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40mm CUTMASTER™ Service Manual

1. 6 1 6 01 sss 6 1 6 02 Ordering Informations rera 6 1 6 03 Power Supply Replacement 6 1 6 04 Major External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement 6 4 6 07 Right Side Replacement Parts 2 2 4002200 0 0 0 6 5 6 08 Options 6 6 6 09 Replacement Parts for Hand Torch 6 7 6 10 Replacement Parts for Machine Torches with Unshielded Leads 6 8 6 11 Replacement Shielded Machine Torch Leads Assemblies 6 10 6 12 Torch Consumable Parts SL100 SV 6 11 SECTION 7 REPLACEMENT PROCEDURES iii 7 1 7 01 Ies 7 1 7 02 Anti Static Handling 7 1 7 03 Parts Replacement General Information 7 1 7 04 Major External ocio petentes oer nn netu ud e 7 2 7 05 Front Panel Parts Replacement 7 3 7 06 Left Side Internal Parts Replacement
2. 7 4 7 07 Rear Panel Parts 7 6 7 08 Right Side Internal Parts 7 8 APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4 APPENDIX 5 APPENDIX 6 TABLE OF CONTENTS SEQUENCE OF OPERATION BLOCK A 1 DATA TAG INFORMATION niteretur e ta cn A 2 TORCH PIN OUT 5 eene A 3 TORCH CONNECTION DIAGRAMS iii A 4 SYSTEM SCHEMATIC 380 415V A 6 PUBLICATION HISTORY A 8 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Rear Cover This Page Intentionally Blank 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 informa tion which requires additional emphasis or is help ful in efficient operation of the system A CAUTION A procedure which if not properly followed may cause damage to the equipment WARNING A procedure which if not properly followed may cause injury to the operator or others in the op erating area A WARNING Gives information re
3. 3 1 3 01 Et 3 1 3 02 Lifting eee 3 1 3 03 Primary Input Power Connections 3 1 8 04 Gas CONNeCtiOns eee son ten 3 2 SECTION 3 TORCH 6226 Pelea aa ra ei re d tdt 3T 1 3101 Torch Connections ecce crea Prid eig a cerei 3T 1 02 Setting Up Mechanical enne 3T 1 SECTION 4 SYSTEM OPERATION ecc 4 1 4 01 Front Panel Controls Features 4 1 4 02 Preparations for 4 2 5 cxi rada da n dad 4 1 4 01 Torch Parts Selection 4 1 41 02 Cut Quialily 4T 2 4T 03 General Cutting Information 4T 2 41 04 Hand Torch Op rations nnne ia denses 4T 3 4T 05 0 4T 7 4T 06 Mechanized Torch Operation 4T 8 4T 07 Parts Selection for SL100 Torch 4T 9 4T 08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip AT 10 4T 09 Recommended Cutting Speeds for SL100 To
4. mm m R70 R64 L di 4125 10 40AMP PCB 5 LAYOUT 5 34 OUT_1 SEC2 PMTH3 PRI3 J9 Art A 08506 Manual 0 5085 CUTMASTER 40MM A 40AMP PCB 5 SIGNALS 12 FAN 2 1 12VDC Supply for Fan MOT 2 Active Low to enable Fan MOT 2 Supply for Fan MOT 3 J2 2 FAN Active Low to enable Fan MOT 3 Signal Source Destination J3 1 12VDC 12VDC Supply C 40A J3 2 Common 12VDC Return C 40A J4 4 OVERTEMP Active Low signal when OVERTEMP 40 14 5 FAN_ON Active Low to enable Fans M 40A J4 6 CSR Active low to Enable PWM M 40A J4 7 CUR_SET 1 2 4VDC Cut Current Demand M 40A J4 8 MAIN_PCB_ID 0 Ohms to common 40A M J4 9 Not Used J4 10 Common 40A M B TEST POINTS 80 _ 1 AC Input Phase 1 80A AC2 AC Input Phase 2 80A AC3 AC Input Phase 3 40A ACT AC Input Phase 1 40A A
5. Art A 07886 5678 910 Temp Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Let the unit cool before continuing operation Gas Indicator Indicator is ON when minimum input gas pressure for power supply operation is present Minimum pressure for power supply operation is not sufficient for torch operation DC Indicator Indicator is ON when DC output circuit is active Fault Error Indicator Indicator is ON when Fault circuit is active See sec tion 5 for explanations of fault lights 10 Pressure Indicators Art A 08170 The Indicators will illuminate according to the pressure set by the Pressure Control Knob number 4 OPERATION CUTMASTER 40mm 4 02 Preparations for Operation At the start of each operating session A WARNING E Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies Torch Parts Selection Check the torch for proper assembly and appropri ate torch parts The torch parts must correspond with the type of operation and 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 Thermal Dynamics model SL100 Manual or SL100 Mechanical Torches may be connected to this Power Supply
6. i Not Connected Art A 07115 Manual 0 5085 A 5 APPENDIX CUTMASTER 40MM APPENDIX 5 YSTEM HEMATI 415V UNIT PRIS 1 2 BIAS 3 SUPPLY 5 PRI2 INRUSH A EN RESISTORS PRI pua at tem INRUSH Havoc D1 BIAS SUPPLY 08040708 E UNITS ONLY pour EM FILTER wi mon Aet dv Lo 1 ac2_ ace 12 2 2 9 T 1 acs acs L3 4s lt GND 380 400 415V OR 600V 3 PH AC INPUT PRIMARY POWER CONNECTIONS USE LI 2 13 amp GND 1 2 IFAN Em 05 08 09 010 5 1 gt 2 3 SOLENOID g 1 2 24VAC RET LI sync 1 3avoc sera port 2 E Ro 3 RXD JOVERTEMP 4 5 2 ON 3 icsR 4 CUR SET 57 5 MAN PCB D PCB1 MANPCBASSY COMMON FERRITE FILTER mee 1 2 PRIT D PRIS a 1 m sc 4 soa act S 2 C Ac2 2 Aci Aca x pi PCB2 INPUT CAPACITOR PCB
7. mo 00 oss o s ws was s avo psa sun vo 0 10s seo fur H N OPERATION 4T 18 Manual 0 5085 CUTMASTER 40mm mR 0 20 0 50 1 00 5 2 19 19 19 19 i6 19 19 iG 10 i0 Type Material Stainless Steel Type Secondary Gas Single Gas Torch Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Type Secondary Gas Single Gas Torch 75 Type Secondary Gas Single Gas Torch 070 3 05 LE 020 y meis TES Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Type Plasma Gas Air Type Plasma Gas Air Tip Tip Type Torch SL100 With Shielded Tip Type Plasma Gas Air Tip Type Torch SL100 With Shielded Tip Type Material Aluminum m o 2 o kK o E o o 5 I o ES rm OPERATION NOTES 4T 19 Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads refer to section 4 02 Operating P
8. 5 esz 128 100 oss 79 se WW 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 Flow Pierce Height n2 Amps Inches Inches mm Plasma Total Inches m 0190 2 oms s 0 0 1 131 40 D N 0 0 n2 D N 1 0 s212 iw 100 25 065 0225 5 2 N Manual 0 5085 4T 13 OPERATION CUTMASTER 40mm Type Material Mild Stee Thickness Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height nche nch bar Plasma Inches mm 150 38 o 360 o 0 360 875222 9805 160 120 25 100 98288 164 120 20 ost i n s s e a co gt 5 co pA co pA k pA N T 6 0
9. C10 may not be installed PMTH4 09130 PCBS 4050 amp PRIA PRIA APPENDIX Manual 0 5085 CUTMASTER 40MM I z I x 1TORCH SWITCH n TORCH SWITCH 5 5 2 CHOKE ATC CONNECTOR 1 1 TEMP 2 2 AE 2 2 TORCH SOLENOID 3 3 A 5 5 7 7 8 8 H 7 lt K ELECTRO i E35 T m g
10. 120 so ossa 45 s oo 025 20 120 jonas 10 e0 om 7 025 e8211 120 025 64 65 aso 120 0 100 T ossos oem 125 a0 so 127 oss ws 2 2 143 80 2 5 san Secondary Gas Single Gas Torch Thickness Amperage Speed Per Minute Standoff 120 so 360 30 9821 124 300 762 0 25 88 48 98211 14 180 6 64 98211 128 95 98211 136 55 140 025 890 80 80 1 4s we 4 4 3 ost oss 4 4 m as 240 wm ws s om as ns ao wn Slo 5 L iem Cas os 025 os 025 oa a 10 oss 025 Lois 5 4 12 Manual 0 5085 CUTMASTER 40mm Speed Per Minute Standoff Flow CFH Pierce Heig Plasma nches m 8 0 0 6 8 0 4 gt ela 2 Thickness Speed Per Minute Standoff Flow Pierce Pierce Height ne we so 230 75 seme 71 we ws 040 10 nR
11. 6 co 5 5 6 k k e o A Speed Per Minute Standoff Plasma Gas Press Flow Pierce Pierce Height 180 025 6 100 025 0500 127 98258 120 60 152 019 360 025 6 26 06 025 1250318 593 10 1 9 023 025 Standoff Plasma Gas Press Flow CFH Pierce Pierce Height 025 6 360 025 64 5 028 7 025 NOTES Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 leads refer to section 4 02 Operating Pressure Total flow rate includes plasma and secondary gas flow OPERATION 4T 14 Manual 0 5085 CUTMASTER 40mm 4T 09Recommended Cutting Speeds for 51100 Torch With Shielded fooss 40 432 or fas es 4s ss ooo 54 946 1 5 120 40 220 ore es 45 ss vo 51 121 40 203 ose es 4s vo 54 12 40 75 ose e es 45 ss o 040 02 54 esae 123 40 ore es 4s 55 vo oe 02 51 foa7s as 1 11 028 or es 45 55 vo NR NR 1e 7 o or es 45 vo N
12. pst Pilot A 03701 2 ct t 2 B Mechanized Machine Torch Pin Out Diagram ATC Male Connector MACHINE TORCH ATC Female Receptacle Front View Front View Negative Plasma ive Plasma 8 Green Fez 4 Switch Far 3 Whit Pendant 4 Of e ill 3 Switch Connec tor 3 2 4 2 PIP 1 PIP N 5 DES Art 08576 C Automation Machine Torch Pin Out Diagram ATC Male Connector ATC Female Receptacle Front View ZA n Negative Plasma noe 5 45 Torch Solenoid 108 cnm 1 Black Sa PIP B Pilot Solenoid Pilot Solenoid 2 Orange D 7 6 Open eben 25 JON PIP 2 Circuit Manual 0 5085 A 3 APPENDIX CUTMASTER 40MM 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 Power Supply white Circuitry
13. Return to authorized service center for repair or replacement Hand tighten the shield cup until it is snug Insure torch ATC is securely fastened to unit Replace torch and leads or return to authorized service center or repair or replacement 4 Return to authorized service center for repair or replacement 1 Start can be active for one of the following Hand torch switch held closed Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Replace torch and leads or return to authorized service center or repair or replacement 3 Return to authorized service center for repair or replacement 5 6 Manual 0 5085 CUTMASTER 40MM roblem Symptom Possible Cause Recommended Action Nothing happens when torch switch 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 FAULT and 90 PSI indicators flashing Manual 0 5085 1 Torch shield cup is loose 1 Tighten shield cup by hand Do not overtighten 2 Torch tip electrode or start 2 Turn OFF power supply Remove shield cup Install missing cartridge missing parts 3 Torch start cartridge is stuck 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
14. 1 1 1 01 Notes Cautions and Warnings ss 1 1 1 02 Important Safety Precautions 0 2 000000 1 1 1 03 Publications rios 1 2 1 04 Note Attention et Avertissement 1 3 1 05 Precautions De Securite Importantes 1 3 1 06 Documents De Reference ss 1 5 1 07 Declaration of 1 6 1 08 Statement of Warranty sienne 1 7 SECTION 2 SYSTEM INTRODUCTION 4 2 2 1 2 01 How To Use This 2 1 2 02 Equipment IderntiflCatlon cuire peto Ceu ea Fa oe a xo lane 2 1 2 03 Receipt O ceti ciue ite th teca etd ute 2 1 2 04 Power Supply 2 2 2 05 Input Wiring Sp cifications rene ee 2 3 2 06 Power Supply Features su 2 4 SECTION 2 TORCH INTRODUCTION nnne rrr nennen nennen nnns 2T 1 21 01 Scope of Manual retra etre e odes eite o ee 2T 1 21 02 General Description eit rnit kac 2T 1 2T 03 Specifications iii 2T 1 2T 04 Options And Accessories 2T 2 2T 05 Introduction to Plasma 2T 2 SECTIONS SYSTEM INSTALLATION
15. 1 14 24 MDC 25 COMMON 28 COMMON 29 ID ML 34 ML 35 LM 37 ML COMMON LM 2 00 n SECT CHOKE v ERRORIND FAULT ac OVER PRESSURE 90 INTERNAL ERROR a5 SHORTED TORCH A overtemp 59 CONSUMABLES MISSING 90 START ERROR 7 PARTS IN PLACE A 55 INPUT POWER Gas MIN UNDER PRESSURE c TEST POINTS Tei GND 7 2 5 VDC T ERROR TPA 33VDC 75 GAS CONTROL TPS 0v 50VDC O t00PSI 18VDC Y GURRENT DEMAND Sr REGULATOR Lec SOLENOID Current Control 47 VANE dif Love 2 NLET LATCH RUN asus RAR A T 09 81 0 5 0 2 1 PCB3 Locic Pca SF Rav Revisions INTRO ECO 81357 055109 LIYNAMICS AB Eco B1399 RWH 05 05 09 Mem AB Bier 050505 Company 81908408 01718 Date information Proprietary to THERMAL DYNAMICS CORPORATION MARCH 30 2009 Not For Release Reproduction or Distribution without Written Consent E Unless Otherwise Specified Resistors are In Ohms 1 4W 5 RAWH Capacitors are in Microfarads UF TITLE SCHEMATIC Size DWG No 70219 CM102 152 35mm 40mm A80 A120 380 400 415 6 02 42X1330 I I T Manual 0 5085 A 7 APPENDIX CUTMASTER 4
16. 2 3 If the test reveals a failed component replace removed form unit Main PCB 1 If no problem is found reconnect wire to Main PCB 1 Usinganohmmeter perform the following checks J PCB 2 Capacitor Relay Test with PCB 2 input Diere Mecuie DiI GI 20805 removed from the unit Test points are located on PCB 5 1 Using an ohmmeter perform the following checks Pm Forward Blased Diode PCB 2 Capacitor amp Relay Test AC2 Forward Biased Diode MTH 4 Charging PMTH 1 Reverse Biased Diode MTH 7 Charging PMTH 1 Reverse Biased Diode MTH 4 Open PMTH 1 Reverse Biased Diode MTH 2 Open PMTH 4 Forward Biased Diode MTH 4 Open PMTH 4 Forward Biased Diode Most meters will show a charging action Initially a PMTH 4 Forward Biased Diode low resistance will be shown and then the resistance AC1 Reverse Biased Diode will start to increase If the meter probes are reversed AC2 the reading will decrease to zero then start charging in the opposite polarity Reverse Biased Diode AC3 Reverse Biased Diode PMTH 4 2 Forward Biased Diodes 2 Iftest reveals a failed component replace Capaci tor PCB 2 2 Ifthe test reveals a failed component replace 40A PCB 5 Manual 0 5085 5 23 SERVICE CUTMASTER 40MM 1 Test With 2 removed from unit 1 Using ohmmeter perform the following checks PCB 1 01 Test points located veero on PCB 1 Forward Biased Diode Reverse Biased Diode Revers
17. Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C 3 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 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 two screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Manual 0 5085 10 11 12 13 14 CUTMASTER 40mm Disengage the Front and Rear panel 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 Trans former to the base Remove the Main Transformer carefully guiding all its wires through from the right side of the unit Install replacement Transformer by reversing the above steps Reinstall the power supply cover D Output Inductor L1 Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Remove the two large and one small gas hoses per subsection 7 05 C 3 Remove the Gas Solenoid per subsection 7 05 F 10 11 12 13 14 Disconnect Ou
18. Effective Supply Current Input Power Specifications Phase AC or DC Hertz Rating Manufacturer s Electrical Schematic File Number NO 1 2 APPEN Rated Supply Voltage Note 2 Degree of Protection TES 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 DIX A 2 and Revision Level Standard Symbols AC DC 0 Phase Art A 03288 Manual 0 5085 CUTMASTER 40MM APPENDIX 3 TORCH PIN OUT DIAGRAM A Hand Torch Pin Out Diagram 4 Green 8 Open 8 Ground Switch 7 c Ne 7 Open 7 Open il SUC SIE score 15 2011 7 NS 49 1 aye 5 Open 5 Open SSS 1 PIP ERN 3 White Switch 3 gt 252 A Ko OS 6 Open y
19. OPERATION 4 4 Manual 0 5085 SECTION 4 TORCH OPERATION 4T 01Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used Type of operation Drag cutting standoff cutting or gouging Torch parts Shield Cup Cutting Tip Electrode and Starter Cartridge NOTE Refer to Section 4T 07 and following for ad ditional information on torch parts Change the torch parts for a different operation as follows A WARNING a Disconnect primary power at the source before assembling or disassembling torch parts or torch and leads assemblies NOTE The shield cup holds the tip and starter car tridge in place Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup assem bly from the torch head Manual 0 5085 CUTMASTER 40mm 2 Remove the Electrode by pulling it straight out of the Torch Head Torch Head Electrode Start Cartridge Shield Cup A 03510_AB Torch Parts Drag Shield Cap amp Shield Cup Body Shown 3 Install the replacement Electrode by push ing it straight into the torch head until it clicks 4 Install the starter cartridge and desired tip for the operation into the torch head 5 Hand tighten the shield cup assembly until it is seated on the torch head If resistance is felt when installing the cup check the threads before proce
20. Standoff Guide Torch Tip N 7 Workpiece Art A 04034 Manual 0 5085 Shield Cup With Straight Edge The drag shield cup can be used with anon conduc tive straight edge to make straight cuts by hand WARNING The straight edge must be non conductive Non Conductive Straight Edge Cutting Guide A 03539 Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less NOTE 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 tion 1 Install the drag cutting tip and set the out put current 2 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the holding technique that feels most comfort able and allows good control and move ment Manual 0 5085 AT 5 CUTMASTER 40mm 4 Keep the torch in contact with the work piece during the cutting cycle Hold the torch away from your body 6 Slide the trigger release toward the back of the torch handle while simul
21. 0154 46 1 J3 D11 D13 J1 Pinout Art 08504 LOGIC PCB 3 LAYOUT A LOGIC PCB 3 SIGNALS n J3 1 J3 2 J3 3 SERVICE Signal info is the same as MAIN PCB1 J2 connector 5VDC Pressure Transducer output 0 5 to 5 VDC 0 100 psi Common 5 32 Manual 0 5085 CUTMASTER 40MM B 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 D4 85 PSI X 5 Shorted torch Output Fault D5 80 PSI XA Tip Missing D6 75 PSI X 3 Start Signal active during power up D7 70 PSI X 2 Parts In Place Fault PIP D8 65 PSI X 1 Input Power Fault D9 MIN PRESSURE X 0 Low Pressure D10 AC 1 D11 OVERTEMP 2 X D12 GAS 3 X D13 DC 4 X D14 ERROR 5 X C LOGIC PCB 3 TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV TP5 0 5 105 VDC 0 100 psi TP6 1 8VDC TP7 Potentiometer Current Demand 0 3 3V Manual 0 5085 5 33 SERVICE CUTMASTER 40MM 5 15 40AMP Logic PCB Layout amp Signals PMTH4 AC2 AC3 2 SERVICE B m m m NET TAMEN M mi TP MNT Ji J2 J3 J4 J5 e J5 93 44 Ji mm mm wm 37 um
22. 6 as ws 0 ve so faz e as ws 020 0 va s 25 sz 6 as ws 0 eo or fas 4s vs 96 025 64 os ore fas 4s vs oe 025 os fas s 4s ns 075 138 141 142 0625 155 27 10 s te 019 ae es 4s vs 20 wR u ua roars 222 1 so e oo or es s ns se ne ne WM Fem so e ois or aa as u nn OPERATION 4 17 Manual 0 5085 CUTMASTER 40mm fo af os o a os o fo os 125 100 amp 150 oss as 75 sz too sw os 1920051 osofia osea 1 ww ss 75 s2 130 sm 029 511 ose 144 100 1s oo as 75 sz too nr wmm ws o sa ssme wo s zs 52 sos ws ws Type Torch SL100 With Shielded Tip Type Material Aluminum I Plasma Gas Air Type Secondary Gas Single Gas Torch Per Minute Standoff Plasma Gas Press Flow CFH Pierce Height wo sere cm s 5 ws ser we es vs es 45 se meer om pe vs es we 05 m m vs 48 ww Jaze
23. LA RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement e Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure e Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommen dation qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e Courant Are Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 INFORMATIONS G N RALES 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
24. Pilot Arc Test There are three types of START signals which can be used to begin system operation 1 Hand Torch Operator switch mounted on the torch handle 2 Machine torch or Automation torch A Hand held pendant switch B CNC cable interfaced to controller 1 Provide a START signal to establish a pilot arc and note the following Cooling fans MOT 1 3 turn ON Gas solenoid opens Gas flows e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing DC LED comes e Pilot arc is established 2 Remove the START signal and not the follow ing Gas continues to flow DCLED goes OFF After 20 second post flow time Gas solenoid closes Gas flow stops This completes the Pilot Arc Test If the above are all correct then proceed to the next section G Main Arc and Controls Test If the unit does not function as stated above then note the symptom and proceed to Section 5 08 Pilot Arc Problems G Main Arc and Controls Test Connect work Cable to the work piece provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc Main Cutting Arc Establishes On PCB 1 D59 turns OFF and D78 turns ON 1 Clamp DC ammeter around the work cable Out put will be 120 amps SERVICE 2 While cutting adjust the CURRENT CONTROL POTENTIOMETER from maxi
25. Remove jumper from the CNC connector OK TO MOVE signal OFF Meter shows continuity Gas continues to flow DC LED goes OFF After 20 second Post flow time Gas solenoid closes Gas flow stops If the unit has the Basic CNC Interface harness the test is 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 There are three 3 ARC VOLTS signals available from the J1 connector a J1 9 to J2 7 b 2 5 to J2 6 Auto Interface PCB 4 con nector P1 with no jumper installed ARC VOLIS divided by 16 67 c J2 5 to J2 6 Auto Interface PCB 4 con nector P1 with jumper installed between pins 1 and 2 ARC VOLTS divided by 30 J2 5 to J2 6 Auto Interface PCB 4 con nector P1 with jumper installed between pins 2 and 3 ARC VOLTS divided by 50 d wa Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximately as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 18 VDC 6 VDC c 10 VDC 3 3 VDC d 6 VDC 2 VDC This completes the CNC Interface Test If the above are all correct then the unit is functioning correctly If the unit does not function as stated then note the symptom and proceed to Section 5 10 CNC Interface
26. Using anohmmeter check continuity between the following points PCB 1 Q2 Test points located on PCB 1 amp PCB 2 Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias 5 22 PCB 5 IGBT Test 1 Disconnect transformer wires from 40 Amp 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 Metro PRI 1 1 PRI 1 PMTH 2 1 PRI 1 2 PRI 1 PRI 2 PMTH 1 PRI 2 PMTH 2 PMTH 1 PRI 2 PMTH 2 PRI 2 Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias 3 Disconnect transformer wire from 40 Amp PCB 5 terminal PRIA 4 Using ohmmeter perform the following checks PCB 5 02 Test points located on PCB 2 AND PCB 5 PRI 4 PMTH 3 PRI 4 PMTH 4 PMTH 3 PRI 4 PMTH 4 PRI 4 PRI 3 PMTH 3 PRI 3 PMTH 4 PMTH 3 PRI 3 PMTH 4 PRI 3 Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias G PCB 1 Output Diode D3 Test 1 Disconnect transformer wires from Main PCB 1 terminal SEC1 2 Using an ohmmeter perform the following checks PGB 1 D3 Test points located on PCB 1 amp PCB 2 CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 SEC1 CHOKE1
27. de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz e N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs e phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e e produit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq 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 touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage 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 1 3 INF
28. work ft D Main Cutting Arc DC power is also used for the main cutting arc The To ATC a Shield Qup negative output is connected to the torch electrode 9 through the torch lead The positive output is con lt nected to the workpiece via the work cable and to the torch through a pilot wire CNC Start To ATC PIP Switch Shield Cup 4 i Art A 08168 Automation Torch PIP Switch Shield Cup P Parts In Place Circuit Diagram for Machine Torch Manual 0 5085 2T 3 INTRODUCTION CUTMASTER 40mm This Page Intentionally Blank INTRODUCTION 2T 4 Manual 0 5085 SECTION 3 SYSTEM INSTALLATION 3 01 Unpacking 1 Use the packing lists to identify and ac count for each item 2 Inspect each item for possible shipping damage If damage is evident contact your distributor and or shipping company before proceeding with the installation 3 Record Power Supply and Torch model and serial numbers purchase date and ven dor name in the information block at the front of this manual 3 02 Lifting Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNING Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate p
29. 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the power supply Address all inquiries to your authorized distributor 6 03 Power Supply Replacement The following items are included with the replacement power supply work cable amp clamp input power cable gas pressure regulator filter and operating manual Description log 1 CutMaster 40mm CE Power Supply with 380 400 415VAC 3 phase input power cable 3 1930 3 1 CutMaster 40mm Non CE Power Supply with 380 400 415VAC 3 phase input power cable 3 1930 4 Manual 0 5085 6 1 PARTS LIST CUTMASTER 40mm 6 04 Major External Replacement Parts Item Description log 1 1 Cover with labels 9 0224 2 1 Base Enclosure Assembly 9 0186 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0230 5 1 Rear Panel 9 0101 Art 08564 NOTE Illustration may vary slightly from unit PARTS LIST 6 2 Manual 0 5085 CUTMASTER 40mm 6 05 Front Panel Replacement Parts Item Description Ref log 1 1 Output Current Control and Function Control Knobs 9 8527 2 1 Toggle On Off Switch SW1 9 0109 3 1 Work Cable with Clamp 20 Ft 6 1 m 9 0189 Not Shown 1 Wire harness from SW1 w EMI Choke CE Power Supplies Only 9 0247 Illustration may vary slightly from unit Manual 0 5085 6 3 PARTS LI
30. 1 between J5 1 to J5 3 for 12 VDC If voltage is present change SOL 1 2 Defective Logic PCB 3 a Measure on Main PCB between J2 12 to test point GND1 12 If voltage is present replace Logic PCB 3 3 Defective Main PCB 1 a Replace Main PCB 1 SERVICE CUTMASTER 40MM If gas DOES flow out of SOL1 when the unit is in SET mode reconnect SOL1 to the ATC connector 4 Defective torch solenoid a Measure the coil terminals of the torch mount ed gas solenoid SOL2 for 24VAC If present replace SOL2 5 Defective Main PCB 1 a Measure on Main PCB 1 between J2 20 to 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 GNDI 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 changes but display does not 3 Faulty Logic PCB 3 a Measure on Logic PCB 3 for 12 VDC between 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 c
31. 400 VAC Voltage level to identify Main PCB 1 1VDC 5 27 M L M L M L L M M L M L M L L M M L M L SERVICE CUTMASTER 40MM J3 1 J3 2 J4 2 4 3 J4 4 74 5 J5 1 5 2 5 3 J6 1 J6 2 J7 1 J7 2 J8 J9 1 9 2 J9 3 9 4 9 5 J9 6 J9 7 J10 1 J10 2 J10 3 J10 4 J10 5 J10 6 J10 7 J10 8 J12 1 J12 2 J12 3 N A Common 3 3VDC TXD RXD Common D 12VDC Not used SOLENOID 24VAC Supply for W1 24VAC Return 12VDC FAN Not Used PIP Common TORCH SWITCH START Common Automation Torch solenoid 24VAC supply Not Used Automation Torch solenoid 24VAC return OK TO MOVE Not used OK TO MOVE Not used Common Common 12VDC START Remote Pendant CNC Signal N A 12VDC 400VAC N AC SERVICE J13 1 J13 2 ON J13 3 5 J13 4 SET J13 5 MAIN ID J13 6 Common B MAIN PCB 1 LED INDICATORS D59 PCRIndicates Pilot IGBT gate signal is ON D78 CSR Indicates cutting arc has been established C MAIN PCB 1 TEST POINTS 12V1 12V2 48V1 48V2 AC2 AC3 ELECTRODE1 GND1 GND2 I DMD1 PRI 1 A PRI 2 B PRI 3 D PRI 4 C SECI SEC2 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TIP1 V_OUT1 WORK1 5 28 12VDC 12VDC 48VDC 48VDC AC Input AC Input AC Input Negative DC output to L1 Negative DC output to torch Common Common Current
32. 9 8206 9 8243 40A 9 8208 Drag Shield Cup 9 8235 50 60A Tips 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 40 120A GOUGING Art A 08066_AG Manual 0 5085 50 55 9 8209 60A 9 8210 L Shield Cup Tips 70A 9 8231 80A 9 8211 90 100 9 8212 120A Auto 9 8233 120A Manual 9 8253 Shield 9 8237 Tips Tip 9 8225 40 Amps Tip 9 8226 50 120 Amps Tip C 9 8227 60 120 Amps Tip D 9 8228 60 120 Amps Tip 9 8254 60 120 Amps 4T 9 CT Cup Body Shield Cap Machine 50 60A 9 8238 Shield Cap Deflector 9 8243 Drag Shield Cup 70 100 9 8236 Drag Shield Cup 120A 9 8258 Shield Cap Machine 70 100A 9 8239 Shield Cap Machine J 120A 9 8256 Shield Cap Deflector 9 8243 Shield Cup Gouging 9 8241 OPERATION CUTMASTER 40mm 4T 08Recommended Cutting Speeds for SL100 Torch With Exposed Type Torch SL100 With Exposed Tip Im Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Per Minute Standoff Pierce Height ses au spe 45 5 1 5 9 8208 108 40 250 019 48 65 55 170 i9 40 190 es 5 wejes seme 65 55 40 40 40 40 3 ols 3 o 3
33. Adjust pressure Regulator to minimum Mea sure 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 Manual 0 5085 CUTMASTER 40MM O AC LED ON TEMP LED OFF GAS LED ON Gas flows DC LED 8 FAULT indictor OFF W1 contactor does not energize 1 Defective W1 Contactor a Measure for 24VAC between wire 5 to wire 6 on W1 If voltage is present replace W1 2 Defective Logic PCB 3 a Measure voltage on Main PCB 3 between J2 9 to GNDI If voltage is 12VDC replace the Logic PCB 3 3 Defective Main PCB 1 a 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 2 Defective Logic PCB 3 a Measure on Main PCB 1 signal SOL_ON between J2 12 to test point for 12VDC If voltage is present replace Logic PCB 3 3 Defective 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 mode 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB
34. Current Control Sets the desired output current Output settings up to 60 Amps may be used for drag cutting with the torch tip contacting the workpiece or higher for standoff cutting Function Control Function Control Knob Used to select between the different operating modes SET ra Used to purge the air through the unit and torch and leads and to adjust gas pressure RUN c t Used for general cutting operations RAPID AUTO RESTART o o Allows for faster restarting of the Pilot Arc for uninterrupted cutting LATCH Used for longer hand held cuts Once a cutting arc is established the torch switch can be released The cutting arc will remain ON until the torch is lifted away from the work piece the torch leaves the edge of the work piece the torch switch is activated again or if one of the system interlocks is activated ON OFF Power Switch ON OFF Switch controls input power to the power supply Up is ON down is OFF Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock NY AC Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is in pro tective interlock mode Shut unit OFF shut OFF or disconnect input power correct the fault and restart the unit Refer to Section 5 for details Manual 0 5085 CUTMASTER 40mm
35. Demand Signal 1 5VDC during Pilot 1 2 4 VDC During Cut IGBT Bank A Output to T1 IGBT Bank A Output to T1 IGBT Bank B Output to T1 IGBT Bank B Output to T1 T1 Secondary T1 Secondary Capacitor Bank A Capacitor Bank A Capacitor Bank B Capacitor Bank B Capacitor Bank A Capacitor Bank A Capacitor Bank B Capacitor Bank B Positive Tip DC Output Negative DC output Positive DC output Manual 0 5085 CUTMASTER 40MM This Page Intentionally Blank Manual 0 5085 5 29 SERVICE CUTMASTER 40MM 5 13 Capacitor PCB Layout amp Signals 80A_AC3 Art A 08505AB A CAPACITOR PCB 2 SIGNALS J1 1 12VDC J1 2 400VAC J1 3 N A J2 1 12VDC J2 2 Common SERVICE 2 PMTH3 180 189 uL s 00000000 e H emm R42 o 9 1 P 12 R9 4 40A_ACS PRI2 MTH4 80 _ 1 2 2 1 40 _ 1 40 _ 40 _ 2 CAPACITOR PCB 2 LAYOUT 5 30 Manual 0 5085 B CAPACITOR PCB 2 TEST POINTS MTH 1 MTH 2 MTH 4 MTH 6 MTH 7 MTH 8 PMTH 1 PMTH 2 PMTH 3 PMTH 4 80 _ 1 80 _ 2 80A AC3 40 _ 1 40 _ 2 0 5085 CAP BANK A CAP BANK A CAP BANK A CAP BANK
36. Input voltage pus HE Suggested Sizes Flexible Flexible Cord Cord Min Min mm NE x 40 Line Voltages with 8 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 eff is taken at TDC 100 rated duty cycle Manual 0 5085 2 3 INTRODUCTION Handle and Leads Wrap 2 06 Power Supply Features CUTMASTER 40mm S E nd m 7 5 5 E 2 59 Se 5 98 x 2 _ all NO S q p Nes GE K WAS e V 5 op Port for Optional Automation Interface Cable Input Power Cord Filter Assembly Art A 08359 Gas Inlet Port 2 4 Manual 0 5085 INTRODUCTION 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 Mech anized Plasma Cutting Torches Service of this equipment is restricted to properly trained person nel unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in
37. Item Description log 1 1 Torch Handle Replacement Kit includes items No 2 amp 3 9 7030 2 1 Trigger Assembly Replacement Kit 9 7034 3 1 Handle Screw Kit 5 each 6 32 x 1 2 cap screw and wrench 9 8062 4 1 Torch Head Assembly Replacement Kit includes items No 5 amp 6 9 8219 5 1 Large O Ring 8 3487 6 1 Small O Ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 2 total 9 7031 Art A 07993_AB Manual 0 5085 6 7 PARTS LIST CUTMASTER 40mm 6 10 Replacement Parts for Machine Torches with Unshielded Leads Item No Oty Description Catalog No 1 1 Torch Head Assembly without leads includes items 2 3 and 14 9 8220 2 1 Large O Ring 8 3487 3 1 Small O Ring 8 3486 4 1 PIP Switch Kit 9 7036 5 Unshielded Automated Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7850 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7851 1 25 foot 7 6 m Leads Assembly with ATC connector 4 7852 1 50 foot 15 2 m Leads Assembly with ATC connector 4 7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7843 1 25 foot 7 6 m Leads Assembly with ATC connector
38. PILOTIGET N 2 T WORK WORK 1 ze 2 8 ISTART 3 2p 24VAC RETURN 5 22 CNC INTERFACE STANDARD ON amp A120 UNITS 24VAC SUPPLY 7 CNC INTERFACE OPTIONAL ON CM102 amp CM152 UNITS SI ee Lr 1s 1 2 E 1 1 1 CNC PINOUT 6A 250vac 1 sovoc 3 5 5 2 D H 7 7 a ISTART I STOP 2 40 PIN RIBBON CABLE SIGNALS FULL FEATURED AUTOMATION INTERFACE PCB OPTION d TEST POINTS 1 OUT SIGNAL ML 059 PCR 2 me vous mP SENSE To configure DIVIDED ARC VOLTS signal output GNDZ COMMON Ham No jumper installed for VOLTS 1667 12 VDC SUPPLY 5 PIN LM LLL Jumper pins 1 2 for ARC VOLTS 30 148 VDC SUPPLY 6 CUR SET LM Jumper pins 2 8 3 for ARG VOLTS 80 LDMD 1 CURRENT DEMAND 7 AUTO RESTART LM TP SEN DRAG SENSE ANRUSH 8 LM 10 SHON LM 11 SOLENOID LM 3 12 ISOLENOID ON LM 3 IE En ape 1 E stor 14 1 m 5 Fox 15 ACTIVE 2 2 2 ARC VOLTS 16 TORCH SWITCH 3 LES Tome Mc H 18 AC ON ML 5 5 OW TIN ses ere 19 CSR 10 rmm 20 TORCH SOLENOID DETECT ML 7 7 7 PCB4 11 21 coe 2 ME AUTOMATION okromove 23 INTERFACE
39. Problems SERVICE CUTMASTER 40MM C Gas flows with ON OFF SWITCH in OFF 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 For Non EMC units Check wiring of primary power cable to the W1 contactor Input Power Cable Connections 380 415 VAC Three Phase 30 L2 1401 GND b For EMC units Check wiring of primary pow er cable to the EMC Filter terminal block EMC Input Power Filter Art 08752 Three Phase Input Power Wiring 2 W1 contactor points are stuck closed a Check per section 5 11 A 3 Primary plug not wired correctly a Check manufacturer s plug installation in structions 4 Primary input cable is defective a Check cable for shorts B Primary line fuses blow immediately after ON OFF SWITCH SW1 is turned to ON position 1 Shorted Input Diode Module a Check per section 5 11 B and 5 11 C 2 Shorted Input Capacitor PCB 2 a Check per section 5 11 D SERVICE 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 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
40. SEC2 CHOKE WORK1 SEC1 WORK1 SEC2 SEC1 WORK1 SEC2 WORK1 Forward Bias Reversed Bias Reversed Bias Reversed Bias Reversed Bias Forward Bias Forward Bias Manual 0 5085 CUTMASTER 40MM H PCB 5 Output Diode D2 Test K PCB 1 Input Diode Test With PCB 2 1 Disconnect transformer wires from Main PCB 5 removed form unit terminal 1 Using an ohmmeter perform the following checks 2 Using ohmmeter perform the following checks Input Diode Module 01 on PCB 1 PCB 5 02 Test points located PCB 5 Meter meer Test points located on PCB 1 Meter Forward Biased Diode Forward Biased Diode CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 Forward Bias Forward Biased Diode SEC1 CHOKE1 Reversed Bias SEC2 CHOKE1 Reversed Bias Reverse Biased Diode OUT_1 SEC1 Reversed Bias Reverse Biased Diode OUT_1 SEC2 Reversed Bias Biased Binds SEC1 OUT_1 Forward Bias Forward Biased Diode SEC2 OUT_1 Forward Bias Biased PCB 1 Pilot IGBT Test A Reverse Biased Diode 1 Disconnect wire E35 from Main PCB 1 terminal Reverse Biased Diode TIP1 2 Forward Biased Diodes 2 Using a multimeter with a diode test scale place the positive probe on PCB 1 terminal TIP1 and 2 If the test reveals a failed component replace the negative probe on PCB 1 terminal WORK1 Main PCB 1 and check for a forward Biased diode reading L PCB 5 Input Diode Test With
41. With Exposed Tip Type Plasma Gas Air Daey 5 o as 9 ms os 020 81 amp fae vo 9 ns 020 sr 076 ors fae as 9 zs os 620 51 amp os faa v 9 ns o 020 51 sx os aa ro 4s ze 20 151 s os as oo zs ws ws WR amp es eal ae zs ww ws wn Con fae 4e o0 zs 046 123 118 122 120 130 132 130 142 Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow CFH Pierce Height Tip TI N lt e co a Ts m D a N 9 a T i TEE e x 2 5 T ej s gjald lt 8 e a gt a gt 5 N id o T a 5 5 045 159 582 Corso Type Torch SL100 With Exposed Tip Type Material Aluminum Type Secondary Gas Single Gas Torch Speed Per Minute Standoff Plasma Gas Press Pierce Pierce Height Type Plasma Gas Air z TES was 02s 4s oo zs 025 ite oss ea as 025 ess oz eal ro 4s
42. a e ca 9 B 10 130 I ala lt olo 5 MT ur 45 45 65 45 55 45 45 m ao 025 secos 111 a e as f ss oss a 7 os id gt Z Oy or or Di c 8 a NIN B o 2 2 AIAIAJAJAJAJSA Oo Type Torch 51100 With Exposed Gas Air emos m se owe oo we om sw sss sos es as ss vo 40 ows s2 es 4s 55 170 02 ss se uo or jr 078 oe e ao os 6 ss 2 sa oss 126 4o 10 025 Jov ae es as ss 170 NR ne Type Torch 51100 With Exposed Type Material Aluminum LP Plasma Gas Air Type Secondary Gas Single Gas Torch DES nce ass ao _ 2 4o sse 87 44 es
43. cantly affect the bevel angle Reducing standoff will generally result in a more square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touch ing the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cut ting arc as quickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut be ing more square than the other Viewed along the direction of travel the right side of the cut is more square than the left 1 ut Angle Right Side Cut Angle A 00512 Side Characteristics Of Cut To make a square edged cut along an inside diameter of a circle the torch should move coun terclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Manual 0 5085 CUTMASTER 40mm Dross When dross is present on carbon steel it is com monly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate dis tance Top dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is
44. disponible aupr s de la National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOU DAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Manual 0 5085 14 15 CUTMASTER 40mm 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 di
45. move freely Spring Loaded Lower End Fitting Full Compression Spring Loaded Lower End Fitting at Reset Full Extension 3 Worn or faulty torch parts Manual 0 5085 CUTMASTER 40MM a Inspect torch consumables parts Replace if necessary 4 Shorted Torch leads a Disconnect torch from unit With consumables removed from the torch check continuity of torch at ATC between negative plasma lead connection to pilot lead connection Negative Plasma Lead 4 Torch Switch R 3 Torch Switch Hits 2 PIP 1 PIP A Pilot Lead Art A 08124 If a short is found the problem is in the torch and leads assembly Remove the torch head from the leads and check the leads and head to determine which is defective 5 Low primary input power or missing phase a Measure primary input voltage between L1 L2 amp L3 on W1 contactor under load 6 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 7 Shorted Sync cable connected between J14 on Main PCB 1 to J9 on 40A PCB 5 a Check continuity 8 Open connection between J12 on Main PCB 1 to J1 on Capacitor PCB 2 a Check continuity 9 Open connection between J2 on Capacitor PCB 2 to J3 on 40A PCB 5 a Check Continuity 10 Open connection between J2 on Main PCB 1 to 1 on Logic PCB 3 a Check continuity 11 Defective L
46. of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as but not limited to damage or loss of purchased or replacement goods or claims of customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty bec
47. oil grease or any foreign material Briefly open each cylin der valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 Ipm 4 Connect supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure cylinder regulator Supply hose must be at least 1 4 inch 6 mm 1 0 For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch INSTALLATION Manual 0 5085 SECTION 3 TORCH INSTALLATION 3T 01Torch Connections If necessary connect the torch to the Power Sup ply Connect only the Thermal Dynamics model SL100 Manual or SL100 Mechanical Torch to this power supply Maximum torch leads length is 100 feet 30 5 m including extensions WARNING Disconnect primary power at the source before connecting the torch 1 Align the ATC male connector on the torch lead with the female receptacle Push the male connector into the female receptacle The connectors should push together with a small amount of pressure 2 Secure the connection by turning the lock ing nut clockwise until it clicks DO NOT use the locking nut to pull the co
48. oo ss 025 wo 4s zo oo 245 nz 025 oa Cas zu ozs eal as oo zs 030 025 Cas vw om vo as 00 ss 050 025 Cao or ozs eal 4s oo ss 025 os oz sa as ss ws un un os vo as oo as wa un Cat No Volts VDC 060 1 5 9 8210 Tip 1 9 9 8210 3 0 9 8210 15 19 34 3 4 9 8210 OPERATION 4 11 Manual 0 5085 CUTMASTER 40mm 15 eo sm e13 1491 os as 0 049 458 ws eo zw s34 6 as 049 45 ns so s orfas as 049 45 1m4 eo vo 386 6 as 0 nz 049 02 eem ma eo m zs 1491 e as wo 030 oio a o orfas es as 0 040 fotas 120 so o ui e 6 as 0 049 earn 133 eo os as 0 075 049 48 ve eo o4 orfas os as u WR roars 222 earn 133 eo 10 025 019 148 es as oar 19 eo o 023 orfas os as fun Type Plasma Gas Air oo
49. per subsection 7 04 A Remove Capacitor PCB per subsection 7 08 A Remove the two large gas hoses per subsection 705 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 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 Manual 0 5085 C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 2 7 Remove the Cover per subsection 7 04 Remove all wires from W1 noting the location and orientation of each wire Loosen the two 2 Torx head screws securing the Main Contactor to the base Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mount ing screws Lift Main Contactor up and out of the unit 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 2 3 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 s
50. phone number in your area listed in the inside back cover of this manual Include the Service Manual number and equipment identification numbers Manual 0 5085 CUTMASTER 40mm Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link http www thermal dynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a data tag attached to the rear panel Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely attached card or the shipping container Record these numbers on the bottom of page i for future reference 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to ship ping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or ship ping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the
51. rateurs et au personnel TOUS les dangers possibles Afin d viter les bles sures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions Manual 0 5085 pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz e Les sortes de gaz et de fum e provenant de l arc de plasma d pen dent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des rensei gnements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant e Pour des informations sur la mani re de tester la fum e et les gaz
52. speed too slow 2 fan for proper operation and adequate air Formation 2 Torch standoff too high from workpiece 2 Inspect torch for any cracks or exposed wires 3 Worn torch parts replace if necessary 4 Improper cutting current 5 Non Genuine Thermal Dynamics 3 Inspect input power cable for damage or exposed parts used wires replace if necessary Six Months or Every 720 Cutting Hours 6 Incorrect gas pressure Short Torch Parts Life Oil or moisture in air source 2 Exceeding system capability 1 Check the in line air filter s clean or replace as i required material too thick 3 Excessive pilot arc time 2 Check cables and hoses for leaks or cracks replace 4 Gas pressure too low if necessary 5 Improperly assembled torch 3 Check all contactor points for severe arcing or dh i al pits replace if necessary Difficult Starting 1 Worn torch parts 4 Vacuum dust and dirt out of the entire machine A CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical com ponents and cause damage to the unit SERVICE 2 Non Genuine Thermal Dynamics parts used 3 Incorrect gas pressure Manual 0 5085 5 04 Fault Indicator At initial power up two lights will temporarily illumi nate for 2 3 seconds to show the version of software used To determine the first digit count the func
53. tabs engage the mating holes in the base For complete removal of panel disconnect any other item still attached to the panel and another component of the power supply Manual 0 5085 7 05 Front Panel Parts Replacement Refer to section 6 05 for Front Panel Replacement Parts and overall detailed drawing A Current Control Potentiometer A Knob Replacement Tools required Flat Screw Driver 1 Turn the potentiometer fully clockwise and note the location of the pointer mark on the knob 2 Loosen the screw securing the Current Control Knob to the potentiometer shaft and remove the knob 3 Replace the knob on the potentiometer shaft with the pointer in the same position as noted in step 1 Function Control Switch Knob Replacement Tools required Flat Screw Driver 1 Turn the Function Control Switch until the pointer on the knob is in the LATCH position 2 Loosen the screw securing the knob to the switch shaft and remove the knob 3 Replace the knob on the switch shaft with the pointer in the position noted in step 1 C Replacing Gas Hoses Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Push the gas fitting locking ring back A small open end wrench works well for this 1 2 3 3 Pull the hose from the fitting Art A 08150 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pull ing on the hose If done correctly it
54. te Worn Electrode Art A 03284 Electrode Wear 7 Reinstall the Electrode by pushing it straight into the torch head until it clicks 8 Reinstall the desired starter cartridge and tip into the torch head 9 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the cup check the threads before proceeding This completes the parts replacement procedures Manual 0 5085 CUTMASTER 40mm 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 Machine Torches with Unshielded Leads Section 6 11 Replacement Shielded Machine Torch Leads Assemblies Section 6 12 Torch Consumable Parts SL100 SV NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authoriza tion will not be accepted 6
55. 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 ionized the plasma gas the superheated column of gas flows through the small orifice in the torch tip which is focused on the metal to be cut A single torch lead provides gas from a single source to be used as both the plasma and second ary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 2T 05 Introduction to Plasma on page 27 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 Manual 0 5085 2T 1 CUTMASTER 40mm 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 Art A 03322_
56. unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit 2 1 INTRODUCTION CUTMASTER 40mm 2 04 Power Supply Specifications CutMaster 40mm Power Supply Specifications 380 VAC 360 440 VAC Three Phase 50 60 Hz 400 415 VAC 360 440 VAC Three Phase 50 Hz Power Supply includes input cable Output Current 30 120 Amps Continuously Adjustable Power Supply Gas Filtering Particulates to 5 Microns Ability CutMaster 40mm Power Supply Duty Cycle Input Power Duty Cycle Ratings Q 40 C 104 F Ambient Temperature Operating Range 0 50 C Duty Cycle 100 ane Curent 120 t DC Voltage 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 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 20 273 16 375 416 Art 07925 63 Ib 28 6 kg INTRODUCTION 2 2 Manual 0 5085 CUTMASTER 40mm 2 05 Input Wiring Specifications CutMaster 40mm Power Supply Input Cable Wiring Requirements E
57. will not pull out 5 Reinstall the power supply cover Manual 0 5085 CUTMASTER 40mm 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 Loosenand remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 6 Remove the Pressure Transducer from the regu lator and install on new regulator using liquid pipe thread sealant 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 Removethe air hose from Gas Solenoid per sub section 7 05 C 4 The Solenoid utilizes the same type locking fit ting as the gas hoses Using a flat blade screw driver push the loc
58. will turn ON for one 1 second and then turns OFF The fans will turn ON when a START signal Torch Switch Remote Pendant switch or CNC START is active and will remain ON for ten 10 minutes after the START signal is removed If an over temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condition is cleared Manual 0 5085 2 Measure for 12VDC on the Logic PCB 3 between J7 1 to J7 1 after the START signal is activated If voltage is not present replace Main 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 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 obstruc tions preventing MOT 1 fan blades from turn ing Replace MOT 1 Either 2 MOT 3 do not turn ON after START signal is activated 1 Fan wires not connected to 40A PCB 5 a Check and reconnect to 40A PCB 5 2 Defective fan a Check to be sure there is no physical obstruc tions preventing fan blades from turning Replace respective fan J Fans MOT 2 amp MOT 3 do not turn ON after START signal is activated 1 Open connection between Main 1 J13 to 40A PCB 5 J4 a Verify connectors are
59. 0 D c 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 Female Receptacle Remote Pendant Connector ATC Female Receptacle Male ATC Leads Connector EN _ _ _ _ Power NEN Torch Supply Head Leads PIP O Black Switch To Power Supply O Orange Circuitry 0 White Not MEN Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry gt Pilot Art A 08577 APPENDIX A 4 Manual 0 5085 CUTMASTER 40MM C Automation Torch Connection Diagram Automated CutMaster Power Supply with ATC Torch Receptacle Automated SL100SV Torch w Solenoid on Positioning Tube Torch Lead with ATC Connector ATC Male ATC Female Torch Leads Connector Torch Receptacle 1 Torch Head 1 Torch Leads Power Supply Pin No s PIP Black 1 401 21 Main Board White pee 5 Main PC Board Green 7 Main PC Board Not Connected Negative Plasma Lead Pilot Lead
60. 00 500 scfh 142 235 Ipm Operating Pressure Refer to NOTE Maximum Input Pressure Gas Flow Cutting and Gouging A WARNING This torch is not to be used with oxygen 0 NOTE Operating pressure varies with torch model op erating amperage and torch leads length Refer to gas pressure settings charts for each model H Direct Contact Hazard For standoff tip the recommended standoff is 3 16 inches 4 7 mm 2T 04Options And Accessories For options and accessories see section 6 INTRODUCTION 2T 2 2T 05Introduction to Plasma A Plasma Gas Flow Plasma is a gas which has been heated to an ex tremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece The metal to be cut or removed is melted by the heat of the arc and then blown away While the goal of plasma arc cutting is separation of the material plasma arc gouging is used to remove metals to a controlled depth and width In a Plasma Cutting Torch a cool gas enters Zone B where a pilot arc between the electrode and the torch tip heats and ionizes the gas The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C Power Supply A le e I Workpiece A 00002 Typical Torch Head Detail By forcing the p
61. 0MM APPENDIX PUBLICATION HISTORY Cover Date Bev A 5 0 0 0 0 0 0 00 0 0 0 0 000 Dec 10 2008 Dec 23 2008 May 29 2009 Jan 7 2010 Jan 25 2010 Feb 25 2010 Aug 31 2010 Sept 14 2010 Jan 16 2012 Mar 20 2012 April 25 2012 APPENDIX AA AB AC AD AE AG AH Al AJ AK Manual released Revised to correct Section 6 catalog numbers Corrected Section 3 Art size Added art for Logic PCB to section 5 Updated 400V 600V schematic in appendix per ECOB1399 Corrected part num bers in section 6 per ECOB1201 Updated Power Supply Input Cable Wiring Requirements with metric cable sizes in Section 2 Updated Torch Consumable Parts in Section 6 Updated system schematic in Appendix Updated torch consumables art section 4T and 6 Updated automation interface and harness descriptions and part numbers per ECOB1282 Updated and corrected Main PCB and transformer numbers in section 6 per 1630 Updated CNC cable part numbers in section 6 per ECOB1637 Updated logic PCB in Section 6 per ECO B1800 Updated section 4T consumables art per ECOB1819 Updated Duty Cycle page 2 2 per ECOB2183 Updated ART A 08066 and changed COO text per ECOB2149 Updated ART A 07994 per 2136 A 8 Manual 0 5085 This Page Intentionally Blank Printed in Mexico U S Customer Care 800 426 1888 FAX 800 535 0557 gt Canada Customer Care 905 827 4515 FAX 800 588 1714 In
62. 1inch 25mm away d Older revision 40A PCB 5 Replace if PCB 5 revi sion is AC or earlier C Main arc transfers but current cannot be adjusted 1 Defective Logic PCB 3 a While main arc is transferred measure volt age on Main PCB between test points GND1 toI DMDI Adjust CURRENT CONTROL POTENTIOM ETER from maximum to minimum Voltage should vary from 4VDC at max to 1 VDC at min If voltage does not vary with CURRENT CONTROL POTENTIOMETER replace Logic PCB 3 2 Defective Main PCB 1 a Replace Main PCB 1 D In LATCH mode when the START signal is released the arc shuts OFF immediately 1 Defective Logic PCB 3 a Replace Logic PCB3 amp SERVICE CUTMASTER 40MM E With CURRENT CONTROL POTENTIOMETER set at maximum output current is only 60 amps 1 Tip is touching the work piece Drag mode a Lift tip off work piece 2 Defective Pilot IGBT on Main PCB 1 a Check per section 4 10 I 3 Open Sync cable between 14 on Main PCB 1 and 40Amp PCB 5 a Check continuity and replace if open 4 Open connection between J13 on Main PCB 1 to J4 on 40A PCB 5 a Check continuity 5 Defective 40Amp PCB 5 a Replace 40Amp PCB 5 G 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 microproces
63. 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 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 OK proceed with the trouble shooting guide A CAUTION Due to the close proximity of the Main PCB to the Capacitor PCB It is recommended to use an insu lated meter probe when making measurements on the J2 connector on the Main PCB Do not short between the pins Do not short to the Capacitor PCB connections Manual 0 5085 D 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 Connect gas supply to rear of Power Supply 2 Turn ON gas supply and set operating pressure per pressure setting label on power supply 3 Set the Power Supply controls as follows ON OFF SWITCH to OFF position Turn FUNCTION CONTROL SWITCH to SET position CURRENT CONTROL POTENTIOMETER to MAXIMUM position fully clockwise E Main Input and Internal Power Test 1 C
64. 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 7 2896 13 1 PIP Plunger and Return Spring Kit 9 7045 1 Pinion Assembly Not shown 7 2827 1 5 126 mm Positioning Tube Not shown 9 7042 NOTE Does not include Control Cable Adapter or Through Hole Protector PARTS LIST 6 8 Manual 0 5085 CUTMASTER 40mm Manual 0 5085 6 9 PARTS LIST CUTMASTER 40mm 6 11 Replacement Shielded Machine Torch Leads Assemblies Item Description 1 1 Mechanized Shielded Leads Assemblies with ATC Connectors 1 5 foot 1 5 m Leads Assembly with ATC Connector 4 7846 1 10 foot 3 05 m Leads Assembly with ATC Connector 4 7847 1 25 foot 7 6 m Leads Assembly with ATC Connector 4 7848 1 50 foot 15 2 m Leads Assembly with ATC Connector 4 7849 Remote Pendant Adapter is Torch Continuity present on Mechanized leads only Switch 7 A 03684 PARTS LIST 6 10 Manual 0 5085 CUTMASTER 40mm 6 12 Torch Consumable Parts SL100 SV Ohmic Clip Automation Torch Ohmic Clip 9 8224 Manual Torch 9 8259 20 40A Tip STANDOFF Shield Cap Machine 40A 9 8245 L 0 Shield Cap Deflector 9 8243 ED 20 9 8205 Shield Cup 9 8206 40 9
65. 4s se vo 02 5 e seme sas se me so e ss NN NN o s 3 5 co a EE ojojo 254 es 4s ss ro 040 o2 51 Los 24 osr as es 4s ss ro o2 51 Cie oat as ss ro NR NR OPERATION 4T 10 Manual 0 5085 CUTMASTER 40mm Type Material Mild Steel Type Secondary Gas Single Gas Torch zar as 70 48 90 Type Torch SL100 With Exposed Tip Type Plasma Gas Air asr 48 9o 245 010 132 0 19 0 19 0 19 0 19 0 19 0 19 Pierce Height 0 10 0 20 0 30 0 50 0 75 CFH 245 245 245 245 245 245 245 245 Flow ba 48 eo 040 Plasma Gas Press 2s 203 Per Minute Speed 100 50 s ots o N 120 119 21 119 124 126 127 134 140 p Ti 9 8210 9 8210 9 8210 9 8210 0 060 0 075 Cat 9 8210 9 8210 0 500 12 7 9 8210 0 625 15 9 9 8210 0 750 19 1 9 8210 1 000 25 4 9 8210 Type Material Stainless Steel Type Secondary Gas Single Gas Torch Type Torch SL100
66. 7s 1s oi sz ae 9 oz amp a s 132 zo as 9 2 2 sa 2 on 32 zo as 9 2 oz m ee 4a as 9 zs 0 120 121 129 135 110 Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip roars is ne c us 48 oo 26 JET ns e 1 a o e 2 D m i H o oa a a a gt E gt 53 Co e o 0500 12 aos 15 Type Torch 51100 With Shielded Type Material Aluminum Type Secondary Gas Single Gas Torch Type Plasma Gas Air Tip Output Amperage Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Manual 0 5085 4 16 OPERATION CUTMASTER 40mm Type Material Mild Steel Type Secondary Gas Single Gas Torch Type Torch SL100 With Shielded Tip Type Plasma Gas Air E uc i ic c gp a c5 lt a E wn 5 gt wn gt D 2 lt 5 5 i Tip Type Material Stainles
67. 8208 Drag Shield Cup 9 8235 50 60A Tips STANDOFF CUTTING ant 50 55A 9 8209 60A 9 8210 Shield Cap Machine 50 60A 9 8238 Shield Cap Deflector 9 8243 Drag Shield Cup 70 100A 9 8236 Electrode Starter Heavy Duty Auto 9 8232 Cartridge Starter Cartridge Tips Drag Shield Cup Manual 9 8215 9 8213 Non HF Only 9 8277 120A 9 8258 a Shield Cap Machine 70 1 20A 70 9 8231 70 100A 9 8239 STANDOFF 80A 9 8211 Shield Cap Machine CUTTING 90 100A 9 8212 120A Auto 9 8233 120A Manual 9 8253 V 120A 9 8256 Ca Shield Cap Deflector 9 8243 40 120A GOUGING Shield Body gt 9 8237 Tips Tip 9 8225 40 Amps Shield Cup Gouging 9 8241 9 8226 50 120 Amps Tip C 9 8227 60 120 Amps Tip 9 8228 60 120 Amps Art 08066 AG Tip 9 8254 60 120 Amps Manual 0 5085 6 11 PARTS LIST CUTMASTER 40mm This Page Intentionally Blank PARTS LIST 6 12 Manual 0 5085 SECTION 7 REPLACEMENT PROCEDURES 7 01 Scope This section describes parts replacement procedures which may be performed on the CutMaster 40mm Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 7 02 Anti Static Handling Procedures A CAUTION PC Boards can be irreparably damaged by improper handling
68. 9 J2 10 J2 12 2 13 2 14 2 15 2 16 J2 17 J2 18 J2 19 J2 20 2 21 J2 22 72 23 72 24 2 25 72 26 72 27 72 28 72 29 72 30 72 31 72 32 72 33 72 34 72 35 72 36 72 37 72 38 72 39 72 40 VOUT TIP VOLTS TIP_SEN 400V_IN N A CUR_SET RAR INRUSH W1_ON SHDN TRCH_SOL SOL_ON OK_TO_MOVE FAN_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 Manual 0 5085 CUTMASTER 40MM Signal Source Destination OUTPUT VOLTAGE Active high when tip is installed Approx 100VDC while cutting w tip OFF work Active low in Drag Mode Active low with 400VAC primary input voltage Current demand signal Variable 1 4VDC Active low when in Rapid Auto Restart mode Active low after inrush time expires Active low to enable W1 contactor Active low enables PWM circuit Active low to enable Torch Solenoid Active low to enable Power Supply solenoid Active low to enable OK_TO_MOVE CNC Active low to enable fans Active low when Latch mode is active during cut Active low 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 2 6VDC
69. AB 7 1 17 29 mm 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly Le 15 875 403 mm e 9 285 236 mm F 1 375 35mm 1 75 44 5 mm B Torch Leads Lengths Hand Torches are available as follows 20 ft 6 1 m with ATC connectors 50 ft 15 2 m with ATC connectors Machine Torches are available as follows 5 foot 1 5 m with ATC connectors 10 foot 3 05 m with ATC connectors 25 foot 7 6 m with ATC connectors 50 foot 15 2 m with ATC connectors C Torch Parts Starter Cartridge Electrode Tip Shield Cup D Parts In Place PIP Torch Head has built in switch 1 175 30 inis 4 95 126 mm 0 625 16mm w Art A 02998 12 VDC circuit rating E Type Cooling Combination of ambient air and gas stream through torch INTRODUCTION CUTMASTER 40mm F Torch Ratings Manual Torch Ratings Ambient 104 F Temperature 40 C Duty Cycle 100 120 Amps 400 scfh Voltage V oa 500V Arc Striking Voltage 7kV Mechanized Torch Ratings Temperature 40 C DutyCycle 100 120 Amps 400 scfh 120 Amps 500V Gas Requirements Manual and Mechanized Torch Gas Specifications Gas Plasma and Secondary Compressed Air 60 95 psi 4 1 6 5 bar 125 psi 8 6 bar 3
70. B CAP BANK B CAP BANK B CAP BANK A CAP BANK A CAP BANK B CAP BANK B AC line 1 AC line 2 AC line 3 AC line 1 AC line 2 AC line 3 5 31 CUTMASTER 40MM SERVICE CUTMASTER 40MM 5 14 Logic PCB Layout amp Signals D1 TP6 R5 R32 R37 R38 C16 R40 ci8 R41 R51 R44 cao R39 ces R53 us R52 R46 R57 C28 cal us 29 R58 2 5 s R68 C34 R73 T 22 s R69 R71 R72 C35 C36 R87 cle oz D g 8 T R86 884 caa cat 876 a 5
71. BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie e Pour prot ger votre contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail e mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs e Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 PLOMB AVERTISSEMENT Ce produit contient des produits chimiques comme le plomb ou engendre des produits chimiques reconnus par l tat de Californie comme pouvant tre l origine de cancer de mal formations f tales ou d autres probl mes de reproduction Il faut se laver les mains apr s toute manipulation Code de Californie de la s curit et sant paragraphe 25249 5 et suivants 1 4 Manual 0 5085 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites a celles ci pour de plus amples renseignements 1 OSHA NORMES DE SECURITE DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing O
72. C Board in the equip ment and make all necessary connections Place the failed PC Board in the ESD protective bag and seal for return shipping Replace the power supply cover 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equip ment 7 03 Parts Replacement General Information The parts replacement procedures described in this manual except for filter replacement require that the Power Supply be disassembled The part to be replaced will determine to what extent the Power Supply must be disassembled Before removing any connection mark each wire with the connection designation When reassembling make sure the wires go to the proper terminals Note the routing of wires and make sure the wires are put back in the same place when re assembling the unit Each subsection is referenced to Section 6 for parts lists and overall detailed drawings WARNING Disconnect primary power from the source before opening or disassembling the power supply PARTS REPLACEMENT CUTMASTER 40mm 7 04 Major External Parts A Cover Removal Tools required T20 Torx Driver 1 2 Carefully pull the Cover up and away from the Art A 08429 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 screw
73. C2 AC Input Phase 2 40A AC3 AC Input Phase 3 MTH 1 Capacitor Bank A MTH 2 Capacitor Bank A MTH 4 Capacitor Bank A MTH 6 Capacitor Bank B MTH 7 Capacitor Bank B MTH 8 Capacitor Bank B PMTH 1 Capacitor Bank A PMTH 2 Capacitor BankA PMTH 3 Capacitor Bank B PMTH 4 Capacitor Bank B Manual 0 5085 5 35 SERVICE CUTMASTER 40MM 5 16 Right Side Wiring Diagram NOT USED TOSW2 TOPCB3 MAIN PCB J4 MAIN PCB J12 MAIN PCB J4 09 rag 2 7 5 5 ier a Vos Te 0 Tm me D EET us 049 nis an cas loso 8 EN Sia B OUTI Tes Ur T 2 RAZ i 105 a ces RIZZL 2 1 35 USED a Li CHOKE 682 6167 R169 R185 R186 F a er tre m
74. Check that cable is connected to primary power 2 Primary line fuse breaker is blown tripped a Replace fuse or reset breaker 3 Defective ON OFF SWITCH a Check continuity 4 Defective Main PCB 1 a Measure Main PCB power supply voltages at the following test points to 12V 12VDC to 48V 48 VDC Replace Main PCB 1 if not correct 5 Defective Ribbon Cable a Check continuity 6 Defective Logic PCB 3 a Replace Logic PCB 3 E AC LED ON W1 contactor does not energize In earlier revision units the fan MOT 1 will come ON after approximately 20 seconds 1 Defective contactor a Measure for 24VAC between wires 5 amp 6 If voltage is present replace W1 2 Defective Logic PCB 3 a Measure W1_ON signal on Logic PCB 3 be tween J1 9 to TP1 Voltage should be 12VDC then drop to less than 1VDC 2 seconds after turning SW1 to ON Manual 0 5085 CUTMASTER 40MM 3 Open or improperly connected ribbon cable 2 PARTS IN PLACE PIP FAULT The connector on Main PCB 1 FAULT Indicator and 70 PSI LED flashing a Inspect connection and check continuity Re After 20 seconds fan MOT 1 turns ON place if open 1 Shield Cup loose 4 Defective Main PCB 1 a Hand tighten the shield cup to close the PIP a Replace Main PCB 1 switch F UNDER PRESSURE FAULT AC LED ON 2 Torch not properly connected to power supply FAULT Indicator and 60 PSI LED flashing a Insure torch ATC is securely fasten
75. Es uin oss D m0000000 ge WORK CABLE 5 ree TOTS1 CM152 ONLY CNC HARNESS TO MOT1 5011 OPTIONAL Art 08620 SERVICE 5 36 Manual 0 5085 CUTMASTER 40MM 4UA DUA FLD JZ 4UA 5VA FLD 24 40A 50A PCB 1 40A 50A PCB J3 2 Art A 08620 Manual 0 5085 5 37 SERVICE CUTMASTER 40MM This Page Intentionally Blank SERVICE 5 38 Manual 0 5085 CUTMASTER 40mm SECTION 5 TORCH SERVICE 5T 01General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE Refer to Previous Section 5 System for com mon and fault indicator descriptions Upper O Ring in Correct Groove Threads Cleaning Torch Lower O Ring Art 03725 Even if precautions are taken to use only clean air Torch Head O Ring with a torch eventually the inside of the torch be comes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch A WARNING Disconnect primary power to the system be fore disassembling the torch or torch leads ATC Male Connector DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads and cleaned m
76. IHERMAL DYNAMICS 40m CUTMASTER PLASMA CUTTING SYSTEM IHERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 426 1888 or visit us on the web at www thermal dynamics com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery Superior customer service and technical support together with excellence in sales and marketing expertise Abo
77. ORMATIONS G N RALES CUTMASTER 40mm e Montez et maintenez le mat riel conform ment au Code lectrique 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 e 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 le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables e Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et soudez pas les conteneurs ayant pu renfermer des mati res combustibles e Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie e Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm
78. Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5 microns Connect the air supply as follows 1 Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly NOTE For a secure seal apply thread sealant to the fit ting threads according to manufacturer s instruc tions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch 2 Connect the two stage filter outlet hose to the inlet port of the Regulator Filter As sembly 3 Use customer supplied fittings to connect the air line to the Filter A 1 4 NPT to 1 4 hose barbed fitting is shown as an example Regulator Filter Assembly 2 Stage Filter Inlet Port IN Regulator Input Outlet Port OUT Two Stage Filter Assembly Gas Supply gt 1 4 NPT to 1 4 6mm Fitting Art A 07945_AC Optional Two Stage Filter Installation 3 3 INSTALLATION CUTMASTER 40mm 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 proce dures for high pressure regulators 2 Examine the cylinder valves to be sure they are clean and free of
79. R 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 operation CONSUMABLES MISSING Indicates that the elec trode start cartridge or tip is missing or exces sively worn SHORTED TORCH OUTPUT FAULT This indicator has two modes of operation 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 Air restriction in torch resulting in low voltage during pilot 3 Low voltage during cutting due to torch or consumable problem In all three cases to reset the machine remove the START signal INTERNAL ERROR Indicates a microprocessor err
80. R NR es ws esoe s oo ore es 45 ss vo NA NR Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Speed Per Minute Inches Volts VDC Amps Meters 036 0 9 9 8208 109 Inches mm o D ROLE ROLE oO ls 0 187 48 65 4 10 65 9 gt 2 A Plasma Gas Air Type Secondary Gas Single Gas Torch Speed Per Minute Flow Pierce Pierce Height Inches mm psi bar Plasma Total Inches m 220 55 17 0 81 0 3 12 8 1 00 PN MIM 20 Manual 0 5085 4T 15 OPERATION CUTMASTER 40mm 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 Ti Type Material Stainless Steel Type Secondary Gas Single Gas Torch Type Torch SL100 With Shielded Tip Type Plasma Gas Air 0 10 0 10 zo o aa wo ams on Day 4i oi sz om
81. RAPID AUTO RESTART position when the torch leaves the work piece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded metal or gratings or in gouging or trimming operations when an uninter rupted restart is desired And with the knob in the LATCH position the main cutting arc will be main tained after the torch switch is released Manual 0 5085 CUTMASTER 40mm Typical Cutting Speeds Cutting speeds vary according to torch output am perage the type of material being cut and operator skill Refer to Section 4T 08 and following for greater details Output current setting or cutting speeds may be reduced to allow slower cutting when following a line or using a template or cutting guide while still producing cuts of excellent quality Postflow Release the trigger to stop the cutting arc Gas con tinues to flow for approximately 20 seconds During post flow if the user moves the trigger release to the rear and presses the trigger the pilot arc starts The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece Shutdown Turn the OFF switch to OFF down All Power Supply indicators shut OFF Unplug the input power cord or disconnect input power Power is removed from the system OPERATION CUTMASTER 40mm This Page Intentionally Blank
82. ST CUTMASTER 40mm 6 06 Left Side Replacement Parts Item Description Ref log 1 1 Main PCB Assembly PCB 1 9 0123 1b 1 Main PCB Assembly 50 Amp PCB 5 9 0122 2 1 Logic PCB PCB 3 9 0107 3 1 Center Chassis Molded Plastic 9 0190 4 1 Fan 3 total MOT 1 3 9 0232 5 1 Transformer Main T1 9 0119 5b 1 Transformer Main 60 Amp T2 9 0117 6 1 Inductor Output L1 9 0105 6b 1 Inductor Output 40 Amp 12 9 0195 Not Shown Clamp On Wire Harness Ferrite Filter On Logic PCB Ribbon Cable 9 0249 Jj A ij Art 08560 PARTS LIST 6 4 Manual 0 5085 CUTMASTER 40mm 6 07 Right Side Replacement Parts Item Description Ref log 1 1 Contactor 4 Pole W1 9 8587 2 1 Solenoid 12V SOLI 9 0114 3 1 Spare Parts Box 7 3267 4 1 Spare Parts Box Cover 7 3266 5 1 Console Quick Disconnect 9 0161 6 1 Regulator with knob and mounting nut 9 0115 7 1 Assembly PCB Input Capacitors PCB 2 9 0202 8 1 Filter Auto Drain 9 0116 9 1 3 Phase Input Line EMI Filter CE Power Supplies Only 9 0253 Not Shown 1 Power Cable Strain Relief all units Kit includes both styles 9 0111 1 Input Power Cable 380 400 415 V 3 phase 9 0216 NOTE 9 0115 regulator 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 wi
83. See Section 3T of this manual Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power requirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to supply power to the system Air Source Ensure source meets requirements refer to Section 2 Check connections and turn air supply ON Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 04509 OPERATION Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator NV turns ON Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cool ing fans turn ON NOTE Minimum pressure for power supply 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 Press
84. TIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards As sociation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 5085 CUTMASTER 40mm 1 04 Note Attention et Avertissement Dans manuel les mots note attention et avertissement sont FUMEE et GAZ utilis s pour mettre en relief des informations a caract re important Ces mises en relief sont classifi es co
85. al shock Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX CE GENERAL INFORMATION 1 6 Manual 0 5085 CUTMASTER 40mm 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER 1Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon no
86. blow air into the heatsink Install replacement fan by reversing the above steps Reinstall the power supply cover Manual 0 5085 B Main Transformer T1 Replacement Tools required T20 Torx Driver 1 2 10 11 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 the transformer wires 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 Trans former to the base Remove the Main Transformer carefully guiding all its wires through from the right side of the unit Install replacement Transformer by reversing the above steps Reinstall the power supply cover C Main Transformer T2 Replacement Tools required T20 Torx Driver 1 2
87. car tridge in place Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be removed may effect the performance of the System 2 Inspect the cup for damage Wipe it clean or replace if damaged Art A 08067 Shield Cups 3 torches 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 between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Art 03878 SERVICE 4 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip Co 2 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 lt New Electrode
88. crews 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 Manual 0 5085 CUTMASTER 40mm PARTS REPLACEMENT CUTMASTER 40mm This Page Intentionally Blank PARTS REPLACEMENT 7 10 Manual 0 5085 CUTMASTER 40MM APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ON OFF switch to ON Close external disconnect switch RESULT Power to system RESULT AC indicator ON GAS indicator ON when inp pressure is adequate for power supply operation Power circuit ready ACTION Connect work cable to workpiece Set output amperage RESULT System is ready for operation ACTION Protect eyes and activate Torch switch START RESULT Fans turn on Gas flows briefly then stops Gas restarts DC indicator Pilot arc established ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will continue to run for 10 minutes after the Torch switch START is removed Manual 0 5085 ACTION ACTION RUN Rapid Auto Restart RUN SET LATCH Rapid Auto Restart switch to RUN 6 SET LATCH switch os to SET for most applications a or to Rapid Auto Restart RESULT 222 for gouging trimming Gas flows to set or expanded metal pressure applicatio
89. ctor 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 lock ing tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit Remove the two screws securing the Output Inductor to the base Remove the Output Inductor carefully guid ing its wires through from the right side of the unit 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 illustration Art A 07989 Remove the fitting from the filter ele
90. d or machine torch and the amount of material to be removed Manual 0 5085 CUTMASTER 40mm 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 output current setting and torch travel speed The recommended lead angle is 35 Ata lead angle greater than 45 the molten metal will not be blown out of the gouge and may be blown back onto the torch If the lead angle is too small less than 35 less material may be removed requiring more pass es Insome applications such as removing welds or working with light metal this may be desirable AN 35 Torch Head Standoff Height Workpiece A 00941_AB Gouging Angle and Standoff Distance Standoff Distance The tip to work distance affects gouge quality and depth Standoff distance of 1 8 1 4 inch 3 6 mm allows for smooth consistent metal removal Smaller standoff distances may result in a severance cut rather than a gouge Standoff distances greater than 1 4 inch 6 mm may result in minimal metal removal or loss of transferred main arc Slag Buildup 4 7 Slag generated by gouging on materials such as car bon and stainless steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to the side of the gouge path Ho
91. ding US Pat No s 6914211 D493183 t s Pending US Pat No s 6914211 D505309 t s Pending US Pat No s 6914211 D505309 t s Pending t s Pending US Pat No s 6914211 D496951 t s Pending US Pat No s 6914211 D496951 t s Pending US Pat No s 6914211 D505309 t s Pending US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6774336 7145099 6933461 US Pat No s 6914211 D501632 D511633 Manual 0 5085 CUTMASTER 40mm Catalog Description Patent s 9 8245 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237 Shield Cup 9 8238 Shield Cap 9 8239 Shield Cap 9 8244 Shield Cap 9 8245 Shield Cap Manual 0 5085 4T 21 OPERATION CUTMASTER 40mm This Page Intentionally Blank OPERATION AT 22 Manual 0 5085 CUTMASTER 40MM SECTION 5 SYSTEM SERVICE 5 01 General Maintenance Maintain more often Warning if used under severe Disc
92. due to electrostatic dis charge ESD Replacement PC Boards are shipped in a protective en closure to prevent damage from electrostatic discharge ESD during shipping A ground strap is included with each replacement board to prevent static damage during installation WARNING Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclo sure or removing the replacement PC board from its protective enclosure A General Disconnect primary power to the system be fore disassembling the torch torch leads or power supply enclosure Where these instructions include specific torquing instructions failure to torque prop erly will cause component damage Do not operate the equipment or test equip ment under power while wearing the ground ing wrist strap Manual 0 5085 CUTMASTER 40mm Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Unroll the rest of the band and peel the liner from the copper foil at the opposite end Attach the copper foil to a convenient and ex posed electrical ground Connect the equipment primary cable ground to the same electrical ground as the wrist strap Open the equipment enclosure and remove the failed PC board Carefully open the ESD protective bag and re move the replacement PC Board Install the replacement P
93. e Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode PCB 102 Test points located on PCB 1 eur Meter 3 If the test reveals a failed component replace Main PCB 1 PCB 5 IGBT Test With 2 removed from unit 1 Using ohmmeter perform the following checks Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode PCB 5 Q1 Test points located Meter meer PMTH 1 PMTH 2 PRI 1 PRI 1 PMTH 1 PMTH 2 PRI 2 PRI 2 SERVICE on PCB 5 Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Forward Biased Diode 5 24 PCB 5 Q2 Test points located on PCB 5 Meter PMTH 3 Forward Biased Diode PMTH 4 Reverse Biased Diode PRI 4 Reverse Biased Diode PRI 4 Forward Biased Diode PMTH 4 Forward Biased Diode PMTH 3 Reverse Biased Diode PRI 3 Reverse Biased Diode PRI 3 Forward Biased Diode If the test reveals a failed component replace 40Amp PCB 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 de
94. e as shown below Torch Shield Cup Standoff Distance 1 8 3 8 3 9mm Standoff Distance 3 Hold the torch away from your body 4 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will Start Trigger Release A 02986 5 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch OPERATION AT 4 Trigger 4 P 6 Cut as usual Simply release the trigger assembly to stop cutting 7 Follow normal recommended cutting practices as provided in the power supply operator s manual NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components 8 For a consistent standoff height from workpiece install the standoff guide by sliding it onto the torch shield cup Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc During operation posi tion the legs of the standoff guide against the workpiece Shield Cup
95. e problem 3 Faulty components in unit 1 Air flow through or around the unit is obstructed 2 Duty cycle of the unit has been exceeded 3 Failed components in unit 1 Gas supply not connected to unit 2 Gas supply not turned ON 3 Gas supply pressure too low 4 AIR PRESSURE CONTROL regulator set too low 5 Failed components in unit 1 Shield Cup loose 2 Torch not properly connected to power supply 3 Problem in torch and leads PIP Circuit 4 Failed components in unit 1 Start signal is active when ON OFF SWITCH is turned to ON position 2 Problem in the torch and leads Switch circuit 3 Failed components in unit Recommended Action 1 Turn primary power disconnect switch to ON position 2 a Have qualified person check primary fuses breakers b Connect unit to known good primary power receptacle 3 Return to authorized service center for repair or replacement 1 Check that appropriate line voltage is connected to unit 2 Have qualified person check primary voltage to insure it meets unit requirements see section 2 04 3 Return to authorized service center for repair or replacement Refer to clearance information section 2 04 Allow unit to cool Return to authorized service center for repair or replacement Connect gas supply to unit Turn gas supply ON Set air supply inlet pressure to unit to 120 psi Adjust regulator to set air pressure see section 4 02
96. ective 40A PCB 5 Measure for 12VDC on the 40A PCB 5 between J4 4 to J4 10 Replace 40A 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 volt age is not present Defective Logic PCB 3 a Change Logic PCB 3 Manual 0 5085 AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing 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 Mea sure voltage on Logic PCB 3 between J3 1 to J3 2 If voltage is more than 2VDC replace Pressure Transducer Faulty Logic PCB 3 a Replace Logic PCB 3 M INTERNAL ERROR FAULT Indicator and 90 PSI LED flashing There has been 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
97. ed to unit 1 Air pressure source to unit is too low 3 Problem with torch and leads PIP circuit a Set input pressure source to 90 100 PSI 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 a Adjust unit regulator to increase pressure or PIP switch Negative Plasma L _ 3 Defective Logic 3 eee a Measure for 5VDC on the Logic PCB 3 be tween J3 3 to J3 1 Replace Logic PCB 3 if voltage is not present or low 4 Torch Switch A 2 Regulator set too low b Measure for voltage on the Logic PCB 3 be 3 Torch Switch Urs MTS Mi S tween J3 2 to J3 1 If the voltage is between 9 PIP a A 3 4 5VDC replace the Logic PCB 3 4 Defective Pressure Transducer a Replace Pressure Transducer Pilot Lead S G INPUT POWER FAULT AC LED ON FAULT Indicator and 65 PSI LED flashing 4 Defective Logic PCB3 1 Primary line voltage out of tolerance range a Measure the voltage on Main PCB 1 between J2 17 to test point GND1 for 12VDC If the a Connect unit to voltage with unit specifica voltage is less than 2VDC replace Logic PCB tions See section 2 04 Power supply speci fications If using a generator connect unit 5 Defective Main PCB 1 to receptacle to see if problem is cor a Replace Main PCB 1 rected 2 Defective Main PCB 1 a Measure voltage on Main PCB 1 between test point GND1 t
98. eding OPERATION CUTMASTER 40mm 4T 02Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Cut quality requirements differ depending on application For instance nitride build up and bevel angle may be major factors when the sur face will be welded after cutting Dross free cut ting is important when finish cut quality is desired to avoid a secondary cleaning operation The following cut quality characteristics are illustrated in the following figure Kerf Width m 98 Dross Build Up Cut Surface Bevel Angle Rounding A 00007 Cut Surface Drag Lines Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece OPERATION 4 2 Bottom Dross Buildup Molten material which i
99. efer to the following standards or their latest revisions for more information 1 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NA
100. einstall the power supply cover H ON OFF Switch SW1 Replacement Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Disconnect the wires on the rear of the switch noting the location and orientation of each wire as shown below Switch Art 08169 3 Squeeze together the clips on the back of the switch then remove the switch through the front panel 4 Install the replacement switch by reversing the above steps 5 Reinstall the power supply cover PARTS REPLACEMENT 7 4 Fan MOT 1 1 2 3 7 Remove the Cover per subsection 7 04 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 T 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
101. es away from the torch tip and op erator rather than directly back into it until the pierce is complete Ina portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line Hold the torch per pendicular to the workpiece after the pierce is complete Hold the torch away from your body Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start OPERATION Trigger Release A 02986 6 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTES The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components 7 Clean spatter and scale from the shield cup and the tip as soon as possible Spraying the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Cutting 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 4T 6 T
102. est continuity between terminals while engag ing the contacts manually This can be done by pushing down on the recessed actuator button on the top of W1 or pushing down on the actuator arm on the side of W1 L1to T1 L2to T2 L3 to T3 L4 to T4 The contacts should be closed Continuity 3 Visually check W1 contact points To take the cover OFF remove the two cover screws shown in the previous illustration If contacts are stuck together or show excessive arcing or pitting re place W1 B PCB 1 Input Diode D1 Test 1 Using ohmmeter perform the tests in the chart Input Diode Module D1 on PCB 1 Test points located on PCB 2 Meter Meter 80A_AC1 MTH 1 80A_AC2 MTH 1 80A_AC3 MTH 1 MTH 1 80A_AC1 MTH 1 80A_AC2 Indication Forward Biased Diode Forward Biased Diode Forward Biased Diode Reverse Biased Diode Reverse Biased Diode MTH 1 80A_AC3 MTH 7 80A_AC1 MTH 7 80A_AC2 Reverse Biased Diode Forward Biased Diode Forward Biased Diode CUTMASTER 40MM C PCB 5 Input Diode D1 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 40A_AC1 40A_AC2 40A_AC3 PMTH 1 PMTH 1 PMTH 1 PMTH 4 PMTH 4 PMTH 4 40A_AC1 40A_AC2 40A_AC3 PMTH 4 Meter PMTH 1 PMTH 1 PMTH 1 40A_AC1 40A_AC2 40A_AC3 40A_AC1 40A_AC2 40A_AC3 PMTH 4 PMTH 4 PMTH 4 PMTH 1 Indication Forward Biased Diode Forward Biased Diode Fo
103. ffice Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OPERATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Miami FL 33126 NIOSH LA SECURITE ET LA SANTE LORS DES OPERATIONS DE COUPE DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 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 741 1 NORMES POUR LES CHAUSSURES TECTRICES disponible aupr s de National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z49 2 PREVENTION DES INCENDIES LORS DE L EMPLOI DE PROCEDES DE COUPE ET DE SOUDAGE disponible aupr s de 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
104. for wear or foreign debris 3 For Automation Torch only Tip 3 Cut with Tip OFF the plate contacted work piece during cut ith output correct set above 45 For these modes to reset the machine remove the START signal 1 Internal Error 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized service center for repair 1 Work cable not connected to 1 Connect work cable ork piece 2 Work cable connector broken 2 Replace work cable 3 Failed components in unit 3 Return to an authorized service center for repair 1 Incorrect current setting 1 Check and adjust to proper setting 2 Worn torch consumables 2 Check torch consumables and replace as needed 3 Poor work cable connection to 3 Check the connection of the Work Lead to the work piece ork piece 4 Torch being moved too fast 4 Reduce cutting speed 5 Excessive oil or water in torch Refer to Check air quality in section 3 Torch 6 Failed components in unit 6 Return to an authorized service center for repair 5 7 SERVICE CUTMASTER 40MM 5 06 Circuit Fault lsolation A WARNING Se The following procedures should not be attempted by anyone who has not had proper training or authorized to do so A Cover Removal 1 Removethe NOTE 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
105. garding 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 HAZARD OUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Manual 0 5085 CUTMASTER 40mm GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases 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 Vou must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Merc
106. hange 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 SERVICE S AC LED ON TEMP LED is OFF GAS LED is ON Fan MOT 1 turns ON plasma gas not flowing Earlier revision units 1 Openconnection between J2 connector on Capaci tor PCB 2 to J3 connector on 40A PCB 5 a 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 a Disconnect plug from J2 connector on Capaci tor PCB 2 and measure for 12VDC between J2 1 to J2 2 If low or missing replace PCB 2 4 Defective 40A PCB 5 a Disconnect plug from J4 on 40A 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 flow 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 a For hand torches check continuity of torch switch circuit at ATC pins 3 amp 4 Negative Plasma Lead re VUA XS TK Pilot Lead 3 Torch Switch 2 PIP 1 PIP Art 08124 b For machine t
107. hysical strength should lift the unit Lift 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 Manual 0 5085 CUTMASTER 40mm 3 03 Primary Input Power Connections A CAUTION Check your power source for correct voltage before plugging in or connecting the unit The primary power source fuse and any extension cords used must conform to local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 Connections for Three Phase Input Power WARNING Disconnect input power from the power supply and input cable before attempting this procedure These instructions are for installing the input power cable to the power supply and connecting to 380 400 415VAC three phase Primary Input Power 1 Remove the Power Supply cover per in structions found in section 5 2 Loosen the strain relief on the back panel of the power supply 3 Using a customer supplied four conductor input power cable for rated voltage strip back the insulation on the individual wires 4 Pass the cable being used through the input cable opening strain relief in the back panel of the power supply Refer to Sec tion 2 for power cable specifications A CAUTION The primary power source and
108. if fitting does not move freely A Open conductor in torch leads 4 Replace torch and leads or return to authorized service center or repair or replacement 5 Problem in the torch and leads 5 Replace torch and leads or return to authorized service center switch circuit or repair or replacement 6 Failed components in unit 6 Return to authorized service center for repair or replacement 1 Problem in the torch and leads 1 Take Torch and Leads Remote Pendant to Authorized Repair switch circuit Remote pendant Facility switch circuit 2 CNC Contoller device not 2 Contact Controller manufacturer providing Start signal 3 Failed components in unit 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 rong position upper O Ring position correct if necessary 2 Torch start cartridge is stuck 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 Worn or faulty torch parts 3 Inspect torch consumable parts Replace if necessary 4 Shorted Torch 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
109. king ring towards the Sole noid while pulling the Solenoid away from the 5 Install the replacement Gas Solenoid by reversing the above steps 6 Reinstall the power supply cover 7 3 PARTS REPLACEMENT CUTMASTER 40mm G Logic PCB PCB 3 Replacement Work Cable Replacement Tools required T20 Torx Driver Flat Screw Driver gt Tools required T20 Torx Driver wrench 1 Remove the cover per subsection 7 04 A 2 Remove the two large and one small gas hoses from the pressure regulator per subsection 7 05 3 Unplug the connector J2 from the Main PCB 4 Disconnect cable from the Pressure Transducer 5 Disconnect front panel from base per subsection 7 04 D 6 Remove the Current Control Potentiometer Knob and nut securing the potentiometer shaft to the front panel per subsection 7 05 A 7 2 5 7 06 Left Side Internal Parts 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 Replacement A Fan Replacement 7 Remove the Function Control Switch Knob and the nut securing the switch shaft to the front Tools required T20 Torx Driver panel per subsection 7 05 B 8 Install the replacement Logic PCB by reversing the above steps 9 R
110. lasma gas and electric arc through a small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arcis shown in Zone Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast slag free cut Manual 0 5085 CUTMASTER 40mm B Gas Distribution E Parts In Place PIP The single gas used is internally split into plasma The torch includes Parts In Place PIP circuit and secondary gases When the shield cup is properly installed it closes a switch The torch will not operate if this switch The plasma gas flows into the torch through the is Open negative lead through the starter cartridge around P c the electrode and out through the tip orifice Torch Switch Torch Trigger 1 The secondary gas flows down around outside e Wiring 9 6 of the torch starter cartridge and out between the bre tip and shield cup around the plasma arc PIP Switch Shield Cup O Pilot Arc Parts In Place Circuit Diagram for Hand Torch When the torch is started a pilot arc is established between the electrode and cutting tip This pilot Remote Pendant arc creates a path for the main arc to transfer to the
111. ll need to be ordered Art 08759 NOTE Illustration may vary slightly from unit Manual 0 5085 6 5 PARTS LIST CUTMASTER 40mm 6 08 Options and Accessories ee PARTS LIST Description Ref Single Stage Filter Kit includes Filter amp Hose Replacement Filter Body Replacement Filter Hose not shown Replacement Filter Element Two Stage Filter Kit includes Hose Bracket amp Mounting Screws Bracket Filter Mounting not shown Two Stage Air Filter Assembly First Stage Cartridge Second Stage Cartridge Extended Work Cable 50 ft 15 2 m with Clamp Automation Interface Kit for Start Stop OK to move and Divided Arc Voltage Automation Harness for Start Stop and OK to move 25 7 6 m CNC Cable for Automation Interface Kit 35 10 7 CNC Cable for Automation Interface Kit 50 15 2 m CNC Cable for Automation Interface Kit Housing Filter Element Cat No 9 7741 Soo O ring Cat No 9 7743 Assembled Filter Cover a5 Fitting Art A 02476 Optional Single Stage Filter Kit Stage Cartridges as marked Optional Two Stage Filter Kit log 7 7507 9 7740 9 7742 9 7741 9 9387 9 9386 9 7527 9 1021 9 8529 First amp Second Art A 02942 Manual 0 5085 CUTMASTER 40mm 6 09 Replacement Parts for Hand Torch
112. ment as sembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration Manual 0 5085 6 Disconnect the input line from the filter element assembly 7 Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disas sembly Art 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 Input Power Cable Replacement Tools required Phillips Head Screwdriver Flathead Screwdriver 1 Remove the Cover per subsection 7 04 A 2 Disconnect the input cable wires from the W1 contactor terminals and ground lug For CE units Disconnect input cable from the CE Input Power Filter 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 revers ing above steps 6 Reinstall the power supply cover Manual 0 5085 CUTMASTER 40mm 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 Fil
113. mme suit La fum e et les gaz produits par le proc d de jet de plasma peuvent NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me A ATTENTION Toute proc dure pouvant r sulter l endomma gement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question A AVERTISSEMENT Fournit l information concernant des dommages possibles de choc lectrique Des avertissements seront enferm s dans une bo te de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn ti que 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
114. mum setting to minimum setting Current adjusts from 120 amps down to 30 amps 3 Set the CURRENT CONTROL POTENTIOM ETER to maximum position 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 e Tip Saver circuit will activate 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 Lift tip 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 Cutting arc extinguishes Gas solenoid closes Gas flow stops momentarily then restarts when solenoid opens e Pilot arc ignites 7 Open the torch switch e DCLED turns OFF After 20 second post flow time Gas solenoid closes Gas flow stops 8 Set the FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode 9 Provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc 10 While cutting keep the torch switch closed and bring the torch OFF the edge of the material Pilot Arc re ignites immediately Manual 0 5085 11 Open the torch swi
115. nnection together Do not use tools to secure the connection 3 The system is ready for operation Manual 0 5085 CUTMASTER 40mm Check Air Quality To test the quality of air 1 Put the awl OFF switch in the ON up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn on the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02Setting Up Mechanical Torch NOTE An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine torch WARNING Disconnect primary power at the source before disassembling the torch or torch leads The mechanical torch includes a positioning tube with rack and pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the sur face of the workpiece 3T 1 INSTALLATION CUTMASTER 40mm Pinch Block Assembly Workpiece A 02585 Mechanical Torch Set Up 3 The proper torch parts shield cup tip start cartridge and electrode must be installed for the type of operation Refer to Section 4T 07 Torch Parts Selection for details INSTALLATION 3T 2 Manual 0 5085 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering Identification 1 Output
116. normally present on the bot tom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding 4T 04Hand Torch Operation Standoff Cutting With Hand Torch AT 3 NOTE For best performance and parts life always use the correct parts for the type of opera tion 1 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the holding technique that feels most comfort able and allows good control and move ment NOTE The tip should never come in contact with the workpiece except during drag cutting operations OPERATION CUTMASTER 40mm 2 Depending on the cutting operation do one of the following a For edge starts hold the torch perpen dicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start b For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiec
117. notes 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 5085 CUTMASTER 40MM This Page Intentionally Blank Manual 0 5085 5 25 SERVICE CUTMASTER 40MM 5 12 Main PCB Layout amp Signals J2 PINOUT TP2 ciel p EOD eem pooh PRI 2 AO S8 FERE g wet DII om 12V2 VOU TY a 7 2 waite TE 4811 D78 Com gr ge i 2S messes cu A E h 8 J11 J9 J8 J7 J6 J5 Art A 08518 AB CHOKE1 SEC2 121 WORK 1 GND2 MAIN PCB 1 LAYOUT A 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 SERVICE 5 26 Manual 0 5085 4 2 3 2 4 2 5 2 6 p J2 8 2
118. ns or to LATCH is used for specific applications torch switch can be released after main arc transfer RESULT Gas flow stops ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts PILOT ARC ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfers Pilot arc off ACTION ACTION Unplug input power cord or open external disconnect ON OFF switch to OFF RESULT RESULT All indicators off No power to system Power supply fans shut off Art A 08793 A 1 APPENDIX CUTMASTER 40MM APPENDIX 2 DATA TA INFORMATION THERMAL DYNAMICS A THERMADYNE Company West Lebanon NH USA 03784 Manufacturer s Name and or Logo Location Model and Model S N Revision Level Serial Number Date of Mr Made in USA and Production Code Type of Power zl Regulatory Standard Covering Supply Note 1 VS This Type of Power Supply Output Current Type Duty Cycle Factor Output Range Amperage Voltage Plasma Cutting Symbol TT X Uo Duty Cycle Data Note 3 U2 Rated d Conventional Load Voltage Load Voltage Rated Maximum Supply Current Input Power Symbol NN U4 4g 10
119. o J2 22 400 VAC input approximately 2 6 VDC If voltage is less than 2VDC replace Main PCB 1 3 Defective Ribbon cable a Check continuity of the ribbon cable connect ing between the Main PCB 1 and the Logic PCB 3 4 Defective Logic PCB 3 a Replace Logic PCB 3 Manual 0 5085 5 13 SERVICE CUTMASTER 40MM 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 CNC START signal is active low Release the START signal source 2 Problem in the torch and leads switch circuit a Check continuity of torch switch circuit at 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 cycles 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 sys tem Remove the shield cup tip start cartridge and elect
120. ogic PCB 3 a Measure Logic PCB 3 CUR_SET signal be tween J1 6 to TP1 If no voltage replace PCB SERVICE CUTMASTER 40MM b Measure Logic PCB 3 for SHDN signal be tween J1 10 to TP1 Normally 12VDC signal should drop to less than 1VDC when START signal is active If voltage does not drop re place PCB 3 c Measure Logic PCB 3 Signal 400_IN between J1 4 to TP1 for less than 2VDC If signal measures 12 VDC replace the Logic PCB3 12 Defective Main PCB 1 a Measure for approximately 325VDC on Ca pacitor PCB 2 between MTH 1 to MTH 7 under load If voltage is not present replace PCB 1 13 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 14 Defective 40Amp PCB 5 a Isolate the 40A PCB 5 by disconnecting plug from J4 the Sync cable from J9 and the wire from terminal CHOKEI Supply a START signal If the FAULT is cleared replace PCB 5 15 Defective Main PCB 1 a Replace PCB 1 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 set tings above 45 amps the tip has contacted the work piece a Check standoff height 2 Air restriction in torch resulting in low voltage during pilot a Check torch consumables for wear or debris 3 Low voltage during cutting due to
121. omes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 5085 1 7 GENERAL INFORMATION CUTMASTER 40mm This Page Intentionally Blank GENERAL INFORMATION 1 8 Manual 0 5085 SECTION 2 SYSTEM INTRODUCTION 2 01 How To Use This Manual This Service Manual applies to just specification or part numbers listed on page 1 To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows NOTE An operation procedure or background infor mation which requires additional emphasis or is helpful in efficient operation of the system A CAUTION A procedure which if not properly followed may cause damage to the equipment WARNING A procedure which if not properly followed may cause injury to the operator or others in the op erating area A WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box such as this Additional copies of this manual may be purchased by contacting Thermadyne at the address and
122. onnect Primary Line power to the unit 2 Turn the ON OFF SWITCH SW1 to ON position and observe the following Software version is displayed See section 5 04 Fault Indicators After approximately three 3 seconds Inrush relay on PCB 1 energizes starting pre charging of working capacitors AC and GAS Indicators come ON Gas flows After 4 seconds W1 energizes For earlier units Fan MOT 1 turns ON for one 1 second then shuts OFF Manual 0 5085 CUTMASTER 40MM 3 Adjust the pressure regulator to set the gas pres sure as specified in charts STANDOFF CutMaster 102 Gas Pressure Settings Leads Length SL100 SL100 Hand Torch Torch Up to 25 75 psi 75 psi 7 6 m 5 2 bar 5 2 bar Each additional Add 5 psi Add 5 psi 25 7 6 m 0 4 bar 0 4 bar CutMaster 102 Gas Pressure Settings Leads SL100 Length Mechanized Torch 80 psi 5 5 bar Add 5 psi 0 4 bar Up to 25 7 6 m Each additional 25 7 6 m 4 Turn FUNCTION CONTROL SWITCH to RUN position Solenoid turns OFF gas stops flowing pres sure display may increase slightly when gas is not flowing This completes the Main Input and Internal Power Test If the above are all correct then proceed to the next section Pilot Arc Test If the unit does not function as stated above then note the symptom and proceed to Section 5 07 Main Input and Internal Power Problems 5 9 SERVICE CUTMASTER 40MM F
123. onnect input power before maintaining conditions Each Use Visual check of torch tip and electrode Weekly 42 oe SS mmm 7 gt Visually inspect the torch body tip Replace as needed electrode start cartridge and shield cup 3 Months Replace all Clean broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 07938_AB Manual 0 5085 5 1 SERVICE CUTMASTER 40MM 5 02 Maintenance Schedule 5 03 Common Faults Problem Symptom NOTE The actual frequency of maintenance may need to be adjusted according to the operating environ ment Daily Operational Checks or Every Six Cutting Hours 1 Check torch consumable parts replace if dam aged worn or when cut performance has dimin ished Insufficient Penetration Main Arc Extinguishes 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics parts used 7 Incorrect gas pressure 1 Cutting speed too slow 2 Torch standoff too high from workpiece 2 Check pl d d ly and P pod rx EL 3 Cutting current too high 4 Work cable disconnected 3 Purge plasma gas line to remove any moisture 5 Worn torch parts build up Weekly or Every 30 Cutting Hours Excessive Dross 6 Non Genuine Thermal Dynamics parts used 1 Cutting
124. or SERVICE CUTMASTER 40MM 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 second and then turns OFF The fans will turn ON when a START signal Torch Switch Remote Pendant switch or CNC START is active and will remain ON for ten 10 minutes after the START signal is removed If an over temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condition is cleared SERVICE 5 4 Manual 0 5085 CUTMASTER 40MM This Page Intentionally Blank Manual 0 5085 5 5 SERVICE CUTMASTER 40MM 5 05 Basic Troubleshooting Guide A WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose repair unless you have had training in power electronics measurement and troubleshooting techniques Problem Symptom Possible Cause indicators flashing SERVICE 1 Primary power disconnect is in OFF position 2 Primary fuses breakers are blown or tripped 3 Faulty components in unit 1 Incorrect Primary line Voltage 2 Primary input voltag
125. orch parts wear Air quality Line voltage fluctuations Torch standoff height Proper work cable connection Manual 0 5085 4T 05Gouging WARNING Be sure the operator is equipped with proper gloves clothing eye and ear protection and that all safety precautions at the front of this manual have been followed Make sure no part of the operator s body comes in con tact with the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power supply A CAUTION Sparks from plasma gouging can cause damage to coated painted or other surfaces such as glass plastic and metal Check torch parts The torch parts must correspond with the type of operation Refer to Section 4 07 Torch Parts Selection Gouging Parameters Gouging performance depends on parameters such as torch travel speed current level lead angle the angle between the torch and workpiece and the distance between the torch tip and workpiece standoff A CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear Torch Travel Speed NOTE Refer to Appendix Pages for additional infor mation as related to the Power Supply used Optimum torch travel speed is dependent on current setting lead angle and mode of operation hand or machine torch Current Setting Current settings depend on torch travel speed mode of operation han
126. orches using a remote pendant check continuity of Pendant switch circuit c Check CNC START signal 2 Defective Logic PCB 3 Manual 0 5085 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 I_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 I DMDI for 1 4 VDC Replace PCB 1 if voltage is present B SHORTED TORCH OUTPUT FAULT Fault indicator and 85 PSI Indicators are flashing at 1 cycle per second This is a Latched Failure Mode After START signal is activated 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 posi tion a Remove shield cup from torch check position of the upper o ring and correct if needed Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art A 03725 2 Torch start cartridge is stuck a Turn OFF power supply Bleed down the sys tem Remove the shield cup tip start cartridge and electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not
127. ore thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air A Art 03791 CAUTION ATC O Ring Dry the torch thoroughly before reinstalling NOTE O Ring Lubrication DO NOT use other lubricants or grease they An o ring on the Torch Head and ATC Male Connec may not be designed to operate within high tor requires lubrication on a scheduled basis This temperatures or may contain unknown ele will allow the o rings to remain pliable and provide ments that may react with the atmosphere a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to potential performance problems 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 lubricant Catalog 8 4025 to the o rings on a weekly basis Manual 0 5085 5T 1 SERVICE CUTMASTER 40mm 5T 02Inspection and Replacement of Consumable Torch Parts A WARNING Disconnect primary power to the system be fore 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
128. orn 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 GENERAL INFORMATION CUTMASTER 40mm 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 tibles Provide a fire watch when working 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 decibel
129. plugged in Check con tinuity b Measure voltage at J4 2 to J4 10 on 40Amp PCB 5 for 12VDC The voltage should drop to less than 2VDC after a START signal is ac tive 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 40 PCB 5 a Measure the voltage between J1 1 to J1 2 on the 40AMP PCB 5 for 12VDC after the START signalis activated If 12VDC is present replace 40AMP PCB 5 3 Defective Fans MOT 2 and 3 a If 12VDC is present on J1 and J2 connectors on 40A PCB 5 replace fans MOT 2 amp MOT 3 Manual 0 5085 CUTMASTER 40MM 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 con nection of cable to clamp is secure B 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 40A PCB 5 is broken loose or missing Wires SEC1 and SEC2 routed to close to compo nent U2 on 40A PCB 5 Re route to space a least
130. power cable must conform to local electrical code and the recom mended circuit protection and wiring require ments refer to table in Section 2 3 1 INSTALLATION CUTMASTER 40mm 5 Connect the wires as follows For non CE units gt p lt lt DES Art A 08753 Terminal d Three phase wires to L1 L2 and L3 on the W1 contactor It does not matter what order these wires are attached See previous illustration and on label in the power supply e Green Yellow wire to Ground Termi nal For CE units EMC Input Power Filter Art A 08752 AA Three phase wires to L1 L2 and L3 on the CE Input Power Filter It does not matter what order these wires are at tached See previous illustration and on label in the power supply Green Yellow wire to Ground 6 With a little slack in the wires tighten the strain relief to secure the power cable 7 Reinstall the Power Supply cover per in structions found in section 5 8 Connect the opposite end of individual wires to a customer supplied plug and plug into an appropriate input power receptacle or connect directly to main disconnect 9 Close the main disconnect switch to supply power to the unit INSTALLATION 3 04 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders Refer to the following two subsections if an optional air line filter is
131. rch With Shielded Tip AT 15 TABLE OF CONTENTS PATENT INFORMATION 4 20 SECTION 5 SERVIC E det vx x de ERR 5 1 5 01 General Maintenance session reset weed evo ee rd eto 5 1 5 02 Maintenance 5 2 5 03 Common Faults iii 5 2 5 04 cT ERA 5 3 5 05 Basic Troubleshooting Guide 5 6 5 06 Circuit geret 5 8 5 07 Main Input and Internal Power 5 12 5 08 Pilot Arc Problems 5 16 5 09 Main Arc and Controls Problems 5 19 5 10 CNC Interface Problems sistema 5 20 5 11 TOSEPIOCCQUIOS naines 5 20 5 12 M in PCB Layout dr 5 26 5 13 Capacitor PCB Layout amp 5 30 5 14 Logic PCB Layout Signals 5 32 5 15 40AMP Logic PCB Layout amp Signals 5 34 5 16 Right Side Wiring Diagramm m Eee eie 5 36 SECTION 5 TORCH SERVICE seed oci a en 5T 1 5T 01 General Maintenance iii 5T 1 5T 02 Inspection and Replacement of Consumable Torch 5T 2 SECTION 6 PARTS EIST S vii
132. ressure Total flow rate includes plasma and secondary gas flow Manual 0 5085 CUTMASTER 40mm PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U S and Foreign Patents as follows Patent s Catalog 9 8215 9 8213 9 8205 9 8206 9 8207 9 8252 9 8208 9 8209 9 8210 9 8231 9 8211 9 8212 9 8253 9 8225 9 8226 9 8227 9 8228 9 8241 9 8243 9 8235 9 8236 9 8237 9 8238 9 8239 9 8244 OPERATION Description Electrode Cartridge Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Tip Shield Cap Shield Cap Shield Cap Shield Cap Shield Cup Shield Cap Shield Cap Shield Cap 4T 20 6703581 D504142 Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa Other Pa US Pat No s 6163008 6987238 Other Pat s Pending US Pat No s 6903301 6717096 6936786 D496842 D511280 D492709 D499620 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 Other Pat s Pending US Pat No s 6774336 7145099 6933461 t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending t s Pending US Pat No s 6914211 D505309 t s Pen
133. rode 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 08064 SERVICE Open conductor in torch leads a Check continuity Defective Main PCB 1 b Measure voltage between J2 2 connector on Main PCB 1 to test point for 12VDC If voltage is present replace Main PCB 1 Defective Logic PCB 3 a Replace Logic PCB3 K AC LED ON yellow TEMP LED is ON red FAULT Indicator is flashing all three fans turn ON Air flow through unit is restricted a Provide adequate airflow See Ventilation Clearance Requirements section 2 04 2 Exceeded duty cycle of the power supply a Allow unit to remain ON but at idle with fan running to cool power supply See Power Supply Specifications section 2 04 for duty cycle information 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 CNC START is active and will remain ON for ten 10 minutes after the START signal is removed If an over temperature condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period after the condition is cleared Def
134. rward 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 Using an ohmmeter perform the tests in the chart INPUT CAPACITORS PCB 2 Meter Meter Indication MTH 2 MTH4 Charging MTH 8 MTH7 Charging MTH 7 80A AC1 80A AC2 80A AC3 MTH 7 Manual 0 5085 80A AC3 MTH 7 MTH 7 MTH 7 MTH 1 Forward Biased Diode Reverse Biased Diode Reverse Biased Diode Reverse Biased Diode 2 Forward Biased Diodes Most meters will show a charging action Initially a low resistance will be shown and then the resistance will start to increase If the meter probes are reversed the reading will decrease to zero then start charging in the opposite polarity 2 Using an ohmmeter perform the tests in the chart INPUT VOLTAGE SELECTION RELAYS PCB 2 Meter Meter Indication Charging Charging Charging MTH 7 MTH 4 MTH 8 MTH 2 MTH 8 MTH 4 5 21 SERVICE SERVICE CUTMASTER 40MM E PCB 1 IGBT Test 1 Disconnect transformer wire from PCB 2 Terminal A 2 Using an ohmmeter check continuity between the following points PCB 1 01 Test points located 2 Forward Bias Capacitor Charging Capacitor Charging Forward Bias Forward Bias Capacitor Charging Capacitor Charging Forward Bias 3
135. s sound do not exceed safe levels For information on how to test for noise see item 1 in Subsec tion 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC 749 1 Minimum Protective Suggested Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece Ph LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq GENERAL INFORMATION 1 03 Publications R
136. s Steel Type Secondary Gas Single Gas Torch Type Torch SL100 With Shielded Tip Type Plasma Gas Air z Duy Ge us v8 2 6 s wo 040 055 64 ous es as 0 sa o omw es 45 ws so 100 0 o s om ous az s 45 wm un 5 om 2 es as so u un 123 133 135 144 137 w 8 Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip 25 4 0 500 12 7 9 8211 0 625 15 9 9 8211 0 750 19 1 0 875 22 2 9 8211 000 1 s aso 45 ns su oo oz 51 x ns es 6 4s ws on oz 51 eo 625 es 4s ws on oz 51 na m 170 425 1 2 ss 45 ws 90 o 02 sa oso we e 213 ss 4s ws su os oz 51 Type Torch 51100 With Shielded Type Material Aluminum Type Secondary Gas Single Gas Torch Type Plasma Gas Air Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip ba DITES zi Fo saan ws s sm ui 32 6 as vs 30 sear vo ao 20 sz
137. s 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 unit B Cover Installation 1 Reverse previous procedures for cover installa tion NOTE When installing the upper screws attempt to reuse the original threads The easiest way to do this is by turning the screw counter clockwise until you feel the threads line up then begin to turn the screw clockwise to tighten Do not over tighten PARTS REPLACEMENT C Tube Handle Replacement Tools required T20 Torx Driver D 7 2 5 Remove the cover per subsection 7 04 A Remove the screws securing the tube handles to the base of the unit Remove the Tube Handles Replace the Tube Handles by reversing the above steps Reinstall the power supply cover Disconnecting Front and Rear Panels from the base In many of the replacement procedures it may be help ful to disconnect the front or rear panel from the base in order to allow more room to access the parts Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 While grasping the panel close to the base pull the panel directly from the base to release the locking tabs 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
138. s not blown out of the cut area and resolidifies on the plate Excessive dross may require secondary cleanup operations after cutting Kerf Width The width of the cut or the width of material re moved during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has become elongated 4T 03General Cutting Information WARNING Disconnect primary power at the source be fore disassembling the power supply torch or torch leads Frequently review the Important Safety Pre cautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece while the torch is activated 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 Manual 0 5085 Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also signifi
139. sor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error 2 Defective Logic PCB 3 a Replace Logic PCB 3 5 10 CNC Interface Problems A Nothing happens when jumper is installed between J2 3 to J2 4 1 Defective Automation Interface PCB 4 a Measure voltage on PCB 4 between J1 6 to J1 8 for 12VDC If 12VDC is present replace Automation Interface PCB 4 2 Defective Main PCB 1 a Measure voltage on Main PCB 1 between J1 6 to J1 8 for less than 2VDC If voltage is less than 2VDC replace Main PCB 1 SERVICE 5 20 B No OK TO MOVE signal while cutting 1 Defective Main PCB 1 a Measure voltage on PCB 4 between J1 1 to J1 3 for 12VDC while cutting If 12VDC is present replace PCB 1 2 Defective Automation Interface PCB 4 a Measure voltage on PCB 4 between J1 1 to J1 3 for less than 2VDC while cutting If voltage is less than 2VDC replace PCB 4 C ARC VOLTS signals are low or not present 1 Defective Automation Interface PCB 4 a Replace PCB 4 5 11 Test Procedures A Main Contactor W1 Test 1 Check continuity between L1 to T1 L2 to T2 L3 to T3 L4 to T4 The contacts should be open no continuity If con tinuity is found disconnect J1 from the Main PCB 1 and recheck If continuity still exists replace W1 If disconnecting J1 from Main PCB 1 removes the short replace the Main PCB 1 Cover Screws Art 08704 Manual 0 5085 Ret
140. sponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 INFORMATIONS G N RALES CUTMASTER 40mm 1 07 Declaration of Conformity Manufacturer Thermal Dynamics Corporation Address 82 Benning Street West Lebanon New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive 2006 95 EC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC 50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 50192 EN50078 applicable to plasma cutting equipment and associated accessories For environments with increased hazard of electric
141. stem WARNING EE eae Always turn OFF the air supply and bleed the system before disassembling the Filter As sembly as injury could result Loosen the two bolts on the top of the Filter As sembly enough to allow the Filter Elements to move freely Note the location and orientation of the old Filter Elements Slide out the old Filter Elements First amp Second Stage Cartridges Optional Two Stage Filter Replacement Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 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 Slowly apply air pressure to the assembly check ing for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures PARTS REPLACEMENT 7 08 Right Side Internal Parts Replacement A Capacitor PCB PCB 2 Replacement Tools required T20 Torx Driver 2 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 2 3 Remove the Cover
142. taneously squeezing the trigger The pilot arc will start Trigger Release A 02986 7 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch Trigger 4 U 8 Cut as usual Simply release the trigger assembly to stop cutting 9 Follow normal recommended cutting practices as provided in the power supply operator s manual OPERATION CUTMASTER 40mm NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components Piercing With Hand Torch 1 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the technique that feels most comfortable and allows good 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 particl
143. tch DCLED turns OFF After 20 second post flow time Gas solenoid closes Gas flow stops For Automation Torches Skip steps 12 amp 13 12 Set the FUNCTION CONTROL SWITCH to LATCH mode 13 Start a cut and remove the START signal Maincutting arc will remain ON until the torch is lifted away from the plate approximately 34 19 mm or until the torch is brought OFF the edge of the metal Once the arc has extinguished DCLED turns OFF After 20 second post flow time e Gas solenoid closes Gas flow stops e Ten 10 minutes after the Start signal is re moved the cooling fans turn OFF This completes the Main Arc and Controls Test If the above are all correct then proceed to the next section H CNC Interface Test If the unit does not function as stated above then note the symptom and proceed to Section 5 09 Main Arc and Controls Problems H CNC INTERFACE TEST If the unit has one of the two factory supplied options for CNC interface installed proceed with this section otherwise the tests are complete 1 Connect an ohmmeter between CNC connector Pins 12 amp 14 OK TO MOVE signal Position the torch to pilot Check the OK TO MOVE signal by connecting a jumper between CNC connector pins 3 amp 4 START Pilot arc is established 2 Bring the torch to the work piece and transfer to cutting arc OK TO MOVE signal is present Meter shows continuity Manual 0 5085 CUTMASTER 40MM 3
144. ter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele ment 3 Disconnect gas supply hose 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 Spring O ring Cat No 9 7743 Assembled Filter Cover Barbed Fitting Art A 02476 Optional Single Stage Filter Element Replacement 5 Remove the Filter Element from the Housing and set Element aside to dry 6 Wipe inside of housing clean then insert the replacement Filter Element open side first 7 Replace Housing on Cover 8 Reattach gas supply 9 Reinstall the power supply cover NOTE If unit leaks between housing and cover inspect the O ring for cuts or other damage 7 7 PARTS REPLACEMENT CUTMASTER 40mm Optional Two Stage Filter Element Replacement The Two Stage Air Filter has two Filter Elements When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unac ceptable Refer to Section 6 Parts List for replacement filter element catalog number 1 Shut OFF primary input power 2 Shut OFF air supply and bleed down sy
145. ternational Customer Care 940 381 1212 FAX 940 483 8178 www thermal dynamics com THERMADYNE A Global Cutting amp Welding Market Leader WORLD HEADQUARTERS 16052 Swingley Ridge Road Suite 300 St Louis Missouri 63017 U S A THE AMERICAS EUROPE ASIA PACIFIC Denton TX USA Miami FL USA Chorley United Kingdom Cikarang Indonesia Melbourne Australia Shanghai China U S Customer Care Sales Office Latin America Customer Care Customer Care Australia Customer Care Sales Office Ph 1 800 426 1888 tollfree Ph 1 954 727 8371 Ph 44 1257 261755 Ph 6221 8990 6095 Ph 1300 654 674 tollfree Ph 86 21 64072626 Fax 1 800 535 0557 tollfree Fax 1 954 727 8376 Fax 44 1257 224800 Fax 6221 8990 6096 Ph 61 3 9474 7400 Fax 86 21 64483032 International Customer Care Fax 61 3 9474 7391 1 040 281 Oakville Ontario Canada Milan Italy Rawang Malaysia Singapore Ph 1 940 381 1212 International Fax 1 940 483 8178 Canada Customer Care Customer Care Customer Care Ph 61 3 9474 7508 Sales Office Ph 1 905 827 4515 Ph 39 0236546801 Ph 603 6092 2988 Fax 61 3 9474 7488 Ph 65 6832 8066 Fax 1 800 588 1714 tollfree Fax 39 0236546840 Fax 603 6092 1085 Fax 65 6763 5812 2010 Thermadyne Industries Inc www thermadyne com
146. the arc moves from side to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle or around a corner slowing down the travel speed will result in a squarer cut The power source output should be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required Piercing With Machine Torch 4 8 pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the front end of the torch When operating with a cutting machine a pierce or dwell time is required Torch travel should not be enabled until the arc penetrates the bottom of the plate As motion begins torch standoff should be reduced to the recommended 1 8 1 4 inch 3 6 mm distance for optimum speed and cut quality Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Manual 0 5085 CUTMASTER 40mm 4T 07Parts Selection for SL100 Torch Cutting Ohmic Clip Automation Torch Ohmic Clip 9 8224 Manual Torch 9 8259 20 40A Tip Shield Cap Machine STANDOFF 40 9 8245 CUTTING CD 6 20 9 8205 Shield Cap Deflector mm 30A
147. tification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermal Dynamics will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Product Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 12 This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups O rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event
148. tion indicators left to right 1 through 5 To determine the second digit count the pressure indicators reading from bottom to top 0 through 7 In the example below the Temp indica tor and 75 psi indicators are on indicating the version would be 2 3 NW Art A 07988 1234 5 When the Fault indicator is ON or blinking it will be accompanied by one of the pressure indica tor lights depending on what the Fault is Only one of these faults will be displayed at one time If more than one fault exists when the first fault is corrected and cleared the next fault will then be displayed It is possible to have a fault indicated in the function indicators and another fault indicated in the pres sure indicators The following table shows each of the Faults possible Pressure Fault Indicator Max 90 Internal Error Shorted Torch 80 Missing Under Pressure NOTE Fault explanations are covered in the basic trouble shooting guide later in this chapter Min Manual 0 5085 CUTMASTER 40MM Explanation of Faults UNDER PRESSURE Indicates that operating pres sure is set too low and power supply output power will be disabled INPUT POWER Indicates primary line voltage is out side the operating limits of the power supply PART IN PLACE Indicates that the shield cup is not properly installed or tightened START ERRO
149. to be installed 1 Connect the air line to the inlet port The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Regulator Filter Assembly N Y Inlet Port Hose Clamp Gas Supply Hose Art A 07943 Air Connection to Inlet Port 3 2 Manual 0 5085 Installing Optional Single Stage Air Filter An optional filter kit is recommended for im proved filtering with compressed air to keep moisture and debris out of the torch 1 Attach the Single Stage Filter Hose to the Inlet Port 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instruc tions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Con nect as follows Regulator Filter Assembly Hose Clamp Gas Supply 1 4 NPT to 1 4 Hose 6mm Fitting Optional Single Stage Filter Installation Manual 0 5085 Inlet Port A 07944 Hose Clamp ENS CUTMASTER 40mm Installing
150. torch or con sumable problem a Check torch consumables for wear or debris In all three cases to reset the machine remove the START signal SERVICE 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 a Install jumper on Main PCB 1 between test point GND1 to terminal b Apply START signal If Pilot starts replace Main PCB 1 E AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicator OFF Pilot Arc is intermittent 1 Defective Main contactor a Check W1 per Pre Power UP checks 2 Defective Logic PCB 3 a Measure for 12VDC on Main PCB between test Point GND1 to J2 8 If 12VDC is present replace Logic PCB 3 3 Defective Main PCB 1 a 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 a 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 J1 25 on Logic PCB 3 for 12VDC The voltage should drop to less than 2VDC after aSTART 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
151. tput Inductor wires from Choke1 terminal on the Main PCB and from the ATC Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the two screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis Disengage 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 lock ing tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit Remove the two screws securing the Output Inductor to the base Remove the Output Inductor carefully 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 CUTMASTER 40mm E Output Inductor L2 Tools required T20 Torx Driver 1 2 10 11 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 terminal 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 conta
152. upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower Screws Art A 07947 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover installa tion NOTE When installing the upper screws attempt to reuse the original threads The easiest way to do this is by turning the screw counter clockwise until you feel the threads line up then begin to turn the screw clockwise to tighten to 15 18 in lbs Do not over tighten SERVICE C Pre Power Up Tests Prior to applying primary line power to the unit perform the following checks to prevent component failure or blowing primary fuses The troubleshoot ing guide will assume these tests were done and no failure was found or that any failures found were corrected Main Contactor W1 Check Section 5 11 A PCB 1 Input Diode D1 Test Section 5 11 B PCB 5 Input Diode D1 Test Section 5 11 C PCB 2 Capacitor Relay Test Section 5 11 D PCB 1 IGBT Test Section 5 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 I SP m rc 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
153. ure 1 Place the Power Supply Function Control knob to the SET flow position Gas will 2 For Standoff cutting adjust gas pressure from 70 85 psi 4 8 5 9 bar LED s in center of control panel Refer to the Standoff chart for pressure setting details 1 2 Art A 07946 4 2 Manual 0 5085 STANDOFF CutMaster 40mm Gas Pressure Settings SL100 Leads 51100 Mechanized Torch Length Hand Torch SL 100 SV Automation Torch Up to 50 75 psi 75 psi 7 6 m 5 2 bar 5 2 bar Each additional Add 5 psi Add 5 psi 25 7 6 0 4 bar 0 4 bar 3 For Drag cutting adjust gas pressure from 75 95 psi 5 2 6 5 bar LED s in center of control panel Refer to the Drag Cutting chart for pressure setting details DRAG 60 amps or less CutMaster 40mm Gas Pressure Settings Leads 51100 Length Hand Torch Up to 25 80 psi 7 6 m 5 5 bar Each additional Add 5 psi 25 7 6 m 0 4 bar Select Current Output Level 1 Place the Function Control Knob in one of the three operating positions available RUN RAPID AUTO RESTART o or LATCH 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 operations with the Function Control Knob in the RUN position there is a brief delay in restarting the pilot arc With the knob in the
154. ury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlo rinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq 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 w
155. ve all we are committed to developing technologically ad vanced products to achieve a safer working environment within the welding industry WARNING Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Plasma Cutting Power Supply CutMaster 40mm SL100 1Torch Service Manual Number 0 5085 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2008 2009 2010 2012 by Thermadyne Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date December 9 2008 Revision Date April 25 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial This Page Intentionally Blank TABLE OF CONTENTS SECTION 1 GENERAL 4 464440000000
156. wever slag build up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc The build up is most often a result of improper travel speed lead angle or standoff height OPERATION CUTMASTER 40mm 4T 06Mechanized Torch Operation Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC 1 To start a cut at the plate edge position the center of the torch along the edge of the plate Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate The arc can be one of the following 1 Straight Arc A straight arc is perpendicular to the workpiece surface This arc is generally recommended for the best cut using air plasma on stainless or aluminum 2 Leading Arc The leading arc is directed in the same direction as torch travel A five degree leading arc is generally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direc tion as torch travel Standoff Distance A 02586 Trailing Arc M Leading Arc Mechanized Torch Operation OPERATION For optimum smooth surface quality the travel speed should be adjusted so that only the leading edge of the arc column produces the cut Ifthe travel speed is too slow a rough cut will be produced as

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40mm CUTMASTER™ Service Manual