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82 CUTMASTER™ Service Manual

1. 12VDC P 2 swi 1047 ne 4 fil 58 SN e 22 g O J NS A7 wi PRIMARY L1 AC INPUT LT Ti L2 12 T2 JUMPER L3 L3 T3 GND Q2 PRIMARY POWER CONNECTIONS 3PH USE L1 L2 L3 amp GND REMOVE JUMPER BETWEEN L2 TO L3 1PH USE L1 L2 amp GND INSTALL JUMPER BETWEEN L2 TO L3 ale pt oe SSI gt IN 7 INPUT VOLTAGE SELECTOR CM52 amp A40 Closed for 230VAC input amp C5 not installed 2AVAG 2 INPUT CAPACITOR 5 em TEST POINTS 24 RETURN GND1 COMMON GND2 COMMON GND3 COMMON 6 12V1 12 VDC SUPPLY P 48V1 48 VDC SUPPLY LDMD CURRENT DEMAND D59 PCR SEN DRAG SENSE 3 3VDC TXD SERIAL PORT La 4 D78CSR H2VDC PCB1 MAIN ASSY Prem SOLENOID 40 CIRCUIT RIBBON CABLE 40 PIN RIBBON CABLE SIGNALS anal 47 ERRORIND FAULT 2 VOLTS ML MAX 3 SENSE ML AC 4 14
2. CM82 A60 ONLY OOO 1TORCH PIP SWITCH Fv vv __ 575 SEC2 CHOKE1 V 9 206 TORCH SWITCH 4 o o TEMP ATC CONNECTOR 1 a K AUTOMATION 2 A TORCH SOLENOID 4 4 NTC 2 6 6 7 T 8 8 vour1 v E64 7 ELECTRODE1 D3 E35 a5 E PILOT IGBT WORK1 5 4 78 c IPIP ISTART 4 24VAC RETURN 5 82 6 83 24VAC SUPPLY il 7 INTERFACE STANDARD ON A40 amp A60 UNITS CNC INTERFACE OPTIONAL 52 amp CM82 UNITS J2 P10 14 4 13 ok ToMove 1 1 12 WONNE 1 1 250VAC 30VDC J2 PINOUT 3 3 10 4 4 9 5 5 8 12006 6 6 7 7 6 8 5 4 START STOP H Sink 50mA 12VDC 1 FULL FEATURED AUTOMATION INTERFACE PCB OPTION B voc avoc To configure DIVIDED VOLTS signal output EAN No jumper installed for ARC VOLTS 16 67 Jumper pins 1 amp 2 for ARC VOLTS 30 Jumper pins 2 amp 3 for ARC VOLTS 50 JI Ja V OUT 1 4 on PCB1 32 O 2 10 M 2 5 1 1 5 yO em 5 96 DVIDED VoLTS P 3 Pm y VOLTS MOT MOT2 4 H WI 100K IN SERIES 2 6 6 10 7 7 11 s 5 KaL i OK TO MOVE Tu AUTOMATION 4 INTERFACE 09131 AB ja Rev Revisions By Date PCB No INTRO ECO B534
3. PRI 1 lm CT 3 5 UB ACT zn 1w e AC2 TP5 PRI 2 TP6 TIP1 ELECTRODE1 48V2 12V2 0011 48V1 gm D vaL H0000000 5000000 r m ao E aon Ji J9 J8 J7 J6 J5 Art A 08518_AB CHOKE1 SEC2 12 1 WORK 1 GND2 SERVICE 5 26 Manual 0 4980 MAIN PCB SIGNALS 71 1 71 2 71 3 71 4 J1 5 J3 1 J3 2 5 1 5 2 5 3 16 1 16 2 7 1 172 78 1 18 2 79 1 79 2 79 3 79 4 79 5 79 6 19 7 J10 1 J10 2 J10 3 J10 4 J10 5 J10 6 J10 7 J10 8 J11 1 J11 2 712 1 712 2 712 3 L1 Primary AC Line Not used Not used Not used L2 Primary AC Line 230VAC Common For factory use 12VDC Not used SOLENOID 24VAC Supply for W1 24VAC Return 12VDC FAN 12VDC FAN PIP Common TORCH SWITCH Start Common Torch solenoid 24VAC supply Not
4. 4 46440 0 1 1 1 01 Notes Cautions and Warnings 0 1 1 1 02 Important Safety Precautions 0 00000 1 1 1 03 P blicatiOns ia 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 Conformity 1 6 1 08 Statement of Warranty 1 7 SECTION 2 SYSTEM INTRODUCTION 0000 0000 001 rn nennen nennen 2 1 2 01 How To Use This Manual ss 2 1 2 02 Equipment Identification 2 1 2 03 Receipt Of Equipment si 2 1 2 04 Power Supply Specifications sse 2 2 2 05 Input Wiring Specifications 1 2 3 2 06 Power Supply Features ii 2 4 SECTION 2 TORCH INTRODUCTION 2T 1 21 01 Scope of Manual imet ert te t ettet penat bre eco dent 2T 1 2T 02 General nnne 2T 1 21 03 SpecifiCatiOrls t Pe rere Eo pe 2T 1 2T 04 Options And nennen 2T 2 2T 05 Introduction to Plasma 2T 2 SECTION 3 SYSTEM INSTALLATION r aae nnne nnne 3 1 3 01 eiit eto n a tutu t ete 3 1 3 02 Lifti
5. 2 02 esd Pel io D3 TP6 gt lt Ho D4 2 1 x 5 D5 Di Luo D6 lt 07 lt dpi 08 dis Ho HO D9 SM HIE TP5 014 011 013 J1 Pinout Art A 08179 SERVICE 5 22 Manual 0 4980 CUTMASTER 82 L IC PCB SIGNAL ame for MAIN PCB J2 ignal Source Destination 71 1 VOUT OUTPUT VOLTAGE M L J1 2 TIP VOLTS Active high when tip is installed M L J1 3 TIP_SEN Approx 100VDC while cutting with tip not in M L contact w work piece Active low when tip contact work during cut Drag Mode J1 4 460V IN Active low with 460VAC primary input voltage L M J1 5 230V IN Active low with 230VAC primary input voltage L M J1 6 CUR SET Current demand signal Variable 1 4VDC L M J1 7 RAR Active low when in Rapid Auto Restart mode L M J1 8 INRUSH Active low after inrush time expires L M J1 9 W1 ON Active low to enable W1 contactor L M J1 10 SHDN Active low enables PWM circuit J1 11 TRCH_SOL Active low to enable Torch Solenoid L M 71 12 SOL ON Active low to enable Power Supply solenoid L M 1 13 OK MOVE Active low to enable OK TO MOVE CNC L M J1 14 FAN_ON Active low to enable fans L M 1 15 LATCH ACTIVE Active low when Latch mode is active during cut L M J1 16 TRCH_SW Active low START is active Torch switch CNC M L J1 17 PIP Active low PARTS IN PLACE satisfied M L J1 18 AC_ON Pulse signal M L J1 19 CSR Active high during main transfer M L J1 20 TORCH SOL DETECTED Active low for torch wi
6. 2221 so 10 oss ozs sa m ae us o nn NR We 9 6 fous os m 48 us 9e w W Ww EM 2 2 ares sse va e0 7 as ns EN 2 2 ojo NOTES Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads set gas pressure to 70 psi 4 8 bar Total flow rate includes plasma and secondary gas flow OPERATION 4T 12 Manual 0 4980 CUTMASTER 82 4T 09Recommended Cutting Speeds for Mechanized Torch With Shielded Tip sop s oro an Le um ps 19 sano 1 257 602 049 25 0 9920 128 9 250 584 oto me ox o s sa seno 8 0 e ser 00 040 es 128 18 318 oss ECHTE 0250 64 98210 123 60 208 019 ows ss eeno 12 c 086 019 02 oso waz eemo 187 eo 23 oss 48 9 075 02 51 ugs i59 sso 139 14 oss 70 48 eo 25 NR NR omo 19 98210 145 eo 14 ose 48 48 90 245 NR 25 eo 4 48 9o 265 wr M Fon is s is ais o ae os roars 1s e is so ox sa vo 4e w os oz 51 1 ns o fus os sz
7. 2 vs ao m s os as ws s 02 si eam va s ie ase oso aa aa ws s cx oz si 128 eo vs ois ae 4s ws 90 o2 02 51 131 eo 100 251 oxo mo 48 ws 90 uz 51 95 oan xw m ao 1m oae ae ws s 080 02 eam as ao ow ois ae ws s oe 02 jonas eam ws w os osse ae ws 90 o7 uz 51 Loop sam eo w oae ois mo 4s ws 90 wa Ws WR Casper eam ws m o2 oi ae ae ws so ws Ws WR semi 16 m s oz ae ws so ws Ns Ww saan eo sw sso m se oo 02 oan ns eo 200 680 ws sw 02 oan ms s a0 625 7 ss ws ox 02 51 sees saan va eo 170 425 ws se ox 02 o2sofea eo s zm ws se 02 se ss e vs m 5 1 2 ws 025 64 s 18 1 2 wis sun 0 025 64 oss saan 135 eo 16 oos 48 ws se 10 025 64 eo e 70 4s usse w n
8. 8 12 2 up 9 L3 LR GND 4 4 Q2 el 380 400 415V fr OR 600V 3 PH AC INPUT NL PRIMARY POWER CONNECTIONS USE 11 12 13 amp GND 7 P PCB2 INPUT CAPACITOR PCB 24VAC 5 a CMS2 12mm 20mm A40 C3 amp C5 may not be installed TEST POINTS w 2 24 VAC RETURN o GND2 COMMON GND3 COMMON 6 12 12 VDC SUPPLY 48V1 48 VDC SUPPLY LDMD 1 CURRENT DEMAND SEN DRAG SENSE 1 SERIAL PORT 2 4 D78 CSR 2VDC 5 MAIN PCB ASSY SOLENOID n B 40 CIRCUIT RIBBON CABLE 40 PIN RIBBON CABLE SIGNALS P 1 OUT SIGNAL ML P 2 VOLTS ML ERRORIND FAULT MAX 3 SENSE ML AC H 4 60 LM MAX OVER PRESSURE 5 230V N LM 2 90 INTERNAL ERROR 6 CUR SET LM 85 SHORTED TORCH 90 7 IRAR RAPID AUTO RESTART LM OVERTEMP 80 CONSUMABLES MISSING 8 INRUSH LM 75 START ERROR LM gt 70 PARTS IN PLACE 10 SHDN LM 65 INPUT POWER 85 11 TORCH SOLENOID LM GAS MIN UNDER PRESSURE 12 SOLENOID ON LM 2 13 OK TO MOVE LM 2 14 IFAN_ON LM T TEST POINTS 80 48 ACTIVE LM ait 16 TORCH SWITCH ML Ls we GAS CONTROL 18 AN Hs ERROR TP4 3 3 VDC 20 TORCH_SOLENOID_DETECT ML Te REGULATOR 21 OVERTEMP ML 5 ATC 22 VIN ME POT DEMAND 4 VALVE AT 23 12VDC ML x 24 12VDC ML 4 25 ML Current Control 65 FILTER 26 COMMON ML 2VDC AIR 29 MAIN PCB_ID ML 2 INLET
9. DutyCycle 100 100 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 300 500 scfh 142 235 Ipm WARNING This torch is not to be used with oxygen 0 NOTE Operating pressure varies with torch model operating amperage and torch leads length Refer to gas pressure settings charts for each model H Direct Contact Hazard Operating Pressure Refer to NOTE Maximum Input Pressure Gas Flow Cutting and Gouging 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
10. 07 2307 IMERMAL DYNAMICS ME ode hija iud Assy No AB ECO B890 04 23 08 7 Fr no Scale Supersedes lis B855 05 09 08 Company AD ECO B1159 MNC 10 03 08 Information Proprietary to THERMAL DYNAMICS CORPORATION Th E reday March 27 2008 1357 RWH 03 31 09 Not For Release Reproduction or Distribution without Written Consent ursday NOTE UNLESS OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF CHR Sheet 1 of 1 TITLE SCHEMATIC Size DWG No aet Moaie Moncey Mach CUTMASTER 52 82 A40 A60 230 460V C 42X1298 Manual 0 4980 A 7 APPENDIX CUTMASTER 82 APPENDIX 6 HEMATI V UNIT PRI2 PRI 1 PRI4 Li BIAS D SUPPLY ps 12VDC 1 Toi 1 2 at 207 of 5 AU EMI 55 CHOKI 29 28 SR j CE UNITS E ONLY EMI FILTER wi L1 1 1 z
11. 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 I 10 125 257 mm gt Art 03322_ 1 17 29 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly Le 15 875 403 mm 9 285 LIN 1 1 Y 1 375 35 1 75 44 5 mm 1 175 30 Dn 4 95 126 mm 0 625 16mm 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 Art 02998 12 VDC circuit rating E Type Cooling Combination of ambient air and gas stream through torch INTRODUCTION CUTMASTER 82 F Torch Ratings Manual Torch Ratings Ambient 104 F Temperature 40 C Duty Cycle 100 60 Amps 400 scfh Voltage V oa 500V Arc Striking Voltage 7kV Mechanized Torch Ratings Temperature 40 C
12. 2 Carefully pull the Cover up and away from the unit B Cover Installation 5 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 7 2 2 6 Tools required T20 Torx Driver 1 Disconnect the Torch and Leads from the unit Remove the cover per subsection 7 04 A Remove the screws securing the tube handles to the base of the unit NOTE Some of the earliest manufactured units have Tube Handles that are joined together under the base of the unit Later versions are not joined together 4 Remove the power supply from the Tube Han dles Replace the Tube Handles by reversing the above steps Reinstall the power supply cover D Disconnecting Front and Rear Panels from the base In many of the replacement procedures it may be help ful to disconnect the front or rear panel from the base in order to allow more room to access the parts Tools required T20 Torx Driver 1 2 Remove the cover per subsection 7 04 A For earlier models remove the Tube Handles per subsection 7 04 C The earlier model Tube Handles join together under the base Later mod els do not and there is enough room to perform this procedure without remov
13. OVER PRESSURE Indicates that operating pressure is set too high The Error Indicator will not flash when the pressure is above 95 PSI This LED will remain ON and the system will operate but pilot starting and cut performance may be affected NOTE The cooling fans will turn ON as soon as the unit is turned ON After the unit is idle for ten 10 minutes the fans will turn OFF The fans will come back ON as soon as the torch switch Start Signal is activated or if the unit is turned OFF then turned ON again If an over 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 SERVICE CUTMASTER 82 5 05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Problem Symptom Possible Cause Recommended Action ON OFF Switch 1 Primary power disconnect is in Turn primary power disconnect switch to ON position is ON but the A C OFF position Indicator does not 2 Primary fuses breakers are light blown or tripped 3 Faulty components in unit 2 a Have qualified person check primary fuses breakers b Connect unit to known good primary power receptacle 3 Return to authorized service center for repair or replacement 1 INPUT VO
14. 07941 LEN Art A 07925 AB 16 375 416 mm Pd 4 mm lt lt lt lt M NA 24 Pd 610 mm 43 Ib 19 5 kg INTRODUCTION 2 2 Manual 0 4980 CUTMASTER 82 2 05 Input Wiring Specifications CutMaster 82 Power Supply Input Cable Wiring Requirements _ inputvottage Freg Powerinput Suggested Sizes Flexible Cord max Leff Fuse amps Min en 10 39 1 9 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment Manual 0 4980 2 3 INTRODUCTION CUTMASTER 82 2 06 Power Supply Features Handle and Leads Wrap 5 A 5 Torch Leads Receptacle WS GOs PN Friis AD Ji ASSES lt 27 w U Y U A Art A 07942 N Work Cable and Clamp Art A 07981 po Port for Optional Automation Interface Cable Input Power Selection Filter Assembly Input Power Cord Gas Inlet Port 2 4 Manual 0 4980 INTRODUCTION SECTION 2 TORCH INTRODUCTION 2T 01Scope of Manual This manual contains descriptions operating instructions and maintenance procedures for the I Torch Models SL6
15. Pilot 3 Switcl APPENDIX CUTMASTER 82 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 EM Head Leads PIP 4 Black To Power Supply Switch Orange Circuitry Torch JUL Green Switch es White To Power Supply Circuitry gt gt OY BB O1 Negative Plasma Negative Plasma Pilot Pilot Art A 03797 B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector To Remote Control Power Supply with ATC Female Receptacle Male Female Leads UT Receptacle Connector p _ _ _ _ Power mE Torch Supply Head Leads 1 Switch o MEN Green Negative Plasma Lead Negative Plasma Pilot Lead To Power Supply Circuitry White To Power Supply Circuitry ND Pilot Art 03798 APPENDIX 4 Manual 0 4980 CUTMASTER 82 This Page Intentionally Blank Manual 0 4980 A 5 APPENDIX CUTMASTER 82 APPENDIX 5 SYSTEM SCHEMATIC 208 460V UNIT
16. ae oo us nw sr Fuss ne e eo 20 or sz w os nw st as samo vm e 7s i9 or s2 ae wo us nz st 02 o i5 ae oz 51 ams ss ve om o sz o ae wo us 020 st 05 pez samo ms e v os oi vo ae 9o os 020 st 06 ss 15 s 14 os ou ae 9o os NA NA oroj eeo we e 16 o2 ae w ws NR NR Foo rs sso eo ss am 9o ne ooo 020 51 Foo no eo zs ns 020 51 os ao eo zs 6s se 4s 6 020 51 sez 122 oo wo s56 1 2 7 ae oo 245 020 020 51 foal sexo 131 e so 203 vo 9o ns oso 020 51 Fosm as ssno wo o as iw oi aa mo 9o ns os 020 5 oso farl eo 25 oss ois as oo 25 oso 020 51 oss fssfosnof ws oo 19 os ou ae oo 205 ws ozo 5 e is os oro aa as 9 2 ws ws JN 70 9 48 70 48 9 48 70 487 48 70 48 48 70 48 48 70 487 48 70 48 Manual 0 4980 4T 13 OPERATION CUTMASTER 82 00 15 128 eo rn os 4s ws oo oo 02 51
17. 460 IN ML 35 EM Larcu Di MIN 37 RXD ML sr 79 v 38 COMMON LM lt 39 D ML RUN e 5VDC TN eo 1 RAR 0 100PSI 0 4 5VDC 2 5 3 LOGIC PCB lt APPENDIX Manual 0 4980 CUTMASTER 82 3 I 2 I T 1 D 1 n 1TORCH B PIP SWITCH a E CHOKE 7 j TORCH SWITCH o o TEMP OVERTEMP ATC CONNECTOR A 1 1 AUTOMATION 2 5 TORCH SOLENOID 5 5 NTC 2 H 7 7 8 8 VOUT1 77 4 4 E64 ELECTRODE1 D3 5 Y 4 as PILOT IGBT VS WORKI WORK EJ 78 c PP 18 80 ISTART 3 ie 24VAC RETURN 5 83 24VAC SUPPLY 7 L CNC INTERFACE STANDARD ON A40 amp A60 UNITS CNC INTERFACE OPTIONAL ON 52 amp CM82 UNITS 2 P10 14 13 okromove 1 1 2 5A 250VAC 30VDC OK TO MOVE I 2 2 H J2 PINOUT
18. Install the replacement Work Cable by reversing the above steps 5 Reinstall the power supply cover 7 06 Left Side Internal Parts Replacement A Fan Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04 A 2 Unplug J7 and J8 connectors from Main 3 Carefully feed the fan wires through the center chassis wire slot 4 Remove the fan by pushing the fan retaining clips apart and pulling the fan out of the center chassis PARTS REPLACEMENT 7 On the replacement fan s note the direction of air flow as labeled on the fan housing and orient so fan will blow air into the unit Install replacement fan by reversing the above steps Reinstall the power supply cover B Main Transformer T1 Replacement Tools required T20 Torx Driver 12 Nut Driver 1 2 3 10 11 12 13 14 15 16 Remove the Cover per subsection 7 04 A Remove the Tube Handle per subsection 7 04 C Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 E Disconnect the transformer wires from terminals PRI 1 A PRI 2 B PRI 3 C PRI 4 D SEC1 SEC2 on Main PCB Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief Disengage the Rear panel from the base per sec tion 7 04 D Guide
19. L3 13 L2 L3 5 14 5 Ee _ GND 5 Single Phase Input Power Wiring Three Phase 30 and Jumper Settings Store copper jumper in spare parts box L1 Ea uo Jumper L1 L4 L2 GND E E Three Phase Input Power Wiring NOTE There is only one jumper setting that changes between the single and three phase settings To change from single phase to three phase the jumper connected to L2 needs to be re moved and placed on the other L3 connection so both ends of the jumper are attached to the same electrical point INSTALLATION CUTMASTER 82 A Connections to Single Phase Input Power A WARNING LEE Disconnect input power from the power sup ply and input cable before attempting this procedure These instructions are for changing the input power and or cable on the 208 230 400 460 VAC Power Supply to Single Phase input power 1 Remove the Power Supply cover per in structions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chassis ground connection 3 Loosen the through hole protector on the back panel of the power supply Pull the original power cable out of the power sup ply 4 If the power cable being used is not the factory supplied cable use a three con ductor input power cable for the voltage desired and strip
20. Manual 0 4980 14 15 CUTMASTER 82 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM MANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 INFORMATIONS G N RALES CUTMASTER 82 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 European Council Directive 73 23 EEC as amended by Council Directive 93 68 EEC and to the National legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the Directive European Council Directive 89 336 EEC and to the National legislation for the enforcement of this Directive Serial numbers are unique with each individual piece of equipment and details description parts used to manufacture a unit and date of manufacture National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements
21. Power Supply Dimensions amp Weight Ventilation Clearance Requirements on page 2 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 2 04 Power Supply Specifications on page 2 2 for duty cycle information Fan s not turning a Measure voltage at plug between J7 1 to J7 2 and between J81 to J8 2 on Main PCB for 12VDC If voltage is present replace fan Defective Main PCB a Measure voltage at plug between J7 1 to J7 2 and between 8 1 to J8 2 on Main PCB for 12VDC If voltage is missing at either recep tacle replace Main PCB Defective Logic PCB a Replace Logic PCB J AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing Gas is not flowing 1 Gas supply not connected to unit a Connect gas supply to unit 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 SERVICE K INTERNAL ERROR FAULT Indicator and 90 PSI Indicator flashing T There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error L MAX PRESSURE ERROR MAX Pressure LED is lit 1 Gas pressure set too high a Reduce gas pre
22. RESULT All indicators off No power to system Power supply fans shut off Art A 07979_AB A 1 APPENDIX CUTMASTER 82 Type of Power Supply Note 1 Plasma Cutting Symbol Input Power Symbol Input Power Specifications Phase AC or DC Hertz Rating NOTES 1 TU Degree of Protection APPENDIX 2 DATA TA INFORMATI N THERMAL DYNAMICS A Company Model Date of Mr West Lebanon NH USA 03784 S N Made in USA Manufacturer s Name and or Logo Location Model and Revision Level Serial Number and Production Code Regulatory Standard Covering This Type of Power Supply Output Current Type Duty Cycle Factor Output Range Amperage AC Voltage Uo Duty Cycle Data Note 3 U2 Rated No 7 Conventional Load Voltage Load Voltage Rated Maximum Supply Current U1 4g 1max ig ef 30 30 Maximum Effective Supply Current Manufacturer s Electrical Schematic File Number Rated Supply Voltage Note 2 Symbol shown indicates single or three phase AC input static frequency converter transformer rectifier DC output 2 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 3 Top row Duty cy
23. re sz es ur 0 e oz ss ws sw wv nm we 10 s s oz 7 ss nus se ww Ws m OPERATION 4T 14 Manual 0 4980 CUTMASTER 82 Type Torch Mechanized With Shielded Tip Type Plasma Gas Air Thickness Standoff bar 006 1 5 98201 115 320 813 013 32 70 340 000 025 6 4 80 240 610 0413 32 70 2 2 1 losn 120 9 ors sz 70 4 suo 1 0 Cie 4 e sr ow faa 48 or 4a m 4 ois 4a 70 ss vs wn aE Co ss vs o m 5 ws 100 om as 4s us 340 NOTES Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads set gas pressure to 70 psi 4 8 bar Total flow rate includes plasma and secondary gas flow Manual 0 4980 4T 15 OPERATION CUTMASTER 82 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U S and Foreign Patents as follows Catalog Description Patent s 9 8215 Electrode US Pat No s 6163008 6987238 Other Pat s Pending 9 8213 Cartridge US Pat No s 6903301 6717096 6936786 6703581 0496842 0511280 0492709 0499620 0504142 Other Pat s Pending 9 8205 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8206 Tip US Pat No s 6774336 7145099 6933461 Other
24. well as shield cup life Standoff may also signifi cantly affect the bevel angle Reducing standoff will generally result in a more square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touch ing the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cut ting arc as quickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut be ing more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Left Side Cut 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 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
25. 25249 5 et seq ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected GENERAL INFORMATION CUTMASTER 82 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 in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated
26. 3 3 10 4 4 9 5 5 8 H2VDC H H 5 7 7 6 8 8 5 4 sTART STOP 3 Sink 50mA 12VDC 1 FULL FEATURED AUTOMATION INTERFACE PCB OPTION 5 H2VDC H2VDC To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS 16 67 Jumper pins 1 amp 2 for ARC VOLTS 30 Jumper pins 2 amp 3 for ARC VOLTS 50 To VOUT 1 RES on PCB1 Ei 2 2 P10 3 E 1 1 5 o 2 2 M9 DIVIDED ARC VOLTS 1 1 1 C arc VOLTS W 100K IN SERIES 2 MOT2 5 5 9 2 2 6 10 7 7 11 8 8 KIT 1 AUTOMATION 4 INTERFACE A 09133 AC Rev Revisions By Date Sene PCB No INTRO ECO B1357 033100 ZIHERMAL DYNAMICS TER ijo Re Road Assy No AB Eco B1399 RWH 05 05 09 Sul 300 Scale Supersedes A THERMADYNE Company Stau MO BIT USA Date Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent Thursday March 27 2008 Drawn References NOTE UNLESS OTHERWISE SPECIFIED RWH 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk Sheet 1 of 1 Size DWG No SCHEMATIC Fest Dj 0813 CM52 82 12mm 20mm 25mm A40 A60 380 400 415 600 42 1329 3 I 2 I T Manual 0 4980 A 9 APPENDIX CUTMASTER 82 AP
27. 5 Improperly assembled torch 6 Non Genuine Thermal Dynamics 3 Check all contactor points for severe arcing or parts used y pits replace if necessary Difficult Starting 1 Worn torch parts 4 Vacuum dust and dirt out of the entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit SERVICE 2 Non Genuine Thermal Dynamics parts used 3 Incorrect gas pressure Manual 0 4980 5 04 Fault Indicator At initial power up two lights will temporarily illu minate for 2 3 seconds to show the version of software used To determine the first digit countthe function indicators left to right 1 through 5 To determine the second digit count the pressure indicators reading from bottom to top 0 through 7 In the example below the Temp indica tor and 75 psi indicators are ON indicating the version would be 2 3 ort NW gt o Art A 07988 1234 5 When the D Fault indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is Only one of 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
28. Among them are UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of electrical shock Power Supplies bearing the 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 GENERAL INFORMATION 1 6 Manual 0 4980 CUTMASTER 82 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER plasma cutting systems sold after the effective date of this warranty are free of defects in mater
29. J2 3 and J2 4 START signal e Pilot arc is established 2 Bringthe torch to the work piece and transfer to cutting arc e OK TO MOVE signal is present Meter shows continuity 3 Remove jumper from J6 OK TO MOVE signal OFF Meter shows no continuity e Gas continues to flow DCLED 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 Subsection 5 11 CNC Interface Problems page 5 17 If the unit has the Automation Interface PCB installed continue with this section 4 There are three 3 ARC VOLTS signals available from the J6 connector a J2 9 to J2 7 b J2 5 to J2 6 Auto Interface PCB J3 con nector with jumper installed between pins 1 and 2 ARC VOLTS divided by 50 2 5 toJ2 6 Auto Interface PCB J3 con nector with jumper installed between pins 2 and 3 ARC VOLTS divided by 16 Manual 0 4980 CUTMASTER 82 Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximate as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 6 VDC 2 VDC c 19 VDC 6 VDC This completes the CNC Interface Test If the above are all correct then the unit is functioning correctly If the unit does not function as
30. Pat s Pending 9 8207 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8252 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8208 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8209 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8210 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8231 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8226 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8227 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8228 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8241 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8243 Shield Cap US Pat No s 6914211 D493183 Other Pat s Pending 9 8235 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8236 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8237 Shield Cup US Pat No s 6914211 D501632 D511633 Other Pat s Pending 9 8238 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending 9 8239 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending 9 8244
31. Place Circuit Diagram for Hand Torch When the torch is started a pilot arc is established between the electrode and cutting tip This pilot Remote Pendant arc creates a path for the main arc to transfer to the work pd E D Main Cutting Arc DC power is also used for the main cutting arc The To ATC PIP Switch Shield Qup negative output is connected to the torch electrode through the torch lead The positive output is con nected to the workpiece via the work cable and to the torch through a pilot wire CNC Start PIP Switch Shield Cup Art 08168 Automation Torch 5 PIP Switch Shield Cup Parts In Place Circuit Diagram for Machine Torch Manual 0 4980 2T 3 INTRODUCTION CUTMASTER 82 This Page Intentionally Blank INTRODUCTION 2T 4 Manual 0 4980 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 CUTMASTER 82 3 03 Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit Check the Voltage Selec
32. Slow speed dross is normally present on the bot tom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding Manual 0 4980 AT 3 CUTMASTER 82 4T 04Hand Torch Operation Standoff Cutting With Hand Torch NOTE For best performance and parts life always use the correct parts for the type of operation 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 opera tions 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 1 to start b For standoff cutting hold the torch 1 8 3 8 in 3 9
33. Torches with Unshielded Leads 6 8 6 11 Torch Consumable Parts Manual and Mechanized Torches 6 10 SECTION 7 REPLACEMENT PROCEDURES iii 7 1 7 01 SCODO i dh e Ead acd epe Dd edens 7 1 7 02 Anti Static Handling Procedures essen 7 1 7 03 Parts Replacement General Information 7 1 7 04 Major External Parts iier ete ten bee ER ERE Een 7 2 7 05 Front Panel Parts 7 3 7 06 Left Side Internal Parts Replacement 7 4 7 07 Rear Panel Parts Replacement 7 5 7 08 Right Side Internal Parts 7 7 APPENDIX 1 APPENDIX 2 APPENDIX 3 APPENDIX 4 APPENDIX 5 APPENDIX 6 APPENDIX 7 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION TABLE OF CONTENTS SEQUENCE OF OPERATION BLOCK A 1 DATA TAG INFORMATION A 2 TORCH PIN OUT 5 nier A 3 TORCH CONNECTION DIAGRAMS iii 4 SYSTEM SCHEMATIC 208 460V UNITS A 6 SYSTEM SCHEMATIC 600V UNITS A 8 Publication 10 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 h
34. aede 5 2 5 04 Fault Indicator 5 3 5 05 Basic Troubleshooting 2 5 4 5 06 Power Supply Basic Parts 5 6 5 07 Circuit Fault Isolation 5 8 5 08 Main Input and Internal Power 5 11 5 09 Pilot Arc Problems iE un Ebr uices 5 15 5 10 Main Arc and Controls Problems 5 17 5 11 CNC Interface Problems 5 17 5 12 Test 5 cle gen 5 18 SECTION 5 TORCH SERVICE ii nnne nnns nennen nnne 5 1 5T 01 General Maintenance 5T 1 5T 02 Inspection and Replacement of Consumable Torch Parts 5T 2 SECTION 6 PARTS LISTS ED E ee dr eee tere ranae fe ti 6 1 6 01 E 6 1 6 02 Ordering Informaltion dicic et ne edt ee re e ete enden 6 1 6 03 Power Supply Replacement 6 1 6 04 Major External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement Parts 6 4 6 07 Right Side Replacement Parts sss 6 5 6 08 Options and Accessories 6 6 6 09 Replacement Parts for Hand Torch 6 7 6 10 Replacement Parts for Mechanized
35. back the insulation on the individual wires 5 Pass the cable being used through the access opening in the back panel of the power supply Refer to Section 2 for power cable specifications A CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 6 Connect the wires as follows Set Jumper wires on the contactor See previous illustrations e Green Yellow wire to Ground e Remaining wires to L1 and L2 input It does not matter what order these wires are attached 7 With a little slack in the wires tighten the through hole protector to secure the power cable 8 Reinstall the Power Supply cover per in structions found in section 5 INSTALLATION 3 2 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power cable or close the main disconnect switch to supply power B Connections to Three Phase Input Power A WARNING Disconnect input power from the power sup ply and input cable before attempting this procedure These instructions are for changing the input power and or cable on the 208 230 400 460 VAC Power Supply to Three Phase input power 1 Remove the Power Supply cover per in structions found in section 5 2 Disconnect the original input power cable from the main input contactor and the chass
36. be checked per the Maintenance Schedule Subsection 5 02 and either cleaned or replaced 1 5 Remove power from the power supply turn OFF the gas supply and bleed down the system Remove the system cover See A Cover Re moval in this section Locate the internal air line and the fitting from the filter assembly Number 1 in the following illustration Hold a wrench or similar tool against the lock ing ring on the filter assembly fitting then pull on the hose to release it Numbers 2 and 3 in the following illustration Art A 07989 2 lt 7 Remove the fitting from the filter element as sembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration Manual 0 4980 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 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 automaticall
37. cleared Set Operating Pressure 1 Place the Power Supply Function Control knob to the SET 4 position Gas will flow 2 For Standoff cutting adjust gas pressure from 70 85 psi 4 8 5 9 bar LED s in center of control panel Refer to the Standoff chart for pressure setting details Art A 07946 Manual 0 4980 STANDOFF CutMaster 82 Gas Pressure Settings Leads SL60 SL100 Length Hand Torch Mechanized Torch Up to 25 75 psi 75 psi 7 6 m 5 2 bar 5 2 bar Add 5 psi Add 5 psi additonal i 0 4 bar 25 7 6 m 3 For Drag cutting adjust gas pressure from 75 95 psi 5 2 6 5 bar LED s in center of control panel Refer to the Drag Cutting chart for pressure setting details CutMaster 82 Gas Pressure Settings SL60 Leads 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 n 2 1 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 RAPID AUTO RESTART pos
38. function indicators and another fault indicated in the pressure indicators The following table shows each of the Faults possible Pressure Fault Indicator Max Over Pressure NOTE Fault explanations are covered in the follow ing tables Manual 0 4980 CUTMASTER 82 Explanation of Faults UNDER PRESSURE Indicates that operating pres sure is set too low and power supply output power will be disabled INPUT POWER Indicates primary line voltage is outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit Low is 208 230 VAC and high is 460 VAC Art A 08316 PART IN PLACE Indicates that the shield cup is not properly installed or tightened START ERROR Indicates that the START SIGNAL was active ie Torch Trigger depressed hand held pendant switch ON or CNC signal for torch ON during one of three conditions 1 During initial power up when ON OFF switch is turned to ON position 2 When fault which had been disabling the system is cleared 3 When the FUNCTION CONTROL SWITCH Mode is moved from SET position to any of the other three 3 modes of operation CONSUMABLES MISSING Indicates that the elec trode start cartridge or tip is missing or exces sively worn SHORTED TORCH Indicates the torch or lead has a shorted condition between positive and nega tive leads INTERNAL ERROR Indicates a microprocessor er ror
39. gas fitting locking ring back A small open end wrench works well for this Hue 3 Pull the hose from the fitting Art A 08150 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pull ing on the hose If done correctly it will not pull out 5 Reinstall the power supply cover Manual 0 4980 CUTMASTER 82 D Air Regulator Replacement Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Remove the three 3 air hoses from the regulator per subsection 7 05 C 3 Pull the Air Regulator adjusting knob from the shaft 4 Loosenand remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 5 Install replacement Air Regulator by reversing the above steps 6 Reinstall the power supply cover E Gas Solenoid Replacement Tools required T20 Torx Driver Flat Screw Driver 1 Remove the cover per subsection 7 04 A 2 Disconnect J5 connector from the Main PCB 3 Remove the air hose from Gas Solenoid per sub section 7 05 C 4 The Solenoid utilizes the same type locking fit ting as the gas hoses Using a flat blade screw driver push the locking ring towards the Sole noid while pulling the Solenoid away from the ATC 5 Install the replacement Gas Solenoid by reversing the above steps 6 Reinstall the power supply cover F Logic PCB PCB 3 Replacement Tools required T20 Torx Driver Flat Screw D
40. nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail e touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la 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 e Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 1 3 INFORMATIONS G N RALES CUTMASTER 82 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration e 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 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 Procurez une bonne a ration de toutes les fum es inflammables explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati
41. 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 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 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 Ce produit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq 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
42. res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie 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 LA RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement e Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure 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 lenti
43. 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 Manual 0 4980 CUTMASTER 82 7 07 Rear Panel Parts Replacement A Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Subsection 5 02 and either cleaned or replaced 1 Remove power from the power supply turn OFF the gas supply and bleed down the system Remove the system cover See A Cover Re moval in this section Locate the internal air line and the fitting from the filter assembly Number 1 in the following illustration Hold a wrench or similar tool against the locking ring on the filter assembly fitting then pull on the hose to release it Numbers 2 and 3 in the following illustration Art A 07989 Remove the fitting from the filter element as sembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration PARTS REPLACEMENT CUTMASTER 82 6 Disconnect
44. shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele ment 3 Disconnect gas supply hose 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 O ring Cat No 9 97743 Assembled Filter Cover 5 Barbed Fitting Jg 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 6 Manual 0 4980 7 08 Right Side Internal Parts Replacement A Capacitor PCB PCB 2 Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Remove the eight screws securing PCB 2 to the Main PCB Install the replacement PCB by reversing the above steps B Main PCB PCB 1 Replac
45. subsections if an optional air line filter is to be installed 1 Connect the air line to the inlet port The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Regulator Filter Assembly Hose Clamp Gas Supply Hose Art A 07943 Air Connection to Inlet Port 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 3 3 INSTALLATION CUTMASTER 82 NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s in structions 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 Connect as follows Regulator Filter Assembly Inlet Port Art A 07944 Hose Clamp Gas Supply 1 4 NPT to 1 4 Hose 6mm Fitting Optional Single Stage Filter Installation Installing Optional Two Stage Air Filter K
46. 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 A WARNING Disconnect primary power from the source before opening or disassembling the power supply PARTS REPLACEMENT CUTMASTER 82 7 04 Major External Parts C Tube Handle Replacement A Cover Removal Tools required T20 Torx Driver 1 Remove the upper and lower screws which secure the cover to the main assembly Do not 3 loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower Screws for this Art A 07947
47. the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit INTRODUCTION CUTMASTER 82 2 04 Power Supply Specifications Input Power 460 VAC 414 506 VAC Single Phase 60 Hz 460 VAC 414 506 VAC Three Phase 60 Hz 600 VAC 540 630 Three Phase 60 Hz Power Supply includes input cable Cable for 208 230 input power includes molded plug Output Current 20 80 Amps Continuously Adjustable Power Supply Gas Filtering Ability Particulates to 5 Microns CutMaster 82 Power Supply Duty Cycle Duty Cycle Ratings 40 C 104 F Ambient Temperature Operating Range 0 50 C IEC Rating Duy DC Voltage NOTE The duty cycle will be reduced if the primary input power AC is low or the output voltage DC is higher than shown in this chart NOTE IEC Rating is determined as specified by the International Electro Technical Commission These specifications include calculating an output voltage based upon power supply rated current To facilitate comparison between power supplies all manufacturers use this output voltage to determine duty cycle Power Supply Dimensions amp Weight Ventilation Clearance Requirements 10 75 A Art
48. then transfers to the workpiece through the column of plasma gas in Zone C Power Supply A le e i B Workpiece A 00002 Typical Torch Head Detail By forcing the plasma gas and electric arc through a smallorifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arcis shown in Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast slag free cut Manual 0 4980 CUTMASTER 82 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 T Torch Switch Torch Trigger t The secondary gas flows down around the outside C 2 e Wiring o of the torch starter cartridge and out between the tip and shield cup around the plasma arc PIP Switch Shield Cup y 4 O C Pilot Arc Parts In
49. 0 Manual and SL100 Mecha nized Plasma Cutting Torches Service of this equipment is restricted to properly trained person nel unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual at the risk of voiding the Warranty Read this manual thoroughly A complete under standing of the characteristics and capabilities of this equipment will assure the dependable opera tion for which it was designed 2T 02General Description Plasma torches are similar in design to the auto motive spark plug They consist of negative and positive sections separated by a center insulator Inside the torch the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip Once the pilot arc has ionized the plasma gas the superheated column of gas flows through the small orifice in the torch tip which is focused on the metal to be cut A single torch lead provides gas from a single source to be used as both the plasma and second ary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 2T 05 Introduction to Plasma for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional specifications as related to the Power Supply used Manual 0 4980 2T 1 CUTMASTER 82 2T 03Specifications A Torch Configurations
50. 0 N W LeJeune Rd Miami FL 33126 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 4980 CUTMASTER 82 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont FUM E et GAZ utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme 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 ATTENTION Toute proc dure pouvant r sulter du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question A AVERTISSEMENT Fournit l information concernant des dommages pos sibles de choc lectrique Des avertissements seront enferm s dans une bo te de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OPERA TION ET LA MAINTENANCE DU MA TERIEL DE SOUDAGE A L ARC AU JET DE PLASMA PEUVENT PRE SENTER DES RISQUES ET DES DANGERS DE SANTE Coupant l arc au jet de p
51. 0A 9 8235 Shield Cap Deflector 9 8243 Standoff Guide 9 8281 N 70 100A 9 8236 Le Shield Cap Deflector 9 8243 O Ring No D Ci Shield Cap Drag IN Start Cartridge 50 55A 9 8209 9 8213 60A 9 8210 STANDOFF te CUTTING F DRAG SHIELD p bes CUTTING 9 8215 70 120 CUTTING RS 70 9 8231 80A 9 8211 90 100A 9 8212 120A 9 8253 STANDOFF CUTTING 40 120A GOUGING Tip Gouging 9 8225 40 Amps Max Gouging 9 8226 50 100 Amps Gouging 9 8227 60 120 Amps Tip Gouging 9 8228 60 120 Amps Tip Gouging 9 8254 60 120 Amps Manual 0 4980 4 9 Standoff Guide 9 8281 Shield Cap Gouging 9 8241 CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less OPERATION CUTMASTER 82 4T 08Recommended Cutting Speeds for Mechanized Torch With Exposed Tip no s ze 757 orlas 4a o ms om us as roars 1 eo ss z2 orfas 4s zs ox 301 9420 xo eo 160 asr orlas vo ss o uus 34 94201719 eo wo 4s orlas m0 ss Fores 11 eo 100 zs orlas 5 020 usw as rozso ns s orlas a ss o us as as ss seno xa eo so 127 orlas o s o
52. 1 to I DMDI for 1 4 VDC Replace Main PCB if voltage is present SERVICE CUTMASTER 82 B SHORTED TORCH FAULT After torch switch is closed gas flows for two 2 seconds then momentarily shuts OFF then back ON FAULT INDICATOR flashes and 85 PSI LED flashes 1 UpperO Ring on torch head is in the wrong posi tion a Remove shield cup from torch check position of the upper o ring and correct if needed Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Art A 03725 2 Torch start cartridge is stuck a Turn OFF power supply Bleed down the sys tem Remove the shield cup tip start cartridge and electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not move freely Spring Loaded Lower End Fitting Full Compression Spring Loaded Lower End Fitting at Reset Full Extension Art A 08064 AC 3 Worn or faulty torch parts a Inspect torch consumables parts Replace if necessary 4 Shorted Torch a Disconnect torch from unit With consumables removed from the torch check continuity of torch at between negative plasma lead connection to pilot lead connection Negative Plasma Lead 3 Torch Switch Tr Lf 2 PIP S 1 PIP Pilot Lead Art A 08124 SERVICE 5 16 C AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED O
53. 60V_IN LM MAX OVER PRESSURE 5 230V IN LM E 90 INTERNAL ERROR 8 CUR SET LM 85 SHORTED TORCH 90 7 IRAR RAPID AUTO RESTART LM OVERTEMP 80 CONSUMABLES MISSING 8 INRUSH LM 75 9 WON LM 2 TO PARTS IN PLACE 10 SHDN LM 65 INPUT POWER 85 11 TORCH SOLENOID LM GAS MIN UNDER PRESSURE 12 SOLENOID ON LM A 2 13 OK TO MOVE LM 4 14 IFANLON rM a TEST POINTS 4 80 15 ACTIVE LM 16 TORCH SWITCH ML 2 2 17 ML 4 5 VDC 75 18 ACON ERHOR 4 GAS CONTROL 20 TORCH SOLENOID DETECT M L RU ore LA REGULATOR NO 21 JOVERTEMP ML 70 ATC A 2 VN POT DEMAND 4 VALVE 23 T2VDC ML X 4 es 24 12VDC ML d 25 COMMON ML Current Control 65 FILTER 26 COMMON ML 2VDC AIR AN 29 PCB ID ML INLET 34 460_IN ML LMI 01 4 MN PRESSURE Fen wr amp TRANSDUCER 38 COMMON LM lt 39 D ML RUN 5VDC TR 1 RAR 0 100PSI 0 4 5VDC 2 5 3 8 PCB3 Losic PCB lt 5 z 3 z APPENDIX A 6 Manual 0 4980 CUTMASTER 82
54. CB between J2 20 to GND1 for less than 2VDC If voltage is 12VDC replace Main PCB b Measure on Main PCB between J2 11 to GND1 for less than 2VDC If voltage is less than 2VDC replace Main PCB 6 Defective Logic PCB a Measure on Main PCB between J2 11 to GND1 for less than 2VDC If voltage is 12VDC re place Logic PCB O Cannot adjust gas pressure in the SET mode 1 Inlet gas pressure is too low a Increase inlet gas pressure to 95 120 psi 2 Faulty regulator a Replace Regulator Manual 0 4980 5 15 ON Nothing happens when torch switch or remote switch is closed Or CNC START signal is active No gas flow DC LED OFF Problem in the torch and leads switch circuit or remote pendant or CNC signal missing a For hand torches check continuity of torch switch circuit at ATC pins 3 amp 4 Negative Plasma Lead 3 Torch Switch Tin Le 2 PIP n 1 PIP Pilot Lead Art A 08124 b For machine torches using a remote pendant check continuity of Pendant switch circuit c For CNC input see H TIP MISSING FAULT Defective Logic PCB a Jumper on Main PCB between J2 16 and test point GND1 If gas does not flow replace Logic PCB b With Torch Switch closed measure voltage on Main PCB between test points GND1 to I_DMD1 for 1 4VDC Replace Logic PCB if voltage is not present Defective Main PCB a With Torch Switch closed measure voltage on Main PCB between test points GND
55. Current settings depend on torch travel speed Cutting With Mechanized Torch mode of operation hand or machine torch and the 9 amount of material to be removed The mechanized torch can be activated by remote control pendant or by a remote interface device Lead Angle such as CNC The angle between the torch and workpiece depends 1 To start a cut at the plate edge position the on the output current setting and torch travel speed The recommended lead angle is 35 At alead angle greater than 45 the molten metal will not be blown out of the gouge and may be blown back onto the Travel Speed torch If the lead angle is too small less than 35 less material may be removed requiring more pass es In some applications such as removing welds or working with light metal this may be desirable center of the torch along the edge of the plate 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 Torch Head surface This arc is generally recommended 2 for the best cut using air plasma on stainless or aluminum 35 2 Leading Arc The leading arc is directed in the same direction as torch travel A five degree leading arc is gener ally recommended for air plasma on mild steel p Standoff Height pE o 3 Trailing Arc Workpiece The trailing arc is directed in the oppos
56. D 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 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 equipment un der power while wearing the grounding wrist strap eS Manual 0 4980 CUTMASTER 82 Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist Unroll the rest of the band and peel the liner from the copper foil at the opposite end Attach the copper foil to a convenient and ex posed electrical ground Connect the equipment primary cable ground to the same electrical ground as the wrist strap Open the equipment enclosure and remove the failed PC board Carefully open the ESD protective bag and re move the replacement PC Board Install the replacement PC Board in the equip ment and make all necessary connections Place the failed PC Board in the ESD protective bag and seal for return shipping Replace the power
57. FF Fault Indicators OFF No arc in torch 1 Defective Logic PCB a Measure voltage at Main PCB between test point GND1 to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after torch switch is de pressed If voltage does not drop replace Logic PCB b While pilot arc is established measure volt age on Main PCB between test points GND1 to I DMDI for 1 4 VDC If voltage is low or not present replace Logic PCB 2 Defective Main PCB a Measure voltage at Main PCB between test point GND1 to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after torch switch is de pressed If voltage does not drop to less than 2VDC for approximately one 1 second then replace Main PCB D AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicators OFF No arc in torch 1 Defective Main PCB a Installjumper on Main PCB between test point GND1 to terminal b Closetorch switch If Pilot starts replace Main PCB E ACLED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicators OFF Pilot Arc is intermittent 1 Defective Logic PCB a Measure for 12VDC on Main PCB between test Point 1 to J2 8 If 12VDC is present replace Logic PCB 2 Defective Main PCB a Replace Main PCB F INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF
58. HING 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 5 11 CNC Interface Problems A Nothing happens when jumper is installed between J2 3 to J2 4 1 Defective Automation Interface PCB PCB 4 a Measure voltage on PCB 4 between J1 6 to J1 8 for 12VDC If 12VDC is present replace PCB 4 2 Defective Main PCB a Measure voltage on Main PCB between 1 6 to J1 8 for less than 2VDC If voltage is less than 2VDC replace PCB 1 B No OK TO MOVE signal while cutting 1 Defective Main PCB PCB 1 a Measure voltage on PCB 4 between 1 1 to J1 3 for 12VDC while cutting If 12VDC is present replace PCB 1 2 Defective Automation Interface PCB PCB 4 a Measure voltage on PCB 4 between J1 1 to J1 3 for less than 2VDC while cutting If voltage is less than 2VDC replace PCB 4 C ARC VOLTS signals are low or not present 1 Defective Automation Interface PCB PCB 4 a Replace PCB 4 SERVICE CUTMASTER 82 5 12 Test Procedures A Main Contactor W1 Test 1 Check continuity between to T1 L2 to T2 L3 to L4 to The contacts should be open no continuity CutMaster 52 amp 82 W1 contactor wired for 1PH Cover Screws Actuator Jumper Main Contactor Input ae Art Z A 08157 AR Retest continuity between terminals while engag ing the contacts manually This can be done by pushing down on the reces
59. IHERMAL DYNAMICS CUTMASTER PLASMA CUTTING SYSTEM 2012 EEEE IHERMAL DYNAMICS WARNING LXI 2 2 o o eX 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 82 SL100 1Torch Operating Manual Number 0 4980 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2007 2008 2009 2010 2011 2012 by Thermadyne Corporation rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Original Publication Date October 7 2007 Revision Date April 25 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial ff Torch Serial This Page Intentionally Blank TABLE OF CONTENTS SECTION 1 GENERAL
60. ION 4T 2 Bottom Dross Buildup Molten material which is not blown out of the cut area and resolidifies on the plate Excessive dross may require secondary cleanup operations after cutting Kerf Width The width of the cut or the width of material re moved during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has become elongated 4T 03General Cutting Information WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review the Important Safety Pre cautions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact With the workpiece while the torch is activated CAUTION Sparks from the cutting process can cause damage to coated painted and other surfaces such as glass plastic and metal NOTE Handle torch leads with care and protect them from damage Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life Manual 0 4980 Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as
61. Industries Inc www thermadyne com
62. LTAGE SELECTION SWITCH set for incorrect voltage 2 Primary input voltage problem 1 Turn OFF power to unit then set INPUT VOLTAGE SELECTION SWITCH to match primary input voltage 2 Have qualified person check primary voltage to insure it meets unit requirements see section 2 04 3 Faulty components in unit 3 Return to authorized service center for repair or replacement FAULT and MIN pressure indicators indicators flashing FAULT and 75 PSI 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 Refer to clearance information section 2 04 Allow unit to cool Return to authorized service center for repair or replacement Connect gas supply to unit Turn gas supply ON Set air supply inlet pressure to unit to 120 psi Adjust regulator to set air pressure see section 4 02 Return to authorized service center for repair or replacement Hand tighten the shield cup until it is snug Insure torch is securely fastened to uni
63. O RESTART mode 9 Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 3 9 mm of the work piece to establish main cutting arc 10 While cutting keep the torch switch closed and bring the torch OFF the edge of the material Pilot Arc re ignites immediately 11 Open the torch switch DCLED turns OFF After 20 second post flow time Gas solenoid closes Gas flow stops 12 Set the FUNCTION CONTROL SWITCH to LATCH mode 13 Start a cut and release the torch switch Maincutting arc will remain ON until the torch is lifted away from the plate approximately 94 19 mm or until the torch is brought OFF the edge of the metal Once the arc has extinguished e DC LED turns OFF Manual 0 4980 After 20 second post flow time Gas solenoid closes e Gas flow stops This completes the Main Arc and Controls Test If the above are all correct then proceed to the next section H CNC Interface Test If the unit does not function as stated above then note the symptom and proceed to Section 5 10 Main Arc and Controls Problems on page 5 17 H CNC INTERFACE TEST If the unit has one of the two factory supplied options for CNC interface installed proceed with this section otherwise the tests are complete 1 Connect an ohmmeter between J2 12 to J2 14 START signal Position the torch to pilot Check the OK TO MOVE signal by connecting a jumper between
64. PENDIX 7 P lication Histor Cover Rev Change s SSS Oct 1 2007 Apr 15 2008 Apr 28 2008 May 16 2008 July 17 2008 Jan 27 2009 Apr 24 2009 May 29 2009 Sept 2 2009 Feb 25 2010 Feb 8 2011 Mar 20 2012 April 25 2012 APPENDIX AA AB AC AD AE AF AG AH AI AJ AK AL AM Manual released Per 752 updated firmware changes to pgs 4 1 and 5 5 Per 845 correct ed drag cutting statement to pg 4T 5 Per 803 releasing 400 460V sys tems Per ECOB890 Updated system schematic to Rev AB Updated section 2 spec chart and input wiring chart per ECOB880 for CSA approval Added information to section 6 about regulator logic PCB kit upgrade for older systems per 908 Updated input power and cable charts in section 2 Updated 208 460V System schematic Added Hi Lo voltage selection switch part number section 6 per 1001 Corrected art in section 3 to show all information per 1248 Added 600V system information to sections 2 6 and Appendix per ECOB1346 Updated 400 600V schematic in appendix per ECOB1399 Updated 230 460v schematic per 1357 Updated section 6 with 600v numbers per 1520 Updated cable part numbers in section 6 per 1637 Per 1859 corrected Schematics with art number 09131 and A 09133 to show proper ARC Volts for Automation Interface PCB Changed COO t
65. ROCESSES 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 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards As sociation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 55
66. STER 82 Check Air Quality To test the quality of air 1 Put the ON OFF O switch in the onl up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn ON the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02Setting Up Mechanical Torch NOTE An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine torch A WARNING Disconnect primary power at the source before disassembling the torch or torch leads The mechanical torch includes a positioning tube with rack and pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the sur face of the workpiece 3T 1 INSTALLATION CUTMASTER 82 Pinch Block Assembly Workpiece 02585 Mechanical Torch Set Up 3 The proper torch parts shield cup tip start cartridge and electrode must be installed for the type of operation Refer to Section AT 07 Parts Selection for Manual and Mechanized Torch Cutting on page 4 9 for details INSTALLATION 3T 2 Manual 0 4980 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering Identification 1 Output Current Control Sets the desired output current Output settings up to 60 Amps may b
67. Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending OPERATION 4T 16 Manual 0 4980 CUTMASTER 82 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 4980 4T 17 OPERATION CUTMASTER 82 This Page Intentionally Blank OPERATION 4T 18 Manual 0 4980 CUTMASTER 82 SECTION 5 SYSTEM SERVICE 5 01 General Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of torch tip and electrode N Weekly AD mmm 7 gt Visually inspect the torch body tip Replace as needed electrode start cartridge and shield cup 3 Montlis Replace all Clean broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 07938_AB Manual 0 4980 5 1 SERVICE CUTMASTER 82 5 02 Maintenance Schedule NOTE 5 03 Common Faults Problem Symptom The actual frequency of maintenance may need to be adjusted according to the operating environment Daily Operational Checks or Every Six Cutting Hours 1 Check torch consumable parts replace if da
68. T Modules Test 1 Disconnect transformer wires from Main PCB terminals PRI 1 A and PRI 4 D 2 Usinganohmmeter perform the following checks PRI 1 A MTH2 Forward Bias PRI 1 A Reverse Bias MTH 2 Reverse Bias MTH 4 Forward Bias PRI 2 B Forward Bias PRI 2 B Reverse Bias MTH2 PRI2 B Reverse Bias MTH 4 PRI 2 B Forward Bias MTH6 Forward Bias Reverse Bias Reverse Bias Forward Bias Forward Bias Reverse Bias PRI 4 D Reverse Bias PRI 4 D Forward Bias 3 If the test reveals a failed component replace Main PCB and perform main contactor test Sec tion 5 11 A If no problem is found reconnect the transformer wires to Main PCB E Output Diode Module Test 1 Disconnect transformer wires from Main PCB terminal SEC 1 2 Using an ohmmeter perform the tests in the chart SEC 1 Forward Bias SEC 1 Reverse Bias WORK 1 Reverse Bias CHOKE 1 Forward Bias SEC 2 Forward Bias SEC 2 Reverse Bias WORK 1 Reverse Bias CHOKE 1 Forward Bias 3 If the test reveals a failed component replace Main PCB If no problem is found reconnect the transformer wires to Main PCB Manual 0 4980 5 19 SERVICE CUTMASTER 82 F Pilot IGBT Test 1 Disconnect wire from Main PCB terminal TIP1 2 Measure continuity on Main PCB between test point GND1 to terminal 3 PCB Signal Information If the test reveals a failed component replace Main PCB If no problem is found reconnect wire to Main Man
69. Used Torch solenoid 24VAC return OK TO MOVE Not used OK TO MOVE Not used Common Common Not used START Torch Switch Jumper installed Jumper installed 12VDC 460VAC 230VAC Manual 0 4980 CUTMASTER 82 LED INDICATORS D59 PCRIndicates Pilot IGBT gate signal is ON D78 CSRIndicates cutting arc has been established MAIN PCB TEST POINTS GND1 Common GND2 Common GND3 Common 12V1 12VDC 48V1 48VDC I DMD10 4VDC Current Demand Signal 5 27 SERVICE CUTMASTER 82 This Page Intentionally Blank SERVICE 5 28 Manual 0 4980 CUTMASTER 82 SECTION 5 TORCH SERVICE 5T 01General Maintenance Upper Groove with Vent Holes Must Remain Open NOTE Refer to Previous Section 5 System for common and fault indicator descriptions Upper O Ring in Correct Groove Threads Cleaning Torch Lower O Ring Art A 03725 Even if precautions are taken to use only clean air Torch Head O Ring with a torch eventually the inside of the torch be comes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch A WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be remove
70. a Gas Press Flow noos osam 120 sei ox 120 s s 0 eo ow zi 0 120 s wo ss oss 120 a0 100 254 0 ve so 127 oss 27 osen 19 s 20 oz oss vs 20 ost oss us w io ox 222 osen s 9 023 oss we s s 020 Manual 0 4980 T 4T 11 T ssl sl olojoj ojoj o o oj o o o ba r Type Secondary Gas Single Gas Torch Pierce Plasma Total Delay Sec Inches Pierce Height 3 oo 3 e T 9g gs o on 5 OPERATION CUTMASTER 82 Thickness Standoff Flow CFH Pierce Height s mm Cat No Volts VDC Amps Inches psi bar Plasma mm aso ass oss eal vo 4s Fs ze 0 79 as vs p y N mo az 025 as v wo 99 Css 14v ozs ea m s nus o osoo 127 ozs m ws wo 060 025 oe 5 osm ue s 26 oss aa ws 025 oa een 15 9 oer nus o ws wn
71. cle 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 4 Sections of the Data Tag may be applied to separate areas of the power supply APPENDIX A 2 ow and Revision Level Standard Symbols AC DC Phase Art A 03288 Manual 0 4980 APPENDIX A Hand Torch Pin Out Diagram TORCH PIN ATC Male Connector Negative Front View Plasma 4 Green Switch ATC Male Connector 6 Open Negative Plasma far 8 Green Pendant Connector 7 Green Not Used 6 Open Front View 4 Black Pendant Connector 3 White TOR Pendant 4 Connector J 2 Orange 1 EN Manual 0 4980 Pilot 5 White Not Used 6 Open 5 Open 5 Open Pi ATC Female Receptacle lj lot 8 Ground A 3 ENS 7 Open 7 Open 1 B Suc 4 7 2 SET CUTMASTER 82 T DIAGRAM Negative Plasma Front View 4 Switch SY Lo 3 Switch dl ATC Female Receptacle Front View Negative Plasma p SZ lt f Switc ml 2 gt 94 SS 1 PIP
72. d rear panels DO NOT use the finer threaded lower screws for this Q P Lower Screws i got AS Slots Lower p 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 lbs Do not over tighten 5 8 Manual 0 4980 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 1 Main Contactor W1 Check Section 5 11 A 2 Input Diode Module Test Section 5 11 B 3 Input Capacitor PCB Test Section 5 11 C 4 IGBT Modules Test Section 5 11 D 5 Output Diode Module Test Section 5 11 E 6 Pilot IGBT Test Section 5 11 F If all of the Pre Power Up Tests are OK proceed with the trouble shooting guide CAUTION Due to the close proximity of the Main PCB to the Capacitor PCB It is recommended to use an insulated meter probe when making measurements on the J2 connector on Main PCB Do not short between t
73. d cups O rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective 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 whet
74. d from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air CAUTION Art 03791 7 O Ring Dry the torch thoroughly before reinstalling ATC O Ring ATC Male Connector O Ring Lubrication NOTE DO NOT use other lubricants or grease they may not be designed to operate within high tempera tures or may contain unknown elements that may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life An o ring on the Torch Head ATC Male Connec tor requires lubrication on a scheduled basis This will allow the o rings to remain pliable and provide a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to potential performance problems It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o rings on a weekly basis Manual 0 4980 5T 1 SERVICE CUTMASTER 82 5T 02Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter cartridge
75. e 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 A GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection 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
76. e 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 Used to purge the air through the unit and torch and leads and to adjust gas pressure RUN gt Used for general cutting operations RAPID AUTO RESTART Allows for faster restarting of the Pilot Arc for uninterrupted cutting I 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 4980 CUTMASTER 82 Art A 07886 5678 9 10 Temp Indicator Indicator is n
77. ed on the torch head If resistance is felt when installing the cup check the threads before proceeding OPERATION CUTMASTER 82 4T 02Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff alignment with the workpiece cutting speed gas pres sures and operator ability Cut quality requirements differ depending on ap plication For instance nitride buildup and bevel angle may be major factors when the surface will be welded after cutting Dross free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation The fol lowing cut quality characteristics are illustrated in the following figure Kerf Width 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 OPERAT
78. ement Tools required T20 Torx Driver T 2 9 Remove the Cover per subsection 7 04 A Remove the two large gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 5 05 E Remove Capacitor PCB per subsection 7 08 A Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector Remove the four 4 mounting screws securing the PCB to the center chassis Carefully guide the PCB assembly up and out of the unit Install the replacement PCB by reversing the above steps Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Remove all wires from W1 noting the location and orientation of each wire Loosen the two 2 Torx head screws securing the Main Contactor to the base Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mount ing screws Lift Main Contactor up and out of the unit Install the replacement Contactor by reversing the above steps Reinstall the power supply cover Manual 0 4980 CUTMASTER 82 PARTS REPLACEMENT CUTMASTER 82 This Page Intentionally Blank PARTS REPLACEMENT 7 8 Manual 0 4980 CUTMASTER 82 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ON OFF switch to ON Close external disconnect switch RESULT Power to s
79. ew Electrode CE UTE Worn Electrode e 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 4980 CUTMASTER 82 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Power Supply Replacement Section 6 04 Major External Replacement Parts Section 6 05 Front Panel Replacement Parts Section 6 06 Left Side Replacement Parts Section 6 07 Right Side Replacement Parts Section 6 08 Options and Accessories Section 6 09 Replacement Parts for Hand Torch Section 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Section 6 11 Torch Consumable Parts Manual and Mechanized Torches NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns Ifa product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Informati
80. ext per ECOB2149 Updated ART A A 07994 per 2136 A 10 Manual 0 4980 This Page Intentionally Blank Printed in Mexico U S Customer Care 800 426 1888 rax 800 535 0557 gt Canada Customer Care 905 827 4515 rax 800 588 1714 International 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 Ph 1 940 381 1212 Oakville Ontario Canada Milan Italy Rawang Malaysia International Singapore 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 439 0236546801 Ph 4603 6092 2988 Fax 61 3 0474 7498 Ph 65 6832 8066 Fax 1 800 588 1714 tollfree Fax 39 0236546840 Fax 603 6092 1085 Fax 465 6763 5812 2010 Thermadyne
81. han directly back into it until the pierce is complete 3 In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line Hold the torch per pendicular to the workpiece after the pierce is complete 4 Hold the torch away from your body 5 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start 4T 5 OPERATION CUTMASTER 82 Trigger Release 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 character istic of the power supply and not a function 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 Torch parts wear Air quality Li
82. he pins Do not short to the Capacitor PCB connections D Initial Set up Conditions This section is to help isolate the defective circuit before troubleshooting identify symptoms and test the unitfor proper operation Follow the instructions as given to identify the possible symptom s and the defective circuit After repairs are complete run the following tests again to verify that the unit is fully operational 1 Connect gas supply to rear of Power Supply 2 Turn ON gas supply and set operating pressure per pressure setting label on power supply 3 Setthe Power Supply controls as follows e ON OFF SWITCH to OFF position Turn FUNCTION CONTROLSWITCH to SET position CURRENT CONTROL POTENTIOMETER to MAXIMUM position fully clockwise Manual 0 4980 CUTMASTER 82 E Main Input and Internal Power Test 1 Connect Primary Line power to the unit 2 Turnthe ON OFFSWITCH SW1 to ON position and observe the following e Software version is displayed See subsection 5 04 Fault Indicator on page 5 3 After approximately three 3 seconds Inrush relay on PCB 1 energizes starting charging of working capacitors e W1 energizes e AC and GAS Indicators come ON e Gas flows Fans turn ON 3 Adjust the pressure regulator to set the gas pres sure as specified in charts STANDOFF CutMaster 82 Gas Pressure Settings SL60 SL100 Hand Torch Mechanized Torch 75 psi 75 psi 5 2 bar 5 2 bar Add 5 p
83. her arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 4980 1 7 GENERAL INFORMATION CUTMASTER 82 This Page Intentionally Blank GENERAL INFORMATION 1 8 Manual 0 4980 SECTION 2 SYSTEM INTRODUCTION 2 01 How To Use This Manual This Owner s Manual applies to just specification or part numbers listed on page i To ensure safe operation read the entire manual including the chapter on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particular attention to the information provided under these headings These special annotations are easily recognized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is helpful in efficient operation of the system CAUTION A procedure which if not properly followed may cause damage to the equipment A WARNING A procedure which if not properly followed may cause injury to the operator or others in the oper ating area A WARNING Give
84. ial and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and 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 39 CUTMASTER 52 CUTMASTER 62 CUTMASTER 102 CUTMASTER 152 This warranty does not apply to 1 Consumable Parts such as tips electrodes shiel
85. igger 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 character istic of the power supply and not a function of the torch Trigger 7 4 a m Manual 0 4980 8 Cutas usual Simply release the trigger assembly to stop cutting 9 Follow normal recommended cutting practices as provided in the power supply operator s manual 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 opera tions 2 Angle the torch slightly to direct blowback particles away from the torch tip and op erator rather t
86. ighlights are categorized as follows NOTE An operation procedure or background information which requires additional emphasis or is helpful in ef ficient operation of the system CAUTION A procedure which if not properly followed may cause damage to the equipment WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area A WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in a box such as this 1 02 Important Safety Precautions WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health 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 amp GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Manual 0 4980 CUTMASTER 82 Keep all fumes and gases f
87. ign 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 fans do not run Main Contactor W1 does not close 1 Primary power not connected a Check that cable is connected to primary power 2 Primary line fuse breaker is blown tripped a Replace fuse or reset breaker 3 Defective ON OFF SWITCH a Check continuity 4 Defective Main PCB a Measure Main PCB power supply voltages at the following test points GNDI to 12V 12 VDC GNDI to 48V 48 VDC Replace Main if not correct 5 Defective Ribbon Cable a Check continuity 6 Defective Logic a Replace Logic PCB SERVICE INPUT POWER FAULT AC LED ON FAULT Indicator and 65 PSI LED is flashing 1 INPUT VOLTAGE SELECTOR SWITCH SW2 set for incorrect voltage a Set SW2 to correspond to the primary line voltage Turn SW1 to OFF position then back to ON position to clear the error 2 Defective SW2 a Check continuity 3 Primary line voltage out of tolerance range a Connect unit to voltage with unit specifica tions See Subsection 2 04 Power Supply Specifications on page 2 2 If using a gen erator connect unit to a wall receptacle to see if problem is corrected 4 Defective Main PCB a Measure voltage on Main PCB between test point GND1 to J2 22 460 VAC input ap
88. in place Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be re moved may effect the performance of the system 2 Inspect the cup for damage Wipe it clean or replace if damaged Art 08067 Shield Cups 3 Ontorches with a shield cup body and a shield cap or deflector ensure that the cap or deflector is threaded snugly against the shield cup body In shielded drag cutting operations only there may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 SERVICE 4 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip Co 27 03406 Example of 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 A 08064 AC 6 Pullthe Electrode straight out of the Torch Head Check the face of the electrode for excessive wear Refer to the following figure lt N
89. ing them While grasping the panel close to the base pull the panel directly from the base to release the locking tabs Tore engage the panel position the panel so that the locking tabs are above the base then push the panel back onto the base until the locking 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 4980 7 05 Front Panel Parts Replacement Refer to Section 6 05 Front Panel Replacement Parts on page 6 3 and overall detailed drawing A Current Control Potentiometer A Knob Replacement Tools required Flat Screw Driver 1 Turn the potentiometer fully clockwise and note the location of the pointer mark on the knob 2 Loosen the screw securing the Current Control Knob to the potentiometer shaft and remove the knob 3 Replacethe knob on the potentiometer shaft with the pointer in the same position as noted in Step 1 B Function Control Switch Knob Replacement Tools required Flat Screw Driver 1 Turn the Function Control Switch until the pointer on the knob is in the LATCH position 2 Loosen the screw securing the knob to the switch shaft and remove the knob 3 Replace the knob on the switch shaft with the pointer in the position noted in Step 1 C Replacing Gas Hoses Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Push the
90. is ground connection 3 Loosen the through hole protector on the back panel of the power supply Pull the original power cable out of the power sup ply 4 Using a customer supplied four conductor input power cable for the voltage desired strip back the insulation on the individual wires 5 Pass the cable being used through the access opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 Manual 0 4980 6 Connect the wires as follows SetJumper wires on the contactor See illustration e Green Yellow wire to Ground Remaining wires to L1 L2 and L3 in put It does not matter what order these wires are attached See the previous illustrations 7 With a little slack in the wires tighten the through hole protector to secure the power cable 8 Reinstall the Power Supply cover per in structions found in section 5 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power cable or close the main disconnect switch to supply power Manual 0 4980 CUTMASTER 82 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
91. it 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 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 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 INSTALLATION Regulator Filter Assembly 2 Stage Filter Inlet Port IN Regulator Input Outlet Port OUT Two Stage Filter Hose Clamp M RL Assembly Gas Supply Hose Optional Two Stage Filter Installation Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply 1 Refer to the manufacturer s specifications for installation and maintenance proce dures for high pressure regulators Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign material Briefly open each cylin der valve to blow out any dust which may be present 3 The c
92. ite direc 00941 tion as torch travel 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 e 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 Standoff Distance d Slag Buildup 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 Trailing Arc side of the gouge path However slag build up can Sd 9 cause inconsistencies and irregular metal removal if large amounts of material build up in front of the 02586 NI arc The build up is most often a result of improper Leading Arc travel speed lead angle or standoff height Mechanized Torch Operation Manual 0 4980 4T 7 OPERATION CUTMASTER 82 For optimum smooth surface quality the travel speed should be adjusted so that only the leading edge of the arc column produces the cut If the travel speed is too slow a rough cut will be produced as the arc moves from side to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle o
93. ition 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 4980 CUTMASTER 82 Typical Cutting Speeds Cutting speeds vary according to torch output am perage the type of material being cut and opera tor skill Refer to Section 4T 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip and 4T 09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 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 postflow 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 exl OFF 9 switch to OFF down Power Supply indicators shut OFF Unplug the input power cord or disconnect inp
94. lasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre pro fessionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertis sements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 1 603 298 5711 ou votre distributeur local si vous avez des questions Manual 0 4980 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
95. lle qui est sugg r e dans le recommen dation qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e urant Ar Protective Num r Num r Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail INFORMATIONS G N RALES 1 4 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 Pour prot ger votre ouie 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 faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 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 C
96. m 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 2 Check plasma and secondary supply and pres MM P y P 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 speed too slow 1 2 fan for proper operation and adequate air Formation Torch standoff too high from orkpiece 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 Inspectinput 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 material too thick required man 3 Excessive pilot arc time 2 Checkcables and hoses for leaks or cracks replace 4 Gas pressure too low if necessary
97. 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 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 4980 CUTMASTER 82 Manual 0 4980 6 9 PARTS LIST CUTMASTER 82 6 11 Torch Consumable Parts Manual and Mechanized Torches Start Cartridge 9 8213 Electrode 9 8215 Art A 08065 AE PARTS LIST DRAG TIP CUTTING A 20A 9 8205 30A 9 8206 40A 9 8207 60A 9 8252 DRAG SHIELD CUTTING 40A CUTTING Shield Cap Deflector 9 8243 Shield Cap Deflector 9 8243 40A 9 8208 STANDOFF CUTTING e 50 60A CUTTING Tip
98. mm from the workpiece as shown below Torch Shield Cup Standoff Distance 1 8 3 8 3 9mm Pers eS 00024 Standoff Distance OPERATION CUTMASTER 82 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 character istic of the power supply and not a function of the torch 4 03383 6 Cutas 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 OPERATION 8 Fora consistent standoff height from the workpiece install the standoff guide by sliding it onto the torch shield cup Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc During operation posi tion the legs of the standoff g
99. ne voltage fluctuations Torch standoff height Proper work cable connection OPERATION 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 contact With the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power Supply CAUTION Sparks from plasma gouging can cause dam age to coated painted or other surfaces such as glass plastic and metal Check torch parts The torch parts must cor respond with the type of operation Refer to 41 07 Parts Selection for Manual and Mechanized Torch Cutting on page 4T 9 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 AT 6 Manual 0 4980 CUTMASTER 82 Current Setting 4T 06Mechanized Torch Operation
100. ng Option S tae eere eer rens 3 1 3 03 Primary Input Power Connections 3 1 3 04 Gas Connections ce ER CE TERT 3 3 SECTION TORCH INSTALLATION i i i i naneti 3T 1 3T 01 Torch Connections ana a a a ArT anas 3T 1 3T 02 Setting Up Mechanical Torch 3T 1 SECTION 4 SYSTEM OPERATION 4 1 4 01 Front Panel Controls Features 4 1 4 02 Preparations for Operation 1 4 2 SECTION 4 TORCH OPERATION 4 1 4T 01 Torch Parts Selection ice 4 1 AT 02 CutiQualily iain Biles od 4T 2 4T 03 General Cutting Information 4T 2 4T 04 Torch 4T 3 gt rasa 4 6 4T 06 Mechanized Torch Operation 0 2 4400 11 020000 4T 7 4T 07 Parts Selection for Manual and Mechanized Torch Cutting 4 9 4 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip eine RR DER 4T 10 4T 09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T 13 TABLE OF CONTENTS PATENT INFORMATION oit etait a e e 4T 16 SECTION 5 SYSTEM SERVICE esse ded ete 5 1 5 01 General Maintenance ui 5 1 5 02 Maintenance Schedule 5 2 5 03 Common
101. nnected to this Power Supply See Section 3T of this manual Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power requirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to supply power to the system Air Source Ensure source meets requirements refer to Section 2 Check connections and turn air supply ON Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 04509 OPERATION Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator 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
102. ode de Californie de la s curit et sant paragraphe 25249 5 et suivants Manual 0 4980 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements ds 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 Office 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 Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE DE SOUDAGE A LARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PRO TECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI 249 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROCEDES DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 d
103. on 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 t Description talog 1 CutMaster 82 Power Supply 208 230 460VAC Single or 3 Phase 60Hz with input power cable and plug 3 1130 1 460VAC Single or 3 Phase 60Hz with input power cable 3 1130 2 600VAC 3 Phase 60Hz with input power cable 3 1130 5 Manual 0 4980 6 1 PARTS LIST CUTMASTER 82 6 04 Major External Replacement Parts Item t Description talog 1 1 Cover with labels 9 0128 2 1 Base Enclosure Assembly 9 0118 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0127 5 1 Rear Panel 9 0101 Art A 08120 NOTE Illustration may vary slightly from unit PARTS LIST 6 2 Manual 0 4980 CUTMASTER 82 6 05 Front Panel Replacement Parts t Description Ref talog 1 1 Output Current Control and Function Control Knobs 9 8527 2 1 Toggle ON OFF Switch SW1 9 0109 3 1 Work Cable with Clamp 20 Ft 6 1 m 9 0184 NOTE Illustration may vary slightly from unit 6 3 PARTS LIST Manual 0 4980 CUTMASTER 82 6 06 Lef
104. oo 28 020 025 ea naso 4 12 es 216 o as oo se ooo oss ea 10 o as fin zs 025 oa oso pmz semo ws o a0 oz o as 245 025 oa os ss ws 60 20 ost o as oo ss w wm ne oro ws o 18 ou o as oo wm NR OPERATION 4T 10 Manual 0 4980 Type Torch Mechanized With Exposed Tip Type Plasma Gas Air Thickness Output Amperage Speed Per Minute Inches Cat Volts VDC Amps a e 120 ms pea 0278 0 625 15 9 ojojo ume e e 25 oean 132 180 7457 019 ss 09 25 ro o m os fur a 18 046 0 19 10 oz 049 0 23 0 19 EI s CUTMASTER 82 Plasma Total T Lim a 340 0 T 7 340 0 e ps co e LE c pire c pe c Ap pure c 21 c RES c e c Ap Type Material Mild Steel Type Secondary Gas Single Gas Torch Standoff Plasma Gas Press Flow Pierce Height nches 3 aje 3 A A Type Torch Mechanized With Exposed Tip Type Material Stainless Steel Type Plasma Gas Air Speed Per Minute Standoff Plasm
105. or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For information on how to test for noise see item 1 in Subsec tion 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear 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 whe
106. ormally OFF Indicator is ON when internal temperature exceeds normal limits Let the unit cool before continuing operation Gas Indicator Indicator is ON when minimum input gas pressure for power supply operation is present Minimum pressure for power supply operation is not sufficient for torch operation DC Indicator Indicator is ON when DC output circuit is active b Fault Error Indicator Indicator is ON when Fault circuit is active See sec tion 5 for explanations of fault lights 10 Pressure Indicators Art A 08170 The Indicators will illuminate according to the pressure set by the Pressure Control Knob number 4 OPERATION CUTMASTER 82 4 02 Preparations for Operation At the start of each operating session WARNING m 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 appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 80 amps maximum Refer to Section 4T 07 Parts Selection for Manual and Mechanized Torch Cutting on page 4T 9 and fol lowing for torch parts selection Torch Connection Check that the torch is properly connected Only Thermal Dynamics model SL60 Manual or 51 100 Mechanical Torches may be co
107. position and then turn to ON position to clear the error Manual 0 4980 5 10 Main Arc and Controls Problems A Main arc will not establish LED D59 on Main PCB remains ON while pilot arc is striking the work piece 1 Work Cable not connected a Connect cable to work piece 2 Work cable open broken a Check continuity of work cable Insure con nection of cable to clamp is secure B Main arc transfers but current cannot be adjusted 1 Defective Logic PCB a While main arc is transferred measure volt age on Main between test points GND1 toI DMDI b Adjust CURRENT CONTROL POTENTIOM ETER from maximum to minimum Voltage should vary from 4VDC at max to 1 VDC at min If voltage does not vary with CURRENT CONTROL POTENTIOMETER replace Logic PCB 2 Defective Main PCB a Replace Main PCB C In LATCH mode when the torch switch is released the arc shuts OFF immediately 1 Defective Logic PCB a Replace Logic PCB D With CURRENT CONTROL POTENTIOMETER set at maximum output current is only 60 amps 1 Tipis touching the work piece Drag mode a Lifttip off work piece 2 Defective Pilot IGBT on Main PCB a Check per section 4 10 I E In RAPID AUTO RESTART mode with torch switch closed the pilot does not start immediately when the cutting arc extinguishes 1 Defective Logic PCB a Replace Logic PCB Manual 0 4980 CUTMASTER 82 F INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLAS
108. prox 3 VDC 230 VAC input approx 1 5 VDC b With all power removed from the unit dis connect the ribbon cable from J2 connector on Main PCB Check continuity between J2 34 to test point GND 1 With SW2 in LOW position continuity should be present with SW2 in the HIGH position It should read open If not correct replace Main PCB assembly 5 Defective Logic assembly a Replace Logic PCB PARTS IN PLACE PIP FAULT The FAULT Indicator and 70 PSI LED is flashing 1 Shield Cup loose a Hand tighten the shield cup to close the PIP switch 2 Torch not properly connected to power supply a Insure torch ATC is securely fastened to unit 3 Problem with torch and leads PIP circuit a Check continuity of torch PIP circuit at ATC pins 1 amp 2 Manual 0 4980 CUTMASTER 82 Negative Plasma e H TIP MISSING FAULT The FAULT Indicator and 80 PSI LED is flashing Gas solenoid cycles ON and OFF 1 TorchShield Cup is loose 2 PIP 1 PIP a Tighten shield cup by hand Do not over tighten 2 Torch tip electrode or starter cartridge missing a Turn OFF power supply Replace missing part s 3 Starter Cartridge is stuck Pilot Lead Art A 08124 4 Defective Logic PCB a Measure the voltage on Main PCB between J2 17 to test point GND1 for 12VDC If the voltage is less than 2VDC replace Logic PCB a Turn OFF power supply Bleed down the sys tem Remove the shield cup tip sta
109. put Capacitors 600V Only 9 0163 8 1 Filter Auto Drain 9 0116 NOTE 9 0115 regulator If the serial number of the power supply is prior to 05078755 then kit number 9 0201 will be needed to replace not only the regulator 9 0115 but the logic PCB as well Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting If there is a transducer and wire harness instead of the tube the kit is not needed Art 08121 NOTE Illustration may vary slightly from unit Manual 0 4980 6 5 PARTS LIST CUTMASTER 82 6 08 Options and Accessories Qty Description Catalog 1 Single Stage Filter Kit includes Filter amp Hose 7 7507 1 Replacement Filter Body 9 7740 1 Replacement Filter Hose not shown 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose amp Mounting Screws 9 9387 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 Automation Interface Kit 9 8311 1 25 7 6m CNC Cable for Automation Interface Kit 9 1008 1 35 10 7 m CNC Cable for Automation Interface Kit 9 1010 1 50 15 2 m CNC Cable for Automation Interface Kit 9 1011 1 Nylon Dust Cover 9 7071 Filter Element Cat No 9 7741 Soin O ring Cat No 9 7743 Assembled Filter Firs
110. r 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 To pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the front end of the torch When operating with a cutting machine a pierce or dwell time is required Torch travel should not be enabled until the arc penetrates the bottom of the plate As motion begins torch standoff should be reduced to the recommended 1 8 1 4 inch 3 6 mm distance for optimum speed and cut quality Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize the amount of scale which adheres to it OPERATION 4T 8 Manual 0 4980 DRAG TIP CUTTING 14 20 9 8205 30A 9 8206 40A 9 8207 60A 9 8252 DRAG SHIELD CUTTING 40A CUTTING CUTMASTER 82 4T 07Parts Selection for Manual and Mechanized Torch Cutting Shield Cap Deflector 9 8243 0 Shield Cap Deflector 9 8243 40A 9 8208 STANDOFF CUTTING 50 60A CUTTING Standoff Guide 9 8251 Shield Cap Drag 50 6
111. r supply and bleed down system A WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter As sembly as injury could result 3 Loosen the two bolts on the top of the Filter As sembly enough to allow the Filter Elements to move freely 4 Note the location and orientation of the old Filter Elements 5 Slide out the old Filter Elements First amp Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 7 Hand tighten the two bolts evenly then torque each bolt to 20 30 in Ibs 2 3 3 4 Nm Improper torque may damage the gasket 8 Slowly apply air pressure to the assembly check ing for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures SERVICE 5 07 Circuit Fault lsolation A WARNING The following procedures should not be at tempted by anyone who has not had proper training or authorized to do 50 A Cover Removal 1 Removethe upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front an
112. re the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece Pb LEAD WARNING This product contains chemicals including lead or otherwise pro duces chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq GENERAL INFORMATION 1 03 Publications Refer to the following standards or their latest revisions for more information 1 10 11 12 13 14 15 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 787 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 P
113. river 1 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 C 3 Unplug the connector J2 from the Main PCB 4 Remove the Current Control Potentiometer Knob and nut securing the potentiometer shaft to the front panel per subsection 7 05 A 5 Remove the Function Control Switch Knob and the nut securing the switch shaft to the front panel per subsection 7 05 B 6 Pull the top of the front panel forward slightly and carefully remove the Logic PCB from unit 7 Install the replacement Logic PCB by reversing the above steps 8 Reinstall the power supply cover 7 3 PARTS REPLACEMENT CUTMASTER 82 G 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 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 H Work Cable Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04 A 2 Disconnect the work cable from the terminal on Main PCB 3 Squeeze the top and bottom of the Work Cable Strain Relief and remove from the front panel 4
114. rom the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlo rinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec
115. rt cartridge and electrode Check the lower end unit of the 5 Defective Main PCB start cartridge for free movement Replace the cartridge if the lower end unit does not move a Replace Main PCB freely G TRIGGER LOCKED DURING POWER UP iM cec ower End Fitting at Reset FAULT The FAULT Indicator and 75 PSI Full Compression Full Extension LED is flashing 1 Start signal is active when SW1 is turned to ON position a Start can be active for one of the following e Hand torch switch held closed Art 08064 Hand pendant switch held closed START signal is active low 4 Open conductor in torch leads a Check continuity Release the START signal source 5 Defective Main PCB 2 Problem in the torch and leads switch circuit b Measure voltage at Main PCB between 2 2 a Check continuity of torch switch circuit at ATC to test point GND1 for 12VDC If voltage is pins 3 amp 4 See previous illustration present replace Main PCB 3 Shortin CNC cable 6 Defective Logic PCB a Check continuity a Replace Logic PCB 4 Defective Logic PCB PCB 3 a Measure voltage at Main PCB between J2 16 to test point GND1 for 12VDC If voltage is present replace Logic PCB 5 Defective Main PCB a Replace Main PCB Manual 0 4980 5 13 SERVICE CUTMASTER 82 AC LED ON yellow TEMP LED is ON red FAULT Indicator is flashing 1 Air flow through unit is restricted a Provide adequate airflow See
116. rvice center 1 Connect work cable 2 Replace work cable 3 Return to an authorized service center for repair 1 Check and adjust to proper setting 2 Check torch consumables and replace as needed 3 Check the connection of the Work Lead to the work piece 4 Reduce cutting speed 5 Refer to Check air quality in section 3 Torch 6 Return to an authorized service center for repair 5 5 SERVICE CUTMASTER 82 5 06 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system be fore disassembling the torch leads or power Supply This section describes procedures for basic parts replace ment For more detailed parts replacement procedures refer to the Power Supply Service Manual A Cover Removal 1 2 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover Lower E Screws Art 07947 Carefully pull the Cover up and away from the unit B Cover Installation 1 2 Reconnect the ground wire if necessary Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws Tighten lower screws Reinstall and tighten the upper screws SERVICE C Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should
117. s Standoff Guide 9 8251 0 Shield Deflector 9 8243 gt 50 55 9 8209 60A 9 8210 STANDOFF CUTTING Standoff Guide 9 8281 STANDOFF CUTTING 40 120A GOUGING Tip Gouging 9 8225 40 Amps Max Tip Gouging 9 8226 50 100 Amps Tip Gouging 9 8227 60 120 Amps Tip Gouging D 9 8228 60 120 Amps Tip Gouging E 9 8254 60 120 Amps 6 10 NS DRAG SHIELD O Ring No CO Shield Cap Drag 70 120 CUTTING N amp V 70 100A 9 8236 CUTTING Eu __ 0 Shield Dettectr 9 9 8243 70A 9 8231 80A 9 8211 Standoff Guide 90 100A 9 8212 9 8281 120A 9 8253 Shield Cap Gouging 9 8241 CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less Manual 0 4980 SECTION 7 REPLACEMENT PROCEDURES 7 01 Scope This section describes parts replacement procedures which may be performed on the CutMaster 52 Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other subassemblies of this unit Evidence of unauthorized repairs may void the factory warranty 7 02 Anti Static Handling Procedures CAUTION PC Boards can be irreparably damaged by improper handling due to electrostatic discharge ESD A General Replacement PC Boards are shipped in a protective en closure to prevent damage from electrostatic discharge ES
118. s information regarding possible electrical shock injury Warnings will be enclosed in a box such as this Additional copies of this manual may be purchased by contacting Thermadyne at the address and phone number in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Manual 0 4980 2 1 CUTMASTER 82 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
119. sed actuator button on the top of W1 or pushing down on the actuator arm on the side of W1 L1 to T1 L2 to T2 L3 to T3 L4 to 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 Replace if contacts are stuck together or show excessive arcing SERVICE B Input Diode Module Test 1 2 Using ohmmeter perform the tests in the chart Forward Bias Forward Bias Forward Bias AC1 Reverse Bias AC2 Reverse Bias Reverse Bias AC1 Forward Bias Forward Bias Forward Bias Reverse Bias Reverse Bias Reverse Bias If the test reveals a failed component replace Main PCB and perform main contactor test Sec tion 5 11 A Input Capacitor PCB Test 1 Using an ohmmeter check continuity between the following points MTH 2 Charging MTH 4 Open MTH 6 Charging Most meters will show a charging action Initially a low resistance will be shown and then the resistance willstart to increase If the meter probes are reversed the reading will decrease to zero then start charging in the opposite polarity 2 If a short is found replace Capacitor PCB assem bly Check continuity between the following points opn Open mms Om If a short is found replace Capacitor PCB assem bly Manual 0 4980 CUTMASTER 82 D IGB
120. si Add 5 psi 0 4 bar 0 4 bar Leads Length Up to 25 7 6 m Each additional 25 7 6 m CutMaster 82 Gas Pressure Settings SL60 Hand Torch Leads Length Up to 25 7 6 m Each additional 25 7 6 m 80 psi 5 5 bar Add 5 psi 0 4 bar 4 Turn FUNCTION CONTROL SWITCH to RUN position e 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 F Pilot Arc Test If the unit does not function as stated above then note the symptom and proceed to Section 5 08 Main Input and Internal Power Problems on page 5 11 5 9 SERVICE CUTMASTER 82 F Pilot Arc Test 1 Activate or depress the torch switch Activate START signal to establish a pilot arc and note the following e Gas solenoid opens e Gas flows e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing DC LED comes e Pilot arc is established 2 Open the torch switch Remote Pendant switch or remove CNC start signal Gas continues to flow 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 s
121. so 45 os pr seno ws s 26 oss ow as ss 075 lofas 06 pee xz m oa orlas a 6 ws nA NR orofo o os a m6 ww Ww NR oseo wo s s ois oras o 48 oo ss nn nm NR Type Secondary Gas Single Gas Torch Speed Per Minute Standoff Flow Pierce Pierce Height Inches Meters Inches psi bar Plasma 19 eo os 19 48 Co ox s um 761 oxo Co 019 so seno ws 150 s82 Co as 01 0 5 oss ass 010 oeno 122 eo oo 220 019 48 9 26 Con 245 2 ea 5 2 ss 1 e es 1 for as roars semo 15 e oss as oso fizz e8210 9 2 oss ois as 2 020 5 se e 1s oss oie vo ae 9o wn orofa we o 2 oat vo as o wn an wn Fono vo 60 a ozs s4 o as oo 3e oo oss ea no o a 1148 ozs s4 7 4s oo 245 025 oa 260 ess ozs s4 o a8 oo s nuo oz5 oa 60 wo o as
122. ssure Defective Logic PCB a Replace Logic PCB M AC LED ON TEMP LED OFF GAS LED 5 14 1 ON Gas does not flow in SET mode using a hand torch or a machine torch without remote solenoid Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage is present change SOL 1 Defective Logic PCB a Measure on Main PCB between J2 12 to test point GND1 12VDC If voltage is present replace Main PCB Defective Main PCB a Replace Main PCB Manual 0 4980 CUTMASTER 82 AC LED ON TEMP LED OFF GAS LED 5 09 Pilot Arc Problems ON Gas does not flow in SET mode using a machine torch with remote solenoid A ACLED ON TEMP LED OFF GAS LED Disconnect the gas solenoid SOL1 from the back of the ATC connector If Gas DOES NOT flow out of SOL1 when the unit is in SET mode 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage is present change SOL 1 2 Defective Logic PCB a Measure on Main PCB between J2 12 to test point GND1 for 12VDC If voltage is present replace Main PCB 3 Defective Main PCB a Replace Main PCB If gas DOES flow out of SOL1 when the unit is in SET mode reconnect 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 a Measure on Main P
123. stated then note the symptom and proceed to Subsection 5 11 CNC Interface Prob lems on page 5 17 5 08 Main Input and Internal Power Problems A Primary input line fuse blows as soon as primary disconnect is closed 1 Primary input cable installed incorrectly a Check wiring of primary power cable to the contactor See illustration below 2 jumpers installed incorrectly a Check jumper installation for correct phase being used Single Phase 19 and Jumper Settings N L1 um Jumper L1 L4 2 20 Jumper L3 B L2 L3 5 14 5 _ 5 GND P Single Phase Input Power Wiring Three Phase 39 and Jumper Settings E Store copper jumper in spare parts box L1 Jumper L1 L4 Lop 7 GND E E J Three Phase Input Power Wiring 3 contactor points stuck closed a Check per section 5 11 A 4 Primary plug not wired correctly a Check manufacturer s plug installation in structions 5 Primary input cable is defective a Check cable for shorts SERVICE CUTMASTER 82 B Primary line fuses blow immediately after ON OFF SWITCH SW1 is turned to ON position 1 Shorted Input Diode Module a Check per section 5 11 B 2 Shorted Input Capacitor PCB a Check per section 5 11 C C Gas flows with ON OFF SWITCH in OFF position 1 Fore
124. t 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 e Hand torch switch held closed indicators flashing position Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Replace torch and leads or return to authorized service center or repair or replacement 3 Return to authorized service center for repair or replacement 2 Problem in the torch and leads switch circuit 3 Failed components in unit SERVICE 5 4 Manual 0 4980 CUTMASTER 82 Problem Symptom Possible Cause Recommended Action Nothing happens when torch switch or remote switch indicators flashing Manual 0 4980 1 Torch shield cup is loose 2 Torch tip electrode or starter cartridge missing 3 Torch start cartridge is stuck 4 Open conductor in torch leads 5 Problem in the torch and leads switch circuit 6 Failed components in unit 1 Problem in the torch and leads switch circuit Remote pendant switch circuit 2 CNC Contoller device not providing Start signal wrong position 2 Torch starter cartridge is stuck 3 Worn or faulty torch parts 4 Shorted Torch 1 Tighten shield cup by hand Do not overtighten 2 Turn OFF power supply Remove shield cup Install missing parts 3 Turn OFF power supply Bleed do
125. t amp Second Stage Cartridges Cover as marked 5 Barbed a Fitting Jg Art 02476 Art 02942 Optional Single Stage Filter Kit Optional Two Stage Filter Kit PARTS LIST 6 6 Manual 0 4980 CUTMASTER 82 6 09 Replacement Parts for Hand Torch ltem Qty Description Catalog 1 1 Torch Handle Replacement Kit includes items No 2 amp 3 9 7030 2 1 Trigger Assembly Replacement Kit 9 7034 3 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 SL60 20 foot Leads Assembly with ATC connector 4 7834 1 SL60 50 foot Leads Assembly with ATC connector 4 7835 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 9 7031 10 1 Torch Control Cable Adapter includes item 11 7 3447 11 1 Through Hole Protector 9 8103 Art 07993 AB Manual 0 4980 6 7 PARTS LIST CUTMASTER 82 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Item No Qty 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
126. t Side Replacement Parts Qty Description Ref Catalog 1 1 Main PCB Assembly non 600V PCB 1 9 0125 1 1 Main PCB Assembly 600V Only PCB 1 9 0166 2 1 Logic PCB PCB3 9 0107 3 1 Center Chassis Molded Plastic 9 0102 4 1 Fan MOT 1 2 9 0104 5 1 Transformer Main Non 600V T1 9 0199 5 1 Transformer Main 600V Only T1 9 0170 6 1 Inductor Output L1 9 0105 Not Shown 1 Power Cable Strain Relief for all units 9 0111 1 Input Power Cable 230 V with plug 9 8596 1 Input Power Cable 460 600V 9 8593 1 Hi Lo voltage selection switch 9 0110 NOTE 9 0107 Logic PCB If the serial number of the power supply is prior to 05078755 then kit number 9 0201 will be needed to replace not only the Logic PCB 9 0107 but the regulator 9 0115 as well Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting If there is a transducer and wire harness instead of the tube the kit is not needed Art A 08122 Illustration may vary slightly from unit PARTS LIST 6 4 Manual 0 4980 CUTMASTER 82 6 07 Right Side Replacement Parts Qty Description Ref Catalog 1 1 Contactor 4 Pole 9 8587 2 1 Solenoid 12V 9 0114 3 1 Spare Parts Box 7 3267 4 1 Spare Parts Box Cover 7 3266 5 1 Console Quick Disconnect 9 0161 6 1 Regulator with knob and mounting nut 9 0115 7 1 Assembly PCB Input Capacitors non 600V 9 0126 7 1 Assembly PCB In
127. tated above then note the symptom and proceed to Section 5 09 Pilot Arc Problems on page 5 15 G Main Arc and Controls Test Connect work Cable to the work piece Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 3 9 mm of the work piece to establish main cutting arc Main Cutting Arc Establishes On Main D59 turns OFF and D78 turns ON 1 Clamp DC ammeter around the work cable Out put will be 80 amps 2 While cutting adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to minimum setting Current adjusts from 80 amps down to 20 amps 3 Set the CURRENT CONTROL POTENTIOM ETER to maximum position Current adjusts from 20 amps up to 80 amps SERVICE 4 While cutting touch the tip of the torch to the work piece This is called Drag Mode Tip Saver circuit will activate current drops to 60 amps 5 Lifttip OFF the plate approximately 1 4 6 mm Tip Saver circuit deactivates current goes back to 80 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 Pilot arc ignites 7 Openthe torch switch DCLED turns OFF After 20 second post flow time Gas solenoid closes e Gas flow stops 8 Set the FUNCTION CONTROL SWITCH to RAPID AUT
128. th remote solenoid M L 1 21 OVERTEMP Active low when over temperature M L 22 Input Voltage signal M L 3VDC 460 VAC 1 5VDC 230VAC J1 23 12VDC M L J1 24 12VDC M L J1 25 GND M L J1 26 GND M L J1 27 Not Used J1 28 Not Used J1 29 MAIN BD ID Voltage level to identify Main PCB 1 1VDC M L J1 30 Not Used J1 31 Not Used J1 32 Not Used J1 33 Not Used J1 34 For Factory Use M L J1 35 For Factory Use M L J1 36 For Factory Use M L J1 37 For Factory Use M L J1 38 GND M L J1 39 For Factory Use M L J1 40 Not Used Manual 0 4980 5 23 SERVICE CUTMASTER 82 LED INDICATORS NORMAL INDICATION D1 12VDC D2MAX PRESSURE 90 PSI D4 85PSI D5 80 PSI D6 75 PSI D7 70 PSI D8 65 PSI D9MIN PRESSURE D10 AC D11OVERTEMP D12 GAS D13 DC D14ERROR TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV FIRMWARE VERSION X 7 X 6 5 XA X3 X2 1 X 0 1 X 2 X 3 X 4 X 5 X 5 0 5 to5 VDC 0 100 psi TP6 1 8VDC TP7 Potentiometer Current Demand 0 3 3VDC SERVICE 5 24 ERROR MESSAGE Over Pressure Internal Error Shorted torch Tip Missing Start Signal active during power up Parts In Place Fault PIP Input Power Fault Low Pressure Manual 0 4980 CUTMASTER 82 This Page Intentionally Blank Manual 0 4980 5 25 SERVICE CUTMASTER 82 J2 PINOUT __ 40 22 39 1 PRI 4 7 2
129. the input line from the filter element assembly 7 Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly Filter Element sm Li Art A 07990 8 Install the new or cleaned assembly by reversing these procedures 9 Turn ON the air supply and check for leaks before reinstalling the cover B Voltage Selection Switch Replacement Tools required T20 Torx Driver 9 16 wrench 1 Remove the Cover per subsection 7 04 A 2 Disconnect J3 from the Logic PCB 3 Remove retaining nut securing the switch to the rear panel 4 Feed the wires and connectors out of the panel 5 Install replacement filter by reversing above steps C Input Power Cable Replacement Tools required T20 Torx Driver Phillips Head Screw driver 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 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 PARTS REPLACEMENT 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
130. the rear panel back six 6 inches away from the base Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base Carefully guide the Center Chassis up far enough to lay the Chassis down to the right side 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 Manual 0 4980 C Output Inductor L1 Tools required T20 Torx Driver 12 Nut Driver 1 2 3 10 11 12 13 14 15 16 1 N Remove the Cover per subsection 7 04 A Remove the Tube Handle per subsection 7 04 C Remove the two large and one small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 E Disconnect J2 amp J3 connectors from Main PCB Disconnect Output Inductor wire from terminal Choke1 on Main PCB Disconnect Output inductor wire from ATC con nector Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief Disengage the Rear panel from the base per sec tion 7 04 D Guide the rear panel back six 6 inches away from the base Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs
131. tor at the rear of the unit for correct setting before plugging in or connecting the unit The primary power source fuse and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2 Most units are shipped from the factory with a 230Volt input power cable wired to the input contactor in the single phase configuration 3 02 Lifting Options The following illustrations and directions are for The Power Supply includes a handle for hand changing that configuration to a different voltage lifting only Be sure unit is lifted and transported and or to three phase operation or back again if a 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 physical strength should lift the unit Liftunit by the handles using two hands Do not use straps for lifting Use optional cart or similar device of ad equate capacity to move unit Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle Manual 0 4980 3 1 change had already been made Single Phase 10 and Jumper Settings E L1 Fem uo L1 L4 L2 2 L2 Jumper
132. uide against the workpiece Shield Cup Standoff Guide 7 Torch Workpiece Art 04034 Shield Cup With Straight Edge The drag shield cup can be used with a non conduc tive straight edge to make straight cuts by hand WARNING The straight edge must be non conductive Non Conductive Straight Edge Cutting Guide A 03539 Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less NOTE For best parts performance and life always use the correct parts for the type of operation 1 Install the drag cutting tip and set the out put current Manual 0 4980 CUTMASTER 82 2 The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the holding technique that feels most comfort able and allows good control and move ment 4 Keep the torch in contact with the work 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 simultaneously squeezing the tr
133. ut power Power is removed from the system OPERATION CUTMASTER 82 This Page Intentionally Blank OPERATION 4 4 Manual 0 4980 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 HEEL EE 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 4980 CUTMASTER 82 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 seat
134. wn system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 4 Replace torch and leads or return to authorized service center for repair or replacement 5 Replace torch and leads or return to authorized service center for repair or replacement 6 Return to authorized service center for repair or replacement 1 Take Torch and Leads Remote Pendant to Authorized Repair Facility 2 Contact Controller manufacturer 3 Return to authorized service center for repair or replacement position correct if necessary 2 Turn OFF power supply Bleed down system pressure Remove shield cup tip and starter cartridge Check starter cartridge lower end fitting for free movement Replace if fitting does not move freely 3 Inspect torch consumable parts Replace if necessary 4 Replace torch and leads or return to an authorized service 5 Temporary Short indicated by 5 5 Release torch switch and reactivate 1 Work cable not connected to Work piece 2 Work cable connector broken 3 Failed components in unit 1 Incorrect current setting 2 Worn torch consumables 3 Poor work cable connection to Work piece 4 Torch being moved too fast 5 Excessive oil or water in torch 6 Failed components in unit 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized se
135. y of the signal listed will be low voltage signals that will be in one of two states 12VDC High or OVDC Low with respect to PCB common When signal name is preceded by the mark it denotes that the signal is an active low For example OVERTEMP This signal is normally High but when an over temperature fault exists this line will change state to a Low TE K4 K3 5 a2 R4 o C6 UM MTHS 0 MTH8 MTH7 5 MTH6 MTH1 MTH3 4 MTH2 Art A 08841 J3 CONNECTOR PINOUT SERVICE 5 20 Manual 0 4980 APACITOR PCB SIGNAL J1 1 Capacitor bank A 1 5 Capacitor bank A 2 1 Capacitor Bank J2 5 Capacitor Bank B J3 1 12 VDC J3 2 460 Active low for 460VAC input J3 3 230 Active low for 230VAC input MTH 1 2 Capacitor bank A MTH 3 4 Capacitor bank A MTH 6 8 Capacitor Bank B MTH 5 7 Capacitor Bank B Manual 0 4980 5 21 CUTMASTER 82 ignal Source Destination M C M C SERVICE CUTMASTER 82 LOGIC PCB LAYOUT PCB3 D1 TP3 TP4 TP1 TP7 E M
136. y when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system be fore disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Filter Housing Cover counter clockwise and remove it The Filter Element is located inside the Housing Manual 0 4980 CUTMASTER 82 Filter Element Cat No 9 7741 oom E O ring Cat No 9 97743 Assembled Filter Cover o Barbed S Fitting g 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 NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage SERVICE CUTMASTER 82 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 ai
137. ylinder 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 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 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 3 4 Manual 0 4980 SECTION 3 TORCH INSTALLATION 3T 01 Torch Connections If necessary connect the torch to the Power Sup ply Connect only the Thermal Dynamics model SL60 Manual or SL100 Mechanical Torch to this power supply Maximum torch leads length is 100 feet 30 5 m including extensions A WARNING Disconnect primary power at the source before connecting the torch 1 Align the male connector on the torch lead with the 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 connection together Do not use tools to secure the connection 3 The system is ready for operation Manual 0 4980 CUTMA
138. ystem RESULT AC indicator ON GAS indicator 29 ON when inp pressure is adequate for power supply operation Power circuit ready ACTION Connect work cable to workpiece Set output amperage RESULT System is ready for operation ACTION Protect eyes and activate Torch switch START RESULT Fans turn on Gas flows briefly then stops Gas restarts DC indicator Pilot arc established ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will continue to run for 10 minutes after the Torch switch START is removed Manual 0 4980 ACTION ACTION RUN Rapid Auto Restart RUN SET LATCH Rapid Auto Restart switch to RUN 6 SET LATCH switch to SET for most applications a or to Rapid Auto Restart be RESULT RE for gouging trimming or expanded metal applications or to LATCH is used for specific applications torch switch can be released after main arc transfer Gas flows to set pressure RESULT Gas flow stops ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts PILOT ARC ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfers Pilot arc off ACTION ACTION Unplug input power cord or open external disconnect ON OFF switch to OFF O RESULT

82 CUTMASTER™ Service Manual

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82 CUTMASTER™ Service Manual