Thermal Dynamics CUTMASTER 102, Cutmaster 152 Service Manual

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102

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CUTMASTER

PLASMA CUTTING SYSTEM

Service Manual

Rev. AA Date: September 25, 2008 Manual # 0-4998 Operating Features:

WARNINGS

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™ 102 SL100 1Torch™ Service Manual Number 0-4998

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: September 25, 2008

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ...................................................................................1-1

1.01 Notes, Cautions and Warnings ...................................................................1-1

1.02 Important Safety Precautions .....................................................................1-1

1.03 Publications.................................................................................................1-2

1.04 Note, Attention et Avertissement ................................................................1-3

1.05 Precautions De Securite Importantes .........................................................1-3

1.06 Documents De Reference ...........................................................................1-5

1.07 Declaration of Conformity ...........................................................................1-6

1.08 Statement of Warranty ................................................................................1-7

SECTION 2 SYSTEM:INTRODUCTION .................................................................................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 Speciﬁcations .......................................................................2-2

2.05 Input Wiring Speciﬁcations ..........................................................................2-3

2.06 Power Supply Features ...............................................................................2-4

SECTION 2 TORCH:INTRODUCTION ..................................................................................2T-1

2T.01 Scope of Manual ....................................................................................... 2T-1

2T.02 General Description ..................................................................................2T-1

2T.03 Speciﬁcations ........................................................................................... 2T-1

2T.04 Options And Accessories .......................................................................... 2T-2

2T.05 Introduction to Plasma .............................................................................. 2T-2

SECTION 3 SYSTEM: INSTALLATION ................................................................................... 3-1

3.01 Unpacking ................................................................................................... 3-1

3.02 Lifting Options ............................................................................................. 3-1

3.03 Primary Input Power Connections ..............................................................3-2

3.04 Gas Connections ........................................................................................ 3-4

SECTION 3 TORCH: INSTALLATION .................................................................................... 3T-1

3T.01 Torch Connections .................................................................................... 3T-1

3T.02 Setting Up Mechanical Torch .................................................................... 3T-1

SECTION 4 SYSTEM: OPERATION ........................................................................................4-1

4.01 Front Panel Controls / Features .................................................................. 4-1

4.02 Preparations for Operation ..........................................................................4-2

SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1

4T.01 Torch Parts Selection ................................................................................ 4T-1

4T.02 Cut Quality ................................................................................................ 4T-2

4T.03 General Cutting Information ...................................................................... 4T-2

4T.04 Hand Torch Operation ............................................................................... 4T-3

4T.05 Gouging .................................................................................................... 4T-7

4T.06 Mechanized Torch Operation ....................................................................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 4T-10 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T-13

PATENT INFORMATION ...................................................................................................... 4T-16

TABLE OF CONTENTS

SECTION 5 SYSTEM:SERVICE ..............................................................................................5-1

5.01 General Maintenance .................................................................................5-1

5.02 Maintenance Schedule ............................................................................... 5-2

5.03 Common Faults ...........................................................................................5-2

5.04 Fault Indicator .............................................................................................5-3

5.05 Basic Troubleshooting Guide ...................................................................... 5-6

5.06 Circuit Fault Isolation ..................................................................................5-8

5.07 Main Input and Internal Power Problems ..................................................5-12

5.08 Pilot Arc Problems ....................................................................................5-16

5.09 Main Arc and Controls Problems ..............................................................5-19

5.10 CNC Interface Problems ........................................................................... 5-20

5.11 Test Procedures ........................................................................................5-20

SECTION 5 TORCH:SERVICE .............................................................................................. 5T-1

5T.01 General Maintenance ............................................................................... 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts ........................ 5T-2

SECTION 6:PARTS LISTS .......................................................................................................6-1

6.01 Introduction .................................................................................................6-1

6.02 Ordering Information ................................................................................... 6-1

6.03 Power Supply Replacement ........................................................................6-1

6.04 Major External Replacement Parts .............................................................6-2

6.05 Front Panel Replacement Parts .................................................................. 6-3

6.06 Left Side Replacement Parts .....................................................................6-4

6.07 Right Side Replacement Parts ...................................................................6-5

6.08 Replacement Power Supply Parts ..............................................................6-6

6.09 Options and Accessories ............................................................................6-6

6.10 Replacement Parts for Hand Torch ............................................................6-7

6.11 Replacement Parts - for Machine Torches with Unshielded Leads ............. 6-8

6.12 Torch Consumable Parts (SL100 SV) .......................................................6-10

SECTION 7: REPLACEMENT PROCEDURES .......................................................................7-1

7.01 Scope ..........................................................................................................7-1

7.02 Anti-Static Handling Procedures ................................................................. 7-1

7.03 Parts Replacement - General Information ..................................................7-1

7.04 Major External Parts ..................................................................................7-2

7.05 Front Panel Parts Replacement .................................................................. 7-3

7.06 Left Side Internal Parts Replacement .........................................................7-4

7.07 Rear Panel Parts Replacement ..................................................................7-6

7.08 Right Side Internal Parts Replacement .......................................................7-9

TABLE OF CONTENTS

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) ........................................ A-1

APPENDIX 2: DATA TAG INFORMATION .............................................................................. A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS ...................................................................... A-3

APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................... A-4

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ....................................................... A-6

APPENDIX 6: Publication History ........................................................................................... A-8

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

TABLE OF CONTENTS

cutmaster 102

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in 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 operating area.

1.02 Important Safety Precautions

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or ﬂammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all ﬂammable or explosive vapors from the workplace.

Manual 0-4998 1-1 GENERAL INFORMATION

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• Do not cut or weld on containers that may have held combustibles.

• Provide a ﬁre watch when working in an area where ﬁre hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ ASC Z49.1:

Minimum Protective Suggested Arc Current Shade No. Shade 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.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California

Health & Safety Code § 25249.5 et seq.)

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT- TING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN- ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-4998

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classiﬁées comme suit :

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• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efﬁcacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Aﬁn d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les ﬁches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

Manual 0-4998 1-3 GENERAL INFORMATION

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma

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produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inﬂammables.

• Soyez certain qu’aucune matière combustible ou inﬂammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inﬂammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées 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 à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enﬂammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts aﬁn d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores aﬁn d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.

Il faut s e l a v e r les mains a p r è s t o u t e manipulatio n .

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant ﬁssure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les ﬁltres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

GENERAL INFORMATION 1-4 Manual 0-4998

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

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14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

Manual 0-4998 1-5 GENERAL INFORMATION

cutmaster 102

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA

age Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/ EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Speciﬁcations

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* 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 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

Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Operations Director

GENERAL INFORMATION 1-6 Manual 0-4998

cutmaster 102

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser

that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in 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

(Parts and Labor)

Torch and Leads

(Parts and Labor)

CUTMASTER™ 39 4 Years 1 Year

CUTMASTER™ 52 4 Years 1 Year

CUTMASTER™ 82 4 Years 1 Year

CUTMASTER™ 102 4 Years 1 Year

CUTMASTER™ 152 4 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, ﬁlters.

2. Equipment that has been modiﬁed by an unauthorized party, improperly installed, improperly operated or misused based upon industry

standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics 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 0-4998 1-7 GENERAL INFORMATION

cutmaster 102

GENERAL INFORMATION 1-8 Manual 0-4998

cutmaster 102

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication

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:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

2.02 Equipment Identiﬁcation

The unit’s identication number (specication or

part number), model, and serial number usually appear on a data tag attached to the rear panel. Equipment which does not have a data tag such

as torch and cable assemblies are identied only by the specication or part number

printed on loosely attached card or the shipping container. Record these numbers on the bottom of page 1 for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the car-

rier immediately to le a claim. Furnish complete

information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identication 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.

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermadyne at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment

identication numbers.

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

Manual 0-4998 2-1 INTRODUCTION

cutmaster 102

30.5"

774.7 m

63 lb / 28.6 kg

10.75"

273 mm

16.375"

416 mm

Art # A-08358

150 mm

24"

0.6 m

150 mm

Art # A-07925

2.04 Power Supply Speciﬁcations

CutMaster 102 Power Supply Speciﬁcations

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz

230 VAC (187 - 253 VAC), Three Phase, 60 Hz

Input Power

230 VAC (187 - 253 VAC), Three Phase, 50 Hz

400 VAC (360 - 440 VAC), Three Phase, 50 Hz

460 VAC (414 - 506 VAC), Single Phase, 60 Hz

460 VAC (414 - 506 VAC), Three Phase, 60 Hz

Input Power Cable Power Supply includes input cable.

Output Current 30 - 100 Amps, Continuously Adjustable

Power Supply Gas

Particulates to 5 Microns

Filtering Ability

CutMaster 102 Power Supply Duty Cycle *

Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)

Opperating Range 0° - 50° C

Duty Cycle 50% 60% 100%

Current 100 95 90

All Units

IEC TDC IEC TDC IEC TDC

DC Voltage 120 120 118 120 116 120

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is higher than shown in this chart.

NOTE

IEC Rating is determined as speciﬁed by the International Electro-Technical Commission. These speciﬁcations include calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

INTRODUCTION 2-2 Manual 0-4998

2.05 Input Wiring Speciﬁcations

CutMaster 102 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I eff Fuse (amps)

208 60 19 90 80 100 2

cutmaster 102

Flexible Cord

(AWG)

1 Phase

230 60 20 85 78 100 2

460 60 27 57 50 60 4

208 60 19 52 45 60 6

230 60 18 45 43 60 6

3 Phase

460 60 22 27 24 40 10

230 50 14 34 22 40 12

400 50 19 27 17 30 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

The suggested sizes are based on ﬂexible power cable with power plug installations. For hard-wired installations refer to local or national codes.

I1max is taken at TDC rated minimum duty cycle.

I1eff is taken at TDC 100% rated duty cycle.

Manual 0-4998 2-3 INTRODUCTION

cutmaster 102

Handle and Leads Wrap

Torch Leads Receptacle

Control Panel

Art # A-08359

Work Cable and Clamp

Art # A-08360

Input Power Cord

Port for Optional Automation Interface Cable

Gas Inlet Port

Filter Assembly

Input Power Selection

2.06 Power Supply Features

INTRODUCTION 2-4 Manual 0-4998

cutmaster 102

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" / 16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL100/Manual and SL100/Mechanized Plasma Cutting Torches. Service of this equipment is restricted to properly trained person-

nel; unqualied personnel are strictly cautioned

against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

2T.03 Speciﬁcations

A. Torch Conﬁgurations

1. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly.

2. Mechanized Torch, Model

The standard machine torch has a positioning tube with rack & pinch block assembly.

Plasma torches are similar in design to the automotive spark plug. They consist of negative and positive sections separated by a center insulator. Inside the torch, the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of

gas ows through the small orice 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 ow is divided inside the torch

head. Single - gas operation provides a smaller sized torch and inexpensive operation.

NOTE

Refer to Section 2T.05, Introduction To Plasma, for a more detailed description of plasma torch operation.

Refer to the Appendix Pages for additional speciﬁcations as related to the Power Supply used.

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors Machine Torches are available as follows:

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

C. Torch Parts

Start Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

Manual 0-4998 2T-1 INTRODUCTION

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

cutmaster 102

A-00002

Workpiece

Power

Supply

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

peak

Mechanized Torch Ratings

peak

100% @ 100 Amps @ 400 scfh

)

100% @ 100 Amps @ 400 scfh

)

G. Gas Requirements

Manual and Mechanized Torch Gas

Specications

104° F

40° C

100 Amps

500V

7kV

104° F

40° C

120 Amps

500V

7kV

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.

While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with oxygen (O2).

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.04 Options And Accessories

For options and accessories, see section 6.

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.

INTRODUCTION 2T-2 Manual 0-4998

cutmaster 102

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

PIP Switch

Shield Cup

To ATC

CNC Start

PIP Switch

Shield Cup

PIP Switch

Shield Cup

Remote Pendant

Automation Torch

To ATC

Art # A-08168

B. Gas Distribution

The single gas used is internally split into plasma and secondary gases.

The plasma gas ﬂows into the torch through the negative lead, through the start cartridge, around the electrode, and out through the tip oriﬁce.

The secondary gas ﬂows down around the outside of the torch start cartridge, and out between the tip and shield cup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.

E. 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.

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4998 2T-3 INTRODUCTION

Parts - In - Place Circuit Diagram for Machine

Torch

cutmaster 102

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4998

cutmaster 102

SECTION 3 SYSTEM:

INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account for each item.

2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.

3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.

3.02 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNING

Do not touch live electrical parts.

Disconnect input power cord before moving unit.

FALLING EQUIPMENT can cause serious personal injury and can damage equipment.

HANDLE is not for mechanical lifting.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handles, using two hands. Do not use straps for lifting.

• Use optional cart or similar device of adequate capacity to move unit.

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Manual 0-4998 3-1 INSTALLATION

cutmaster 102

Art # A-08493

Input Power Cable Connections

Three-Phase (3ø)

Store copper jumpers on base plate

Single-Phase (1ø) and Jumper Settings

GND

3.03 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as speciﬁed in Section 2.

The following illustration and directions are for changing phase of the power supply.

Single and Three Phase Input Power Wiring

NOTE

There are two jumpers used for the single phase 230V setting and none for three phase.

A. Connections to Single Phase Input Power

WARNING

Disconnect input power from the power supply 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 instructions found in section 5.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out of the power supply.

4. If the power cable being used is not the factory - 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 access opening in the back panel of the power supply. Re-

fer to Section 2 for power cable specications.

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).

INSTALLATION 3-2 Manual 0-4998

cutmaster 102

6. Connect the wires as follows.

• Connect Bus Bar Jumpers on the contactor as shown in prior illustration and on label in the power supply.

• Green / Yellow wire to Ground.

7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

10. Connect the input power cable (or close the main disconnect switch) to supply power.

B. Connections to Three Phase Input Power

WARNING

Disconnect input power from the power supply 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 instructions found in section 5.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out of the power 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 access opening in the back panel of the power supply. Re-

fer to Section 2 for power cable specications.

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.

• Wires to L1, L2 and L3 input. It does not matter what order these wires are attached. See

previous illustration and on label in the power supply.

• Green / Yellow wire to Ground.

7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

10. Connect the input power cable (or close the main disconnect switch) to supply power.

Manual 0-4998 3-3 INSTALLATION

cutmaster 102

Art # A-07943

Hose Clamp

Regulator/Filter Assembly

Inlet Port

Gas Supply Hose

1/4 NPT or ISO-R to 1/4” (6mm) Fitting

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 lter is to be installed.

1. Connect the air line to the inlet port. The illustration shows typical ttings as an example.

NOTE

For a secure seal, apply Permatex PX56521 or equivalent thread sealant to the ﬁtting threads, according to the manufacturer’s instructions. Do not use Teﬂon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Air Connection to Inlet Port

INSTALLATION 3-4 Manual 0-4998

cutmaster 102

Art # A-07944

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Regulator/Filter Assembly

Inlet Port

Gas Supply Hose

Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for improved ltering 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 lter hose.

3. Connect the air line to the Filter. The illustration shows typical ttings as an example.

NOTE

Optional Single - Stage Filter Installation

Manual 0-4998 3-5 INSTALLATION

cutmaster 102

Art # A-07945_AB

Regulator/Filter Assembly

Regulator Input

2-Stage Filter Inlet Port (IN)

Outlet Port (OUT)

Two Stage Filter Assembly

Gas Supply Hose

1/4 NPT to 1/4” (6mm) Fitting

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter 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 lter assembly.

NOTE

2. Connect the two stage lter outlet hose to the inlet port of the Regulator / Filter Assembly.

3. Use customer - supplied ttings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose barbed tting is shown as an example.

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

Optional Two - Stage Filter Installation

1. Refer to the manufacturer’s specications 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 mate-

rial. Briey 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 ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the regulator.

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) I.D.

For a secure seal, apply Permatex PX56521 or equivalent 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.

NOTE

INSTALLATION 3-6 Manual 0-4998

cutmaster 102

Art # A-07885

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.

WARNING

Disconnect primary power at the source before connecting the torch.

1. Align the ATC male connector (on the

torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.

2. Secure the connection by turning the lock-

ing nut clockwise until it clicks. DO NOT

use the locking nut to pull the connection together. Do not use tools to secure the connection.

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON

(up) position.

2. Put the Function Control switch in the SET

position.

3. Place a welding lter 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.02 Setting Up Mechanical Torch

NOTE

An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine torch.

WARNING

Disconnect primary power at the source before disassembling the torch or torch leads.

The mechanical torch includes a positioning tube with rack and pinch block assembly.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece.

Connecting the Torch to the Power Supply

3. The system is ready for operation.

Manual 0-4998 3T-1 INSTALLATION

cutmaster 102

A-02585

Workpiece

Square

Pinch Block Assembly

Mechanical Torch Set - Up

3. The proper torch parts (shield cup, tip, start

cartridge, and electrode) must be installed for the type of operation. Refer to Section 4T.07, Torch Parts Selection for details.

INSTALLATION 3T-2 Manual 0-4998

SECTION 4 SYSTEM:

PSI BAR

MAX MAX

MIN MIN

1 2

Art# A-07886

MIN

MAX

PSI BAR

MAX MAX

MIN MIN

5.5

85 5.9

90 6.3

5.2

4.8

4.5

Art # A-08170

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identiﬁcation

1. Output Current Control

Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

2. Function Control

Function Control Knob, Used to select between the different operating modes.

cutmaster 102

SET Used to purge the air through the unit and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster restarting of the Pilot Arc for uninterrupted cutting.

LATCH Used for longer hand held cuts. Once a cutting arc is established, the torch switch can be released. The cutting arc will remain on until the torch is lifted away from the work piece, the torch leaves the edge of the work piece the torch switch is activated again or if one of the system interlocks is activated.

3. On Off Power Switch

ON / OFF Switch controls input power to the power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure

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 op-

eration. 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 0-4998 4-1 OPERATION

6. Temp Indicator

Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Let the unit cool before continuing operation.

7. 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.

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. !Fault Error Indicator

Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights.

10. Pressure Indicators

The Indicators will illuminate according to the pressure set by the Pressure Control Knob (number 4).

cutmaster 102

Art # A-04509

PSI BAR

MAX MAX

MIN MIN

Art# A-07946

MIN

MAX

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 Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (100 amps maximum). Refer to Section 4T.07 and following for torch parts selection.

Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torches may be connected to this Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit

per Section 2, Specications.

2. Connect the input power cable (or close the

main disconnect switch) to supply power to the system.

Air Source

Power On

Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator 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 operation is lower than minimum for torch operation.

When the unit is turned on the cooling fans MOT1 & MOT2 will remain off. (In earlier units MOT1 will turn on for one (1) second and then turn off) The fans will turn on when a START signal ( Torch Switch, Remote Pendant switch, or CNC START) is active and will remain on for ten (10) minutes after the START signal is removed. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period after the condition is cleared. Set Operating Pressure

1. Place the Power Supply Function Control

knob to the SET position. Gas will

ow.

2. For Standoff cutting, adjust gas pressure

from 70 - 85 psi / 4.8 - 5.9 bar (LED's

in center of control panel). Refer to the Standoff chart for pressure setting details.

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.

OPERATION 4-2 Manual 0-4998

cutmaster 102

STANDOFF

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional

25'

(7.6 m)

SL100

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

SL100

(Mechanized Torch)

80 psi

5.5 bar

Add 5 psi

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.

STANDOFF

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each additional

25'

(7.6 m)

SL100

(Mechanized Torch)

70 psi

4.8 bar

Add 5 psi

0.4 bar

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Section 4T.08 and following for greater details.

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality.

Postﬂow

Release the trigger to stop the cutting arc. Gas continues to ﬂow for approximately 20 seconds. During post - ﬂow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

Shutdown

Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.

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 ow stops.

2. Set the output current to desired amperage with the Output Current Control Knob.

Cutting Operation

When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece. (Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in gouging or trimming 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 0-4998 4-3 OPERATION

cutmaster 102

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4998

cutmaster 102

A-03510_AB

Electrode

Start Cartridge

Tip

Shield Cup

Torch Head

SECTION 4 TORCH:

OPERATION

4T.01 Torch Parts Selection

Depending on the type of operation to be done determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Start Cartridge

NOTE

Refer to Section 4T.07 and following for additional information on torch parts.

Change the torch parts for a different operation as follows:

WARNING

Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies.

NOTE

The shield cup holds the tip and start cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

2. Remove the Electrode by pulling it straight out of the Torch Head.

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.

4. Install the start cartridge and desired tip for

the operation into the torch head.

5. Hand tighten the shield cup assembly until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

1. Unscrew and remove the shield cup assembly from the torch head.

Manual 0-4998 4T-1 OPERATION

cutmaster 102

Kerf Width

Cut Surface Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

4T.02 Cut Quality

NOTES

Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cut-

ting is important when nish cut quality is desired

to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated

in the following gure:

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.03 General Cutting Information

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Cut Quality Characteristics

Cut Surface

The desired or speciﬁed condition (smooth or rough) of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups may create difﬁculties if the material is to be welded after the cutting process.

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

NOTE

Handle torch leads with care and protect them from damage.

Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

OPERATION 4T-2 Manual 0-4998

cutmaster 102

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

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.

Edge Starting

For edge starts, hold the torch perpendicular to the workpiece 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.

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. "Top 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.

4T.04 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE

For best performance and parts life, always use the correct parts for the type of operation.

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 edge along an outside diameter cut, the torch should travel in a clockwise direction.

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 comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting operations.

Manual 0-4998 4T-3 OPERATION

cutmaster 102

A-00024_AB

Shield Cup

Torch

Standoff Distance

1/8" - 3/8" (3 - 9mm)

A-02986

Trigger

Trigger Release

Art # A-03383

Trigger

Trigger Release

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

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.

6. Cut as usual. Simply release the trigger assembly to stop cutting.

7. Follow normal recommended cutting practices as provided in the power supply

operator's manual.

NOTE

3. Hold the torch away from your body.

4. Slide the trigger release toward the back

5. Bring the torch within transfer distance to

Standoff Distance

of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

The gas preﬂow and postﬂow are a characteristic

of the power supply and not a function of the torch.

OPERATION 4T-4 Manual 0-4998

cutmaster 102

A-03539

Non-Conductive

Straight Edge Cutting Guide

A-02986

Trigger

Trigger Release

Art # A-03383

Trigger

Trigger Release

Shield Cup With Straight Edge

The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.

WARNING

The straight edge must be non - conduc-

tive.

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.

piece 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 squeezing the trigger. The pilot arc will start.

7. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

The gas preﬂow and postﬂow are a characteristic of the power supply and not a function of the torch.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm) thick or less.

NOTE

Drag cutting can only be performed at 60 amps or less.

For best parts performance and life, always use the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current.

2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

4. Keep the torch in contact with the work-

Manual 0-4998 4T-5 OPERATION

8. Cut as usual. Simply release the trigger assembly to stop cutting.

9. Follow normal recommended cutting practices as provided in the power supply

operator's manual.

NOTE

cutmaster 102

A-02986

Trigger

Trigger Release

Piercing With Hand Torch

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTES

The gas preﬂow and postﬂow are a characteristic of the power supply and not a function of the torch.

7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage uctuations

• Torch standoff height

• Proper work cable connection

OPERATION 4T-6 Manual 0-4998

cutmaster 102

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

4T.05 Gouging

WARNINGS

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 before disassembling the torch, leads, or power supply.

CAUTION

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.07, Torch Parts Selection.

Pressure Setting

Even though the setting is within the speciﬁed range, if the torch does not pilot well the pressure may need to be reduced.

Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. 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.

Gouging Parameters

Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).

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 information as related to the Power Supply used.

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

Current Setting

Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

Gouging Angle and Standoff Distance

Standoff Distance

The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.

Slag Buildup

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.

Manual 0-4998 4T-7 OPERATION

cutmaster 102

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.

1. To start a cut at the plate edge, position the center of the torch along the edge of the plate.

Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A ﬁve degree leading arc is generally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.

Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

Mechanized Torch Operation

OPERATION 4T-8 Manual 0-4998

cutmaster 102

Start

Cartridge

9-8213

Electrode

9-8215

Tips:

20A 9-8205 30A 9-8206 40A 9-8207 60A 9-8252

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag 70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

Art # A-08065_AB

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

NOTE CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less

4T.07 Parts Selection for Manual and Mechanized Torch Cutting

Manual 0-4998 4T-9 OPERATION

cutmaster 102

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed

Tip

Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 70 4.8 90 245 0.00 0.19 4.8

0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 70 4.8 90 245 0.20 0.19 4.8

0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.19 4.8

0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 70 4.8 90 245 0.50 0.19 4.8

0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 70 4.8 90 245 0.75 0.19 4.8

0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4

0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 70 4.8 90 245 0.20 0.25 6.4

0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 70 4.8 90 245 0.30 0.25 6.4

0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 70 4.8 90 245 0.50 0.25 6.4

0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 70 4.8 90 245 0.80 0.25 6.4

0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 70 4.8 90 245 NR NR NR

OPERATION 4T-10 Manual 0-4998

cutmaster 102

Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 70 4.8 115 340 0.00 0.19 4.8

0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8

0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8

0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 70 4.8 115 340 0.20 0.19 4.8

0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.19 4.8

0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 70 4.8 115 340 0.40 0.19 4.8

0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 70 4.8 115 340 0.60 0.19 4.8

0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 70 4.8 115 340 0.75 0.19 4.8

0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 70 4.8 115 340 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4

0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 70 4.8 115 340 0.80 0.25 6.4

0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 70 4.8 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 70 4.8 115 340 NR NR NR

Manual 0-4998 4T-11 OPERATION

cutmaster 102

Type Torch: Mechanized With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 70 4.8 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 70 4.8 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 70 4.8 115 340 NR NR NR

NOTES

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar. ** Total ﬂow rate includes plasma and secondary gas ﬂow.

OPERATION 4T-12 Manual 0-4998

cutmaster 102

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded

Tip

Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1

0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 70 4.8 90 245 0.20 0.2 5.1

0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.2 5.1

0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 70 4.8 90 245 0.50 0.2 5.1

0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 70 4.8 90 245 0.75 0.2 5.1

0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 70 4.8 90 245 0.80 0.20 5.1

0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

Manual 0-4998 4T-13 OPERATION

cutmaster 102

Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 70 4.8 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 70 4.8 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 70 4.8 115 340 0.50 0.2 5.1

0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.2 5.1

0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 70 4.8 115 340 0.75 0.2 5.1

0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 70 4.8 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 70 4.8 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 70 4.8 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 70 4.8 115 340 0.75 0.25 6.4

0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 70 4.8 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

OPERATION 4T-14 Manual 0-4998

cutmaster 102

Type Torch: Mechanized With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 70 4.8 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 70 4.8 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 70 4.8 115 340 NR NR NR

NOTES

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar. ** Total ﬂow rate includes plasma and secondary gas ﬂow.

Manual 0-4998 4T-15 OPERATION

cutmaster 102

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; D496842; D511280; D492709; D499620; D504142 Other Pat(s) Pending 9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8241 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8243 Shield Cap US Pat No(s) 6914211; D493183 Other Pat(s) Pending 9-8235 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8236 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633 Other Pat(s) 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 4T-16 Manual 0-4998

cutmaster 102

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 0-4998 4T-17 OPERATION

cutmaster 102

This Page Intentionally Blank

OPERATION 4T-18 Manual 0-4998

SECTION 5 SYSTEM:

Warning! Disconnect input power before maintaining.

Each Use

Visual check of torch tip and electrode

Weekly

Visually inspect the torch body tip, electrode, start cartridge and shield cup

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Visually check and Carefully clean the interior

Maintain more often if used under severe conditions

Art # A-07938_AB

5.01 General Maintenance

cutmaster 102

SERVICE

Manual 0-4998 5-1 SERVICE

cutmaster 102

5.02 Maintenance Schedule

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 deminished.

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.

3. Inspect input power cable for damage or exposed wires, replace if necessary.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air ﬁlter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

5.03 Common Faults

Problem - Symptom Common Cause

Insufﬁcient Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

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 workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

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

4. Vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

SERVICE 5-2 Manual 0-4998

Difﬁcult Starting 1. Worn torch parts.

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

cutmaster 102

PSI BAR

MAX MAX

MIN MIN

Art# A-07988

MIN

MAX

5.04 Fault Indicator

At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.

To determine the ﬁrst digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 75 psi indicators are on indicating the version would be 2.3.

Explanation of Faults

UNDER PRESSURE: Indicates that operating pres-

sure is set too low and power supply output power will be disabled.

INPUT POWER: Indicates primary line voltage is

outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit. Low is 208/230 VAC and high is 460 VAC.

PART IN PLACE: Indicates that the shield cup is not

properly installed or tightened.

START ERROR: Indicates that the START SIGNAL

was active (ie. Torch Trigger depressed, hand held pendant switch on or CNC signal for torch on) during one of three (3) conditions:

1) During initial power up when ON/OFF switch is turned to ON position

2) When fault which had been disabling the system is cleared.

3) When the FUNCTION CONTROL SWITCH

When the !"Fault" indicator is on or blinking it will be accompanied by one of the pressure indica-

Mode is moved from SET position to any of the other three (3) modes of operation.

tor lights depending on what the Fault is. Only one of these faults will be displayed at one time. If more than one fault exists, when the ﬁrst fault is corrected and cleared, the next fault will then be displayed. It is possible to have a fault indicated in the function indicators and another fault indictated in the pressure indicators. The following table shows each of the Faults possible.

CONSUMABLES MISSING: Indicates that the elec-

trode, start cartridge or tip is missing or excessively worn.

SHORTED TORCH (OUTPUT FAULT): This indicator

has two modes of operation:

First is the latched Fault mode. The 85 PSI LED blinks

at 1 cycle per second, indicating that one of two

Pressure Indicator

Max Over Pressure

90 Internal Error

85 Shorted Torch

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

Fault explantions are covered in the basic troubleshooting guide later in this chapter.

Fault

NOTE

fault conditions exist.

1) A shorted condition in the torch , leads or consumables.

2) Low or no output voltage from the inverter circuits.

In both cases, to reset the machine, turn the unit

OFF, indentify and clear the problem and turn back ON.

Manual 0-4998 5-3 SERVICE

cutmaster 102

The second mode is a non-latched mode. The 85 PSI

LED blinks at 5 cycles per second, indicating one of three fault modes exists:

1) While using an Automation Torch at current settings above 45 amps, the tip has contacted the work piece

2) Air restriction in torch resulting in low voltage during pilot.

3) Low voltage during cutting due to torch or consumable problem.

In all three cases, to reset the machine, remove the

START signal.

INTERNAL ERROR: Indicates a microprocessor er-

ror.

OVER PRESSURE: Indicates that operating pressure

is set too high. The Error Indicator will not ﬂash when the pressure is above 95 PSI. This LED will remain on and the system will operate but pilot starting and cut performance may be affected.

NOTE

When the unit is turned on the cooling fans MOT1 & MOT2 will remain off. (In earlier units MOT1 will turn on for .one (1) second and then turns off) The fans will turn on when a START signal ( Torch Switch, Remote Pendant switch, or CNC START) is active and will remain on for ten (10) minutes after the START signal is removed. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period after the condition is cleared.

SERVICE 5-4 Manual 0-4998

cutmaster 102

This Page Intentionally Blank

Manual 0-4998 5-5 SERVICE

cutmaster 102

5.05 Basic Troubleshooting Guide

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch is on but the A/C Indicator does not light

1. Primary power disconnect is in OFF position.

2. Primary fuses / breakers are blown or tripped.

3. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualiﬁed person check primary fuses / breakers. b) Connect unit to known good primary power receptacle

3. Return to authorized service center for repair or replacement.

FAULT indicator ﬂashing, 65 PSI indicator ﬂashing. Fan MOT1 is on.

TEMPERATURE indicator on. FAULT indicator ﬂashing.

GAS indicator off, FAULT and MIN pressure indicators ﬂashing.

FAULT and 70 PSI indicators ﬂashing. After 20 seconds fan MOT1 turns on.

1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air ﬂow through or around the unit is obstructed.

2. Duty cycle of the unit has been exceeded

3. Failed components in unit

1. Gas supply not connected to unit.

2. Gas supply not turned on.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

1. Turn off power to unit then set INPUT VOLTAGE SELECTION SWITCH to match primary input voltage.

2. Have qualiﬁed person check primary voltage to insure it meets unit requirements see section 2.04.

3. Return to authorized service center for repair or replacement.

1. Refer to clearance information – section 2.04

2. Allow unit to cool.

3. Return to authorized service center for repair or replacement.

1. Connect gas supply to unit.

2. Turn gas supply on.

3. Set air supply inlet pressure to unit to 120 psi.

4. Adjust regulator to set air pressure - see section 4.02.

5. Return to authorized service center for repair or replacement.

1. Hand tighten the shield cup until it is snug.

2. Insure torch ATC is securely fastened to unit.

3. Replace torch and leads or return to authorized service center for repair or replacement.

4. Return to authorized service center for repair or replacement.

FAULT and 75 PSI indicators ﬂashing.

SERVICE 5-6 Manual 0-4998

1. Start signal is active when ON/OFF SWITCH is turned to ON position.

2. Problem in the torch and leads switch circuit.

3. Failed components in unit.

1. Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low Release the START signal source

2. Replace torch and leads or return to authorized service center for repair or replacement.

3. Return to authorized service center for repair or replacement.

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI indicators ﬂashing. Gas ﬂow is cycling on and off.

Nothing happens when torch switch or remote switch is closed ( Or CNC START signal is active) No gas ﬂow, DC LED OFF.

FAULT indicator ﬂashing and 85 PSI indicators ﬂashing. at 1 cycle per second.

1. Torch shield cup is loose.

2. Torch tip, electrode or start cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads switch circuit.

6. Failed components in unit.

1. Problem in the torch and leads switch circuit (Remote pendant switch circuit).

2. CNC Contoller device not providing Start signal.

3. Failed components in unit.

1. Upper O-Ring on torch head is in wrong position.

2. Torch start cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

1. Tighten shield cup by hand. Do not overtighten.

2. Turn off power supply. Remove shield cup. Install missing parts.

3. Turn off power supply. Bleed 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. Remove shield cup from torch; check upper O-Ring position; correct if necessary.

2. Turn off power supply. Bleed down system pressure. Remove shield cup, tip and start cartridge. Check start cartridge lower end ﬁtting for free movement. Replace if ﬁtting does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service center for repair.

cutmaster 102

FAULT indicator ﬂashing and 85 PSI indicators ﬂashing. at 5 cycles per second

No Fault lights on, no arc in torch.

FAULT and 85 PSI indicators ﬂashing

Pilot arc is on but cutting arc will not establish

Torch cutting is diminished

1. Low output voltage during pilot.

2. Low output voltage during cut.

3.For Automation Torch only: Tip contacted work piece during cut with output currect set above 45 amps.

1. Failed components in unit. 1. Return to an authorized service center for repair.

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that does

1. Work cable not connected to work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1) Check torch consumable parts for wear or foreign debris.*

2) Check torch consumable parts for wear or foreign debris.*

3) Cut with Tip off the plate.*

*For these modes, to reset the machine, remove the START signal.

not clear the fault, return to an authorized service center for repair.

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.

Manual 0-4998 5-7 SERVICE

cutmaster 102

Upper Screws

Lower Screws

Art # A-07947

Slots

5.06 Circuit Fault Isolation

WARNING

The following procedures should not be attempted by anyone who has not had proper training or authorized to do so.

A. Cover Removal

1. Remove the upper and lower screws which secure the cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover.

Note

The upper screws and lower screws are not the same. Do not mix them. The upper screws are for threading into the plastic of the front and rear panels. DO NOT use the ﬁner threaded lower screws for this.

B. Cover Installation

1. Reverse previous procedures for cover installation.

NOTE

When installing the upper screws, attempt to reuse the original threads. The easaiest way to do this is by turning the screw counter-clockwise until you feel the threads lign up, then begin to turn the screw clockwise to tighten to 15-18 in. lbs.. Do not over tighten.

C. Pre Power Up Tests

Prior to applying primary line power to the unit, perform the following checks to prevent component failure or blowing primary fuses. The troubleshooting guide will assume these tests were done and no failure was found or that any failures found were corrected.

1. Main Contactor (W1) Check - Section 5.11 A

2. PCB 1 Input Diode D1 Test - Section 5.11 B

3. PCB 5 Input Diode D1 Test- Section 5.11 C

2. Carefully pull the Cover up and away from the unit.

4. PCB 2 Capacitor / Relay Test - Section 5.11 D

5. PCB 1 IGBT Test - Section 5.11E

6. PCB 5 IGBT Test - Section 5.11 F

7. PCB 1 Output Diode Test - Section 5.11G

8. PCB 5 Output Diode Test - Section 5.11H

9. PCB 1 Pilot IGBT Test - Section 5.11I

If no fault is found in Pre Power-Up Tests 2-6, skip steps 10-14.

If a fault is found in Pre Power-Up Tests 2-6 remove PCB 2 and perform the following Pre Power-Up Tests to determine which PCBs have failed.

10. PCB 2 Capacitor / Relay Test - Section 5.11J

11. PCB 1 Input Diode (D1) Test - Section 5.11K

12. PCB 5 Input Diode (D1) Test - Section 5.11L

13. PCB 1 IGBT Test - Section 5.11M

14. PCB 5 IGBT Test - Section 5.11N

SERVICE 5-8 Manual 0-4998

cutmaster 102

If all of the Pre Power-Up Tests are ok, proceed with the trouble shooting guide.

CAUTION

Due to the close proximity of the Main Pcb to the Capacitor Pcb, It is recommended to use an insulated meter probe when making measurements on the J2 connector on the Main Pcb. Do not short between the pins. Do not short to the Capacitor Pcb connections.

D. Initial Set up Conditions

This section is to help isolate the defective circuit before troubleshooting, identify symptoms, and test the unit for proper operation. Follow the instructions as given to identify the possible symptom(s) and the defective circuit. After repairs are complete, run the following tests again to verify that the unit is fully operational.

1. Connect gas supply to rear of Power Supply.

2. Turn on gas supply and set operating pressure per pressure setting label on power supply.

3. Adjust the pressure regulator to set the gas pressure as speciﬁed in charts.

STANDOFF

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional

25'

(7.6 m)

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each additional

(7.6 m)

SL100

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

25'

SL100

(Mechanized Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

DRAG

SL100

(Mechanized Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

3. Set the Power Supply controls as follows:

• ON/OFF SWITCH to OFF position

• Turn FUNCTION CONTROL SWITCH to SET position

• CURRENT CONTROL POTENTIOMETER to MAXIMUM position, fully clockwise.

E. Main Input and Internal Power Test

1. Connect Primary Line power to the unit.

2. Turn the ON/OFF SWITCH ( SW1) to ON position and observe the following:

• Software version is displayed (See section 5.04

Fault Indicators)

After approx. three (3) seconds

• Inrush relay on PCB1 energizes, starting pre-

charging of working capacitors.

• W1 energizes

• AC and GAS Indicators come on

• Gas ﬂows

4. Turn FUNCTION CONTROL SWITCH to RUN position

• Solenoid turns off, gas stops ﬂowing (pressure

display may increase slightly when gas is not ﬂowing)

This completes the Main Input and Internal Power Test. If the above are all correct then proceed to the next section "F. Pilot Arc Test". If the unit does not function as stated above, then note the symptom and proceed to Section "5.07, Main Input and Internal Power Problems".

• For earlier units, Fan MOT1 turns on for one (1) second then shuts off.

Manual 0-4998 5-9 SERVICE

cutmaster 102

F. Pilot Arc Test

There are three types of START signals which can be used to begin system operation:

1. Hand Torch - Operator switch mounted on the torch handle.

2. Machine torch or Automation torch:

A. Hand heled pendant switch

B. CNC cable interfaced to cotroller.

1. Provide a START signal to establish a pilot arc and note the following

• Cooling fans MOT1-3 turn on.

• Gas solenoid opens

• Gas ﬂows

• After two seconds the gas solenoid closes

and gas stops ﬂowing momentarily, then gas solenoid re-opens and gas resumes ﬂowing

• DC LED comes on

• Pilot arc is established

2. Remove the START signal and not the following

• Gas continues to ﬂow

• DC LED goes off

After 20 second post ﬂow time

• Gas solenoid closes

• Gas ﬂow stops

This completes the Pilot Arc Test. If the above are all correct then proceed to the next section "G, Main Arc and Controls Test". If the unit does not function as stated above, then note the symptom and proceed to Section "5.08, Pilot Arc Problems".

G. Main Arc and Controls Test

Connect work Cable to the work piece, provide a START signal to establish a pilot arc. Bring torch to within 1/8” – 3/8” of the work piece to establish main cutting arc.

• Main Cutting Arc Establishes

• On PCB 1 D59 turns off and D78 turns on

1. Clamp DC ammeter around the work cable. Output will be 100 amps.

• Current adjusts from 100 amps down to 20 amps

3. Set the CURRENT CONTROL POTENTIOMETER to maximum position.

• Current adjusts from 20 amps up to 100

amps

4. While cutting, touch the tip of the torch to the work piece, This is called Drag Mode.

For Hand and Machine Torches:

• Tip Saver circuit will activate, current drops

to 60 amps.

For Automation Torches:

• The Arc will shut off, the FAULT indicator

and the 85 PSI LED will ﬂash at 5 cycles per second. To reset, lift tip off the work piece, remove and re-apply the START signal and go to step 6.

5. Lift tip off the plate approx 1/4”

• Tip Saver circuit deactivates, current goes back

to 100 amps

6. While cutting keep the torch switch closed, bring the torch off the edge of the material.

• Cutting arc extinguishes

• Gas solenoid closes

• Gas flow stops momentarily then restarts

when solenoid opens

• Pilot arc ignites

7. Open the torch switch

• DC LED turns off

After 20 second post ﬂow time

• Gas solenoid closes

• Gas ﬂow stops

8. Set the FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode.

9. Provide a START signal to establish a pilot arc. Bring torch to within 1/8” – 3/8” of the work piece to establish main cutting arc.

10. While cutting keep the torch switch closed and bring the torch off the edge of the material.

2. While cutting, adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to minimum setting.

SERVICE 5-10 Manual 0-4998

cutmaster 102

• Pilot Arc re-ignites immediately

11. Open the torch switch

• DC LED turns off

After 20 second post ﬂow time

• Gas solenoid closes

• Gas ﬂow stops

For Automation Torches - Skip steps 12 & 13

12. Set the FUNCTION CONTROL SWITCH to LATCH mode

13. Start a cut, and remove the START signal.

• Main cutting arc will remain on until the torch

is lifted away from the plate approx ¾” or until the torch is brought off the edge of the metal

Once the arc has extinguished

• DC LED turns off

After 20 second post ﬂow time

• Gas solenoid closes

• Gas ﬂow stops

• Ten (10) minutes after the Start signal is re-

moved, the cooling fans turn off.

This completes the Main Arc and Controls Test. If the above are all correct then proceed to the next section "H CNC Interface Test." If the unit does not function as stated above, then note the symptom and proceed to Section "5.09, Main Arc and Controls Problems".

H. CNC INTERFACE TEST

If the unit has one of the two factory supplied options for CNC interface installed, proceed with this section, otherwise the tests are complete.

1. Connect an ohmmeter between 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).

• Pilot arc is established

2. Bring the torch to the work piece and transfer to cutting arc.

• OK-TO-MOVE signal is present. (Meter shows

continuity)

3. Remove jumper from J6.

• OK-TO-MOVE signal off (Meter shows no

continuity)

• Gas continues to ﬂow

• DC LED goes off

After 20 second Post ﬂow time

• Gas solenoid closes

• Gas ﬂow stops

If the unit has the Basic CNC Interface harness the test is complete. If the unit does not function as stated above, then note the symptom and proceed to Section "5.10 CNC Interface Problems".If the unit has the Automation Interface PCB installed, continue with this section.

4. There are three (3) ARC VOLTs signals available from the J6 connector.

a) J2-9 (+) to J2-7 (-)

b) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-

nector with jumper installed between pins 1 and 2) = ARC VOLTS divided by 50

c) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-

nector with jumper installed between pins 2 and 3) = ARC VOLTS divided by 16

Measure the voltage between these points while piloting (Open Circuit Voltage) and while cutting. The voltages should approx as listed below

Open Circuit Voltage Cutting Voltage

a) 300 VDC 100 VDC

b) 6 VDC 2 VDC

c) 19 DVC 6 VDC

Manual 0-4998 5-11 SERVICE

cutmaster 102

Art # A-08493

Input Power Cable Connections

Three-Phase (3ø)

Store copper jumpers on base plate

Single-Phase (1ø) and Jumper Settings

GND

This completes the CNC Interface Test. If the above are all correct then the unit is functioning correctly. If the unit does not function as stated, then note the symptom and proceed to Section "5.10, CNC Interface Problems".

5.07 Main Input and Internal Power Problems

A. Primary input line fuse blows as soon as

primary disconnect is closed.

1. Primary input cable installed incorrectly.

a) Check wiring of primary power cable to the

contactor. See illustration below.

2. W1 jumpers installed incorrectly

a) Check jumper installation for correct phase

being used.

C. Gas ﬂows with ON/OFF SWITCH in OFF

position

1. Foreign debris has lodged in gas solenoid.

a) Replace gas solenoid. This is a problem caused

by improperly ﬁltered air supply. Customer needs to add ﬁltration to air supply prior to unit inlet.

D. All front panel indicators are off, Fan MOT1

never turns on. Main Contactor W1 does not close.

1. Primary power not connected.

a) Check that cable is connected to primary

power.

2. Primary line fuse/breaker is blown/tripped.

a) Replace fuse or reset breaker.

3. Defective ON/OFF SWITCH

a) Check continuity

4. Defective Main PCB 1

Single and Three Phase Input Power Wiring

3 W1 contactor points are stuck closed

a) Check per section 5.11A

4. Primary plug not wired correctly.

a) Check manufacturer's plug installation instruc-

tions.

5. Primary input cable is defective.

a) Check cable for shorts.

B. Primary line fuses blow immediately after

ON/OFF SWITCH (SW1) is turned to ON position.

1. Shorted Input Diode Module

a) Check per section 5.11B and 5.11C

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

6. Defective Logic

a) Replace Logic PCB 3

2. Shorted Input Capacitor PCB 2

a) Check per section 5.11D

SERVICE 5-12 Manual 0-4998

cutmaster 102

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

E. UNDER PRESSURE FAULT. AC LED on,

FAULT INDICATOR and 60 PSI Indicator ﬂashing.

1. Air pressure source to unit is too low.

a) Set input pressure source to 90-100PSI.

2. Regulator set too low.

a) Adjust unit regulator to increase pressure.

3. Defective Logic PCB 1

a) Measure for 5VDC on the Logic PCB 3 between

J3-3 to J3-1. Replace Logic PCB 3 if voltage is not present or low.

b) Measure for voltage on the Logic PCB 3 be-

tween J3-2 to J3-1. If the voltage is between 3-4.5VDC, replace the Logic PCB 3.

4. Defective Pressure Transducer

a) Replace Pressure Transducer

F. INPUT POWER FAULT. AC LED on, FAULT

Indicator and 65 PSI LED ﬂashing.

1. INPUT VOLTAGE SELECTOR SWITCH (SW2) set for incorrect voltage

5. Defective Ribbon cable.

a) Check continuity of the ribbon cable connect-

ing between the Main PCB 1 and the Logic PCB 3.

6. Defective Logic PCB 3.

a) Replace Logic PCB 3.

G. PARTS-IN-PLACE (PIP) FAULT. The FAULT

Indicator and 70 PSI LED ﬂashing, After 20 seconds fan MOT1 turns on.

1. Shield Cup loose

a) Hand tighten the shield cup to close the PIP

switch.

2. Torch not properly connected to power supply

a) Insure torch ATC is securely fastened to unit.

3. Problem with torch and leads PIP circuit

a) Disconnect the Torch from the unit and check

continuity of torch PIP circuit at ATC pins 1 & 2. If open, check torch and leads for open lead or PIP switch.

a) Set SW2 to correspond to the primary line

voltage. Turn SW1 to OFF position then back to ON position to clear the error.

2. Defective SW2

a) Check continuity

3. Primary line voltage out of tolerance range.

a) Connect unit to voltage with unit speciﬁca-

tions. See section "2.04 Power supply speciﬁcations". If using a generator, connect unit to a wall receptacle to see if problem is corrected.

4. Defective Main PCB 1

a) Measure voltage on Main PCB 1 between test

point GND1 to J2-22.

460 VAC input = approx 3 VDC

230 VAC input = approx 1.5 VDC

b) With all power removed from the unit, dis-

connect the ribbon cable from J2 connector on Main PCB 1. Check continuity on PCB 1 between J2-34 to test point GND 1. With SW2 in LOW position continuity should be present, with SW2 in the HIGH position. It should read open

If not correct, replace Main PCB 1.

4. Defective Logic Pcb

a) Measure the voltage on Main Pcb between J2-17

to test point GND1 for 12VDC. If the voltage is less than 2VDC, Replace Logic Pcb

5. Defective Main PCB 1

a) Replace Main PCB 1

Manual 0-4998 5-13 SERVICE

cutmaster 102

Art # A-08064

Spring-Loaded Lower End Fitting Full Compression 1/8”

Spring-Loaded Lower End Fitting at Rest / Full Extension

H. START ERROR FAULT. The FAULT

Indicator and 75 PSI LED ﬂashing.

1. Start signal is active when SW1 is turned to ON position.

a) START can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low

Release the START signal source.

2. Problem in the torch and leads switch circuit

a) Check continuity of torch switch circuit at ATC

pins 3 & 4. See previous illustration.

3. Short in CNC cable

a) Check continuity

4. Defective Logic Pcb (PCB3)

a) Measure voltage at Main PCB between J2-16

to test point GND1 for 12VDC. If voltage is present, replace Logic PCB

4. Open conductor in torch leads

a) Check continuity

5. Defective Main PCB 1.

b) Measure voltage at Main Pcb between J2-2

to test point GND1 for 12VDC. If voltage is present, replace Main PCB 1.

6. Defective Logic PCB 3.

a) Replace Logic PCB 3.

J. AC LED on, yellow TEMP LED is on, red

FAULT Indicator is ﬂashing all three fans turn on.

1. Air ﬂow through unit is restricted.

a) Provide adequate airflow. See Ventillation

Clearance Requirements section 2.04.

2. Exceeded duty cycle of the power supply.

a) Allow unit to remain on, but at idle, with fan

running to cool power supply. See Power Supply Speciﬁcations section 2.04 for duty cylcle information.

5. Defective Main PCB 1.

a) Replace Main PCB 1.`

I. 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 start cartridge missing.

a) Turn off power supply. Replace missing

part(s).

3. Start Cartridge is stuck.

a) Turn off power supply. Bleed down the system.

Remove the shield cup, tip,start cartridge and electrode. Check the lower end unit of the start cartridge for free movement. Replace the cartridge if the lower end unit does not move freely.

NOTE

3. Defective 40A PCB 5.

Measure for 12VDC on the 40A PCB 5 between

J4-4 to J4-10. Replace 40A PCB 5 if voltage is not present.

4. Defective Main PCB 1.

a) Measure for 12VDC on Main PCB 1 between

J2-21 to TP GND1. Replace Main PCB 1 if voltage is not present.

5. Defective Logic PCB 3.

a) Change Logic PCB 3.

SERVICE 5-14 Manual 0-4998

cutmaster 102

K. AC LED on, TEMP, GAS, DC LED's are off,

FAULT Indicator is ﬂashing. MIN PRESSURE

LED is ﬂashing.

1. Gas supply not connected to unit.

a) Connect gas supply to unit.

2. Gas supply not turned on.

a) Turn gas supply on.

3. Gas supply pressure too low.

a) Set gas supply pressure to 95-120psi.

4. Air Pressure Control Regulator set too low.

a) Adjust AIR PRESSURE CONTROL to set

pressure as speciﬁed in section 4.02 Setting Operational Pressure.

5. Faulty Pressure Transducer.

a) a) Adjust pressure Regulator to maximum.

Measure voltage on Logic PCB 1 beween J3-1 to J3-2 If voltage is more than 2VDC Replace Pressure Transducer.

6. Faulty Logic PCB 3.

a) Replace Logic PCB 3.

L. 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.

1. Faulty Logic PCB 3.

a) Replace Logic PCB 3.

M. MAX PRESSURE ERROR

MAX Pressure LED is lit.

1. Gas pressure set too high.

a) Reduce gas pressure.

2. Pressure Regulator set too high.

a) Adjust Pressure Reulator.

2. Defective Pressure Transducer.

a) Adjust pressure Regulator to minimum. Mea-

sure voltage on Logic PCB 1 beween J3-1 to J3-2 If voltage is more than 4 VDC Replace Pressure Transducer.

N. AC LED on, TEMP LED off, GAS LED on,

Gas ﬂows. DC LED & FAULT indictor off. W1 contactor does not energize.

1. Defective W1 Contactor.

a) Measure for 24VAC between wire #5 to wire #

6 on W1. If voltage is present replace W1.

2) Defective Logic PCB 3.

a) Measure voltage on Main PCB 3 between J2-9

to GND1. If voltage is 12VDC, Replace the Logic PCB 3.

3) Defective Main PCB 1.

a) Replace Main PCB 3.

O. AC LED on, TEMP LED off, GAS LED on,

Gas does not ﬂow in SET mode using a hand torch or a machine torch without remote solenoid.

1. Defective gas solenoid (SOL1)

a) Measure voltage on Main PCB 1 between

J5-1 to J5-3 for 12 VDC. If voltage is present, change SOL 1

2. Defective Logic Pcb

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.

P. 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 is present, change SOL 1

2. Defective Logic PCB 3.

a) Measure on Main PCB between J2-12 to test

point GND1 for 12VDC. If voltage is present, replace Main PCB 1.

3. Defective Logic PCB

a) Replace Logic PCB.

Manual 0-4998 5-15 SERVICE

cutmaster 102

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

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 SOL2.

5. Defective Main PCB 1.

a) Measure on Main PCB between J2-20 to GND1

for less than 2VDC.

If voltage is 12VDC replace Main PCB 1

b) Measure on Main PCB between J2-11 to GND1

for less than 2VDC. If voltage is less than 2VDC replace Main PCB

6. Defective Logic PCB 3.

a) Measure on Main PCB 1 between J2-11 to GND1

for less than 2VDC. If voltage is 12vdc, replace Logic PCB 3.

Q. Cannot adjust gas pressure.

1. Inlet gas pressure is too low

a) Increase inlet gas pressure to 95-120 psi

2. Faulty regulator.

a) Replace Regulator.

3. Faulty Pressure transducer. (Air ﬂow changes but display does not)

a) Measure on Main PCB between J2-11 to GND1

while adjusting thePressure regulator from Min to Max. VOltage should adjust from 0-

4.5VDC. If voltage does not change, Replace the Pressure Transducer.

4) Faulty Logic PCB 3.

a) Replace PCB 3.

5.08 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.

1. Problem in the torch and leads switch circuit (or remote pendant or CNC signal missing

a) For hand torches, Check continuity of torch

switch circuit at ATC pins 3 & 4.

b) For machine torches using a remote pendant,

Check continuity of Pendant switch circuit

c) Check CNC START signal

2. Defective Logic PCB

a) Jumper on Main PCB between J2-16 and test

point GND1. If gas does not ﬂow, replace Logic PCB

b) With START signal active, measure voltage

on Main PCB between test points GND1 to I_DMD1 for 1.4VDC. Replace Logic PCB if voltage is not present.

3. Defective Main PCB

a) With START Signal active, measure voltage

on Main PCB between test points GND1 to I_DMD1 for 1.4 VDC. Replace Main PCB if voltage is present.

SERVICE 5-16 Manual 0-4998

cutmaster 102

Upper Groove with Vent Holes Must Remain Open

Threads

Upper O-Ring in Correct Groove

Lower O-Ring

Art # A-03725

Art # A-08064

Spring-Loaded Lower End Fitting Full Compression 1/8”

Spring-Loaded Lower End Fitting at Rest / Full Extension

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

B. SHORTED TORCH (OUTPUT) FAULT.

Fault indicator and 85 PSI Indicators are ﬂashing at 1 cycle per second.

This is a Latched Failure Mode. After START signal is activated, gas ﬂows for two (2) seconds then momentarily shuts off then back on, FAULT INDICATOR ﬂashes, and 85 PSI LED ﬂashes. To reset the machine, turn the unit OFF, indentify and clear the problem and turn back ON.

1. Upper O-Ring on torch head is in the wrong position.

a) Remove shield cup from torch; check position

of the upper o-ring and correct if needed.

4. Shorted Torch/leads

a) Disconnect torch from unit. With consumables

removed from the torch, Check continuity of torch at ATC, between negative/plasma lead connection to pilot lead connection.

If a short is found, the problem is in the torch

and leads assembly. Remove the torch head from the leads and check the leads and head to determine which is defective.

5. Defective 40Amp PCB 5.

2. Torch start cartridge is stuck.

3. Worn or faulty torch parts

a) Turn off power supply. Bleed down the system.

Remove the shield cup, tip,start cartridge and electrode. Check the lower end unit of the start cartridge for free movement. Replace the cartridge if the lower end unit does not move freely.

a) Inspect torch consumables parts. Replace if

necessary.

a) Disconnect and isolate the wire from the

CHOKE1 connection on the 40Amp PCB 5. Supply a START signal. If the FAULT is not present, replace the 40 AMP PCB 5.

6. Defective Main PCB 1.

a) Replace Main PCB 1.

C. SHORTED TORCH FAULT. Fault indicator

and 85 PSI Indicators are ﬂashing at 5 cycles per second.

This mode is a non-latched mode.

1. While using an Automation Torch at current settings above 45 amps, the tip has contacted the work piece.

a) Check standoff height

2. Air restriction in torch resulting in low voltage during pilot.

a) Check torch consumables for wear or debris.

3. Low voltage during cutting due to torch or consumable problem.

a) Check torch consumables for wear or debris.

Manual 0-4998 5-17 SERVICE

In all three cases, to reset the machine, remove the

START signal.

cutmaster 102

D. AC LED on, TEMP LED off, GAS LED on,

gas ﬂowing, DC LED, & Fault Indicator off, No arc in torch.

1. Defective Main Pcb

a) On Main PCB 1, LED D59 should be on and

LED D78 should be off. If LEDs are incorrect Replace Main PCB 1.

2. Defective Logic PCB 3.

a) Measure voltage at Main PCB 1 between test

point GND1 (or GND2) to J2-10.

Voltage is normally 12VDC and should drop to less than 2VDC two (2) seconds after START signal is activated. If voltage does not drop replace Logic PCB 3

3. Defective Main PCB 1.

a) Replace Main PCB 1.

E. AC LED on, TEMP LED off, GAS LED on,

gas ﬂowing, DC LED on, Fault Indicator off, No arc in torch.

1. Defective Main PCB 1.

a) Install jumper on Main PCB 1 between test

point GND1 to terminal TIP1.

b) Apply START signal. If Pilot starts, replace

Main PCB 1.

G. Fans MOT1-3 do not not turn on after a

START signal is activated.

1. Defective Logic PCB 3.

a) Measure voltage at J1-14 to J1-25 on Logic PCB

3 for 12VDC. The voltage should drop to less than 2vdc after a START signal is active. If the voltage remains at 12VDC replace the Logic PCB 3.

NOTE

When the unit is turned on the cooling fans MOT1-3 will remain off. (In earlier units MOT1 will turn on for .one (1) second and then turns off) The fans will turn on when a START signal ( Torch Switch, Remote Pendant switch, or CNC START) is active and will remain on for ten (10) minutes after the START signal is removed. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period after the condition is cleared.

2. Measure for 12VDC on the Logic PCB 3 between J7-1 to J7-1 after the START signal is activated. If voltage is not present replace Main PCB 1.

H. Fan MOT1 does not turn on after START

signal is activated. (MOT2 & MOT3 do turn on)

E. AC LED on, TEMP LED off, GAS LED on,

gas ﬂowing, DC LED on, Fault Indicator off, Pilot Arc is intermittent.

1. Defective Main contactor W1.

a) Check W1 per Pre Power-UP checks.

2. Defective Logic PCB 3

a) Measure for 12VDC on Main PCB between

test Point GND1 to J2-8. If 12VDC is present, replace Logic PCB 3.

3 Defective Main PCB 1.

a) Replace Main PCB 1.

F. INTERNAL ERROR. Fault Indicator and 90

PSI Indicators are ﬂashing.

1. There has been a microprocessor problem.

a) Turn ON/OFF SWITCH to OFF position and

then turn to ON position to clear the error.

2. Defective Logic PCB 3.

a) Replace Logic PCB 3.

1. Defective Main PCB 1

a) Turn SW1 to off position. Turn SW1 back to

ON position and measure for 12VDC between J7-1 to J7-2 before START signal is activated. If no voltage is present, Replace Main PCB 1.

2. Defective MOT1

a) Check to be sure there is no physical obstruc-

tions preventing MOT1 fan blades from turning. Replace MOT1.

I. Either MOT2 or MOT3 do not turn on after

START signal is activated.

1. Fan wires not connected to 40A PCB

a) Check and reconnect to 40A PCB 5.

2. Defective fan.

a) Check to be sure there is no physical obstruc-

tions preventing fan blades from turning. Replace respective fan.

J. Fans MOT2 & MOT3 do not turn on after

START signal is activated.

1. Defective Capacitor PCB 2

SERVICE 5-18 Manual 0-4998

cutmaster 102

a) Measure for 12VDC between J2-1 to J2-2 on

PCB 2. If no voltage is present , replace Capacitor PCB 2.

2. Open connection between Capacitor PCB 2 J2 and 40A PCB 5 J3.

a) Verify connectors are plugged in.

Check continuity

3. Open connection between Main PCB 1 J13 to 40A PCB 5 J4.

a) Verify connectors are plugged in. Check con-

tinuity

b) Measure voltage at J4-2 to J4-10 on 40AMP PCB

5 for 12VDC. The voltage should drop to less than 2vdc after a START signal is active. If the 12VDC is not present or does not drop to less than 2VDC after a START signal is activated, then replace the ribbon cable.

4. Defective 40AMP PCB 5

a) Measure the voltage between J1-1 to J1-2 on

the 40AMP PCB 5 for 12VDC after the START signal is activated. If 12VDC is present replace 40AMP PCB 5.

5. Defective Fans MOT2 and 3.

a) If 12VDC is resent on J1 and J2 connectors on

40A PCB 5, replace fans MOT2 & MOT3.

B. Main arc transfers but current cannot be

adjusted.

1. Defective Logic PCB 3.

a) While main arc is transferred,measure voltage

on Main PCB between test points GND1 to I_DMD1.

b) Adjust CURRENT CONTROL POTENTIOM-

ETER from maximum to minimum. Voltage should vary from 4VDC at max to 1 VDC at min

If voltage does not vary with CURRENT CONTROL

POTENTIOMETER, Replace Logic PCB 3.

2. Defective Main PCB 1.

a) Replace Main PCB 1.

C. In LATCH mode, when the torch switch is

released the arc shuts off immediately.

1. Defective Logic PCB`3

a) Replace Logic PCB`3

D. With CURRENT CONTROL

POTENTIOMETER set at maximum, output current is only 60 amps.

1. Tip is touching the work piece, Drag mode.

a) Lift tip off work piece

5.09 Main Arc and Controls Problems

A. Main arc will not establish, LED D59 on

Main PCB remains on while pilot arc is striking the work piece.

1. Work Cable not connected.

a) Connect cable to work piece

2. Work cable open / broken.

a) Check continuity of work cable. Insure connec-

tion of cable to clamp is secure.

2. Defective Pilot IGBT on Main PCB 1

a) Check per section 4.10I

3. Open Sync cable between J14 on Main PCB 1 and 40Amp PCB 5.

a) Check continuity and replace if open..

4. Open ribbon cable between Main PCB 1 and logic PCB 3.

a) Check continuity.

5. Defective 40Amp PCB 5.

a) Replace 40Amp PCB 5

E. In RAPID AUTO RESTART mode, with

torch switch closed, the pilot does not start immediately when the cutting arc extinguishes

1. Defective Logic PCB 3

a) Replace Logic PCB 3

Manual 0-4998 5-19 SERVICE

cutmaster 102

Actuator Arm

Cover Screws

Input

CutMaster 52 & 82

W1 contactor wired for 1PH

Main Contactor

Jumpers

Actuator Button

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

2. Defective Logic PCB 3.

a) Replace Logic PCB 3.

5.10 CNC Interface Problems

A. Nothing happens when jumper is installed

between J2-3 to J2-4.

1. Defective Automation Interface PCB 4.

a) Measure voltage on PCB4 between J1-6 to J1-8

for 12VDC.

If 12VDC is present replace Automation Interface

PCB 4

2. Defective Main PCB 1.

a) Measure voltage on Main PCB 1 between J1-6

to J1-8 for less than 2VDC.

5.11 Test Procedures

A. Main Contactor (W1) Test

1. Check continuity between:

L1 to T1

L2 to T2

L3 to T3

L4 to T4

The contacts should be open – no continuity. If continuity is found, disconnect J1 from the Main PCB 1 and recheck. If continuity still exists, replace W1. If disconnecting J1 from Main PCB 1 removes the short, replace the Main PCB 1.

If voltage is less than 2VDC, replace Main PCB`1.

B. No OK-TO-MOVE signal while cutting.

1. Defective Main PCB`1

a) Measure voltage on PCB4 between J1-1 to J1-3

for 12VDC while cutting.

If 12VDC is present, replace PCB 1

2. Defective Automation Interface PCB 4

a) Measure voltage on PCB 4 between J1-1 to J1-3

for less than 2VDC while cutting.

If voltage is less than 2VDC, replace PCB 4.

C. ARC VOLTS signals are low or not present

1. Defective Automation Interface PCB 4

a) Replace PCB`4

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 previous illustration. If contacts are stuck together or show excessive arcing or pitting, replace W1.

SERVICE 5-20 Manual 0-4998

cutmaster 102

B. PCB 1 Input Diode D1Test

1. Using an ohmmeter perform the tests in the chart:

Input Diode Module D1 on PCB1

Test points located on PCB 2

Meter (+) Meter (-) Indication

80A _AC1 MTH 1 Forward Biased Diode

80A_AC2 MTH 1 Forward Biased Diode

80A_AC3 MTH 1 Forward Biased Diode

MTH 1 80A_AC1 Reverse Biase Diode

MTH 1 80A_AC2 Reverse Biase Diode

MTH 1 80A_AC3 Reverse Biase Diode

MTH 7 80A_AC1 Forward Biased Diode

MTH 7 80A_AC2 Forward Biased Diode

MTH 7 80A_AC3 Forward Biased Diode

80A_AC1 MTH 7 Reverse Biase Diode

80A_AC2 MTH 7 Reverse Biase Diode

80A_AC3 MTH 7 Reverse Biase Diode

MTH 7 MTH 1 2 Forward Biased Diodes

C. PCB 5 Input Diode D1 Test

1. Using an ohmmeter perform the tests in the

chart:

Input Diode Module D1 on PCB5

Test points are located on PCB2

Meter (+) Meter (-) Indication

40A _AC1 PMTH 1 Forward Biased Diode

40A_AC2 PMTH 1 Forward Biased Diode

40A_AC3 PMTH 1 Forward Biased Diode

PMTH 1 40A_AC1 Reverse Biase Diode

PMTH 1 40A_AC2 Reverse Biase Diode

PMTH 1 40A_AC3 Reverse Biase Diode

PMTH 4 40A_AC1 Forward Biased Diode

PMTH 4 40A_AC2 Forward Biased Diode

PMTH 4 40A_AC3 Forward Biased Diode

40A_AC1 PMTH 4 Reverse Biase Diode

40A_AC2 PMTH 4 Reverse Biase Diode

40A_AC3 PMTH 4 Reverse Biase Diode

PMTH 4 PMTH 1 2 Forward Biased Diodes

D. PCB 2 Capacitor / Relay Test

1. Using an ohmmeter perform the tests in the chart:

INPUT CAPACITORS

PCB 2

Meter + Meter - Indication

MTH 2 MTH 4 Charging MTH 8 MTH 7 Charging

Most meters will show a charging action. Initially a low resistance will be shown and then the reststance will start to increase. If the meter probews are reversed the reading will decrease to zero, then start charging in the opposite polarity.

2. Using an ohmmeter perform the tests in the chart:

INPUT VOLTAGE SELECTION RELAYS

PCB 2

Meter + Meter - Indication

MTH 7 MTH 4 Charging MTH 8 MTH 2 Charging MTH 8 MTH 4 Charging

E. PCB 1 IGBT Test

1. Disconnect transformer wire from PCB 2 Terminal PRI1 (A).

2. Using an ohmmeter check continuity between the following points:

PCB 1 Q1

Test points located on PCB 2

Meter (+) Meter (-) Indication

PRI 1 MTH 2 Forward Bias

PRI 1 MTH 4 Capacitor Charging

MTH 2 PRI 1 Capacitor Charging

MTH 4 PRI 1 Forward Bias

PRI 2 MTH 2 Forward Bias

PRI 2 MTH 4 Capacitor Charging

MTH 2 PRI 2 Capacitor Charging

MTH 4 PRI 2 Forward Bias

Manual 0-4998 5-21 SERVICE

cutmaster 102

3. Using an ohmmeter check continuity between the following points:

PCB 1 Q2

Test points located on PCB 1* & PCB 2

Meter (+) Meter (-) Indication

PRI 3* MTH 8 Forward Bias

PRI 3* MTH 7 Capacitor Charging

MTH 8 PRI 3* Capacitor Charging

MTH 7 PRI 3* Forward Bias

PRI 4* MTH 8 Forward Bias

PRI 4* MTH 7 Capacitor Charging

MTH 8 PRI 4* Capacitor Charging

MTH 7 PRI 4* Forward Bias

F. PCB 5 IGBT Test

1. Disconnect transformer wires from 40 Amp PCB 5 terminal PRI 1 (A).

2. Using an ohmmeter perform the following checks:

PCB 5 - Q1

Test points located on PCB 2 AND PCB 5*

Meter (+) Meter (-) Indication

PRI 1* PMTH 1 Forward Bias

PRI 1* PMTH 2 Capacitor Charging

PMTH 1 PRI 1* Capacitor Charging

PMTH 2 PRI 1* Forward Bias

PRI 2* PMTH 1 Forward Bias

PRI 2* PMTH 2 Capacitor Charging

PMTH 1 PRI 2* Capacitor Charging

PMTH 2 PRI 2* Forward Bias

3. Disconnect transformer wire from 40 Amp PCB 5 terminal PRI4 (C).

4 Using an ohmmeter perform the following

checks:

PCB 5 – Q2

Test points located on PCB 2 AND PCB 5*

Meter (+) Meter (-) Indication

PRI 4* PMTH 3 Forward Bias

PRI 4* PMTH 4 Capacitor Charging

PMTH 3 PRI 4* Capacitor Charging

PMTH 4 PRI 4* Forward Bias

PRI 3* PMTH 3 Forward Bias

PRI 3* PMTH 4 Capacitor Charging

PMTH 3 PRI 3* Capacitor Charging

PMTH 4 PRI 3* Forward Bias

G. PCB 1 Output Diode D3 Test

1. Disconnect transformer wires from Main PCB 1 terminal SEC1.

2. Using an ohmmeter perform the following checks:

PCB 1 D3

(Test points located on PCB 1* & PCB 2)

Meter (+) Meter (-) Indication

CHOKE1 SEC1 Forward Bias

CHOKE1 SEC2 Forward Bias

SEC1 CHOKE1 Reversed Bias

SEC2 CHOKE` Reversed Bias

WORK1 SEC1 Reversed Bias

WORK1 SEC2 Reversed Bias

SEC1 WORK1 Forward Bias

SEC2 WORK1 Forward Bias

H. PCB 5 Output Diode D2 Test

1. Disconnect transformer wires from Main PCB 5 terminal SEC1.

2. Using an ohmmeter perform the following checks::

PCB 5 – D2

Test points located on PCB 5

Meter (+) Meter (-) Indication

CHOKE1 SEC1 Forward Bias

CHOKE1 SEC2 Forward Bias

SEC1 CHOKE1 Reversed Bias

SEC2 CHOKE1 Reversed Bias

+OUT_1 SEC1 Reversed Bias

+OUT_1 SEC2 Reversed Bias

SEC1 +OUT_1 Forward Bias

SEC2 +OUT_1 Forward Bias

I. PCB 1 Pilot IGBT Test

1. Disconnect wire E35 from Main PCB 1 terminal TIP1.

2. Using a mutlimeter with a diode test scale, place the positive probe on PCB 1 terminal TIP1 and the negative probe on PCB 1 terminal WORK1. and check for a forward biased diode reading.

3. If the test reveals a failed component, replace Main PCB 1. If no problem is found, reconnect wire to Main PCB.

SERVICE 5-22 Manual 0-4998

cutmaster 102

J. PCB 2 Capacitor / Relay Test (with PCB2

removed from the unit)

1. Using an ohmmeter perform the following checks::

PCB 2 Capacitor & Relay Test

Meter + Meter - Indication

MTH 2 MTH 4 Charging MTH 8 MTH 7 Charging MTH 7 MTH 4 Open MTH 8 MTH 2 Open MTH 8 MTH 4 Open

charging in the opposite polarity.

2. If test reveals a failed component, replace Capacitor PCB 2.

K. PCB 1 Input Diode Test. ( With PCB 2

removed form unit)

L. PCB 5 Input Diode Test. ( With PCB 2

removed form unit)

1. Using an ohmmeter perform the following checks::

Input Diode Module D1 on PCB5

Test points are located on PCB5

Meter (+) Meter (-) Indication

AC1 PMTH 1 Forward Biased Diode

AC2 PMTH 1 Forward Biased Diode

AC3 PMTH 1 Forward Biased Diode

PMTH 1 AC1 Reverse Biase Diode

PMTH 1 AC2 Reverse Biase Diode

PMTH 1 AC3 Reverse Biase Diode

PMTH 4 AC1 Forward Biased Diode

PMTH 4 AC2 Forward Biased Diode

PMTH 4 AC3 Forward Biased Diode

AC1 PMTH 4 Reverse Biase Diode

AC2 PMTH 4 Reverse Biase Diode

AC3 PMTH 4 Reverse Biase Diode

PMTH 4 PMTH 1 2 Forward Biased Diodes

2. If the test reveals a failed component, replace

1. Using an ohmmeter perform the following

Main PCB 5.

checks::

Input Diode Module D1 on PCB1

Test points located on PCB 1

Meter (+) Meter (-) Indication

AC1 TP2 Forward Biased Diode

AC2 TP2 Forward Biased Diode

AC3 TP2 Forward Biased Diode

TP2 AC1 Reverse Biase Diode

TP2 AC2 Reverse Biase Diode

TP2 AC3 Reverse Biase Diode

TP8 AC1 Forward Biased Diode

TP8 AC2 Forward Biased Diode

TP8 AC3 Forward Biased Diode

AC1 TP8 Reverse Biase Diode

AC2 TP8 Reverse Biase Diode

AC3 TP8 Reverse Biase Diode

TP8 TP2 2 Forward Biased Diodes

2. If the test reveals a failed component, replace Main PCB 1.

M. PCB 1 IGBT Test. ( With PCB 2 removed

from unit)

1. Using an ohmmeter perform the following checks::

PCB 1 Q1

Test points located on PCB 1

Meter (+) Meter (-) Indication

PRI 1 TP1 Forward Biased Diode PRI 1 TP5 Reverse Biased Diode

TP1 PRI 1 Reverse Biased Diode

TP5 PRI 1 Forward Biased Diode PRI 2 TP1 Forward Biased Diode PRI 2 TP5 Reverse Biased Diode

TP1 PRI 2 Reverse Biased Diode

TP5 PRI 2 Forward Biased Diode

PCB 1 Q2

Test points located on PCB 1

Meter (+) Meter (-) Indication

PRI 3 TP4 Forward Biased Diode

PRI 3 TP8 Reverse Biased Diode

TP4 PRI 3 Reverse Biased Diode

TP8 PRI 3 Forward Biased Diode

PRI 4 TP4 Forward Biased Diode

PRI 4 TP8 Reverse Biased Diode

MTH 8 TP4 Reverse Biased Diode

MTH 7 TP8 Forward Biased Diode

3. If the test reveals a failed component, replace Main PCB 1.

Manual 0-4998 5-23 SERVICE

cutmaster 102

N. PCB 5 IGBT Test. ( With PCB 2 removed

from unit)

1. Using an ohmmeter perform the following checks::

PCB 5 - Q1

Test points located on PCB 5

Meter (+) Meter (-) Indication

PRI 1 PMTH 1 Forward Biased Diode

PRI 1 PMTH 2 Reverse Biased Diode

PMTH 1 PRI 1 Reverse Biased Diode

PMTH 2 PRI 1 Forward Biased Diode

PRI 2 PMTH 1 Forward Biased Diode

PRI 2 PMTH 2 Reverse Biased Diode

PMTH 1 PRI 2 Reverse Biased Diode

PMTH 2 PRI 2 Forward Biased Diode

PCB 5 – Q2

Test points located on PCB 5

Meter (+) Meter (-) Indication

PRI 4 PMTH 3 Forward Biased Diode

PRI 4 PMTH 4 Reverse Biased Diode

PMTH 3 PRI 4 Reverse Biased Diode

PMTH 4 PRI 4 Forward Biased Diode

PRI 3 PMTH 4 Forward Biased Diode

PRI 3 PMTH 3 Reverse Biased Diode

PMTH 4 PRI 3 Reverse Biased Diode

PMTH 3 PRI 3 Forward Biased Diode

2. If the test reveals a failed component, replace 40Amp PCB 5.

NOTE

Many of the signals listed in the PCB information to follow will be low voltage signals that will be in one of two states: +12VDC (High) or 0VDC (Low) with respect to pcb common.. When a signal name is preceded by the “/” mark, it denotes that the signal is an active low. For example:

/OVERTEMP – This signal is normally High but when an over temperature fault exists, this line will change state to a Low.

SERVICE 5-24 Manual 0-4998

cutmaster 102

This Page Intentionally Blank

Manual 0-4998 5-25 SERVICE

cutmaster 102

J10 J9

D78

J14

D59

GND2

+48V1

CHOKE1

SEC2

SEC1

TIP1

PRI_3

ELECTRODE1

-V_OUT1

J4 J3

TP8

TP7

J13

J12

TP3

I_DMD1

GND1

+12V1

+12V2

+48V2

TP6

PRI_2

TP5

AC3

AC1

AC2

WORK_1

PRI_1

PRI_4

TP4

J11

Art # A-08518

MAIN PCB 1 SIGNALS

J1-1 L1 Primary AC Line

J1-2 Not used

J1-3 Not used

J1-4 Not used

J1-5 L2 Primary AC Line

MAIN PCB 1 LAYOUT

SERVICE 5-26 Manual 0-4998

cutmaster 102

Signal Source/Destination

J2-1 -VOUT (-) OUTPUT VOLTAGE M-L

J2-2 /TIP VOLTS Active high when tip is installed M-L

J2-3 TIP_SEN Approx. 100VDC while cutting w/ tip off M-L work, Active low in Drag Mode

J2-4 /460V_IN Active low with 460vac primary input voltage L-M

J2-5 /230V_IN Active low with 230vac primary input voltage L-M

J2-6 CUR_SET Current demand signal. Variable 1-4VDC L-M

J2-7 /RAR Active low when in Rapid Auto Restart mode L-M

J2-8 /INRUSH Active low after inrush time expires L-M

J2-9 /W1_ON Active low to enable W1 contactor L-M

J2-10 SHDN Active low enables PWM circuit

J2-11 /TRCH_SOL Active low to enable Torch Solenoid L-M

J2-12 /SOL_ON Active low to enable Power Supply solenoid L-M

J2-13 /OK_TO_MOVE Active low to enable OK_TO_MOVE (CNC) L-M

J2-14 /FAN_ON Active low to enable fans L-M

J2-15 /LATCH_ACTIVE Active low when Latch mode is active during cut L-M

J2-16 /TRCH_SW Active low = START is active -Torch switch, CNC M-L

J2-17 /PIP Active low = PARTS IN PLACE satisﬁed M-L

J2-18 AC_ON Pulse signal M-L

J2-19 CSR Active high during main transfer M-L

J2-20 /TORCH_SOL_DETECTED Active low for torch with remote solenoid M-L

J2-21 /OVERTEMP Active low when over temperature M-L

J2-22 V_IN Input Voltage signal M-L 3VDC = 460 VAC / 1.5VDC = 230VAC

J2-23 +12VDC M-L

J2-24 +12VDC M-L

J2-25 GND M-L

J2-26 GND M-L

J2-27 Not Used

J2-28 Not Used

J2-29 MAIN_BD_ID Voltage level to identify Main Pcb = 1.7VDC M-L

J2-30 Not Used

J2-31 Not Used

J2-32 Not Used

J2-33 Not Used

J2-34 For Factory Use M-L

J2-35 +3.3VDC M-L

J2-36 TXD M-L

J2-37 RXD L-M

J2-38 Common M-L

J2-39 D M-L

J2-40 Not Used

J3-1 /230VAC

J3-2 Common

Manual 0-4998 5-27 SERVICE

cutmaster 102

J4-1 3.3VDc

J4-2 TXD

J4-3 RXD

J4-4 Common

J4-5 D

J5-1 +12VDC

J5-2 Not used

J5-3 /SOLENOID

J6-1 24VAC Supply for W1

J6-2 24VAC Return

J7-1 +12VDC

J7-2 /FAN

J8 Not Used

J9-1 /PIP

J9-2 Common

J9-3 /TORCH SWITCH (START)

J9-4 Common

J9-5 Automation Torch solenoid

24VAC supply

J9-6 Not Used

J9-7 Automation Torch solenoid

24VAC return

J10-1 /OK-TO-MOVE

J10-2 Not used

J10-3 /OK-TO-MOVE

J10-4 Not used

J10-5 Common

J10-6 Common

J10-7 +12VDC

J10-8 /START (Remote Pendant / CNC Signal)

J11 N/A

J12-1 +12VDC

J12-2 /460VAC

J12-3 /230VAC

J13-1 /OVERTEMP

J13-2 /FAN_ON

J13-3 /CSR

J13-4 CUR_SET

J13-5 MAIN_PCB_ID

J13-6 Common

MAIN PCB 1 LED INDICATORS

D59 PCR Indicates Pilot IGBT gate signal is on D78 CSR Indicates cutting arc has been established

MAIN PCB 1 TEST POINTS

+12V1 +12VDC

+12V2 +12VDC

+48V1 +48VDC

+48V2 +48VDC

AC1 AC Input

AC2 AC Input

AC3 AC Input

CHOKE1 Negative DC output to L1

ELECTRODE1 Negative DC output to torch

GND1 Common

GND2 Common

I_DMD1 Current Demand Signal

1.5VDC during Pilot

1.2-4 VDC During Cut

PRI_1 (A) IGBT Bank A Output to T1

PRI_2 (B) IGBT Bank A Output to T1

PRI_3 (D) IGBT Bank B Output to T1

PRI_4 (C) IGBT Bank B Output to T1

SEC1 T1 Secondary

SEC2 T1 Secondary

TP1 Capacitor Bank A +

TP2 Capacitor Bank A+

TP3 Capacitor Bank B+

TP4 Capacitor Bank B+

TP5 Capacitor Bank A-

TP6 Capacitor Bank A-

TP7 Capacitor Bank B-

TP8 Capacitor Bank B-

TIP1 Positive Tip DC Output

-V_OUT1 Negative DC output

WORK1 Positive DC output

SERVICE 5-28 Manual 0-4998

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MTH8

MTH6

MTH1

MTH2

PRI1

MTH7

80A_AC3

80A_AC2

80A_AC1

PRI2

MTH4

PMTH2

40A_AC1

40A_AC3

40A_AC2

PMTH1

PMTH4

PMTH3

Art # A-08505AB

CAPACITOR PCB 2 SIGNALS

J1-1 +12vdc

J1-2 /460VAC

J1-3 /230VAC

j2-1 +12VDC

j2-2 Common

CAPACITOR PCB 2 TEST POINTS

MTH1 CAP BANK A +

MTH2 CAP BANK A+

MTH4 CAP BANK A-

MTH6 CAP BANK B+

CAPACITOR PCB 2 LAYOUT

MTH7 CAP BANK B-

MTH8 CAP BANK B+

PMTH1 CAP BANK A+

PMTH2 CAP BANK A-

PMTH3 CAP BANK B+

PMTH4 CAP BANK B-

80A_AC1 AC line 1

80A_AC2 AC line 2

80A/AC3 AC line 3

40A_AC1 AC line 1

40A_AC2 AC line 2

40A/AC3 AC line 3

Manual 0-4998 5-29 SERVICE

cutmaster 102

D10

D11

D12

D13

D14

TP7

TP6

TP5

TP2

D1 TP3 TP4 TP1

Art # A-08504

LOGIC PCB 3 LAYOUT

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LOGIC PCB 3 SIGNALS

J1 Signal info is the same as MAIN PCB 1 J2 connector.

jJ3-1 +5VDC

j3-2 Pressure Transducer output 0.5 to 5 VDC / 0 - 100 psi

J3-3 Common

LOGIC PCB 3 LED INDICATORS

NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE

D1 +12VDC

D2 MAX PRESSURE X.7 Over Pressure

D3 90 PSI X.6 Internal Error

D4 85 PSI X.5 Shorted torch (Output Fault)

D5 80 PSI X.4 Tip Missing

D6 75 PSI X.3 Start Signal active during power up

D7 70 PSI X.2 Parts-In-Place Fault (PIP)

D8 65 PSI X.1 Input Power Fault

D9 MIN PRESSURE X.0 Low Pressure

D10 AC 1.X

D11 OVERTEMP 2.X

D12 GAS 3.X

D13 DC 4.X

D14 ERROR 5.X

LOGIC PCB 3 TEST POINTS

TP1 Common

TP2 +12VDC

TP3 +5VDC

TP4 +3.3DCV

TP5 0.5 to 5 VDC / 0 - 100 psi

TP6 +1.8VDC

TP7 Potentiometer Current Demand (0-3.3VDC)

Manual 0-4998 5-31 SERVICE

cutmaster 102

Art # A-08506

SEC1

CHOKE1

+OUT_1

SEC2

PRI3

PRI4

PRI2

PRI1

PMTH4

AC2

AC3

AC1

PMTH2

PMTH1

PMTH3

J4J3J2J1

I_DMD1

GND1

I_OUT1

SERVICE 5-32 Manual 0-4998

40AMP PCB 5 LAYOUT

cutmaster 102

40AMP PCB 5 SIGNALS

J1-1 +12VDC Supply for Fan MOT2

J1-2 /FAN Active Low to enable Fan MOT2

J2-1 +12VDC Supply for Fan MOT3

J2-2 /FAN Active Low to enable Fan MOT3

Signal Source/Destination

J3-1 +12VDC +12VDC Supply C/40A

J3-2 Common +12VDC Return C/40A

J4-4 /OVERTEMP Active Low signal when OVERTEMP 40A-M

J4-5 /FAN_ON Active Low to enable Fans M-/40A

J4-6 /CSR Active low to Enable PWM M/40A

J4-7 CUR_SET 1.2 -4VDC Cut Current Demand M-/40A

J4-8 MAIN_PCB_ID 825 Ohms to common 40A/M

J4-9 Not Used

J4-10 Common 40A/M

TEST POINTS

80A_AC1 AC Input Phase 1

80A-AC2 AC Input Phase 2

80A_AC3 AC Input Phase 3

40A_AC1 AC Input Phase 1

40A-AC2 AC Input Phase 2

40A_AC3 AC Input Phase 3

MTH1 Capacitor Bank A+

MTH2 Capacitor Bank A+

MTH4 Capacitor Bank A-

MTH6 Capacitor Bank B+

MTH7 Capacitor Bank B-

MTH8 Capacitor Bank B+

PMTH1 Capacitor Bank A+

PMTH2 Capacitor BankA-

PMTH3 Capacitor Bank B+

PMTH4 Capacitor Bank B-

TP1 Common

TP2 +12VDC

TP3 +5VDC

TP4 +3.3DCV

TP5 0.5 to 5 VDC / 0 - 100 psi

TP6 +1.8VDC

TP7 1.5 VDC Pilot Current Demand M-/40A

1.2 -4VDC Cut Current Demand

Manual 0-4998 5-33 SERVICE

cutmaster 102

This Page Intentionally Blank

SERVICE 5-34 Manual 0-4998

cutmaster 102

Upper Groove with Vent Holes Must Remain Open

Threads

Upper O-Ring in Correct Groove

Lower O-Ring

Art # A-03725

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

NOTE

Refer to Previous "Section 5 System" for common 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.

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

It is recommended to apply a very light ﬁlm of oring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis.

Torch Head O-Ring

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

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.

ATC O-Ring

NOTE

DO NOT use other lubricants or grease, they may

not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

Manual 0-4998 5T-1 SERVICE

cutmaster 102

Art # A-08067

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

Good Tip

Worn Tip

A-03406

Art # A-08064

Spring-Loaded Lower End Fitting Full Compression 1/8”

Spring-Loaded Lower End Fitting at Rest / Full Extension

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE

The shield cup holds the tip and start cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup from the torch.

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized oriﬁce). Clean or replace the tip if necessary.

Example of Tip Wear

5. Remove the start cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end ﬁtting for free motion. Replace if necessary.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

Shield Cups

3. On torches with a shield cup body and a shield cap or deﬂector, ensure that the cap or deﬂector is threaded snugly against the shield cup body. In shielded drag cutting operations (only), there may be an O-ring between the shield cup body and drag shield cap. Do not lubricate the O-ring.

6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following ﬁgure.

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired start cartridge and tip into

the torch head.

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

This completes the parts replacement procedures.

SERVICE 5T-2 Manual 0-4998

cutmaster 102

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 Complete 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 Replacement Power Supply Parts

Section 6.09 Options and Accessories

Section 6.10 Replacement Parts for Hand Torch

Section 6.11 Replacement Parts - for Machine Torches with Unshielded Leads

Section 6.12 Replacement Shielded Machine Torch Leads Assemblies

Section 6.13 Torch Consumable Parts (SL100)

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 & clamp, input power cable, gas pressure regulator / ﬁlter, and operating manual.

Qty Description Catalog #

1 CutMaster 102 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with 208/230 single phase input power cable and plug 3-1330-1 with 460V single phase input power cable 3-1330-2

Manual 0-4997 6-1 PARTS LIST

cutmaster 102

Art # A-08564

6.04 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-0128 2 1 Base Enclosure Assembly 9-0186 3 1 Tube, roll handle 9-0121 4 1 Front Panel 9-0187 5 1 Rear Panel 9-0101

NOTE

Illustration may vary slightly from unit.

PARTS LIST 6-2 Manual 0-4997

cutmaster 102

Art # A-08123

6.05 Front Panel Replacement Parts

Item# Qty Description Ref. Catalog #

1 1 Output Current Control and Function Control Knobs 9-8527

2 1 Toggle - On/Off Switch SW1 9-0109

3 1 Work Cable with Clamp, 20 Ft / 6.1 m 9-0189

NOTE

Illustration may vary slightly from unit.

Manual 0-4997 6-3 PARTS LIST

cutmaster 102

Art # A-08560

6.06 Left Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Main PCB Assembly PCB1 9-0108 1b 1 Main PCB Assembly 40 Amp PCB5 9-0194

2 1 Logic PCB PCB3 9-0107* 3 1 Center Chassis Molded Plastic 9-0190 4 1 Fan, (3 total) MOT1-3 9-0104

5 1 Transformer, Main T1 9-0106 5b 1 Transformer, Main 60 Amp T2 9-0196 6 1 Inductor, Output L1 9-0105 6b 1 Inductor, Output 40 Amp L2 9-0195 Not Shown: 1 Power Cable Strain Relief, for all units 9-0111

1 Input Power Cable 230 V with plug, 9-0191

1 Hi/Lo voltage selection switch SW2 9-0110

PARTS LIST 6-4 Manual 0-4997

cutmaster 102

Art # A-08558

6.07 Right Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Contactor, 4 Pole W1 9-8587

2 1 Solenoid, 12V SOL1 9-0114 3 1 Spare Parts Box 7-3267 4 1 Spare Parts Box Cover 7-3266 5 1 Console Quick Disconnect 9-0161 6 1 Regulator, with knob and mounting nut 9-0115* 7 1 Assembly, PCB, Input Capacitors PCB2 9-0192

8 1 Filter, Auto Drain 9-0116

NOTE:

*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom ﬁtting. If there is a transducer and wire harness instead of the tube, the kit is not needed.

Illustration may vary slightly from unit.

Manual 0-4997 6-5 PARTS LIST

NOTE

cutmaster 102

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

First & Second Stage Cartridges (as marked)

Art # A-02942

6.08 Replacement Power Supply Parts

Qty Description Ref. Catalog #

1 Regulator 9-0115 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 208 / 230 V Power Supply 9-0191

6.09 Options and Accessories

Qty Description Ref. Catalog #

1 Single - Stage Filter Kit (includes Filter & 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, Bracket & Mounting Screws) 9-0233 1 Bracket, Filter Mounting (not shown) 9-9386 1 Two - Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 Extended Work Cable ( 50 ft / 15.2 m ) with Clamp 9-8529 1 Multi - Purpose Cart 7-8888 1 Automation Interface Kit PCB4 9-8311 1 Automation Harness 9-9385 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313 1 Nylon Dust Cover 9-7071

PARTS LIST 6-6 Manual 0-4997

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

cutmaster 102

Art # A-07993

6.10 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 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 & 6) 9-8219 5 1 Large O - Ring 8-3487 6 1 Small O - Ring 8-3486 7 Leads Assemblies with ATC connectors (includes switch assemblies) 1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836 1 SL100 , 50 - foot Leads Assembly with ATC connector 4-7837 8 1 Switch Kit (2 total) 9-7031

Manual 0-4997 6-7 PARTS LIST

cutmaster 102

6.11 Replacement Parts - for Machine Torches with Unshielded Leads

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 2 1 Large O - Ring 8-3487 3 1 Small O - Ring 8-3486 4 1 PIP Switch Kit 9-7036 5 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845 6 1 11” / 279 mm Rack 9-7041 7 1 11” / 279 mm Mounting Tube 9-7043 8 1 End Cap Assembly 9-7044 9 2 Body, Mounting, Pinch Block 9-4513 10 1 Pin, Mounting, Pinch Block 9-4521 11 1 Torch Holder Sleeve 7-2896 12 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 0-4997

A-07994

cutmaster 102

Manual 0-4997 6-9 PARTS LIST

cutmaster 102

Starter

Cartridge

9-8213

Electrode

9-8215

Shield Cap, Deflector

9-8243

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Shield Cup, Gouging

9-8241

Shield Cap, Machine

40A 9-8245

20A 9-8205 30A 9-8206 40A 9-8208

Shield

Cup Body,

9-8237

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cup

9-8218

Shield

Cup Body,

9-8237

50-60A

Tip:

Tips:

40-120A

GOUGING

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine

50-60A 9-8238

Shield Cap, Machine

70-100A 9-8239

Art # A-08066_AB

STANDOFF

CUTTING

STANDOFF

70-120A

CUTTING

STANDOFF

20-40A

Shield Cap, Deflector

9-8243

Ohmic Clip

9-8224

6.12 Torch Consumable Parts (SL100 SV)

PARTS LIST 6-10 Manual 0-4997

Thermal Dynamics CUTMASTER 102, Cutmaster 152 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual