Ref talog 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 4988 PARTS LIST 6 3 CUTMASTER 152 6 06 Left Side Replacement Parts RN Dascrinti 1 1 Main Assembly 600V 1 9 0125 1 1 Main Assembly 600V Only PCB 1 9 0166 1b 1 50Amp PCB non 600V PCB 5 9 0203 1b 1 50Amp PCB 600V Only PCB 5 9 0179 2 1 Logic PCB PCB 3 9 0107 3 1 Center
112. 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 START is active Torch switch CNC Active low PARTS IN PLACE satisfied Pulse signal Active high during main transfer Active low for torch with remote solenoid Active low when over temperature Input Voltage signal 3VDC 460 VAC 1 5VDC 230VAC Voltage level to identify Main PCB 1 1VDC SERVICE L M L M L M L M L M L M L M L M M L M L M L M L M L M L M L M L M L M L M L M L M L M L M L M L M L CUTMASTER 152 45 3 SOLENOID J6 1 24VAC Supply for W1 J6 2 24VAC Return J7 1 12VDC 47 2 FAN J8 Not Used J9 1 PIP J9 2 Common J9 3 TORCH SWITCH START J9 4 Common J9 5 Automation Torch solenoid 24VAC supply J9 6 Not Used J9 7 Automation Torch solenoid 24VAC return J10 1 0 0 J10 2 Not used J10 3 OK TO MOVE J10 4 Not used J10 5 J10 6 J10 7 12VDC J10 8 START Remote Pendant CNC Signal J11 N A J12 1 12 00 J12 2 460VAC J12 3 230VAC J13 1 OVERTEMP J13 2 ON J13 3 CSR J13 4 SET 13 5 ID 13 6 5 28 SERVICE Manual 0 4988 N CUTMASTER 152 LOGIC PCB 3 SIGNALS J1 Signal info is the same as MAIN PCB 1 J2 connector J3 1 5
113. lows e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing e DC LED comes ON e Pilot arc is established 2 Remove the START signal and note the following e Gas continues to flow DC LED goes OFF After 20 second post flow time e Gas solenoid closes Gas flow stops This completes the Pilot Arc Test If the above are all correct then proceed to the next section 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 1 Manual 0 4988 Main Arc and Controls Test Connect Work Cable to the work piece Set CURRENT CONTROL POTENTIOMETER to maximum Provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 3 9 mm of the work piece to establish main cutting arc Main Cutting Arc Establishes e On PCB 1 D59 turns OFF and 078 turns ON Clamp DC ammeter around the work cable Output will be 120 amps 2 While cutting adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to minimum setting e Current adjusts from 120 amps down to 20 amps 3 Set the CURRENT CONTROL POTENTIOMETER to maximum position e Current adjusts from 30 amps up to 120 amps 4 While cutting touch the tip of the torch to the work piece this is called Drag Mode For Hand and Machine Torches Tip Saver circuit will acti
114. n 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 recom mendation 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 moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie BRUIT e Pour prot ger votre ou e contre les bruits forts portez des tam pons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail lfaut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 AVERTISSEMENT AVERTISSEMENT Ce produit contient des produits chimiques notammen
115. n the resistance will start to increase If the meter probes are reversed the reading will decrease to zero then start charging in the opposite polarity Meter 2 Using an ohmmeter perform the tests in the chart INPUT VOLTAGE SELECTION RELAYS PCB 2 Meter Meter 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 PRI 1 A 2 Using an ohmmeter check continuity 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 3 Using an ohmmeter check continuity between the following points SERVICE Manual 0 4988 N CUTMASTER 152 BOBO Test points located on PCB 1 amp PCB 2 wee veero Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias F PCB 5 IGBT Test 1 Disconnect transformer wires from 50 Amp PCB 5 terminal PRI 1 A 2 Using an ohmmeter perform the following checks PCB 5 Q1 Test points located on PCB 2 AND PCB 5 veero PRI 1 PMTH 1 Forward Bias PRI 1 PMTH 2 Capacitor Charging PMTH 1 PRI 1 Capacitor Charging PMTH 2 PRI 1 Forward Bias PRI 2 PMTH 1 Forward Bias PRI 2 PMTH 2 Capacitor Charging PMTH 1 PRI 2 Capacitor Charging PMTH2 PRI 2
116. namics product This warranty is invalid if the Victor Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 1 6 GENERAL INFORMATION Manual 0 4988 CUTMASTER 152 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 i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows NOTE An operation procedure or background informa tion 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 AN WARNING A procedure which if not properly followed may cause injury to the operator or others in the op erating area WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box Such as this Additional copies of this manual may be purchased by contacting Victor Technologies 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 manua
117. nd and then turns OFF The fans will turn ON when a START signal Torch Switch Remote Pendant switch or 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 5 4 SERVICE Manual 0 4988 CUTMASTER 152 5 05 Basic Troubleshooting Guide WARNING Da M H HU ay 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 1 Primary power disconnect is 1 Turn primary power disconnect switch to ON position OFF position 2 Primary fuses breakers are 2 a Have qualified person check primary fuses breakers blown or tripped b Connect unit to known good primary power receptacle 3 Faulty components in unit 3 Return to authorized service center for repair or replacement 1 INPUT VOLTAGE SELECTION Turn OFF power to unit then set INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage SWITCH to match primary input voltage 2 Primary input voltage problem 2 Have qualified person check primary voltage to insure it meets unit requirements see section 2 04 3 Faulty components in unit 3 Return to autho
118. nd one small gas hoses from the pressure regulator per subsection 7 05 C Unplug the connector J2 from the Main PCB Disconnect cable from the Pressure Transducer Disconnect front panel from base per subsection 7 04 D Remove the Current Control Potentiometer Knob and nut securing the potentiometer shaft to the front panel per subsection 7 05 A Remove the Function Control Switch Knob and the nut securing the switch shaft to the front panel per subsection 7 05 B 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 Remove the cover per subsection 7 04 A Disconnect the wires on the rear of the switch noting the location and orientation of each wire as shown below 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 PARTS REPLACEMENT l Work Cable Replacement Tools required T20 Torx Driver 1 2 5 Remove the Cover per subsection 7 04 A Disconnect the work cable from the WORK1 terminal on the Main PCB Squeeze the top and bottom of the Work Cable Strain Relief and remove from the front panel Install the replacement Work Cable by reversing the above steps Reinstall the power supply cover 7 06 Le
119. nders Refer to the following 1 Attach the Single Stage Filter Hose to the two subsections if an optional air line filter is to be Inlet Port Installed 2 Attach the Filter Assembly to the filter hose 1 Connect the air line to the inlet port The dap held 3 Connect the air line to the Filter The illus illustration shows typical fittings as an tration shows typical fittings as an example example NOTE NOTE For a secure seal apply Permatex PX56521 or For a secure seal apply Permatex 56521 equivalent thread sealant to the fitting threads equivalent thread sealant to the fitting threads according to the manufacturer s instructions Do according to the manufacturer s instructions Do not use Teflon tape as a thread sealer as small not use Teflon tape as a thread sealer as small particles of the tape may break off and block the particles of the tape may break off and block the small air passages in the torch small air passages in the torch Regulator Filter Regulator Filter Assembly Assembly Inlet Port Art 07943 Hose Clamp Air Connection to Inlet Port Gas Supply Hose 6mm Fitting Optional Single Stage Filter Installation Manual 0 4988 INSTALLATION 33 CUTMASTER 152 Installing Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5
120. ng Art 03791 8 O Ring O Ring Lubrication ATC O Ring An o ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis This will allow NOTE the o rings to remain pliable and provide a proper seal DO NOT use other lubricants or grease they may The o rings will dry out becoming hard and cracked if the not be designed to operate within high tempera lubricant is not used on a regular basis This can lead to tures or may contain unknown elements that potential performance problems may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life It is recommended to apply a very light film of o ring lubri cant Catalog 8 4025 to the o rings on a weekly basis Manual 0 4988 SERVICE 5T UTMASTER 152 5T 02Inspection and Replacement of Consumable Torch Parts A WARNING ue E 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 NOTE The shield cup holds the tip and starter 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 shie
121. ng 9 8238 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending 9 8239 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending 9 8244 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 47 20 OPERATION Manual 0 4988 N CUTMASTER 152 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 7 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 4988 OPERATION 4T 21 CUTMASTER 152 This Page Intentionally Blank 41 22 Manual 0 4988 CUTMASTER 152 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 Weekly SF Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months Replace all broken parts 6 Months Visually check and Carefully clean the interior Art A 07938 Manual 0 4988 SERVICE 5 1 CUTMASTER 152 p 5 02 Maintenance Schedule 5 03 Common Faults Problem Symptom Gauss NOTE The actual fr
122. ngs above 40 amps the tip has contacted the work piece a Check standoff height Air restriction in torch resulting in low voltage during pilot a Check torch consumables for wear or debris Low voltage during cutting due to torch or consumable problem a Check torch consumables for wear or debris In all three cases to reset the machine remove the START SERVICE signal Manual 0 4988 CUTMASTER 152 D AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicator OFF No arc in torch 1 Defective Main PCB 1 Install jumper on Main PCB 1 between test point GND1 to terminal b Apply START signal If Pilot starts replace Main PCB 1 E ACLED 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 Measurefor 12VDC on Main PCB between test Point GND1 to J2 8 If 12VDC is present replace Logic PCB 3 3 Defective Main PCB 1 Replace Main PCB 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 and then turn to ON position to clear the error 2 Defective Logic PCB 3 Replace Logic PCB 3 G Fans MOT 1 3 do not turn ON after a START signal is activated 1 Defective Logic PCB 3 a Measure voltage at J1 14 to
123. nsure torch ATC is securely fastened to unit 3 Problem with torch and leads PIP circuit a Disconnect the Torch from the unit and check continuity of torch PIP circuit at ATC pins 1 amp 2 If open check torch and leads for open lead or PIP switch Negative Plasma Lead lh Le Ux 3 Torch Switch 2 PIP 1 PIP Art A 08124 Pilot Lead Torch Lead Connector 4 Defective Logic PCB 3 a Measure the voltage on Main PCB 1 between J2 17 to test point GND1 for 12VDC If the voltage is less than 2VDC replace Logic PCB 5 Defective Main PCB 1 Replace Main PCB 1 Manual 0 4988 N CUTMASTER 152 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 low Release the START signal source 2 5 Problem in the torch and leads switch circuit a Check continuity of torch switch circuit at ATC pins 3 amp 4 See previous illustration Short in CNC cable a Check continuity Defective Logic PCB 3 a Measure voltage at Main PCB 1 between J2 16 to test point GND1 for 12VDC If voltage is present replace Logic PCB 3 Defective Main PCB 1 a Replace Main PCB 1 J TIP MISSING FAULT The FAULT Indicator and 80 PSI LED is flashing Gas solenoid c
124. nts located on PCB 5 wee Meert 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 Ifthe test reveals a failed component replace 50Amp 5 NOTE Many of the signals listed in the PCB information to follow will be low voltage signals that will be in one of two states 12VDC High or OVDC Low with respect to PCB common When a signal name is preceded by the mark it denotes that the signal is an active low For example OVERTEMP This signal is normally High but when an over temperature fault exists this line will change state to a Low Manual 0 4988 SERVICE 5 25 CUTMASTER 152 p J2 PINOUT PRI 1 ACI AC2 AC3 TP5 PRI 3 PRI 2 D59 TIP1 TP6 ELECTRODE1 SEC 48 2 voli 12 2 078 448V1
125. nty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Victor 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 Victor Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Victor Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Victor 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 Victor Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 39 CUTMASTER 52 CUTMASTER 82 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 Victor Thermal Dynamics Corporation 1 Repair of the defective product 2 Replacement of th
126. on 1900 Arch Street Philadelphia PA 19103 14 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 15 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 4988 N CUTMASTER 152 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 Toute proc dure pouvant r sulter du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question A AVERTISSEMENT Fournit l information concernant des dommages pos sibles de choc lectrique Des avertissements seront enferm s dans une bo te de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE A L ARC AU JET DE PLA
127. 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 D Fault Error Indicator Indicator is ON when Fault circuit is active See section 5 for explanations of fault lights 10 Pressure Indicators Art A 08170 The Indicators will illuminate ac cording to the pressure set by the Pressure Control Knob number 4 Manual 0 4988 OPERATION 11 CUTMASTER 152 4 02 Preparations for Operation At the start of each operating session A WARNING Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies Torch Parts Selection Checkthe torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 120 amps maximum Refer to Section 4T 07 and following for torch parts selection Torch Connection Check that the torch is properly connected Only Victor Thermal Dynamics model SL100 Manual or SL100 Me chanical Torches may be connected to this Power Supply See Section 3T of this manual Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power requirement
128. or Technologies International Inc www victortechnologies com Printed in Mexico
129. orch should travel in a clockwise direction 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 When dross is present on carbon steel it is commonly b For standoff cutting hold the torch 1 8 referred to as either high speed slow speed or top dross _ Dross present on top of the plate is normally caused by 3 8 in 3 9 mm from the workpiece as too great a torch to plate distance Top dross is normally shown below very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut 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 A 00512 Side Characteristics Of Cut Dross Manual 0 4988 OPERATION 113 CUTMASTER 152 p Torch Shield Cup Standoff Distance 1 8 3 8 3 9mm Standoff Distance Hold the torch away from your body Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start Trigger Release A
130. ouble shooting guide SERVICE 5 7 CUTMASTER 152 D CAUTION Due to the close proximity of the Main PCB to the Capacitor PCB It is recommended to use an insu lated meter probe when making measurements on the J2 connector on the Main PCB Do not short between the pins Do not short to the Capacitor PCB connections Initial Set up Conditions This section is to help isolate the defective circuit before troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to identify the possible symptom s and the defective circuit After repairs are complete run the following tests again to verify that the unit is fully operational 1 2 Connect gas supply to rear of Power Supply Turn ON gas supply and set operating pressure per pressure setting label on power supply Set the Power Supply controls as follows e ON OFF SWITCH to OFF position e Turn FUNCTION CONTROL SWITCH to SET position CURRENT CONTROL POTENTIOMETER to MAXIMUM position fully clockwise E Main Input and Internal Power Test 1 2 Connect Primary Line power to the unit Turn the ON OFF SWITCH SW1 to ON position and observe the following e Software version is displayed See section 5 04 Fault Indicators After approximately three 3 seconds e nrush relay on PCB 1 energizes starting pre charging of working capacitors e AC and GAS Indicators come ON Gas flows After 4 seconds
131. ow DC LED OFF fans MOT 1 3 do not turn ON 1 Problem in the torch and leads switch circuit or remote pendant or CNC signal missing For hand torches check continuity of torch switch circuit at ATC pins 3 amp 4 Negative Plasma Lead 4 Torch Switch 3 Torch Switch LIU Op 2 PIP VUA 29 1 PIP NS Art A 08124 Pilot Lead b For machine torches using a remote pendant check continuity of Pendant switch circuit c Check CNC START signal 5 15 CUTMASTER 152 2 Defective Logic PCB 3 a Jumper on Main PCB 1 between J2 16 and test point GND1 If gas does not flow replace Logic PCB 3 b With START signal active measure voltage on Main PCB 1 between test points GND1 to DMD1 for 1 4VDC Replace PCB 3 if voltage is not present 3 Defective Main PCB 1 a With START Signal active measure voltage on Main PCB 1 between test points GND1 to _DMD1 for 1 4 3 VDC Replace PCB 1 if voltage is present B SHORTED TORCH OUTPUT FAULT Fault indicator and 85 PSI Indicators are 4 flashing at 1 cycle per second This is a Latched Failure Mode After START signal is ac tivated gas flows After two seconds FAULT INDICATOR flashes and 85 PSI LED flashes To reset the machine turn the unit OFF identify and clear the problem and turn back ON 1 Upper O Ring on torch head is in the wrong position a Remove shield cup from torch check position of the upper o ring and correct
132. ply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 1 1 01 Notes Cautions and WARNINGS 1 1 1 02 Important Safety Precautions 1 1 WOS si 1 2 1 04 Note 1 3 1 05 Precautions De Securite Importantes od ott base 1 3 TOG Documents De Referente 1 5 t07 Statement of Warranty sees adres 1 6 SECTION 2 SYSTEM INTRODUCTION 2 1 2 01 OW TAS ANNAN suani tedio epu 2 1 2 02 Equipment Id es 2 1 Z3 n rE 2 1 2 04 Power Supply Specifications SR nine 2 2 2 05 Input Wining Specifications 2 2 3 2 06 Power Supply Features 2 2 21 2 4 SECTION 2 TORCH INTRODUCTION 27 1 2101 SEDDE 27 1 IEEE 2T 1 05 tn tile 27 1 BUS ne 27 2 21 05 Introduction to Plasma 2T 2 SECTION 3 SYSTEM INSTALLATION 3 1 3 01 US PR PS 3 1
133. r return to authorized service center switch circuit or repair or replacement 3 Failed components in unit 3 Return to authorized service center for repair or replacement Manual 0 4988 SERVICE 5 5 CUTMASTER 152 p or remote switch is closed Or CNC START signal is active No gas flow indicators flashing at 1 cycle per second FAULT indicator lashing and 85 PSI indicators flashing at 5 cycles per second 1 Torch shield cup is loose 2 Torch tip electrode or start cartridge missing 3 Torch start cartridge is stuck 4 Open conductor in torch leads 5 Problem in the torch and leads switch circuit 6 Failed components in unit 1 Problem in the torch and leads switch circuit Remote pendant switch circuit 2 CNC Contoller device not providing Start signal 3 Failed components in unit 1 Tighten shield cup by hand Do not overtighten 2 Turn OFF power supply Remove shield cup Install missing parts 3 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 4 Replace torch and leads or return to authorized service center 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 Authori
134. rect phase being used Input Power Cable Connections Single Phase 19 and Jumper Settings Three Phase 30 Store copper jumpers on base plate L1 Fem L2 Q L2 Q EC 2 L3 28 L3 F 5 z L4 GND GND Single and Three Phase Input Power Wiring contactor points are stuck closed a Check per section 5 11 A 4 Primary plug not wired correctly a Check manufacturer s plug installation instructions 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 position 1 Shorted Input Diode Module Check per section 5 11 B and 5 11 2 Shorted Input Capacitor PCB 2 a Check per section 5 11 D C Gas flows with ON OFF SWITCH in OFF position 1 Foreign debris has lodged in gas solenoid a Replace gas solenoid This is a problem caused by improperly filtered air supply Customer needs to add filtration to air supply prior to unit inlet Manual 0 4988 D All front panel indicators are OFF Fan MOT 1 never turns ON Main Contactor W1 does not close 1 Primary power not connected a Check that cable is connected to primary power Primary line fuse breaker is blown tripped a Replace fuse or reset breaker Defective ON OFF SWITCH Check continuity Defective Main PCB 1 a Measure Main PCB power supply voltages at th
135. rer s Electrical Schematic File Number Rated Supply Voltage Note 2 Degree of Protection 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 and Revision Level Standard Symbols AC DE Phase Art 03288 AB Manual 0 4988 CUTMASTER 152 T DIAGRAM APPENDIX 3 TORCH PIN A Hand Torch Pin Out Diagram ATC Male Connector ATC Female Receptacle Negative Front View Front View Negative Plasma NN 8 Open 8 ones PER IN WE V Switch 4 ES i 3 Switch Ze 8 PIP 3 6 O pen M 6 Open 5 Open 5 Open 1 Pilot Plasma 4 Green Switch 47 3 White 4 Switch 101 NS M 7 Open 7 Open Iii ES 6 429
136. res from terminals PRI 1 A PRI 2 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 04 D 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 Transformer 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 Manual 0 4988 Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 F Disconnect the transformer wires from terminals PRI 1 A PRI 2 B PRI 3 D PRI 4 C SEC1 SEC2 on the 40A Power PCB Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the
137. rigger Release A 02986 T Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF Non Conductive Straight Edge 1 Guide The gas preflow and postflow a charac teristic of the power supply and not a func tion of the torch Trigger A 03539 Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less NOTE 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 opera 7 4 tion 1 Install the drag cutting tip and set the out Art A 03383 2 Manual 0 4988 put current The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch 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 Keep the torch in contact with the workpiece during the cutting cycle Hold the torch away from your body Slide the trigger release toward the back of the torch handle while simultaneously squeezing th
138. rized service center for repair or replacement 1 Air flow through or around the Refer to clearance information section 2 04 unit is obstructed 2 Duty cycle of the unit has been 2 Allow unit to cool exceeded 3 Failed components in unit Return to authorized service center for repair or replacement 1 Gas supply not connected to Connect gas supply to unit unit 2 Gas supply not turned ON Turn gas supply ON 3 Gas supply pressure too low Set air supply inlet pressure to unit to 120 psi 4 AIR PRESSURE CONTROL Adjust regulator to set air pressure see section 4 02 regulator set too low 5 Failed components in unit Return to authorized service center for repair or replacement 1 Shield Cup loose Hand tighten the shield cup until it is snug 2 Torch not properly connected to 2 Insure torch ATC is securely fastened to unit power supply 3 Problem in torch and leads PIP Replace torch and leads or return to authorized service center circuit or repair or replacement 4 Failed components in unit 4 Return to authorized service center for repair or replacement 1 Start signal is active when ON Start can be active for one of the following indicators flashing OFF SWITCH is turned to ON e Hand torch switch held closed position Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Problem in the torch and leads 2 Replace torch and leads o
139. s 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 Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator w turns ON Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cooling fans turn ON 4 2 OPERATION NOTE Minimum pressure for power supply operation is lower than minimum for torch operation The cooling fans will turn ON as soon as the unit is turned ON After the unit is idle for ten 10 minutes the fans will turn OFF The fans Will come back ON as soon as the torch switch Start Signal is activated or if the unit is turned OFF then turned ON again If an over tempera ture condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period once the condition is cleared Set Operating Pressure 1 Place the Power Supply Function Control knob to the SET position Gas will flow 2 For Standoff cutting adjust gas pressure from 70 85 psi 4 8 5 9 bar LED s
140. s personal injury and can damage equipment HANDLE is not for mechanical lifting NOTE There are two jumpers used for the single phase 230V setting and none for three phase Check the setting of the input voltage selection switch at the rear of the unit before you plug it in Low is 208 230 VAC and high is 460 VAC Only persons of adequate physical strength should lift the unit e ift unit by the handles using two hands Do not use straps for lifting Use optional cart or similar device of ad equate capacity to move unit Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle Art A 08316 Manual 0 4988 INSTALLATION 3 1 CUTMASTER 152 p A Connections to Single Phase Input Power A WARNING ru pc REESE ERE Disconnect input power from the power sup ply 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 in structions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chas sis 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 sup ply 4 f the power cable being used is not the factory supplied cable u
141. s trade dress updated thank you text changed headers and footers changed logo on art on pages A 2 7 A 9 updated rear cover APPENDIX Manual 0 4988 This Page Intentionally Blank THE AMERICAS Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA Sales Office Latin America Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 465 6763 5812 VICTOR TECHNOLOGIES U S Customer Care 800 426 1888 FAX 800 535 0557 Canada Customer Care 905 827 4515 FAX 800 588 1714 International Customer Care 940 381 1212 FAX 940 483 8178 INNOVATION SHAPE THE WORLD O 2012 Vict
142. se a three con ductor input power cable for the voltage desired and strip back the insulation on the individual wires 5 Pass the cable being used through the ac cess opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION The primary power source and power cable must conform to local electrical code and the recom mended circuit protection and wiring require ments refer to table in Section 2 6 Connect the wires as follows e Connect Bus Bar Jumpers on the contac tor as shown in prior illustration and on label in the power supply e Green Yellow wire to Ground 8 Reinstall the Power Supply cover per in structions found in section 5 9 Connect the opposite end of individual wires to a customer supplied plug or main dis connect 10 Connect the input power cable or close the main disconnect switch to supply power INSTALLATION B Connections to Three Phase Input Power A WARNING ER c uu a grep p Disconnect input power from the power sup ply 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 in structions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chas sis ground connection 3 Loosen the through
143. si cord or disconnect input power Power is removed from Each additional Add 5 psi 25 7 6 m 0 4 bar Select Current Output Level 1 Place the Function Control Knob in one of the three operating positions available RUN RAPID AUTO RESTART Je cg or LATCH WI Gas flow stops 2 Set the output current to desired amperage with the Output Current Control Knob Cutting Operation When the torch leaves the workpiece during cutting opera tions with the Function Control Knob in the RUN position there is a brief delay in restarting the pilot arc With the knob in the RAPID AUTO RESTART position when the torch leaves the workpiece 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 trim ming operations when an uninterrupted restart is desired And with the knob in the LATCH position the main cutting arc will be maintained after the torch switch is released Manual 0 4988 OPERATION 4 3 CUTMASTER 152 This Page Intentionally Blank 4 4 OPERATION Manual 0 4988 CUTMASTER 152 SECTION 4 TORCH 2 Remove the Electrode by pulling it straight OPERATION out of the Torch Head a Torch Head 4T 01Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used Type of operation
144. sma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz e N utilisez pas le chalumeau au jet de plasma dans une zone se trouvent des mati res ou des gaz combustibles ou explosifs e ephosg 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 contient des produits chimiques notamment du plomb reconnu par l Etat de la Californie pour causer des malformations cong nitales et d autres dommages touchant le syst me reproductif
145. t du plomb reconnu par l Etat de la Californie pour causer des malformations cong nitales et d autres dommages touchant le syst me reproductif Se laver les mains apr s manipulation INFORMATIONS G N RALES Manuel 0 4988 N CUTMASTER 152 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE A LARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 787 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PRO TECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI 749 2 PR VENTION DES INCENDIE
146. t of this manual have been followed Make sure no part of the operator s body comes in con tract with the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power Supply A CAUTION Sparks from plasma gouging can cause damage to coated painted or other surfaces such as glass plastic and metal Check torch parts The torch parts must cor respond 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 be tween the torch and workpiece and the distance between the torch tip and workpiece standoff CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts Wear Torch Travel Speed NOTE Refer to Appendix Pages for additional infor mation as related to the Power Supply used Optimum torch travel speed is dependent on current set ting lead angle and mode of operation hand or machine torch Current Setting Current settings depend on torch travel speed mode of operation hand or machine torch and the amount of material to be removed 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 The angle between the torch and workpiece depends on the o
147. t 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 amp 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 Manual 0 4988 Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma
148. tallation NOTE When installing the upper screws attempt to reuse the original threads The easiest way to do this is by turning the screw counter clockwise until you feel the threads line up then begin to turn the screw clockwise to tighten to 15 18 Ibs Do not over tighten C Pre Power Up Tests Prior to applying primary line power to the unit perform the followin g checks to prevent component failure or blowing primary fuses The troubleshooting guide will assume these tests were done and no failure was found or that any failures found were corrected 1 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 11 E PCB 5 IGBT Test Section 5 11 F PCB 1 Output Diode Test Section 5 11 G PCB 5 Output Diode Test Section 5 11 H PCB 1 Pilot IGBT Test Section 5 11 1 N o A o m 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 PCB 2 and perform the following Pre Power Up Tests to determine which PCB s have failed 10 PCB 2 Capacitor Relay Test Section 5 11 J 11 PCB 1 Input Diode D1 Test Section 5 11 K 12 PCB 5 Input Diode D1 Test Section 5 11 L 13 PCB 1 IGBT Test Section 5 11 M 14 PCB 5 IGBT Test Section 5 11 N If all of the Pre Power Up Tests are OK proceed with the tr
149. tion on wires from J2 on Capacitor PCB to J3 on 50A PCB No 12VDC Bias Supply voltage from Capacitor PCB from J2 Loose unplugged connections on J12 on Main PCB J1 on Capacitor PCB Air flow does not momentarily turn OFF then back ON after the START signal is active 1 2 Defective start cartridge Torch O ring has moved into wrong groove Internal visual checks Loose unplugged connections on J12 on Main and J1 on Capacitor PCB 5 17 CUTMASTER 152 p If voltage does not go low replace Logic PCB 2 Loose unplugged connections on J2 on Main PCB and J1 on Logic PCB Loose unplugged connections on J2 on Capacitor PCB and J3 on 50A PCB Sync cable unplugged from Main PCB or 50A PCB Loose unplugged connection on J5 on Main PCB 50A PCB exclusion Disconnect J4 amp J9 connectors and remove wire from CHOKE1 terminal Measure Capacitor PCB bias supply between J21 to J2 2 for 12VDC If 50A PCB is at fault the unit will function but with reduced output current Perform Pre power up checks 1 2 w1 Open Input Diode Input rectifier 01 on Main PCB 50A PCB Shorted Open IGBTs Output Diodes On both Main PCB and 50A PCB Torch parts Power checks 1 Low input voltage or missing phase a Measure voltage under load Defective W1 contactor a Measure output of W1 under load Shorted Sync cable Open connection between J2 on Capacitor PCB to J3 on 50A PCB Defective Logic P
150. to be sure there is no physical obstructions preventing fan blades from turning Replace respective fan J Fans MOT 2 amp MOT 3 do not turn ON after START signal is activated 1 Open connection between Main 1 J13 to 50A PCB 5 J4 Verify connectors are plugged in Check continuity b Measure voltage at J4 2 to J4 10 on 50AMP PCB 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 2 Defective 50AMP PCB 5 a Measure the voltage between J1 1 to J1 2 on the 50AMP PCB 5 for 12VDC after the START signal is activated If 12VDC is present replace 50AMP PCB 5 3 Defective Fans MOT 2 and 3 If 12VDC is present J1 and J2 connectors on 50A PCB 5 replace fans MOT 2 amp MOT 3 SERVICE 5 19 CUTMASTER 152 p 5 09 Main Arc and Controls Problems A Main arc will not establish LED D59 on Main PCB remains ON while pilot arc is striking the work piece 1 Work Cable not connected a Connect cable to work piece 2 Work cable open broken a Check continuity of work cable Insure connection of cable to clamp is secure B Main arc transfers if the tip is on the work piece but extinguishes and Pilot Arc restarts if torch tip is lifted off the work piece 1 Defective 50 PCB5 a Disconnect J13 and J14 from Main PCB1 If the main
151. ts Manual and Mechanized Torch Gas Specifications Gas Plasma and Secondary Compressed Air Operating Pressure 60 95 psi Power Refer to NOTE 4 1 6 5 bar Supply A Maximum Input Pressure 125 psi 8 6 bar e Gas Flow Cutting and 300 500 scfh Gouging 142 235 lpm Workpiece WARNING A 00002 This torch is not to be used with oxygen 0 Typical Torch Head Detail NOTE Operating pressure varies with torch model op By forcing the plasma gas and electric arc through a small erating amperage and torch leads length Refer orifice the torch delivers a high concentration of heat to a to gas pressure settings charts for each model small area The stiff constricted plasma arc is shown in H Direct Contact Hazard Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration For standoff tip the recommended standoff is 3 16 inches 147 mm Zone A channels secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing 2T 040ptions And Accessories the molten metal out of the cut allowing for a fast slag free cut For options and accessories see section 6 B Gas Distribution The single gas used is internally split into plasma and secondary gases 212 INTRODUCTION Manual 0 4988 Manual 0 4988 N CUTMASTER 152 The plasma gas flows into the torch through th
152. 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 04 D 10 11 12 13 14 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 Transformer 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 14 PARTS REPLACEMENT Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 F Disconnect Output Inductor wires from Choke1 termi nal 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 the Front and Rear panel from the base per section 7 04 D Carefully guide the Center Chassis towards the center of the baseto disenga
153. utput current setting and torch travel speed The recommended lead angle is 35 At a 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 passes In some applications such as removing welds or working with light metal this may be desirable 2 359 2 Standoff Height Workpiece Torch Head 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 dis tances 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 Slag generated by gouging on materials such as carbon 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 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 4T 7 CUTMASTER 152 p 4T 06Mechanized Torch Operation Cutting With Mechanized
154. utting 2 Function Control Function Control Knob Used to select between the different operating modes SET a Used to purge the air through the unit and torch and leads and to adjust gas pressure RUN Used for general cutting operations RAPID AUTO RESTART oo ao Allows for faster re starting of the Pilot Arc for uninterrupted cutting LATCH E 8 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 mm 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 operation 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 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
155. vate current drops to 60 amps For Automation Torches e 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 approximately 1 4 6 mm Tip Saver circuit deactivates current goes back to 120 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 e Gas flow stops momentarily then restarts when solenoid opens e Pilot arc ignites 7 Open the torch switch e DC LED turns OFF After 20 second post flow time e Gas solenoid closes e Gas flow stops 8 Setthe 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 3 9 mm 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 e Pilot Arc re ignites immediately SERVICE 5 9 CUTMASTER 152 11 Open the torch switch DCLED turns OFF After 20 second post flow time e Gas solenoid closes Gas flow stops For Automation Torches Skip steps 12 amp 13 12 Setthe FUNCTION CONTROL SWITCH to LATCH mode 13 Starta cut and remove the START signal Main cutting arc will remain ON until the torch is lifted away from the plate approximat
156. wer Supply will continue to oper ate but cut quality may become unacceptable Refer to Section 6 Parts List for replacement filter element catalog number 1 Shut OFF primary input power 2 Shut OFF air supply and bleed down system A WARNING lm a M Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely ments Slide out the old Filter Elements First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement Note the location and orientation of the old Filter Ele PARTS REPLACEMENT Manual 0 4988 N CUTMASTER 152 7 08 Right Side Internal Parts Replacement A Capacitor PCB PCB 2 Replacement Tools required T20 Torx Driver 32 Phillips Head Driver 1 2 3 Remove the Cover per subsection 7 04 A Disconnect J1 amp J2 from PCB 2 Note the location and remove all wires connected to PCB 2 Remove the fifteen 15 screws securing PCB 2 to the Main PCB and 40AMP PCB Install the replacement PCB by reversing the above steps B Main PCB PCB 1 Replacement Tools required T20 Torx Driver 1 Manual 0 4988 Remove the Cover per subsection 7 04 A 2 Remove Capacitor PCB per subsection 7 08 A 3 Remove the two large gas hoses per subs
157. ycles ON and OFF 1 Torch Shield Cup is loose a Tighten shield cup by hand Do not over tighten Torch tip electrode or start cartridge missing a Turn OFF power supply Replace missing part s 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 Spring Loaded Lower End Fitting at Reset Full Extension Art A 08064 AC 4 Open conductor in torch leads Manual 0 4988 Check continuity 5 6 Defective Main PCB 1 b Measure voltage between J2 2 connector on Main PCB 1 to test point GND1 for 12VDC If voltage is present replace Main PCB 1 Defective Logic PCB 3 a Replace Logic PCB 3 AC LED ON yellow TEMP LED is ON red 2 3 SERVICE FAULT Indicator is flashing all three fans turn ON 1 Air flow through unit is restricted a Provide adequate airflow See Ventilation Clearance Requirements section 2 04 Exceeded duty cycle of the power supply a Allowunitto remain ON butat idle with fan running to cool power supply See Power Supply Specifications section 2 04 for duty cycle information NOTE When the unit is turned ON the cooling fans MOT 1 3 will remain OFF In earlier units MOT 1 will turn ON
158. zed Repair Facility 2 Contact Controller manufacturer 3 Return to authorized service center for repair or replacement 1 Upper O Ring on torch head is inf Remove shield cup from torch check upper O Ring position wrong position 2 Torch start cartridge is stuck 3 Worn or faulty torch parts 4 Shorted Torch correct if necessary 2 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 3 Inspect torch consumable parts Replace if necessary 4 Replace torch and leads or return to an authorized service center for repair 1 Low output voltage during pilot 1 Check torch consumable parts for wear or foreign debris 2 Low output voltage during cut 2 Check torch consumable parts for wear or foreign debris 3 For Automation Torch only Tip 9 Cut with Tip OFF the plate contacted work piece during cut with output correct set above 45 amps For these modes to reset the machine remove the START signal No Fault lights ON Failed components in unit 1 Return to an authorized service center for repair arc in torch FAULT and 90 PSI indicators flashing 1 Internal Error 1 Work cable not connected to Work piece 2 Work cable connector broken 3 Failed components in unit 1 Incorrect current setting 2 Worn torch consumables 3 Poor wor

Service Manual - Victor Technologies

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