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52 CUTMASTER™ Service Manual

1. 2 T 1 E PIP SWITCH ME 275 7 R 12006 TORCH SWITCH mw 5 apur OVER ATC CONNECTOR A 3 1 AUTOMATION A 1 TORCH SOLENOID 4 4 7 NTC 5 7 7 8 8 E64 2 ELECTRODE1 D3 E35 PILOT IGBT WORK WORK 4 78 IPIP 1 ISTART 80 ic 24VAC RETURN 5L 2 g 83 24VAC SUPPLY 7 L CNC INTERFACE STANDARD ON A40 amp A60 UNITS CNC INTERFACE OPTIONAL ON 52 amp 82 UNITS 22 410 P10 14 hal 13 1 1 2 1 1 in 250VAC 30VDC J2 PINOUT 3 3 10 4 4 9 5 5 8 12006 6 6 7 7 7 6 8 8 5 4 E srarT sToP 3 77 Sink Soma 12 1 FULL FEATURED AUTOMATION INTERFACE OPTION To configure DIVIDED ARC VOLTS signal output FAN 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 V OUT 1
2. 2 AC3 TP5 PRI 2 TP6 48V2 12V2 48V1 Jii J9 J8 J7 J6 J5 Art A 08518_AB CHOKE1 SEC2 12 1 WORK 1 GND2 SERVICE 5 26 Manual 0 4962 CUTMASTER 52 MAIN SIGNALS J1 1 J1 2 J1 3 J1 4 J1 5 J3 1 J3 2 J4 45 1 45 2 45 3 46 1 46 2 47 1 47 2 48 1 48 2 49 1 49 2 49 3 49 4 49 5 49 6 J9 7 J10 1 J10 2 J10 3 J10 4 J10 5 J10 6 J10 7 J10 8 J11 1 J11 2 J12 1 J12 2 J12 3 Manual 0 4962 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 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 LED INDICATORS 059 PCRindicates Pilot IGBT gate signal is ON D 8 CSRindicates cutting arc has been established MAIN PCB TEST POINTS GND1 Common GND2 Common GND3 Common 12V1 12VDC 48V
3. c o Port for Optional Automation Interface Cable Art A 07942 Input Power Selection Filter Assembly Gas Inlet Port Input Power Cord 2 4 Manual 0 4962 INTRODUCTION SECTION 2 INTRODUCTION 2 015 of Manual This manual contains descriptions operating instructions and maintenance procedures for the 1Torch Models SL60 Manual and SL100 Mecha nized Plasma Cutting Torches Service of this equipment is restricted to properly trained person nel unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual at the risk of voiding the Warranty Read this manual thoroughly A complete under standing of the characteristics and capabilities of this equipment will assure the dependable opera tion for which it was designed 2T 02General Description Plasma torches are similar in design to the auto motive spark plug They consist of negative and positive sections separated by a center insulator Inside the torch the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip Once the pilot arc has ion ized the plasma gas the superheated column of gas flows through the small orifice in the torch tip 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 insid
4. e Fitting Art 02476 Optional Single Stage Filter Element Replacement Remove the Filter Element from the Housing and set Element aside to dry Wipe inside of housing clean then insert the replace ment Filter Element open side first Replace Housing on Cover Reattach gas supply NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage SERVICE CUTMASTER 52 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 oper ate but cut quality may become unacceptable Refer to Section 6 Parts List for replacement filter element catalog number 1 Shut OFF primary input power 2 Shut OFF air supply and bleed down system WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter As sembly as injury could result oue 3 Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely 4 Note the location and orientation of the old Filter Ele ments 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
5. N 42 2 P10 3 E start stop 5 1 Fus DIVIDED ARC VOLTS H H arc VOLTS W 100K IN SERIES 2 MOT2 5 5 9 fou 2 10 7 7 11 8 8 12 13 OK TO MOVE AUTOMATION 4 INTERFACE 09133 AC Rev Revisions By Date PRSE No AA INTRO ECO 81357 033109 JHERMAL DYNAMIC bn do Fn Rod Assy No AB B1399 RWH 05 05 09 Suite 300 Scale Supersedes A THERMADYNE Company StLouis MO 63017 USA Date Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent Thursday March 27 2008 Draw References NOTE UNLESS OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Sheet 1 of 1 mE SCHEMATIC DWG Ne Last Modified Wednesday May 06 2009 13 16 28 CM52 82 12mm 20mm 25mm A40 A60 380 400 41 5 600 42 1329 T Manual 0 4962 APPENDIX CUTMASTER 52 APPENDIX 7 Publication History Cover Change Oct 1 2007 Apr 15 2008 May 7 2008 May 16 2008 July 17 2008 Jan 27 2009 Apr 24 2009 May 29 2009 Sept 2 2009 Feb 25 2010 Aug 31 2010 Feb 8 2011 Mar 20 12 April 25 2012 Nov 27 2012 APPENDIX AA AB AC AD AE AF AG AH Al AJ AK AL AM AN AO Manu
6. Weekly 42 TM mmm 7 gt Visually inspect the torch body tip Replace as needed electrode start cartridge and shield cup 8 Months Replace all Clean broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 07938_AB Manual 0 4962 5 1 SERVICE CUTMASTER 52 5 02 Maintenance Schedule 5 03 Common Faults Problem Symptom Common Gauss NOTE 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 damaged worn or when cut performance has diminished 2 Check plasma and secondary supply and pressure 3 Purge plasma gas line to remove any moisture build up Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Inspect torch for any cracks or exposed wires replace if necessary Inspect input power cable for damage or exposed wires replace if necessary Six Months or Every 720 Cutting Hours 1 Check the in line air filter s clean or replace as re quired 2 Check cables and hoses for leaks or cracks replace if necessary 3 Check all contactor points for severe arcing or pits replace if necessary 4 Vacuum dust and dirt out of the entire machine CAUTION Do not blow air into the power supply during cleaning Blowing air
7. 48 55 vo 4 51 e ssme 120 4o o 249 87146 7 48 ss vo 51 250 e so pim mere m se m we for 3 95 134 40 16 70 as ss ro OPERATION 4T 10 Manual 0 4962 CUTMASTER 52 wo e 20 52 9 26 ooo 48 roars 15 20 1 e 52 eo 010 us 48 Fo so ssno 120 c im 52 26 010 us 48 0155 ns c 170 as 52 oo 010 uus 48 Fosse seno 11 e m 254 o 52 9 26 us 48 0250 so a 52 9 ov Fass va c so sz oso us 48 uso 727 __26 c oe sz eo 5 075 uis 48 05 ss _ 27 e io om 90 ww Ws 1 so 1 os 52 25 ww ws Toos eso wo c 6 cis sz 2 nn Ws Foo 15 60 sm oro fas 7 52 w 16 000 51 vos fio osmo we e 300 lot fas 7 52 a ns o0 51 so sse e fas 75 52 9 ss 57 0125 o 5 s a
8. Art A 07886 5678 9 10 Temp Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Let the unit cool before continuing operation Gas Indicator Indicator is ON when minimum input gas pressure for power supply operation is present Minimum pressure for power supply operation is not sufficient for torch operation DC Indicator Indicator is ON when DC output circuit is active D Fault Error Indicator Indicator is ON when Fault circuit is active See Section 5 for explanations of fault lights 10 Pressure Indicators 4 Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock 5 AC Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is in protective interlock mode Shut unit OFF shut OFF or disconnect input power correct the fault and restart the unit Refer to Section 5 for details Manual 0 4962 4 1 Art A 08170 The Indicators will illuminate ac cording to the pressure set by the Pressure Control Knob number 4 OPERATION CUTMASTER 52 4 02 Preparations for Operation At the start of each operating session WARNING Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies Torch Parts Selec
9. FAULT and 85 PSI indicators flashing Manual 0 4962 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 Contoller device not providing Start signal 3 Failed components in unit 1 Tighten shield cup by hand Do not overtighten 2 Turn OFF power supply Remove shield cup Install missing parts 3 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 4 Replace torch and leads or return to authorized service center 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 1 Upper O Ring on torch head is in Remove shield cup from torch check upper O Ring wrong position 2 Torch starter cartridge is stuck 3 Worn or faulty torch parts 1 Work cable not connected to work piece 2 Work
10. 17 Reinstall the power supply cover 3 9 7 5 CUTMASTER 52 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 Removal 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 Num bers 2 and 3 in the following illustration Art 07989 ES 2 PARTS REPLACEMENT CUTMASTER 52 5 Remove the fitting from the filter element assembly by inserting 6 mm hex wrench into the internal hex fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration 6 Disconnect the input line from the filter ele ment 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 A 07990 8 Install the new or cleaned assembly by reversing these procedures 9 Turn ON
11. Tools required T20 Torx Driver 1 Disconnect the Torch and Leads from the unit 2 Remove the cover per subsection 7 04 A 3 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 Handles 5 Replace the Tube Handles by reversing the above steps 6 Reinstall the power supply cover Disconnecting Front and Rear Panels from the base In many of the replacement procedures it may be helpful to disconnect the front or rear panel from the base in order to allow more room to ac cess the parts 7 2 Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 For earlier models remove the Tube Handles per subsection 7 04 C The earlier model Tube Handles join together under the base Later models do not and there is enough room to perform this procedure without removing them 3 While grasping the panel close to the base pull the panel directly from the base to release the locking tabs 4 To re engage the panel position the panel so that the locking tabs are above the base then push the panel back onto the base until the locking tabs engage the mating holes in the base 5 For complete removal of panel disconnect any other item still attached to the panel and another component of the
12. 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 is to start b For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiece as shown below OPERATION CUTMASTER 52 Shield Cup Standoff Distance 1 8 3 8 3 9mm Standoff Distance 3 Hold the torch away from your body 4 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will Start Trigger Release A 02986 5 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a character istic of the power supply and not a function of the torch OPERATION Trigger 4 P m 6 Cut as usual Simply release the trigger as sembly to stop cutting 7 Follow normal recommended cutting practices as provided in the power supply operator s manual NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to
13. 14 Remove the Main Transformer carefully guiding all its wires through from the right side of the unit 15 Install replacement Transformer by revers ing the above steps 16 Reinstall the power supply cover C Output Inductor L1 Tools required T20 Torx Driver gt Nut Driver 1 2 Remove the Cover per subsection 7 04 Remove the Tube Handle per subsection 7 04 Remove the two large and small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 Disconnect J2 amp J3 connectors from Main PCB Disconnect Output Inductor wire from ter minal Choke1 on the Main PCB Disconnect Output inductor wire from ATC connector Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief 10 Disengage the Rear panel from the base per subsection 7 04 D 11 Guide the rear panel back six 6 inches away from the base 12 Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base 13 Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit 14 Remove the two screws securing the Out put Inductor to the base 15 Remove the Output Inductor carefully guiding its wires through from the right side of the unit 16 Install replacement Output Inductor by reversing the above steps
14. 460VAC Single or 3 Phase 60Hz with 230V 1PH input power cable and plug 3 5130 1 460VAC Single or 3 Phase 60Hz with input power cable 3 5130 2 600VAC 3 Phase 60 2 with input power cable 3 5130 5 Manual 0 4962 6 1 PARTS LIST CUTMASTER 52 6 04 Major External Replacement Parts Item Description talog 1 1 Cover with labels 9 0120 2 1 Base Enclosure Assembly 9 0118 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0100 5 1 Rear Panel 9 0101 H C 4 E 24 Les Art A 08120 NOTE Illustration may vary slightly from unit PARTS LIST 6 2 Manual 0 4962 CUTMASTER 52 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 9 0184 Illustration may vary slightly from unit Manual 0 4962 6 3 PARTS LIST CUTMASTER 52 6 06 Left Side Parts Description Ref Catalog 1 1 Main PCB Assembly non 600V PCB 1 9 0108 1 1 Main Assembly 600V Only PCB 1 9 0165 2 1 Logic 3 9 0107 2 1 Logic for 600V systems PCB 3 9 0169 3 1 Center Chassis Molded Plastic 9 0102 4 1 Fan MOT 1 MOT 2 9 0104 5 1 Transformer Main Non 600V 9 0106 5 1 Transformer Main 600V Only 9 0170 6 1 Inductor Output L1 9 0105 Not Sho
15. Use the shade of lens as suggested in the following per ANSI ASC 749 1 Minimum Protective Suggested Arc Current hade No hade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece GENERAL INFORMATION LEAD WARNING This product contains chemicals including lead or otherwise pro duces chemicals known to the State of California to cause birth defects and other reproductive harm Wash hands after handling 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway
16. unit pressure indicators 2 Gas supply not turned ON 2 Turn gas supply ON Gas supply pressure too low Set air supply inlet pressure to unit to 120 psi 4 AIR PRESSURE CONTROL 4 Adjust regulator to set air pressure See Section 4 02 regulator set too low Preparations for Operation on page 4 2 5 Failed components in unit 5 Return to authorized service center for repair or replacement 1 Shield Cup loose 1 Hand tighten the shield cup until it is snug 2 Torch not properly connected to 2 Insure torch is securely fastened to unit power supply 3 Problem in torch and leads PIP 5 Replace torch and leads or return to authorized service center circuit or repair or replacement 4 Failed components in unit 4 Return to authorized service center for repair or replacement 1 Start signal is active when ON Start can be active for one of the following OFF SWITCH is turned to ON Hand torch switch held closed position Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Problem in the torch and leads 2 Replace torch and leads or return to authorized service center switch circuit or repair or replacement 3 Failed components in unit 3 Return to authorized service center for repair or replacement SERVICE 5 4 Manual 0 4962 CUTMASTER 52 Problem Symptom Possible Cause Recommended Action is closed Or CNC START signal is active No gas flow
17. 10018 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible 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 COMPRIM S EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street
18. 16 Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximately as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 6 VDC 2 VDC 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 stated then note the symptom and proceed to Section 5 10 Interface Problems 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 contac tor See illustration below 2 jumpers installed incorrectly a Check jumper installation for correct phase being used Manual 0 4962 5 11 CUTMASTER 52 Single Phase 19 and Jumper Settings N L1 L4 L2 Jumper 2 12 13 5 4 5 _ 5 GND gt 20 Single Phase Input Power Wiring Three Phase 39 and Jumper Settings Store copper jumper in spare parts box J 11 14 o EE 20 20 7 27 13 5 5 14 GND cid ie Three Phase Input Power Wiring W1 contactor points are stuck closed Che
19. 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with connector 4 7843 1 25 foot 7 6 Leads Assembly with connector 4 7844 1 50 foot 15 2 Leads Assembly with connector 4 7845 7 1 11 279 mm Rack 9 7041 8 1 11 279 mm Mounting Tube 9 7043 9 1 End 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 PARTS LIST 6 8 Manual 0 4962 CUTMASTER 52 Manual 0 4962 6 9 PARTS LIST CUTMASTER 52 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 60A 9 8252 DRAG SHIELD CUTTING 40A CUTTING Shield Cap Deflector 9 8243 Shield Cap Deflector 9 8243 e to 40A 9 8208 STANDOFF CUTTING DRAG SHIELD CUTTING 50 60A CUTTING Standoff Guide 9 8251 Shield Cap Deflector 9 8243 LD 50 55A 9 8209 60A 9 8210 STANDOFF CUTTING 70 120A CUTTING Standoff Guide 9 8281 G Shield Cap Drag NX 70 100 9 8236 Shield Cap Deflector 9 8243 90 100A 9 8212 120 9 8253 STANDOFF CUTTING 40 120A GOU
20. 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 4962 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 62 RESULT 222 for gouging trimming Gas flows to set or expanded metal pressure applications or to LATCH is used for specific applications torch switch can be released after main arc transfer RESULT Gas flow stops ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts PILOT ARC ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfers Pilot arc off ACTION ACTION Unplug input power cord or open external disconnect ON OFF switch to OFF RESULT RESULT All indicators off No power to system Power supply fans shut off Art A 07979_AB 1 APPENDIX CUTMASTER 52 of Power Supply Note 1 Plasma Cutting Symbol Input Power Symbol Input Power Specifications Phase AC or DC Hertz Rating APPENDIX 2 DATATA INFORMATI N West Lebanon NH USA 03784 S N IHERMA
21. L J1 26 GND M L 1 27 Not Used J1 28 Not Used J1 29 BD ID Voltage level to identify Main PCB 1 7VDC 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 __ Factory Use M L J1 36 For Factory Use M L J1 37 For Factory Use M L 1 38 GND M L J1 39 For Factory Use M L J1 40 Not Used Manual 0 4962 5 23 SERVICE CUTMASTER 52 LED INDICATORS NORMAL INDICATION lt lt FIRMWARE VERSION _ D1 12VDC D2 MAX PRESSURE D3 90 PSI D4 85 PSI D5 80 PSI D6 75 PSI 07 70 PSI D8 65 PSI D9 MIN PRESSURE D10 AC D11 OVERTEMP D12 GAS D13 DC D14 ERROR TEST POINTS TP1 Common TP2 12VDC TP3 5VDC 4 3 3DCV TPS TP6 1 8VDC TP7 SERVICE 0 5 to 5 VDC 0 100 psi Potentiometer Current Demand 0 3 3VDC 7 6 X5 X4 3 X 2 0 1 X 2X 3 X 4 X 5 X 5 24 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 4962 CUTMASTER 52 This Page Intentionally Blank Manual 0 4962 5 25 SERVICE CUTMASTER 52 PINOUT PRI 1 1
22. New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 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 PIPIN
23. To Power Supply Circuitry gt c O1 an 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 Remote Male Pendant ATC Female ATC Leads Receptacle Connector aN _ _ _ _ Power Torch Supply Head Leads 1 os Black Switch Orange White Not To Power Supply Circuitry To Power Supply Circuitry Green Negative Plasma Lead Negative Plasma Pilot Lead Pilot _ Art A 03798 APPENDIX 4 Manual 0 4962 CUTMASTER 52 This Page Intentionally Blank Manual 0 4962 A 5 APPENDIX CUTMASTER 52 APPENDIX 5 12 swi 1577 o 297 o4 ap 5 8 IINRUSH wi L1 AC INPUT Turm L2 2 JUMPER 3 PRIMARY POWER CONNECTIONS 3PH USE 111213 amp GND 1PH USE L1 L2 amp GND INSTALL JUMPER BETWEEN L2 TO L
24. VDC SUPPLY m LDMD 1 CURRENT DEMAND 069 PCR SEN DRAG SENSE 1 SERALPORT 2 D78CSR H2vDc PCB1 MAIN PCB ASSY SOLENOID 40 CIRCUIT RIBBON CABLE 40 PIN RIBBON CABLE SIGNALS P 1 OUT SIGNAL ML P 2 VOLTS ML ERROR IND FAULT MAX 3 SENSE ML AC H 4 LM MAX OVER PRESSURE 5 230V_IN LM 2 90 INTERNAL ERROR 6 CUR SET LM 85 SHORTED TORCH 90 7 IRAR RAPID AUTO RESTART 1 OVERTEMP 80 CONSUMABLES MISSING 8 INRUSH LM 75 START ERROR gt LM te 70 PARTS IN PLACE 10 SHDN LM 65 INPUT POWER 85 11 TORCH SOLENOID LM GAS MIN UNDER PRESSURE 12 SOLENOID ON LM 2 2 B ANN E E 9 TEST POINTS 80 15 ACTIVE LM D d aD 16 TORCH SWITCH ML 2 17 ML Za TP2 12 VDC 18 AC ON ML 5 GAS CONTROL 48 ERROR TP4 3 3 VDC 20 SOLENOID DETECT ML REGULATOR exo 21 ML 22 VIN M TP7 POT DEMAND 70 VALVE 23 12VDC ML P 24 12VDC ML a 25 COMMON ML Current Control 65 FILTER 26 COMMON ML 12VDC AIR 29 MAIN ID ML 1 oe INLET 34 460 IN ML 2 aame 7 90 mn 37 RXD ML a 15 9 ES e COMMON LM lt 3 D ML RUN svoc 3 ea 1 eo RAR 0 100PSI 0 4 5VDC 2 gt 3 LOGIC lt 5 a APPENDIX A 8 Manual 0 4962 CUTMASTER 52 T
25. ac tive 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 electrode start cartridge or tip is missing or excessively worn SHORTED TORCH Indicates the torch or lead has a shorted condition between positive and negative leads INTERNAL ERROR Indicates a microprocessor error OVER PRESSURE Indicates that operating pressure is set too high The Error Indicator will not flash when the pressure is above 95 PSI This LED will remain ON and the system will operate but pilot starting and cut performance may be affected NOTE 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 5 05 Basic Troubleshooting Guide 5 3 WARNING There are extremely dangerous voltage and power levels present inside th
26. amp 4 Negative Plasma Lead Threads Lower O Ring Art A 03725 2 Torch start cartridge is stuck a Turn OFF power supply Bleed down the system Remove the shield cup tip start cartridge and WES electrode Check the lower end unit of the start 3 Torch Switch 4 Cine gt coin LUNES cartridge for free movement Replace the cartridge pie ns if the lower end unit does not move freely Spring Loaded Spring Loaded Lower End Fitting Lower End Fitting at Reset Full Compression Full Extension Pilot Lead AA el b For machine torches using a remote pendant check continuity of Pendant switch circuit c For input see Section 5 07 Circuit Fault Isolation on page 5 8 Art 08064 AC 2 Defective Logic PCB 3 Worn or faulty torch parts Inspecttorch consumables parts Replace if neces sary 4 Shorted Torch a Jumper on Main 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 _DMD1 for a Disconnect torch from unit With consumables 1 4VDC Replace Logic PCB if voltage is not present removed from the torch check continuity of torch 3 Defective Main PCB at ATC between negative plasma lead connection to pilot lead connection a With Torch Switch closed measure voltage on Main Negative Plasma Lead PCB between test points GND1 to _DMD
27. cutting keep the torch switch closed bring the torch OFF the edge of the material e Cutting arc extinguishes e Gas solenoid closes Gas flow stops momentarily then restarts when solenoid opens e Pilot arc ignites 5 Open the torch switch e DC LED turns OFF After 20 second post flow time SERVICE e Gas solenoid closes Gas flow stops 6 Setthe FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode 7 Close torch switch Pendant switch or activate Start to establish a pilot arc Bring torch to within 1 8 3 8 3 9 5 mm of the work piece to establish main cutting arc 8 While cutting keep the torch switch closed and bring the torch OFF the edge of the material e Pilot Arc re ignites immediately 9 Open the torch switch e DCLED turns OFF After 20 second post flow time e Gas solenoid closes Gas flow stops 10 Setthe FUNCTION CONTROL SWITCH to LATCH mode 11 Start a cut and release the torch switch Main cutting arc will remain ON until the torch is lifted away from the plate approximately 34 19 mm or until the torch is brought OFF the edge of the metal Once the arc has extinguished e DC LED turns OFF After 20 second post flow time e Gas solenoid closes Gas flow stops This completes the Main Arc and Controls Test If the above are all correct then proceed to the next Section Inter face Test If the unit does not function as stated above then note the symptom
28. damage claims or ship ping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error Move the equipment to the installation site before un crating the unit Use care to avoid damaging the equipment when using bars hammers etc to un crate the unit INTRODUCTION CUTMASTER 52 2 04 Power Supply Specifications CutMaster 52 Power Supply Specifications 08 230 VAC 187 253 VAC Single Phase 60 Hz 30 VAC 187 253 VAC Three Phase 50 60 Hz 80 VAC 360 440 VAC Three Phase 50 60 Hz Input Power 400 VAC 360 440 VAC Three Phase 50 60 Hz 414 506 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 Gable Cable for 208 230V input power includes molded plug Output Current 20 60 Amps Continuously Adjustable Power Supply Gas Filtering Ability CutMaster 52 Power Supply Duty Cycle Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C IEC IEC IEC Rating Rating Rating Duty Cycle 100 All Units 60 Amps 50 Amps 30 Amps DC Voltage 92 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 Particulates to 5 Microns Ambient Temperature NOTE IEC Rating is determined as sp
29. hand or steadied with two hands Position work and the pilot arc will shut OFF the hand to press the Trigger on the torch NOTE handle With the hand torch the hand may be positioned close to the torch head The gas preflow and postflow are a character for maximum control or near the back end istic of the power supply and not a function for maximum heat protection Choose the or tng tarah technique that feels most comfortable and When the shield cup is properly installed there allows good control and movement is a slight gap between the shield cup and the torch handle Gas vents through this gap as NOTE part of normal operation Do not attempt to The tip should never come in contact with the force the shield cup to close this gap Forcing workpiece except during drag cutting opera the shield cup against the torch head or torch tions handle can damage components 2 Angle the torch slightly to direct blowback 7 Clean spatter and scale from the shield cup particles away from the torch tip and op and the tip as soon as possible Spraying erator rather than directly back into it until the shield cup in anti spatter compound the pierce is complete will minimize the amount of scale which 3 In a portion of the unwanted metal start the adheres to it pierce off the cutting line and then continue Cutting speed depends on material thickness the cut onto the line Hold the torch perpen a
30. into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit SERVICE Insufficient Penetration Main Arc Extinguishes Excessive Dross Formation 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics parts used 7 Incorrect gas pressure 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 Cutting current too high 4 Work cable disconnected 5 Worn torch parts 6 Non Genuine Thermal Dynamics parts used 1 Cutting speed too slow 2 Torch standoff too high from orkpiece 3 Worn torch parts 4 Improper cutting current 5 Non Genuine Thermal Dynamics parts used 6 Incorrect gas pressure Short Torch Parts Life Oil or moisture in air source Difficult Starting 2 Exceeding system capability material too thick 3 Excessive pilot arc time 4 Gas pressure too low 5 Improperly assembled torch 6 Non Genuine Thermal Dynamics parts used 1 Worn torch parts 2 Non Genuine Thermal Dynamics parts used 3 Incorrect gas pressure Manual 0 4962 5 04 Fault Indicator At initial power up two lights will temporarily illuminate for 2 3 seconds to show the version of software used To determine the first digit count the function indicators left to right 1 through 5 To determine the second d
31. leads up to 25 7 6 m long For 50 15 2 m leads refer to subsection 4 02 Preparations for Operation Total flow rate includes plasma and secondary gas flow OPERATION 4T 12 Manual 0 4962 CUTMASTER 52 4T 09Recommended Cutting Speeds for Mechanized Torch With Shielded Tip m ts rts nn msi wee cts pur our rise ee wo oss ee as ss mo oz far 15 42 120 6 229 or ss o2 54 121 203 ose 55 170 oa o2 12 6 75 ose 55 040 02 54 128 ore vo 55 vo oe 02 51 925 same 125 ss oro s vo 100 o2 54 65 1 6 026 ore 55 NA 1e 7 or vo 55 vo NR 16 9 1e s oo ore 55 vo NA NR Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness NOME ML Speed Per Minute Standoff Flow CFH Pierce Height Inches Cat No Amps Inches mm psi Plasma Inches m 09 9 8208 109 3 105 ss 170 o
32. leads with care and protect them from damage Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff will generally result in a more square cut Manual 0 4962 Edge Starting For edge starts hold the torch perpendicular to the work piece with the front of the tip near not touching the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutting arc as quickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left 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 counterclockwise around the circle To keep the square e
33. move freely Spring Loaded Spring Loaded Lower End Fitting Lower End Fitting at Reset Full Compression Full Extension Art A 08064 Open conductor in torch leads Check continuity Defective Main PCB b Measure voltage at Main PCB between J2 2 to test point GND1 for 12VDC If voltage is present replace Main PCB Defective Logic PCB a Replace Logic PCB AC LED ON yellow TEMP LED is ON red FAULT Indicator is flashing Air flow through unit is restricted a Provide adequate airflow See Ventilation Clearance Requirements in Section 2 04 Power Supply Specifications on page 2 2 Exceeded duty cycle of the power supply a Allow unit to remain ON but at idle with fan run ning to cool power supply See 2 04 Power Supply Specifications on page 2 2 for duty cycle information Fan s not turning SERVICE CUTMASTER 52 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 4 Defective Main PCB a Measure voltage at plug between J7 1 to J7 2 and between J8 1 to J8 2 on Main PCB for 12VDC If voltage is missing at either receptacle replace Main PCB 5 Defective Logic PCB 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 2 Gas supply not turned ON a Turn g
34. power supply Manual 0 4962 7 05 Front Panel Parts Replacement Refer to Section 6 05 Front Panel Replace ment Parts and an overall detailed drawing A Current Control Potentiometer A Knob Replacement Tools required Flat Screw Driver 1 Turn the potentiometer fully clockwise and note the location of the pointer mark on the knob 2 Loosen the screw securing the Current Control Knob to the potentiometer shaft and remove the knob 3 Replace the knob on the potentiometer shaft with the pointer in the same position as noted in step 1 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 posi tion 2 Loosen the screw securing the knob to the switch shaft and remove the knob 3 Replace the knob on the switch shaft with the pointer in the position noted in step 1 C Replacing Gas Hoses Tools required T20 Torx Driver 1 Remove the cover per subsection 7 04 A 2 Push the gas fitting locking ring back A small open end wrench works well for this 1 2 ue 3 Pull the hose from the fitting 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pulling on the hose If done correctly it will not pull out 5 Reinstall the power supply cover Art A 08150 Manual 0 4962 7 3 CUTMASTER 52 D Air Regulator Replacement Tools required T20 Torx Driver 1
35. 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 PARTS REPLACEMENT C Input Power Cable Replacement Tools required T20 Torx Driver Phillips Head Screwdriver Flathead Screwdriver 1 Remove the Cover per subsection 7 04 A 2 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 reversing above steps 6 Reinstall the power supply cover D Optional Single Stage Filter Element Replacement These instructions apply to power supplies where the optional Single Stage Filter has been installed The Power Supply shuts down automati cally 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 Element 3 Disconnect gas
36. the operator or others in the operating area WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in box such as this Additional copies of this manual may be purchased by contacting Victor Technologies at the address and phone number in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identification numbers Manual 0 4962 CUTMASTER 52 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 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 for future reference 2 03 Receipt Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and in spect the equipment for possible damage due to shipping If there is any damage notify the car rier immediately to file a claim Furnish complete information concerning
37. 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 41 07 Parts Selection for Manual and Mechanized Torch Cutting on page 4T 9 for details INSTALLATION 3T 2 Manual 0 4962 SECTION 4 SYSTEM OPERATION 4 01 Front Panel Controls Features See Illustration for numbering Identification 1 Output Current Control Sets the desired output current Output settings up to 60 Amps may be used for drag cutting with the torch tip contacting the workpiece or standoff cutting 2 Function Control Function Control Knob Used to select between the differ ent operating modes eR Used to purge the air through the unit 6 and torch and leads and to adjust gas pressure RUN Used for general cutting operations RAPID AUTO RESTART a Allows for faster re starting of the Pilot Arc for uninterrupted cutting 7 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 8 edge of the work piece the torch switch is activated again or if one of the system interlocks is activated 3 ON OFF Power Switch ON OFF Switch controls input power to the power supply Up is ON down is OFF CUTMASTER 52
38. 1 48VDC 1 DMD10 4VDC Current Demand Signal 5 27 SERVICE CUTMASTER 52 This Page Intentionally Blank SERVICE 5 28 Manual 0 4962 SECTION 5 SERVICE 5T 01General Maintenance NOTE Refer to previous Section 5 System for com mon and fault indicator descriptions Cleaning Torch Even if precautions are taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch WARNING Disconnect primary power to the system be fore disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON The inside ofthe torch should be cleaned with electrical con tact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head and ATC Male Connector 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 ve
39. 1 for 1 4 VDC Replace Main PCB if voltage is present SHORTED TORCH FAULT 4 Torch Switch 3 Torch Switch inis l Cine After torch switch is closed gas flows for two 2 seconds 2 PIP i Ta then momentarily shuts OFF then back FAULT INDICA NN TOR flashes and 85 PSI LED flashes IE 1 Upper O Ring on torch head is in the wrong position Pilot Lead Remove shield cup from torch check position of the upper o ring and correct if needed C ACLED ON TEMP LED OFF GAS LED ON gas flowing DC LED OFF 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 depressed If voltage does not drop replace Logic PCB Manual 0 4962 5 15 SERVICE CUTMASTER 52 b While pilot arc is established measure voltage on Main PCB between test points GND1 tol for 1 4 VDC If voltage is low or not present replace Logic PCB 2 Defective Main PCB 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 depressed 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 F
40. 142 j mo ETE o 200 o e 2 uc c 2 a oO E s ao i 5 o gt lt 5 5 Material Stainless Steel Type Secondary Gas Single Gas Torch Type Torch SL60 With Shielded Tip Type Plasma Gas Air Output Speed Per Minute Standoff Plasma Gas Press Flow Pierce Height Tip Manual 0 4962 4 14 OPERATION CUTMASTER 52 Type Torch 5160 With Shielded Material Aluminum ws e ss um 2 7 52 25 020 51 no so so ss ou sz 7 52 25 020 51 orofo eeo eo zs s 5 sa 25 90 oif sa 12 eo v0 32 52 25 ox 020 511 0250 tw eo 20 48 5 52 zs 51 0376 samo wo e vw oi 48 5 sa se 99 020 sa 0500 rez eamo 1 eo os ora 48 7s sa ses 0625 199 ws s 19 os orfas zs 52 ss ws 0760 11 5 os or 52 25 wm ra NOTE Gas pressure shown is for torches with leads up to 25 7 6 m long For 50 15 2 m leads refer t
41. 2012 Victor Technologies International Inc victortechnologies com Printed in Mexico
42. 3 REMOVE JUMPER BETWEEN L2 TO L3 o INPUT VOLTAGE SELECTOR Closed for 230VAC input CM52 8 A40 C3 amp C5 not installed 24VAC PCB2 INPUT CAPACITOR s TEST POINTS 24 VAC RETURN GND2 COMMON GND3 COMMON 6 12 1 12 VDC SUPPLY P 48V1 48 VDC SUPPLY LDMD 1 CURRENT DEMAND D59 PCR SEN DRAG SENSE 1 2 SERIALPORT 2 2 D78 CSR H2VDC 8 5 PCB1 MAIN PCB ASSY ISOLENOID 40 CIRCUIT RIBBON CABLE 40 PIN RIBBON CABLE SIGNALS P 1 Myers ML ed ERRORIND FAULT MAX 3 SENSE ML AC 4 460V IN L M 5 OVER PRESSURE 5 230V_IN LM 90 INTERNAL ERROR 6 CUR SET L M 85 SHORTED TORCH 90 7 IRAR RAPID AUTO RESTART 1 OVERTEMP 80 CONSUMABLES MISSING ANRUSH LM 75 START ERROR gt 9 ON LM gt 70 PARTS IN PLACE 10 SHDN LM 65 INPUT POWER 85 11 TORCH SOLENOID L M GAS MIN UNDER PRESSURE 12 SOLENOID ON LM 2 f 13 OK TO MOVE LM if 14 ON LM TEST POINTS 80 15 ACTIVE LM Fi eu 16 TORCH SWITCH ML fn 17 ML 7 18 AC ON ML 5506 75 GAS CONTROL 18 AC ME ERROR TP
43. 4 3 3 VDC 20 TORCH_SOLENOID_DETECT PH 0 100 51 La REGULATOR 21 JOVERTEMP ML 70 ATC 2 VIN Mit TP7 POT DEMAND VALVE 23 12VDC ML x 2 24 12VDC ML 25 COMMON ML Current Control 65 FILTER 26 COMMON ML 2VDC AIR 29 MAIN ID ML 34 460_IN ML PS B 37 RXD ML ar TRANSDUCER 38 LM lt 3 D RN 9 5 5 1 e RAR 0 100PSI 0 4 5VDC 2 a 3 8 PCB3 LOGIC PCB lt APPENDIX Manual 0 4962 CUTMASTER 52 82 A60 ONLY e 1TORCH E PIP SWITCH YYA m M D 575 2 CHOKE1 v SWITCH Liaw 5 CONNECTOR AUTOMATION B TORCH SOLENOID 4 4 NTC 5 5 6 6 T 8 8 OUT 1 E64 2 ELECTRODE1 03 E35 2 PILOT IGBT N 2 WORKI WORK 1 79 2 80 ISTART 3 4 81 24VAC RETURN 5 2 5 83 24VAC SUPPLY 7 J INTERFACE STANDARD ON A40 amp 60 UNITS CNC INTERFACE OPTIONAL ON 52 amp CM82 UNITS 32 P10 14 IH 13 OK T
44. 4 inch 6 mm may result in minimal metal removal or loss of transferred main arc Slag Buildup 4T 7 Slag generated by gouging on materials such as carbon and stainless steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to the side of the gouge path However slag build up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc The build up is most often a result of improper travel speed lead angle or standoff height OPERATION CUTMASTER 52 4T 06Mechanized Operation Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC 1 To start a cut at the plate edge position the center of the torch along the edge ofthe plate a rough cut will be produced as the arc moves from side to side in search of metal for transfer Travel speed also affects the bevel angle of a cut When cutting in a circle or around a corner slowing down the travel speed will result in a squarer cut The power source output should be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slow down adjustments that may be required Piercing With Machine Torch Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate The arc can be one of the followin
45. ENTS SECTION 1 GENERAL INFORMATION une 1 1 1 01 Notes Cautions Warnings 1 1 1 02 Important Safety Precautions 1 1 DINER dig eR 1 2 1 04 A Note Attention et Avertissement 1 3 1 05 Precautions De Securite Importantes sss 1 3 1 06 Documents De Reference 1 9 Declaration asciende 1 6 1 08 Statement of Warranty donnant tee terres 1 7 SECTION 2 SYSTEM INTRODUCTION tit 2 1 2 01 How To Use This Manual 2 1 2 02 Equipment Identification 2 1 2 03 Receipt Of Equipment 2 1 2 04 Power Supply 2 2 2 05 Input Wiring OS 2 3 2 06 nur 2 4 SECTION 2 TORCH INTRODUCTION ete miens 27 1 Scope of Manual 2T 1 2102 General 2 21 1 2T 03 Specifications annee ee 27 1 21 04 Options And Accessories 2T 2 2105 Introduction to Plasma tm 2T 2 SECTION 3 SYSTEM INSTALLATION 3 1 3 01 RET A 3 1 202 E de 3 1 3 03
46. G THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 10 11 12 13 14 15 Manual 0 4962 1 04 Note Attention et Avertissement Dans ce manuel les mots note Ces mises en relief sont classifi es comme suit attention et avertissement sont utilis s pour mettre en relief des informations caract re important 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 l endommagement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question A AVERTISSEMENT Fournit l information concernant des dommages possibles de choc lectrique Des avertissements seront enferm s dans une bo te de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OP RA TION ET LA MAINTENANCE DU MA T RIEL DE SOUDAGE A L ARC AU JET DE PLASMA PEUVENT PRE SENTER DES RISQUES ET DES DANGERS DE SANTE Co
47. GING Tip Gouging 9 8225 40 Amps Max Gouging 9 8226 50 100 Amps Tip Gouging C 9 8227 60 120 Amps Tip Gouging D 9 8228 60 120 Amps Tip Gouging 9 8254 60 120 Amps 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 Manual 0 4962 SECTION 7 REPLACEMENT PROCEDURES 7 01 Scope This section describes parts replacement pro cedures which may be performed on the CutMas ter 52 Power Supply Under no circumstances are field repairs to be attempted on Printed Circuits or other subassem blies 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 dis charge ESD Replacement PC Boards are shipped in a pro tective enclosure to prevent damage from electro static discharge ESD during shipping ground strap is included with each replacement board to prevent static damage during installation WARNING Read and understand these instructions and the instructions on the grounding wrist strap package before opening the equipment enclo sure or removing the replacement PC board from its protective enclosure A General Disconnect primary power to the system be fore disassembling the torch t
48. J2 17 to test point GND1 for 12VDC If the voltage is less than 2VDC replace Logic PCB 5 Defective Main PCB a Replace Main PCB G TRIGGER LOCKED DURING POWER UP FAULT FAULT Indicator and 75 PSI LED is flashing 1 Start signal is active when SW1 is turned to ON position Start can be active for one of the following Hand torch switch held closed Hand pendant switch held closed START signal is active low Release the START signal source 2 Problem the torch and leads switch circuit a Check continuity of torch switch circuit at ATC pins 3 amp 4 See previous illustration 3 Short in CNC cable Check continuity 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 H TIP MISSING FAULT The FAULT Indicator and 80 PSI LED is flashing Gas solenoid cycles ON and OFF 1 Torch Shield Cup is loose a Tighten shield cup by hand Do not over tighten 2 Torch tip electrode or starter cartridge missing a Turn OFF power supply Replace missing part s 3 Starter Cartridge is stuck a Turn OFF power supply Bleed down the system Remove the shield cup tip start cartridge and Manual 0 4962 CUTMASTER 52 electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not
49. L DYNAMICS THERMADYNE Company Model Date of Made in USA Manufacturer s Name and or Logo Location Model and Revision Level Serial Number and Production Code QD Regulatory Standard Covering This Type of Power Supply Duty Cycle Factor Output Range Amperage DT Voltage Output Current Type X Duty Cycle Data Note 3 02 Rated P Conventional Load Voltage Load Voltage Rated Maximum Supply Current U1 12 1 Maximum Effective Supply Current Manufacturer s Electrical Schematic File Number Rated Supply Voltage Note 2 Degree of Protection NOTES 1 2 APPENDIX Symbol shown indicates single or three phase AC input static frequency converter transformer rectifier DC output Indicates input voltages for this power supply Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built Top row Duty cycle values IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission TDC duty cycle value is determined under the power supply manufacturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values Sections of the Data Tag may
50. O MOVE 1 1 12 SUE 1 1 a 5 250VAC 30VDC J2 PINOUT 3 3 10 4 4 9 5 5 8 6 6 7 7 6 8 8 5 4 START 3 Sink 50mA 12VDC 3 FULL FEATURED AUTOMATION INTERFACE OPTION 8 DC To configure DIVIDED ARC VOLTS signal output JEAN TEAN 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 V OUT 1 ENS on PCB N Ei 2 2 P10 START STOP 1 1 5 o 5 amp DMDED ARC VOLTS 2 2 PIT ju ARC VOLTS MOT2 4 4 W 100K IN SERIES 2 6 6 10 T 11 8 8 12 13 14 AUTOMATION 4 INTERFACE 09131 AB Rev Revisions Date em PCB No AA INTRO ECO B534 072307 JME RMIAL DYNAMIC 16052 Swingey Ridge Road No AB 890 MNC 04 23 08 Scale Supersedes 8855 05 09 08 A Company AD B1159 MNC 10 03 08 Information Proprietary to THERMAL DYNAMICS CORPORATION Th 5 day March 27 2008 ECO 81357 RWH 03 31 08 Not For Release Reproduction or Distribution without Written Consent Mure NOTE UNLESS OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF CRE Sheet 1 of 1 TITLE SCHEMATIC Size DWG No Node Monday Merc
51. OFF position then back to ON position to clear the error Defective 5 2 a Check continuity Primary line voltage out of tolerance range a Connectunitto voltage with unit specifications See Section 2 04 Power Supply Specifications on page 2 2 If using a generator connect unit to a wall receptacle to see if problem is corrected SERVICE 4 Defective Main PCB a Measure voltage on Main PCB between test point GND1 to J2 22 460 VAC input approx 3 VDC 230 VAC input approx 1 5 VDC b With all power removed from the unit disconnect 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 F PARTS IN PLACE PIP FAULT The FAULT 5 12 Indicator and 70 PSI LED is flashing 1 Shield Cup loose a Handtighten the shield cup to close the PIP switch Torch not properly connected to power supply Insure torch is securely fastened to unit Problem with torch and leads PIP circuit a Check continuity of torch PIP circuit at ATC pins 1 amp 2 Manual 0 4962 Negative Plasma Lead 3 Torch Switch nns Cine 2 PIP e 39 Pilot Lead Art A 08124 4 Defective Logic PCB a Measure the voltage on Main PCB between
52. OTE below 31 02 pg 3T 1 and deleted NOTE text pg 6 8 per ECO B2342 A 10 Manual 0 4962 This Page Intentionally Blank 5 Denton TX USA U S Customer Care Ph 1 800 426 1888 tollfree Fax 1 800 535 0557 tollfree International Customer Care Ph 1 940 381 1212 Fax 1 940 483 8178 Miami FL USA ales Office Latin America 1 954 727 8371 ax 1 954 727 8376 Ut 7 Ontario Canada anada Customer Care 1 905 827 4515 ax 1 800 588 1714 tollfree vO EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 ax 6221 8990 6096 awang Malaysia ustomer Care 603 6092 2988 ax 603 6092 1085 7 lelbourne Australia ustralia Customer Care 1300 654 674 tollfree 61 3 9474 7400 ax 61 3 9474 7391 International Ph 61 3 9474 7508 ax 61 3 9474 7488 1 20 20 2 hanghai China ales Office 86 21 64072626 ax 86 21 64483032 ingapore ales Office 65 6832 8066 ax 65 6763 5812 VICTOR TECHNOLOGIES INNOVATION TO SHAPE THE WORLD UMN n UMM 0 5 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 rax 940 483 8178
53. Philadelphia PA 19103 Manual 0 4962 14 15 CUTMASTER 52 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM MANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 INFORMATIONS G N RALES CUTMASTER 52 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 as amended by Council Directive 93 68 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 in dividual 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 stand
54. Primary Input Power 522 3 1 304 Bas GONG CONS sca an 3 3 SECTION 3 TORCH INSTALLATION e 3T 1 3T 1 31 02 Setting Up Mechanical TOC his ed sn 3T 1 SECTION 4 SYSTEM OP RATION ERR 4 1 4 01 Front Panel Controls Features 4 1 4 02 X Preparations for Operation 4 2 TABLE CONTENTS SECTION 4 TORCH OPERATION 4 1 47 1 47 02 Cut Quality 4T 2 4T 03 General Cutting Information 4 2 4104 Torch Operation 4T 3 4105 ai oaiae 4 7 4106 Mechanized Torch OpefratiOri nrbt naar 4T 8 4T 07 Parts Selection for Manual and Mechanized Torch Cutting 4T 9 4T 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip 4 10 47 09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T 13 PATENT INFORMATION nn ntm 41 16 SECTION 5 SYSTEM rc M 5 1 5 01 General RR EE 5 1 5 02 Maintenance Schedule 5 2 303 COMMONFAUNS scent E 5 2 504 Fault Indicat neunana AR 5 3 5 05 nue 5 3 5 06 Power Sup
55. ROCEDURES 7 1 7 01 SO ne ne a ee an do mm 7 1 7 02 Anti Static Handling 7 1 7 03 Parts Replacement General Information 7 1 7 04 Major External Parts Lais didi nes darti dadak 7 2 7 05 Front Panel Parts RODIACEMEN ete amc ice tintin 7 3 7 06 Left Side Internal Parts 7 4 LUZ Replace nent diee prices n Die ore accus 7 5 7 08 Right Side Internal Parts Replacement 2 22222 7 7 APPENDIX 1 SEQUENCE OPERATION BLOCK DIAGRAM Peor HR A 1 APPENDIX 2 DATA TAG INFORMATION A 2 APPENDIX 3 TORCH PIN OUT 8 A 3 APPENDIX 4 TORCH CONNECTION DIAGRAMS 4 APPENDIX 5 SYSTEM SCHEMATIC 208 460V UNITS A 6 APPENDIX 6 SYSTEM SCHEMATIC 600V 8 A 8 APPENDIX 7 PUBLICATION 10 SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and
56. Remove the cover per subsection 7 04 A 2 Remove the three 3 air hoses from the regulator per subsection 7 05 C Pull Air Regulator adjusting knob from shaft Loosen and remove the locking nut secur ing the Air Regulator to the front Panel then remove the regulator 5 Install replacement Air Regulator by revers ing the above steps 6 Reinstall the power supply cover A 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 subsection 7 05 C 4 The Solenoid utilizes the same type locking fitting as the gas hoses Using a flat blade screw driver push the locking ring towards the Solenoid while pulling the Solenoid away from the ATC 5 Install the replacement Gas Solenoid by reversing the above steps 6 Reinstall the power supply cover F Logic PCB PCB 3 Replacement Tools required T20 Torx Driver Flat Screw Driver 2 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 sub section 7 05 C Unplug the connector J2 from the Main PCB 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 subse
57. Supply must be disassembled Before removing any connection mark each wire with the connection designation When reas sembling 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 52 7 04 Major External Parts A Cover Removal Tools required T20 Torx Driver 1 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the cover NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Art A 07947 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover installation NOTE When installing the upper screws attempt to reuse the original threads The 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 Tube Handle Replacement
58. T 08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip and following for greater details Output current setting or cutting speeds may be reduced to allow slower cutting when following a line or using a template or cutting guide while still producing cuts of excellent quality Postflow Release the trigger to stop the cutting arc Gas continues to flow approximately 20 seconds During post flow if the user moves the trigger release to the rear and presses the trigger the pilot arc starts The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece SL60 Leads Length 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 or LATCH Gas flow stops 2 Set the output current to desired amperage with the Output Current Control Knob Cutting Operation When the torch leaves the workpiece during cutting opera tions with the Function Control Knob in the RUN position there is a brief delay in restarting the pilot arc With the knob in the RAPID AUTO RESTART position when the torch leaves the workpiece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded me
59. TCH mode when the torch switch is released the arc shuts OFF immediately 1 Defective Logic PCB a Replace Logic PCB D 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 E INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error 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 J1 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 Manual 0 4962 CUTMASTER 52 a Measure voltage on PCB 4 between 1 1 to J1 3for Input Diode Module Test 12VDC while cutting If 12VDC is present replace PCB 1 1 Using an ohmmeter perform the tests in the chart Input Diode Module 2 Defective Automation Interface PCB PCB 4 Meter 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 Inte
60. VICTOR THERMAL DYNAMICS CUTMASTER _ PLASMA CUTTING SYSTEM Qo Gm ES SS Service Manual VICTOR THERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 426 1888 or visit us on the web at www thermal dynamics com This Service Manual has been designed to instruct you on the cor rect use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators World wide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies International Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery superior customer service a
61. Warnings Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system 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 erating area WARNING Gives information regarding possible electrical shock injury Warnings will be enclosed in box such as this 1 02 Important Safety Precautions WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARD OUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions Manual 0 4962 CUTMASTER 52 amp GASES AND FUMES Gase
62. a 5 52 99 020 57 Foxes _ 22 e 9 229 faa 5 52 2 020 020 57 0 10 e e 1 fas 5 52 ns 0 51 sse 10 e ora fas 5 sa 9 eas oso 026 57 oso 132 e z oss fas 5 sa 99 eas ors 020 57 os sesso 10 s oss oro faa 5 52 s ws WA NA we v os 025 ea 7s 52 ww NR Manual 0 4962 4T 11 OPERATION CUTMASTER 52 Type Torch 5160 With Exposed Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Cms hne TE NE 00 15 0 wo eo 025 5 52 28 0 54 1 10 eo ao ws 7s 52 25 02564 30 1m6 oo 250 o3 0 ea 52 a 25 00 025 64 34 420 ne 60 170 a32 oss ea 52 025 64 0250 420 132 oo es 216 025 ea 52 025 64 0375 wo as 114 oz 75 52 25 050 025 64 27 osmo ws oo so o7 oss 52 245 oso 025 64 155 10 __16 60 20 os oss ea 76 52 nn ne 0750 mi sso ws eo ie os 52 o an NOTE Gas pressure shown is for torches with
63. ailed 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 Screws Art A 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 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 Cover Removal 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 illustra tion Art A 07989 Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the internal he
64. al released Per ECOB752 updated firmware changes to pgs 4 1 and 5 5 Per ECOB845 corrected drag cutting statement to 14 pg 4T 5 Per 0 803 releasing 400 460V systems 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 ECOB908 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 ECOB1001 Corrected pressure NOTE at the end of each cut chart section in Section 4T Corrected art sizing in Section 3 to show missing information per ECOB1248 Added 600V system information Section 2 6 and Appendix per 1346 Updated 400V 600V schematic in appendix per ECOB1399 Updated 230 460v schematic per ECOB1357 Updated Section 6 with 600v PCB numbers per ECOB1520 Updated CNC cable part numbers in Section 6 per ECOB1637 Add one line for logic PCB to include 600V systems part numbers in Section 6 per 1800 Per ECOB1859 corrected Schematics with art number A 09131 and A 09133 to show proper ARC Volts for Automation Interface PCB Changed COO text per ECOB2149 Updated ART A 07994 per 0 2136 Changed logo on Front Cover and Inside Front Cover from Thermal Dynamics to Victor Thermal Dynamics modified Prop 65 text Section 1 Changed wording for N
65. and proceed to Section 5 09 Main Arc and Controls Problems H CNCINTERFACE TEST 5 10 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 Connectan ohmmeter between J2 12 to J2 14 START signal Position the torch to pilot Check the OK TO MOVE signal by connecting a jumper between J2 3 and J2 4 START signal e Pilot arc is established 2 Bringthetorch to the work piece and transfer to cutting arc Manual 0 4962 e 0 0 signal is present Meter shows continuity 3 Remove jumper from J2 e Arc shuts OFF e OK TO MOVE signal OFF Meter shows no continu ity Gas continues to flow DC LED goes OFF After 20 second Post flow time e Gas solenoid closes Gas flow stops If the unit has the Basic CNC Interface harness the test is complete If the unit does not function as stated above then note the symptom and proceed to Section 5 10 CNC Interface Problems If the unit has the Automation Interface PCB installed continue with this section 4 There are three 3 ARC VOLTs signals available from the J2 connector J2 9 4 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 42 5 to J2 6 Auto Interface PCB J3 con nector with jumper installed between pins 2 and 3 ARC VOLTS divided by
66. ards and technical requirements Among them are UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of electrical shock Power Supplies bearing the 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 Victor Technologies Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX GENERAL INFORMATION 1 6 Manual 0 4962 CUTMASTER 52 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
67. as supply ON 3 Gas supply pressure too low a Set gas supply pressure to 95 120 psi 4 Air Pressure Control Regulator set too low a Adjust AIR PRESSURE CONTROL to set pressure as specified in Setting Operational Pressure in Section 4 02 Preparations for Operation on page 4 2 K INTERNAL ERROR FAULT Indicator and 90 PSI Indicator flashing 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error L MAX PRESSURE ERROR MAX Pressure LED is lit 1 Gas pressure set too high a Reduce gas pressure 2 Defective Logic PCB a Replace Logic PCB M ACLED ON TEMP LED OFF GAS LED ON Gas does not flow in SET mode using a hand torch or a machine torch without remote solenoid 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage is present change SOL 1 SERVICE 5 14 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 PCB a Replace Main PCB N AC LED ON TEMP LED OFF GAS LED ON Gas does not flow in SET mode using a machine torch with remote solenoid Disconnect the gas solenoid SOL1 from the back of the ATC connector If Gas DOES NOT flow out of SOL1 when the unit is in SET mode 1 Defective gas solenoid SOL1 a Measure voltage on Main PCB between J5 1 to J5 3 for 12 VDC If voltage
68. ation is lower than minimum for torch operation The cooling fans will turn ON as soon as the unit is turned ON After the unit is idle for ten 10 minutes the fans will turn OFF The fans Will come back ON as soon as the torch switch Start Signal is activated or if the unit is turned OFF then turned ON again If an over tempera ture condition occurs the fans will continue to run while the condition exists and for a ten 10 minute period once the condition is cleared Set Operating Pressure 1 Place the Power Supply Function Control knob to the SET position Gas will flow 2 For Standoff cutting adjust gas pressure from 70 85 psi 4 8 5 9 bar LED s in center of control panel Refer to the Stand off chart for pressure setting details Art A 07946 4 2 Manual 0 4962 CUTMASTER 52 STANDOFF Typical Cutting Speeds CutMaster 52 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 Each additional Add 5 psi Add 5 psi 25 7 6 m 0 4 bar 0 4 bar 3 For Drag cutting adjust gas pressure from 75 95 psi 5 2 6 5 bar LED s in center of control panel Refer to the Drag Cutting chart for pressure setting details CutMaster 52 Gas Pressure Settings Cutting speeds vary according to torch output amperage the type of material being cut and operator skill Refer to subsection 4
69. ault Indicators OFF No arc in torch 1 Defective Main PCB a Install jumper on Main PCB between test point GND1 to terminal TIP1 b Close torch switch If Pilot starts replace Main PCB E AC LED ON TEMP LED OFF GAS LED ON gas flowing DC LED ON Fault Indicators OFF Pilot Arc is intermittent 1 Defective Logic PCB a Measurefor 12VDC on Main PCB between test Point GND1 to J2 8 If 12VDC is present replace Logic PCB 2 Defective Main PCB 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 position and then turn to ON position to clear the error 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 connection of cable to clamp is secure SERVICE 5 16 B Main arc transfers but current cannot be adjusted 1 Defective Logic PCB a While main arc is transferred measure voltage on Main PCB between test points GND1 to DMD1 b Adjust CURRENT CONTROL POTENTIOMETER from maximum to minimum Voltage should vary from 4VDC at max to 1 VDC at min If voltage does not vary with CURRENT CONTROL POTEN TIOMETER replace Logic PCB 2 Defective Main PCB a Replace Main PCB C In LA
70. be applied to separate areas of the power supply and Revision Level Standard Symbols gt DG Phase Art A 03288 Manual 0 4962 APPENDIX A Hand Torch Pin Out Diagram ATC Male Connector Negative Front View Plasma TORCH PIN CUTMASTER 52 T DIAGRAM ATC Female Receptacle Front View Negative ix M D 7 Open Ope n 5 Open 5 Open Male Connector Front View Negative Plasma 8 Green a P AN Pendant Connector Connector IN ne 3 White C lS 8 pe Connector 3 Cul ot Use 2 Orange 4 6 5 White 2 Not Used Pilot Manual 0 4962 8 Ground A 3 WAS LC iy er Nr Plasma gt Female Receptacle Ze Plasma 3 Switch 2 1 APPENDIX CUTMASTER 52 APPENDIX 4 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 Head Leads PIP 4 Black To Power Supply Switch Circuitry Torch LIT Green Switch Os White
71. 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 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 1 Turn the ON OFF switch OFF then back ON again If that does not clear the fault return to an authorized service 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 SERVICE CUTMASTER 52 5 06 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system be fore disassembling the torch leads or power Supply BR I DD M This section describes procedures for basic parts replacement For more det
72. cedures Manual 0 4962 CUTMASTER 52 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provide a breakdown of all replaceable components The parts lists are arranged as follows Section 6 03 Power Supply Replacement Section 6 04 Major External Replacement Parts Section 6 05 Front Panel Replacement Parts Section 6 06 Left Side Replacement Parts Section 6 07 Right Side Replacement Parts Section 6 08 Options and Accessories Section 6 09 Replacement Parts for Hand Torch Section 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads Section 6 11 Torch Consumable Parts Manual and Mechanized Torches NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the power supply Address all inquiries to your authorized distributor 6 03 Power Supply Replacement The 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 52 Power Supply 208 230
73. ch head If resistance assembling or disassembling torch parts or is felt when installing the cup check the torch and leads assemblies threads before proceeding 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 2 Remove the Electrode by pulling it straight Manual 0 4962 4T 1 OPERATION CUTMASTER 52 4T 02Cut Quality NOTE 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 build up and bevel angle may be major factors when the surface will be welded after cutting Dross free cutting is im portant when finish cut quality is desired to avoid a secondary cleaning operation The following cut quality characteristics are illustrated in the follow ing figure Kerf Width Dross Build Up Cut Surface Bevel Angle Rounding 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 b
74. ck per Section 5 11 A Primary plug not wired correctly Check manufacturer s plug installation instructions Primary input cable is defective Check cable for shorts B Primary line fuses blow immediately after ON OFF SWITCH SW1 is turned to ON position Shorted Input Diode Module Check per Section 5 11 B Shorted Input Capacitor PCB Check per Section 5 11 C C Gasflows with ON OFF SWITCH in OFF position Foreign debris has lodged in gas solenoid a Replace gas solenoid This is a problem caused by improperly filtered air supply Customer needs to add filtration to air supply prior to unit inlet SERVICE CUTMASTER 52 D All front panel indicators OFF fans do not E run Main Contactor W1 does not close 1 Primary power not connected Check that cable is connected to primary power Primary line fuse breaker is blown tripped a Replace fuse or reset breaker Defective ON OFF SWITCH a Check continuity Defective Main PCB a Measure Main PCB power supply voltages at the following test points GND1 to 12V 12VDC GND1 to 48V 48 VDC Replace Main PCB if not correct 5 Defective Ribbon Cable a Check continuity Defective Logic a Replace Logic PCB 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
75. close this gap Forcing the shield cup against the torch head or torch handle can damage components 8 For a consistent standoff height from the workpiece install the standoff guide by slid ing it onto the torch shield cup Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc During operation position the legs of the standoff guide against the work piece d pet Shield Cup p Standoff Guide Torch Tip Workpiece Art A 04034 Manual 0 4962 Shield With Straight Edge The drag shield cup can be used with a non conductive Straight edge to make straight cuts by hand WARNING Li c pom 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 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 torc
76. ction 7 05 B 6 Pull the top of the front panel forward slightly and carefully remove the Logic PCB from the unit T Install the replacement Logic PCB by revers ing the above steps 8 Reinstall the power supply cover A G ON OFF Switch SW1 Replacement Tools required T20 Torx Driver PARTS REPLACEMENT 1 2 4 5 CUTMASTER 52 Remove the cover per subsection 7 04 Disconnect the wires on the rear of the switch noting the location and orientation of each wire as shown below Switch Art 08169 Squeeze together the clips on the back of the switch then remove the switch through the front panel Install the replacement switch by reversing the above steps Reinstall the power supply cover H Work Cable Replacement 1 2 3 Tools required T20 Torx Driver Remove the Cover per subsection 7 04 A Disconnect the work cable from the WORK1 terminal on the Main PCB Squeeze the top and bottom of the Work Cable Strain Relief and remove from the front panel Install the replacement Work Cable by re versing the above steps Reinstall the power supply cover PARTS REPLACEMENT 7 06 Left Side Internal Parts Replacement A Fan Replacement 3 6 rA Tools required T20 Torx Driver 1 2 Remove the Cover per subsection 7 04 A Unplug J7 and J8 connectors from Main PCB Carefully feed the fan wires through the center chassis wire slot Remove the fa
77. d by the mark it denotes that the signal is an active low For example OVERTEMP This signal is normally High but when an over temperature fault exists this line will change state to a Low Manual 0 4962 5 19 SERVICE CUTMASTER 52 SERVICE 5 2 MTH MTH MTH 2 8 2 R4 R3 R1 R2 UM O MTHS MTH8 MTH7 5 6 1 MTH3 MTH4 MTH2 Art 08841 J3 CONNECTOR PINOUT 1 2 3 5 20 Manual 0 4962 CUTMASTER 52 APACITOR SIGNAL ignal Source Destination 41 1 Capacitor bank A J1 5 Capacitor bank J2 1 Capacitor Bank B J2 5 Capacitor Bank B J3 1 12 VDC M C J3 2 460 Active low for 460VAC input M C 43 3 230 Active low for 230VAC input M C MTH 1 2 Capacitor bank 3 4 Capacitor bank A MTH 6 8 Capacitor Bank 5 7 Capacitor Bank B Manual 0 4962 5 21 SERVICE CUTMASTER 52 LOGIC PCB LAYOUT PCB3 01 TP7 TP6 TPS D10 D12 014 D11 D13 J1 Pinout 37 Art 08179 SERVICE 5 22 Ma
78. d 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 Torch to the Power Supply 3 The system is ready for operation Manual 0 4962 CUTMASTER 52 Check Air Quality To test the quality of air 1 Put the ON switch in the up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn ON the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02Setting Up Mechanical Torch NOTE When converting a hand torch or a machine torch system to operate an Automation 100SLV torch one of the CNC interface options will be required A WARNING ga eJ Disconnect primary power at the source before disassembling the torch or torch leads LSE 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 52 Assembly Workpiece
79. d autres probl mes de reproduction Il faut se laver les mains apr s toute manipulation Manual 0 4962 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 05 NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OP RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PRO TECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI 749 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY
80. dge along an outside diameter cut the torch should travel in a clockwise direction Dross When dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance dross is normally very easy to remove and can often be wiped off with a welding glove Slow speed dross is normally present on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cutting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding Manual 0 4962 AT 3 CUTMASTER 52 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
81. dy and a shield cap or deflector ensure that the cap or deflector is threaded snugly against the shield cup body In shielded drag cutting operations only there may be an O ring be tween the shield cup body and drag shield cap Do not lubricate the O ring Shield Cup Body Art A 03878 SERVICE 4 Remove the tip Check for excessive wear indicated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip SZ A 03406 Example of Tip Wear 5 Removethe 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 New Electrode Ce Worn Electrode ES Art 4 A 03284 Electrode Wear 1 Reinstall the Electrode by pushing it straight into the torch head until it clicks 8 Reinstall the desired starter cartridge and tip into 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 pro
82. e 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 6 3487 6 1 Small O Ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 5160 20 foot Leads Assembly with ATC connector 4 7834 1 5160 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 A 07993_AB Manual 0 4962 6 7 PARTS LIST CUTMASTER 52 6 10 Replacement Parts for Mechanized with Unshielded Leads 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 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 4 652 1 50 foot 15 2 m Leads Assembly with connector 4 7853 6 Unshielded Mechanized Leads Assemblies with connectors 1
83. e the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 21 05 Introduction to Plasma on page 2T 2 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 4962 CUTMASTER 52 2T 03Specifications A Torch Configurations 2T 1 1 Hand Manual Torch Models The hand torch head is at 75 to the torch handle The hand torches include a torch handle and torch trigger assembly Le 10 125 257 mm gt Art 03322 AB 1 17 29 mm 2 Mechanized Torch Model The standard machine torch has a positioning tube with rack amp pinch block assembly 15 875 403 mm 9 285 236 mm de ll LX 1 375 35 1 75 0 625 44 5 mm 16mm w 1 175 30 LR 126 mm 4 95 Art A 02998 Torch Leads Lengths Hand Torches are available as follows e 20ft 6 1 m with ATC connectors e 50ft 15 2 m with ATC connectors Machine Torches are available as follows 5 foot 1 5 m with ATC connectors e 10f00t 3 05 m with ATC connectors e 25001 7 6 m with ATC connectors e 50001 15 2 m with ATC connectors Torch Parts Starter Cartridge Electrode Tip Shield Cup Parts In Place PIP Torch Head ha
84. ecified by the International Electro Technical Commission These specifica tions 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 75 273 Art A 07941 Art A 07925 AB 16 375 416 mm 1 nnn Uf 43 Ib 19 5 kg INTRODUCTION 2 2 Manual 0 4962 CUTMASTER 52 2 05 Input Wiring Specifications CutMaster 52 Power Supply Input Cable Wiring Requirements Input voltage Power Input Suggested Sizes Flexible Cord P Hz Leff Fuse amps m 60 50 60 5 60 0 60 9 2 1 Phase 50 60 50 60 Line Voltages with 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 4962 2 3 INTRODUCTION Handle Leads Wrap 2 06 Power Supply Features CUTMASTER 52 5 5 8 nd m n amp lt 8 gt 3 vo S o TOTAS d LES SA I S N CX V Sve Ne A W
85. egulator 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 4962 6 5 PARTS LIST CUTMASTER 52 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 6 CNC Cable for Automation Interface Kit 9 1008 1 35 10 7 CNC Cable for Automation Interface Kit 9 1010 1 50 15 2 Cable for Automation Interface Kit 9 1011 1 Nylon Dust Cover 9 7071 Housing Filter Element Cat No 9 7741 Spring g First amp Second O rin Cat No 9 7743 Stage Cartridges odd as marked 5 Barbed amp Fitting Jg Art A 02476 Art 02942 Optional Single Stage Filter Kit Optional Two Stage Filter Kit PARTS LIST 6 6 Manual 0 4962 CUTMASTER 52 6 09 Replacement Parts for Hand Torch Description Catalog 1 1 Torch Handl
86. evenly then torque each bolt to 20 30 in Ibs 2 3 3 4 Nm Improper torque may damage the gasket 8 Slowly apply air pressure to the assembly checking for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures SERVICE 5 07 Circuit Fault Isolation A WARNING The following procedures should not be at tempted by anyone who has not had proper training or authorized to do so A Cover Removal 1 Remove the upper and lower screws which secure the cover to the main assembly Do not loosen the lower screws inside the cut out slots in the bottom of the COVer NOTE The upper screws and lower screws are not the same Do not mix them The upper screws are for threading into the plastic of the front and rear panels DO NOT use the finer threaded lower screws for this Lower Screws 2 Carefully pull the Cover up and away from the unit B Cover Installation 1 Reverse previous procedures for cover installation NOTE When installing the upper screws attempt to reuse the original threads The 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 4962 CUTMASTER 52 Pre Power Up Tests 2 Turn the ON OFF SWITCH SW1 to ON position and observe the followin
87. g 1 Straight Arc A straight arc is perpendicular to the workpiece surface This arc is generally recommended for the best cut us ing air plasma on stainless or aluminum 2 Leading Arc The leading arc is directed in the same direction as torch travel A five degree leading arc is generally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direction as torch travel 2 Standoff Distance Trailing Arc Leading Arc A 02586 Mechanized Torch Operation For optimum smooth surface quality the travel speed Should be adjusted so that only the leading edge of the arc column produces the cut If the travel speed is too slow OPERATION 4T 8 To pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the front end of the torch When operating with a cutting machine a pierce or dwell time is required Torch travel should not be enabled until the arc penetrates the bottom of the plate As motion be gins torch standoff should be reduced to the recommended 1 8 1 4 inch 3 6 mm distance for optimum speed and cut quality Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize t
88. g Prior to applying primary line power to the unit perform the following checks to prevent component failure or blow e Software version is displayed See Section 5 04 ing primary fuses The troubleshooting guide will assume Fault Indicator on page 5 3 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 Input Diode Module Test Section 5 11 B Input Capacitor PCB Test Section 5 11 C IGBT Modules Test Section 5 11 D Output Diode Module Test Section 5 11 E LESE 3 Adjust the pressure regulator to set the gas pressure If all of the Pre Power Up Tests are OK proceed with the as specified in charts trouble shooting guide STANDOFF 1 CutMaster 52 Gas Pressure Settings Leads SL60 SL100 LLL CAUTION _____ Length Hand Torch Mechanized Torch Due to the close proximity of the Main PCB Up to 25 75 psi 70 psi to the Capacitor PCB It is recommended to 7 6 m 5 2 bar 4 8 bar use an insulated meter probe when making Each additional Add 5 psi Add 5 psi measurements on the J2 connector on the 25 7 6 m 0 4 bar 0 4 bar Main PCB Do not short between the pins Do not short to the Capacitor connections TT D Initial Set up Conditions CutMaster 52 Gas Pressure Settings After approximately three 3 seconds e nrush relay on PCB 1 energizes starting pre charging of working capacitors e W1 energizes e a
89. g high pressure air cylinders as the air Supply 1 Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure regulators 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign material Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 Ipm 4 Connect supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure cylinder regulator Supply hose must be at least 1 4 inch 6 mm 1 For secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Manual 0 4962 SECTION 3 INSTALLATION 3T 01Torch 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 mu P Disconnect primary power at the source before connecting the torch 1 Align the ATC male connector on the torch lea
90. g the PCB to the center chassis T Carefully guide the PCB assembly up and out of the unit 8 Install the replacement PCB by reversing the above steps 9 Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04 A 2 Remove all wires from W1 noting the loca tion and orientation of each wire 3 Loosen the two 2 Torx head screws secur ing the Main Contactor to the base 4 Slide the contactor towards the rear of the unit slightly to allow the contactor to clear the mounting screws Lift Main Contactor up and out of the unit 6 Install the replacement Contactor by revers ing the above steps 7 Reinstall the power supply cover Manual 0 4962 7 7 PARTS REPLACEMENT CUTMASTER 52 This Page Intentionally Blank PARTS REPLACEMENT 7 8 Manual 0 4962 CUTMASTER 52 APPENDIX 1 SEQUENCE OPERATION BLOCK DIAGRAM ACTION ACTION ON OFF switch to ON disconnect switch RESULT Power to system RESULT AC indicator ON GAS indicator 75 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
91. ge Selector at the rear of the for each item unit for correct setting before plugging in 2 Inspect each item for possible shipping or connecting the unit The primary power damage If damage is evident contact your source fuse and any extension cords used distributor and or shipping company before must conform to local electrical code and the proceeding with the installation recommended circuit protection and wiring 3 Record Power Supply and Torch model and requirements as specified in Section 2 serial numbers purchase date and vendor Most units are shipped from the factory with a name in the information block at the front of this manual 3 02 Lifting Options The Power Supply includes a handle for hand 230Volt input power cable wired to the input con tactor in the single phase configuration The fol lowing illustrations and directions are for changing that configuration to a different voltage and or to three phase operation or back again if a change lifting only Be sure unit is lifted and transported safely and securely WARNING Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious per sonal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate physical strength should lift the unit Lift unit by the handles using two hands Do not use straps for lifting Use optional cart or simila
92. h 50 2909 3 CUTMASTER 52 82 A40 A60 230 460V C 42X1298 Manual 0 4962 APPENDIX CUTMASTER 52 APPENDIX 6 SYSTEM SCHEMATI V UNIT 5 a PRI2 PRI1 BIAS D SUPPLY DA z 12VDC moro h 2 i 3 2070 6 4 PN AV 4 50 25 22 M UNITS ONLY FILTER wi L1 1 1 trip 8 L2 12 9 L3 T3 GND 4 4 380 400 415 OR 600V 3 PH AC INPUT PRIMARY POWER CONNECTIONS USE L1 L2 L3 8 GND D IM PCB2 INPUT CAPACITOR 24VAC 5 de CMS2 12mm 20mm A40 8 C5 may not be installed 1 TEST POINTS 2 24 VAC RETURN Ni COMMON GND2 COMMON GND3 COMMON 6 12 1 12 VDC SUPPLY 48V1 48
93. h 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 workpiece during the cutting cycle 5 Hold the torch away from your body 6 Slide the trigger release toward the back of the torch handle while simultaneously Manual 0 4962 CUTMASTER 52 squeezing the trigger The pilot arc will start Trigger Release A 02986 2 T Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a character istic of the power supply and not a function of the torch Trigger 4 g 8 Cut as usual Simply release the trigger as sembly to stop cutting 9 Follow normal recommended cutting practices as provided in the power supply operator s manual NOTE When the shield cup is properly installed there is a slight gap between the shield cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle can damage components OPERATION CUTMASTER 52 Piercing With Hand Torch 6 Bring the torch within transfer distance to 1 The torch can be comfortably held in one the work The main arc will transfer to the
94. he amount of scale which adheres to it Manual 0 4962 CUTMASTER 52 4T 07Parts Selection for Manual Mechanized Cutting Tips DRAG A Shield Cap Deflector CUTTING ant 9 8243 14 20 9 8205 30A 9 8206 40 9 8207 c NOTER P DRAG SHIELD 1 Shield Cap Drag CUTTING 40A 9 8244 40A CUTTING Tip Shield Cap Deflector 2 9 8243 9 40 9 8208 Standoff Guide 9 8251 STANDOFF CUTTING Shield Cap Drag 50 60A 9 8235 Shield Deflector Y 9 8243 50 60A CUTTING Start Cartridge 50 55A 9 8209 9 8213 60A 9 8210 d s STANDOFF 1 CUTTING O Ring TC Shield Cap Drag 98215 70 120 T A 70 100 9 8236 CUTTING xp Shield Cap Deflector 9 8243 70 9 8231 80 9 8211 Standoff Guide 90 100A 9 8212 9 8281 120A 9 8253 STANDOFF CUTTING 40 120A GOUGING Shield Cap Gouging 9 8241 Tip Gouging 9 8225 40 Amps Max CutMaster 52 uses 60 and less Tip G 9 8226 50 100 A ee mps CutMaster 82 uses 80A and less Art A 08065_AE CutMaster 102 uses 100 and less Tip Gouging C 948227 THO Amps CutMaster 152 uses 120 and less Tip Gouging D 9 8228 60 120 Amps Tip Gouging 9 8254 60 120 Amps Manual 0 4962 4 9 OPERATION CUTMASTER 52 4T 08Recommended Cutting Speeds for Torch With Ex
95. hen the torchis started a pilot arc is established between the electrode and cutting tip This pilot arc creates a path for the main arc to transfer to the work Main Cutting Arc DC power is also used for the main cutting arc The nega tive output is connected to the torch electrode through the torch lead The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire Parts In Place PIP The torch includes a Parts In Place PIP circuit When the shield cup is properly installed it closes a switch The torch will not operate if this switch is open Manual 0 4962 CUTMASTER 52 lt lt O Torch Switch Torch Trigger To Control 20 Cable Wiring PIP Switch Shield Cup A 02997 O Parts In Place Circuit Diagram for Hand Torch Remote Pendant l PME To ATC PIP Switch Shield Cup x CNC Start To ATC PIP Switch Shield Cup P Art 08168 Automation Torch 7 PIP Switch Shield Cup Parts In Place Circuit Diagram for Machine Torch INTRODUCTION CUTMASTER 52 This Page Intentionally Blank INTRODUCTION 2T 4 Manual 0 4962 SECTION 3 SYSTEM INSTALLATION 3 01 Unpacking CUTMASTER 52 3 03 Primary Input Power Conn CAUTION Check your power source for correct voltage before plugging in or connecting the unit 1 Usethe packing lists to identify and account Check the Volta
96. hich contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq A ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot e Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications e Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual GENERAL INFORMATION CUTMASTER 52 FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace e Do not cut or weld on containers that may have held combus tibles e Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under alumi
97. igit count the pressure indicators reading from bottom to top 0 through 7 In the example below the Temp indicator and 75 psi indicators are ON indicating the version would be 2 3 NW BOD Art A 07988 12345 When the D Fault indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is Only one of these faults will be displayed at one time If more than one fault exists when the first fault is corrected and cleared the next fault will then be displayed It is possible to have a fault indicated in the function indicators and another fault indicated in the pressure indicators The following table shows each of the Faults possible Indicator Max 90 internal Error 80 Consumables Missing NOTE Fault explanations are covered in the follow ing tables Explanation of Faults UNDER PRESSURE Indicates that operating pressure is set too low and power supply output power will be disabled Manual 0 4962 CUTMASTER 52 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
98. ing points 4 Ifa short is found replace Capacitor PCB assembly Input Capacitors Meter Meter MTH 2 4 Charging MTHS Open mme Ow wma ume wma mms Omm D IGBT Modules Test 1 Disconnect transformer wires from Main PCB terminals PRI 2 Using an ohmmeter perform the following checks SERVICE 1 A and PRI 4 D B MTH4 PRI2 B 0 PRI4 D MTHS MTH6 PRI4 0 MTH5 PRI4 0 If the test reveals a failed component replace Main PCB and perform main contactor test Section 5 11 A If no problem is found reconnect the transformer wires to Main PCB E Output Diode Module Test 1 2 3 Disconnect transformer wires from Main PCB terminal SEC 1 Using an ohmmeter perform the tests in the chart If the test reveals a failed component replace Main PCB If no problem is found reconnect the transformer wires to Main PCB Manual 0 4962 CUTMASTER 52 F Pilot IGBT Test 1 Disconnect wire from Main PCB terminal 2 Measure continuity on Main PCB between test point GND1 to terminal 3 Ifthe test reveals a failed component replace Main PCB If no problem is found reconnect wire to Main PCB Signal Information Many of the signal listed will be low voltage signals that will be in one of two states 12VDC High or 0 06 Low with respect to PCB common When a signal name is precede
99. ip 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 0501632 0511633 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 Shield Cap US Pat No s 6914211 D505309 Other Pat s Pending OPERATION 4 16 Manual 0 4962 CUTMASTER 52 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 4962 4T 17 OPERATION CUTMASTER 52 This Page Intentionally Blank OPERATION 4 18 Manual 0 4962 CUTMASTER 52 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
100. 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 SOL1 to the ATC connector 4 Defective torch solenoid a Measure the coil terminals of the torch mounted gas solenoid SOL2 for 24VAC If present replace 5012 5 Defective Main PCB a Measure on Main PCB 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 replace 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 4962 CUTMASTER 52 5 09 Pilot Arc Problems A AC LED ON TEMP LED OFF GAS LED ON Nothing happens when torch switch or remote switch is closed Or CNC START signal is active No gas flow DC LED OFF Upper Groove with Vent Holes Must Remain Open 1 Probleminthe torch and leads switch circuit or remote ene Upper O Ring pendant or CNC signal missing in Correct Groove a For hand torches check continuity of torch switch circuit at ATC pins 3
101. is unit Do not SERVICE CUTMASTER 52 attempt to diagnose or repair unless you have had training in power electronics measurement trouble shooting techniques Problem Symptom Possible Cause Recommended Action ON OFF Switch 1 Primary power disconnect is in 1 Turn primary power disconnect switch to ON position is ON but the A C OFF position Indicator does not 2 Primary fuses breakers are 2 a Have qualified person check primary fuses breakers light blown or tripped b Connect unit to known good primary power receptacle 3 Faulty components in unit 3 Return to authorized service center for repair or replacement 1 INPUT VOLTAGE SELECTION Turn OFF power to unit then set INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage SWITCH to match primary input voltage 2 Primary input voltage problem 2 Have qualified person check primary voltage to insure it meets unit requirements see Section 2 04 Power Supply Specifications on page 2 2 3 Faulty components in unit 3 Return to authorized service center for repair or replacement 1 Air flow through or around the Refer to clearance information Section 2 04 Power unit is obstructed Supply Specifications on page 2 2 2 Duty cycle of the unit has been 2 Allow unit to cool exceeded 3 Failed components in unit 3 Return to authorized service center for repair or replacement 1 Gas supply not connected to 1 Connect gas supply to unit
102. ivery resale or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 4962 1 7 GENERAL INFORMATION CUTMASTER 52 This Page Intentionally Blank GENERAL INFORMATION 1 8 Manual 0 4962 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 infor mation which requires additional emphasis or is helpful in efficient operation of the system A procedure which if not properly followed may cause damage to the equipment WARNING procedure which if not properly followed may cause injury to
103. les ou explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati 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 3 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 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 ray
104. melted by the heat of the arc and then blown away While the goal of plasma arc cutting is separation of the material plasma arc gouging is used to remove metals to a controlled depth and width In a Plasma Cutting Torch a cool gas enters Zone B where a pilot arc between the electrode and the torch tip heats and ionizes the gas The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C Power Supply A le i B i Workpiece A 00002 Typical Torch Head Detail By forcing the plasma gas and electric arc through a small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma 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 B Gas Distribution The single gas used is internally split into plasma and secondary gases Manual 0 4962 The plasma gas flows into the torch through the negative lead through the starter cartridge around the electrode and out through the tip orifice The secondary gas flows down around the outside of the torch starter cartridge and out between the tip and shield cup around the plasma arc Pilot Arc W
105. n by pushing the fan retain ing clips apart and pulling the fan out of the center chassis On the replacement fan s note the direction of air flow as labeled on the fan housing and orient so fan will blow air into the unit Install replacement fan by reversing the above steps Reinstall the power supply cover B Main Transformer T1 Replacement 7 4 3 8 9 Tools required T20 Torx Driver Nut Driver 1 2 Remove the Cover per subsection 7 04 A Remove the Tube Handle per subsection 7 04 Remove the two large and small gas hoses per subsection 7 05 C Remove the Gas Solenoid per subsection 7 05 Disconnect the transformer wires from ter minals PRI 1 A PRI 2 B PRI 3 C PRI 4 D SEC1 SEC2 on the Main PCB Disconnect J2 amp J3 connectors from Main PCB Remove the two screws securing the Center Chassis to the base Loosen the two screws on the Input Power Cable strain relief Disengage the Rear panel from the base per subsection 7 04 D 10 Guide the rear panel back six 6 inches away from the base 11 Guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base 12 Carefully guide the Center Chassis up far enough to lay the Chassis down to the right side of the unit Manual 0 4962 Manual 0 4962 13 Remove the two screws securing the Main Transformer to the base
106. nd GAS Indicators come ON e Gas flows e Fans turn ON This section is to help isolate the defective circuit before Leads SL60 SL100 troubleshooting identify symptoms and test the unit for Length Hand Torch Mechanized Torch proper operation Follow the instructions as given to identify 7 the possible symptom s and the defective circuit After _ Bd se din ES repairs are complete run the following tests again to verify er that the unit is fully operational Each additional Add 5 psi Add 5 psi 1 Connect gas supply to rear of Power Supply 290700 0 4 bar Oe Par 2 Turn ON gas supply and set operating pressure per pressure setting label on power supply 4 Turn FUNCTION CONTROL SWITCH to RUN position e Solenoid turns OFF gas stops flowing pressure display may increase slightly when gas is not flow e ON OFF SWITCH to OFF position ing e Turn FUNCTION CONTROL SWITCH to SET position This completes the Main Input and Internal Power Test If the above all correct then proceed to the next section Pilot 7 to MAXI Test If the unit does not function as stated above then POSTON TUY CIOCKWISE note the symptom and proceed to Section 5 07 Main Input and Internal Power Problems 3 Setthe Power Supply controls as follows E Main Input and Internal Power Test 1 Connect Primary Line power to the unit F Pilot Arc Test 1 Activate or depress the torch swi
107. nd technical sup port together with excellence in sales and marketing expertise Above all we are committed to developing technologically ad vanced products to achieve a safer working environment within the welding industry WARNING Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Plasma Cutting Power Supply CutMaster 52 5160 1Torch Service Manual Number 0 4962 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 Victor Technologies International Inc All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negli gence accident or any other cause Original Publication Date October 7 2007 Revision Date November 27 2012 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE CONT
108. nd the operator s ability to accurately follow the dicular to the workpiece after the is desired cut line The following factors may have complete an impact on system performance 4 Hold the torch away from your body Torch parts wear 5 Slide the trigger release toward the back Air quality of the torch handle while simultaneously T squeezing the trigger The pilot arc will voltage 5 start Torch standoff height Proper work cable connection Trigger Release A 02986 OPERATION 4T 6 Manual 0 4962 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 subsection 4T 07 Parts Selection for Manual and Mechanized Torch Cutting Gouging Parameters Gouging performance depends on parameters such as torch travel speed current level lead angle the angle be tween the torch and workpiece and the distance bet
109. nual 0 4962 CUTMASTER 52 LOGIC PLB SIGNALS Game far MAIN PER 2 So So Delon J1 1 VOUT OUTPUT VOLTAGE M L J1 2 TIP VOLTS Active high when tip is installed M L J1 3 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 vollage L M J1 5 230V IN Active low with 230VAC primary input vollage L M J1 6 CUR SET Current demand signal Variable 1 4VDC L M 1 7 RAR Active low when in Rapid Auto Restart mode L M 41 8 INRUSH Active low after inrush time expires L M J1 9 W1 ON Active low to enable W1 contactor L M J1 10 Active low enables PWM circuit J1 11 TRCH SOL Active low to enable Torch Solenoid L M J1 12 SOL ON Active low to enable Power Supply solenoid L M 41 13 0 TO MOVE Active low to enable OK TO MOVE CNC L M J1 14 Active low to enable fans L M J1 15 ACTIVE Active low when Latch mode is active during cut L M 41 16 IRCH SW Active low START is active Torch switch M L J1 17 Active low PARTS IN PLACE satisfied M L 41 8 Pulse signal M L J1 19 CSR Active high during main transfer M L J1 20 SOL DETECTED Active low for torch with remote solenoid M L J1 21 OVERTEMP Active low when over temperature M L J1 22 V IN Input Voltage signal M L 3VDC 460 VAC 1 5VDC 230VAC 41 22 412VDC M L J1 24 12006 M L J1 25 GND M
110. num workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion Noise 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 e Noise levels should be measured to be sure the decibels sound do not exceed safe levels e Forinformation on how to test for noise see item 1 in Subsec tion 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear e Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty e Protect others in the work area from the arc rays Use protective booths screens or shields
111. o 15 9 010 20 9 N Cu se fo Css 170 040 Css Pose 55 17 o 0135 34 8208 125 ARTA gt ml 5 oss 70 025 70 To 40 Lr 0 078 2 0 9 8208 120 40 0 40 40 1 40 2 Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Speed Per Minute Standoff Gas Press Pierce Height Inches mm Cat No Inches psi bar Plasma Total Inches 032 051 1 3 9 8208 116 40 16 98208 40 0 079 ve 3 100 wer ose se as eme 0 187 Manual 0 4962 4 13 OPERATION CUTMASTER 52 Type Material Mild Steel Type Secondary Gas Single Gas Torch Type Torch SL60 With Shielded Tip Type Plasma Gas Air Tip 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 2 0 20 0 30 0 50 0 75 245 245 245 245 245 245 245 ae 75 sa w 76 ae 75 52 oas ous as 75 52 90 su ae 75 52 en ses 010 os ae 76 52 3 18 2 03 0 86 230
112. o subsection 4 02 Operating Pressure Total flow rate includes plasma and secondary gas flow Manual 0 4962 4T 15 OPERATION CUTMASTER 52 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 D511280 D492709 D499620 0504142 Other Pat s Pending 9 8205 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8206 US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8207 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8252 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8208 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8209 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8210 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8231 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8226 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8227 T
113. ons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommen dation qui suivent ANSI ASC 749 1 INFORMATIONS G N RALES 1 4 Nuance Minimum Nuance Sugger e rant Arc Protective Num r Num r Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous 40467 vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de 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 I 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 Pb 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 mal formations f tales ou
114. orch leads or power supply enclosure Where these instructions include specific torquing instructions failure to torque prop erly will cause component damage Do not operate the equipment or test equip ment under power while wearing the ground ing wrist strap Manual 0 4962 CUTMASTER 52 B Procedure 1 Open the wrist strap and unwrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and exposed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure and remove the failed PC board 6 Carefully open the ESD protective bag and remove the replacement PC Board 7 Install the replacement PC Board in the equipment and make all necessary connec tions 8 Place the failed PC Board in the ESD protec tive bag and seal for return shipping 9 Replace the power supply cover 10 Remove the grounding wrist strap from your wrist and from the electrical ground connection before reconnecting primary power to the equipment 7 03 Parts Replacement General Information The parts replacement procedures described in this manual except for filter replacement re quire that the Power Supply be disassembled The part to be replaced will determine to what extent the Power
115. ous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des rensei gnements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ce produit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq A CHOC ELECTRIQUE Les chocs lectriques peuvent blesse
116. p 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 instruc tions found in Section 5 2 Disconnect the original input power cable from the main input contactor and the chas sis ground connection 3 Loosen the through hole protector on the back panel of the power supply Pull the origi nal power cable out of the power supply 4 Using a customer supplied four conductor input power cable for the voltage desired strip back the insulation on the individual wires 5 Pass the cable being used through the ac cess opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION The primary power source and power cable must conform to local electrical code and the 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 illustration e Green Yellow wire to Ground e Remaining wires to L1 L2 and L3 input It does not matter what order these wires are attached See the previous il lustrations 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 instruc tions found in Section 5 9 Connect the opposi
117. ply Basic Parts 5 6 5 07 Circuit Fault 5 8 5 08 Main Input and Internal Power Problems 5 11 5 09 Pilot Arc PRODIGING ne 5 15 5 10 Main Arc and Controls Problems 5 16 5 11 5 16 TS PDC QUES 5 17 SECTION 5 TORCH SERVICE nn EN ETE 5T 1 5T 01 General Maintenance en med 5T 1 57 02 Inspection and Replacement of Consumable Torch 5T 2 SECTION 6 PARTS LISTS ae 6 1 6 01 nee 6 1 6 02 MONA eut 6 1 6 03 Power Supply 2 6 1 6 04 Major External Replacement Parts 6 2 6 05 Front Panel Replacement PATIS sin 6 3 6 06 Left Side Replacement Parts nanas 6 4 PARIS nina 6 5 6 08 Options and ACCESSOTIOS sn nent 6 6 6 09 Replacement Parts for Hand 6 7 6 10 Replacement Parts for Mechanized Torches with Unshielded Leads 6 8 611 Torch Consumable Parts Manual and Mechanized Torches 6 10 TABLE CONTENTS SECTION 7 REPLACEMENT P
118. posed Tip IP Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness n Per Minute Standoff Pierce Height afoso 1 se sm fors ls m 1 1 5 9 8208 108 40 250 0 19 55 17 1 108 4o 19 34 55 8 se esee oo oo ore 55 40 40 40 4 72 o 3 3 o gt 2 2 gt o o J 025 sacos 111 019 919 55 2 El Plasma Gas Air a ss 902 osse 4s ss vo ooo 51 EE Loos o zer 0185 32 s ss om 25 122 so 5 ose 4s 55 if 100 51 0375 9 20 126 4o 10 oss oeras 48 ss 10 NR Type Torch SL60 With Exposed Tip Type Material Aluminum LP Plasma Gas Air Type Secondary Gas Single Gas Torch pafos m se vm 2 se vo as s fir em oa fa Gro me mop ove eal vo is ss m foe Ter salos ws 4o 100 254
119. r 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 4962 3 1 had already been made Single Phase 10 and Jumper Settings m Jumper L1 L4 2 L2 2 Jumper 2 3 ESI 14 5 5 GND 2 z i Single Phase Input Power Wiring Three Phase 39 and Jumper Settings Store copper jumper in spare parts box Fam uo Jumper L1 L4 L20 k p EE 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 removed and placed on the other L3 connec tion so both ends of the jumper are attached to the same electrical point See previous illustrations INSTALLATION CUTMASTER 52 Connections to Single Phase Input Power 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 Single Phase input power 1 Remove the Power Supply cover per instruc tions found in Section 5 2 Disconnect the original inp
120. r ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail 1 3 Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage INFORMATIONS G N RALES CUTMASTER 52 R parez ou remplacez toute pi ce us e endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE 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 inflammab
121. r passages in the torch Connect as follows Manual 0 4962 CUTMASTER 52 Regulator Filter Assembly Inlet Port Art A 07944 ind RS d 9 1 4 to 1 4 Fitting Gas Supply Hose 3 3 INSTALLATION CUTMASTER 52 Installing Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5 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 Assembly 3 Use customer supplied fittings to connect the air line to the Filter A 1 4 NPT to 1 4 hose barbed fitting is shown as an example Regulator Filter Assembly 2 Stage Filter Inlet Port IN Regulator Input Outlet Port OUT 2 Two Stage Filter Hose Clamp Assembly Gas Supply Hose Art A 07945_AC Optional Two Stage Filter Installation INSTALLATION 3 4 Using High Pressure Air Cylinders When usin
122. rface PCB PCB 4 a Replace PCB 4 C3 5 12 Test Procedures MTHS 5 A Main Contactor W1 Test 1 Check continuity between L1 to T1 2 Ifthe test reveals a failed component replace Main PCB and perform main contactor test Section 5 11 A L2 to T2 L3 to T3 14 to The contacts should be open no continuity CutMaster 52 amp 82 Cover Screws W1 contactor wired for 1PH Actuator Button Jumpers Main Contactor Side Art 08157_ 2 Retest continuity between terminals while engaging the contacts manually This can be done by pushing down on the recessed actuator button on the top of W1 or pushing down on the actuator arm on the side of W1 L1 to T1 L2 to T2 L3 to T3 L4 to T4 The contacts should be closed Continuity 3 Visually check W1 contact points To take the cover OFF remove the two cover screws shown in the previ ous illustration Replace if contacts are stuck together or show excessive arcing Manual 0 4962 5 17 SERVICE CUTMASTER 52 Input Test 1 Using ohmmeter check continuity between the fol lowing points Most meters will show a charging action Initially a low resistance will be shown and then the resistance will start to increase If the meter probes are reversed the reading will decrease to zero then start charging in the opposite polarity 2 fashort is found replace Capacitor PCB assembly 3 Check continuity between the follow
123. ry light film of o ring lubri cant Catalog 8 4025 to the o rings on a weekly basis Manual 0 4962 CUTMASTER 52 Upper Groove with Vent Holes Must Remain Open Upper O Ring in Correct Groove Threads Lower O Ring Torch Head O Ring Art A 03725 Art A 03791 ATC O Ring NOTE 00 NOT use other lubricants or grease they may not be designed to operate within high temperatures or may contain unknown ele ments that may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent performance or poor parts life 5T 1 SERVICE CUTMASTER 52 5T 02Inspection and Replacement of Consumable Torch Parts WARNING ESE Disconnect primary power to the system be fore disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter car tridge in place Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be removed may effect the performance of the System 2 Inspect the cup for damage Wipe it clean or replace if damaged Art A 08067 Shield Cups 3 Ontorches with a shield cup bo
124. s and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases 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 e 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 e Phosgene a toxic gas is generated from the vapors of chlo rinated solvents and cleansers Remove all sources of these vapors This product when used for welding or cutting produces fumes or gases w
125. s built in switch 12 VDC circuit rating Type Cooling Combination of ambient air and gas stream through torch INTRODUCTION CUTMASTER 52 Ratings Manual Ratings Ambient 104 F Temperature 40 Duty Cycle 100 60 Amps 400 scfh 60 Amps Voltage V 500V Arc Striking Voltage Temperature 40 C Duty Cycle Maximum Current Voltage Are Striking Voltage nv G Gas Requirements Manual and Mechanized Torch Gas Specifications Gas Plasma and Secondary Compressed Air Operating Pressure 60 95 psi Refer to NOTE 4 1 6 5 bar Maximum Input Pressure 125 psi 8 6 bar Gas Flow Cutting and 300 500 scfh Gouging 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 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 extremely high temperature and ionized so that it becomes electri cally 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
126. 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 8 S O ring Cat No 9 97743 Q Barbed Fitting Assembled Filter Art A 02476 Optional Single Stage Filter Element Replacement 7 6 Manual 0 4962 CUTMASTER 52 5 Remove the Filter Element from the Housing 7 08 Right Side Internal Parts and set Element aside to dry Replacement 6 Wipe inside of housing clean then insert the replacement Filter Element open side A Capacitor PCB PCB 2 Replacement first Tools required T20 Torx Driver 7 Replace Housing on Cover 1 Remove the Cover per subsection 7 04 A 8 Reattach gas supply 2 Remove the eight screws securing PCB 2 to 9 Reinstall the power supply cover the Main PCB NOTE 3 Install the replacement PCB by reversing the ee Rae i Ee above steps If unit leaks between housing and cover inspect the O Ring for cuts or other damage B Main PCB PCB 1 Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04 A 2 Remove the two large gas hoses per sub section 7 05 C 3 Remove the Gas Solenoid per subsection 5 05 E 4 Remove Capacitor PCB per subsection 7 08 A 5 Disconnect the wires and connectors from the PCB noting the location and orientation of each wire and connector 6 Remove the four 4 mounting screws securin
127. tal or gratings or in gouging or trim ming operations when an uninterrupted restart is desired And with the knob in the LATCH position the main cutting arc will be maintained after the torch switch is released Manual 0 4962 4 3 Turn the ON 0 OFF switch to OFF down Power Supply indicators shut OFF Unplug the input power cord or disconnect input power Power is removed from the system OPERATION CUTMASTER 52 This Page Intentionally Blank OPERATION 4 4 Manual 0 4962 CUTMASTER 52 SECTION 4 TORCH out of the Torch Head OPERATION Torch Head 4T 01Torch Parts Selection Electrode Depending on the type of operation to be done determines the torch parts to be used Type of operation AAM Drag cutting standoff cutting or gouging Torch parts Tip Shield Cup Cutting Tip Electrode and Starter Cartridge NOTE Shield Cup Refer to subsection 41 07 Parts Selection for EE Manual and Mechanized Torch Cutting and Torch Parts Drag Shield Cap amp Shield Cup Body Shown following for additional information on torch parts 3 Install the replacement Electrode by push Change the torch parts for a different operation as ing it straight into the torch head until it follows clicks 4 Install the starter cartridge and desired tip A for the operation into the torch head WARNING 5 Hand tighten the shield cup assembly until Disconnect primary power at the source before it is seated on the tor
128. tch Activate START signal to establish a pilot arc and note the following e Gas solenoid opens Gas flows Manual 0 4962 5 9 SERVICE CUTMASTER 52 e After two seconds the gas solenoid closes and gas stops flowing momentarily then gas solenoid re opens and gas resumes flowing e DC LED comes ON e Pilot arc is established 2 Open the torch switch Remote Pendant switch or remove CNC start signal e Gas continues to flow e DC LED goes OFF After 20 second post flow time Gas solenoid closes e Gas flow stops This completes the Pilot Arc Test If the above are all correct then proceed to the next Section G Main Arc and Controls Test If the unit does not function as stated above then note the symptom and proceed to Section 5 08 Pilot Arc Problems G Main Arc and Controls Test Connect work Cable to the work piece Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 3 9 5 mm of the work piece to establish main cutting arc Main Cutting Arc Establishes e On Main D59 turns OFF and D78 turns ON 1 Clamp DC ammeter around the work cable Output will be 60 amps 2 While cutting adjust the CURRENT CONTROL POTEN TIOMETER from maximum setting to minimum setting Current adjusts from 60 amps down to 20 amps 3 Set the CURRENT CONTROL POTENTIOMETER to maximum position e Current adjusts from 20 amps up to 60 amps 4 While
129. te 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 3 2 Manual 0 4962 3 04 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders Refer to the following two subsections if an optional air line filter is to be installed 1 Connect the air line to the inlet port The illustration shows typical fittings as an ex ample 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 Art A 07943 Air Connection to Inlet Port Installing Optional Single Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air to keep moisture and debris out of the torch 1 Attach the Single Stage Filter Hose to the Inlet Port 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustra tion shows typical fittings as an example 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 ai
130. this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermal Dynamics will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Thermal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Product Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 39 1 Year CUTMASTER 52 1 Year CUTMASTER 82 1 Year CUTMASTER 102 1 Year CUTMASTER 152 1 Year This warran
131. tion Checkthe torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 60 amps maximum Refer to subsection 4 07 Parts Selection for Manual and Mechanized Torch Cutting and following for torch parts selection Torch Connection Check that the torch is properly connected Only Thermal Dynamics model SL60 Manual or SL100 Mechanical Torches may be connected to this Power Supply See Sec tion 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 o position AC indicator w turns ON Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cooling fans turn ON NOTE Minimum pressure for power supply oper
132. ty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective 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 del
133. uild ups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly per pendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece OPERATION 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 removed during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has 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
134. upant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre pro fessionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d 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 4962 CUTMASTER 52 amp FUM E et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz 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 v
135. ut power cable from the main input contactor and the chas sis ground connection 3 Loosen the through hole protector on the back panel of the power supply Pull the origi nal power cable out of the power supply 4 the power cable being used is not the fac tory supplied cable use a three conductor input power cable for the voltage desired and strip back the insulation on the individual wires 5 Pass the cable being used through the ac cess opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 6 Connect the wires as follows e 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 instruc tions found in Section 5 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power cable or close the main disconnect switch to supply power INSTALLATION B Connections to Three Phase Input Power A WARNING Disconnect input power from the power su
136. ween the torch tip and workpiece standoff CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear Torch Travel Speed NOTE Refer to Appendix Pages for additional infor mation as related to the Power Supply used Optimum torch travel speed is dependent on current set ting lead angle and mode of operation hand or machine torch Current Setting Current settings depend on torch travel speed mode of operation hand or machine torch and the amount of material to be removed Manual 0 4962 CUTMASTER 52 Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed The recommended lead angle is 35 At a lead angle greater than 45 the molten metal will not be blown out of the gouge and may be blown back onto the torch If the lead angle is too small less than 35 less material may be removed requiring more passes In some applications such as removing welds or working with light metal this may be desirable P DX 359 Standoff Height Workpiece A 00941_AB Gouging Angle and Standoff Distance Standoff Distance The tip to work distance affects gouge quality and depth Standoff distance of 1 8 1 4 inch 3 6 mm allows for smooth consistent metal removal Smaller standoff dis tances may result in a severance cut rather than a gouge Standoff distances greater than 1
137. wn 1 Power Cable Strain Relief for all units 9 0111 1 Input Power Cable with plug 230V 1PH 3m 9 8596 1 Input Power Cord for 460 600 V Power Supply 9 8593 1 Hi Lo voltage selection switch 9 0110 NOTE 9 0107 Logic If the serial number of the power supply is prior to 905078755 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 fit ting 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 4962 CUTMASTER 52 6 07 Right Side Replacement Parts Description Ref Catalog 1 1 Contactor 4 Pole W1 9 8587 2 1 Solenoid 12V 5011 9 0114 3 1 Spare Parts Box 7 3267 4 1 Spare Parts Box Cover 7 3266 5 1 Console Quick Disconnect 9 0161 6 1 Regulator with knob and mounting nut 9 0115 7 1 Assembly PCB Input Capacitors non 600V PCB 2 9 0167 7 1 Assembly Input Capacitors 600V Only PCB 2 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 r
138. x fitting and turning it counter clock wise left Numbers 4 and 5 in the previous illustration Disconnect the input line from the filter element as sembly Manual 0 4962 f 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 Filter Element JEN Art A 07990 Install the new or cleaned assembly by reversing these procedures Turn ON the air supply and check for leaks before rein stalling 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 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 2 Remove power from power supply Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element Disconnect gas supply hose Turn the Filter Housing Cover counter clockwise and remove it The Filter Element is located inside the Housing Manual 0 4962 CUTMASTER 52 Filter Element Cat No 9 7741 oom E O ring Cat No 9 97743 Assembled Filter Cover 2

52 CUTMASTER™ Service Manual

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52 CUTMASTER&trade; Service Manual

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52 CUTMASTER™ Service Manual