Tweco 102 User Manual

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100

CUTMASTER™ 102

PLASMA CUTTING SYSTEM

208-

230V

400V

460V 600V

Operating Manual

Art # A-08618_AC

Revision: AN Issue Date: February 10, 2014 Manual No.: 0-4997

VictorThermalDynamics.com

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WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.VictorThermalDynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Victor Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

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WARNING

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply CutMaster® 102 SL100 1Torch™ Operating Manual Number 0-4997

Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.victorthermaldynamics.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.

Original Publication Date: May 30, 2008 Revision Date: February 10, 2014

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________________

Purchase Date:__________________________________ __________________

Power Supply Serial #:___________________________ ___________________

Torch Serial #:___________________________________ _________________

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This Page Intentionally Blank

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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 ..........................................................................1-6

1.07 Declaration of Conformity ...........................................................................1-7

1.08 Statement of Warranty ................................................................................ 1-8

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 Opening the Contactor Cover .....................................................................3-1

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

3.05 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

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TABLE OF CONTENTS

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

4T.05 Gouging ....................................................................................................4T-6

4T.06 Mechanized Torch Operation ...................................................................4T-7

4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ......4T-10

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-14

PATENT INFORMATION .....................................................................................................4T-18

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 ...................................................................... 5-4

5.06 Power Supply Basic Parts Replacement ....................................................5-6

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 Replacement Power Supply Parts ..............................................................6-2

6.05 Options and Accessories ............................................................................6-2

6.06 Replacement Parts for Hand Torch ...........................................................6-3

6.07 Replacement Parts - for Machine Torches with Unshielded Leads ............6-4

6.08 Replacement Shielded Machine Torch Leads Assemblies ........................ 6-6

6.09 Torch Consumable Parts (SL100) ..............................................................6-7

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: SYSTEM SCHEMATIC, 600V UNITS ............................................................. A-8

APPENDIX 7: Publication History......................................................................................... A-10

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SECTION 1:

CUTMASTER 102

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.

GASES AND FUMES

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

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

• Useanair-suppliedrespiratorifventilationisnot

adequate to remove all fumes and gases.

• Thekindsoffumesandgasesfromtheplasmaarc

depend on the kind of metal being used, coatings on the metal, and the different processes. 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.

WARNING

Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.

1.02 Important Safety Precautions

WARNING

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

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

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

• 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.

• WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm.

handling.

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.

Wash hands after

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CUTMASTER 102

• 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ammablematerial

in the workplace. Any material that cannot be removed must be protected.

• Ventilateallammableorexplosivevaporsfromthe

workplace.

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

combustibles.

• Providearewatchwhenworkinginanareawhere

ﬁre hazards may exist.

• Hydrogengasmaybeformedandtrappedunder

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

NOISE

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

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

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

• Forinformationonhowtotestfornoise,seeitem1in

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.

WARNING

WARNING: This product contains chemicals, including lead,

known to the State of California to cause birth defects and other reproductive harm.

Wash hands after handling.

1.03 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

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

GENERAL INFORMATION Manual 0-4997

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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 CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

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

CUTMASTER 102

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.

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

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 :

AVERTISSEMENT

Fournit l'information concernant des dommages possibles de choc électrique. Des avertissements seront enfermés dans une boîte de ce type.

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.

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.

Manual 0-4997 INFORMATIONS GÉNÉRALES

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

• Eloigneztoutefuméeetgazdevotrezonede respiration.

• Utilisezun appareilrespiratoire àalimentation enair si

FUMÉE et GAZ

Gardez votre tête hors de la plume de fumée provenant du chalumeau.

l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

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CUTMASTER 102

• 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:

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

• Liseztoujours lesches 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.

• Débranchez l’alimentationélectriqueavant touttravail

d’entretien ou de réparation.

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

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 produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou

provoquerl’explosiondefuméesinammables.

• Soyezcertainqu’aucunematièrecombustibleouinamma-

ble 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inammables 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enammé.

• AVERTISSEMENT: Ce produit contient des produits chimi-

ques, notamment du plomb, reconnu par l'État de la Californie pour causer des malformations congénitales et d'autres dommages touchant le système reproductif.

Se laver les

mains après manipulation.

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.)

INFORMATIONS GÉNÉRALES Manual 0-4997

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CUTMASTER 102

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.

• 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.

AVERTISSEMENT

AVERTISSEMENT : Ce produit contient des produits chimi-

ques, notamment du plomb, reconnu par l'État de la Californie pour causer des malformations congénitales et d'autres dommages touchant le système reproductif.

Se laver les mains

après manipulation.

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 dúez 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an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.

Manual 0-4997 INFORMATIONS GÉNÉRALES

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CUTMASTER 102

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

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’Asso-

ciation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

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

GENERAL INFORMATION Manual 0-4997

1-6

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CUTMASTER 102

1.07 Declaration of Conformity

Manufacturer: Victor Technologies Address: 16052 Swingley Ridge Road, Suite 300 Chesterﬁeld, MO 63033 USA

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ammabilitytestingforallprinted-circuitboardsused.

* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufac-

turing 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.

*UL60974-1:2012ArcWeldingEquipment;Part1:WeldingPowerSources

* CSA E60974-1: 2012 Arc Welding Equipment - Part 1: Welding Power Sources

* IEC 60974-1: 2012 Arc Welding Equipment - Part 1: Welding Power Sources

Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Joe Mueller Vice President/America's Sales and Marketing Victor Technologies International, Inc. 16052 Swingley Ridge Road, Suite 300 Chesterﬁeld, MO 63033 USA

Manual 0-4997 GENERAL INFORMATION

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CUTMASTER 102

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies, Inc. warrants to the original

retail purchaser that new Victor Thermal Dynamics CUTMASTER® plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Victor Technologies, Inc. shall, upon notiﬁcation thereof and substantiation that the product has been stored operated and maintained in accordance with Victor Thermal Dynamics’ speciﬁcations, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or ﬁtness for a particular purpose.

Victor Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Victor Technologies, Inc. must be notiﬁed within 30 days of any failure, at which time Victor Technologies, Inc.will provide instructions on the warranty procedures to be implemented.

Victor Technologies, Inc. will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Victor Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Product

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 Victor Technologies, Inc.:

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.

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

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

LIMITATION OF LIABILITY: Victor Technologies, Inc. shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors

(hereinafter“Purchaser”)forserviceinterruption.TheremediesofthePurchasersetforthhereinareexclusiveandtheliability

of Victor Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Victor Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor Thermal Dynamics product.

This warranty is invalid if the Victor Thermal Dynamics product is sold by non - authorized persons.

Effective September 4, 2007

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CUTMASTER 102

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just speciﬁcation or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efﬁcient operation of the system.

2.02 Equipment Identiﬁcation

The unit’s identiﬁcation number (speciﬁcation or part number), model, and serial number usually appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identiﬁed only by the speciﬁcation or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to ﬁle 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 identiﬁcation numbers as described above along with a full description of the parts in error.

Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

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.

WARNING

Gives information regarding possible electrical shock injury. Warnings will be enclosed in a box such as this.

Additional copies of this manual may be purchased by contacting Victor Technologies International at the address and phone number in your area listed on the back cover of this manual. Include the Owner’s Manual number and equipment identiﬁcation 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.victorthermaldynamics.com

Manual 0-4997 INTRODUCTION

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CUTMASTER 102

2.04 Power Supply Speciﬁcations

CutMaster 102 Power Supply Speciﬁcations

Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz

230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Three Phase, 50/60 Hz

600 VAC (540 - 630), Three Phase, 50/60 Hz Input Power Cable Power Supply includes input cable. Output Current 30 - 100 Amps, Continuously Adjustable Power Supply Gas

Filtering Ability

Ambient Temperature

All Units Duty Cycle 60% 80% 100%

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

Particulates to 5 Microns

CutMaster 102 Power Supply Duty Cycle *

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

Current 100 80 70

DC Voltage 120 112 108

IEC IEC IEC

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

10.75"

273 mm

Art # A-08358

16.375"

416 mm

63 lb / 28.6 kg

30.5"

774.7 m

24"

610 mm

150 mm

Art # A-07925_AB

150 mm

INTRODUCTION Manual 0-4997

2-2

Page 17

2.05 Input Wiring Speciﬁcations

CutMaster 102 Power Supply Input Cable Wiring Requirements

Input voltage

Volts Hz kVA I max I1eff Fuse

1 Phase

208 50/60 20.6 99 76 100 4 Type W 230 50/60 21.9 95 74 100 4 Type W 460 50/60 27.6 60 46 60 6

3 Phase

208 50/60 17.7 49 38 60 6 230 50/60 17.9 45 36 60 6 380 50/60 18.4 28 22 32 10 400 50/60 18.7 27 22 32 10 460 50/60 23.1 29 22 30 10 600 50/60 22.8 22 17 25 12

Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code

Freq Power

Input

CUTMASTER 102

Suggested Sizes

Flexible Cord

(amps)

(Min. AWG)

NOTE

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. The suggested sizes are based on ﬂexible power cable with power plug installations. For hard-wired installations

refer to local or national codes. I1max is taken at TDC rated minimum duty cycle. I1eff is taken at TDC 100% rated duty cycle.

Manual 0-4997 INTRODUCTION

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CUTMASTER 102

Handle and Leads Wrap

and Clamp

2.06 Power Supply Features

Art # A-08359

Control Panel

To rch Leads Receptacle

Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord

Work Cable

Port for Optional Automation Interface Cable

Art # A-08360

INTRODUCTION Manual 0-4997

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CUTMASTER 102

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 personnel; unqualiﬁed personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

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 ﬂows through the small oriﬁce in the torch tip, which is focused on the metal to be cut.

A single torch lead provides gas from a single source to be used as both the plasma and secondary gas. The air ﬂow is divided inside the torch head. Single - gas operation provides a smaller sized torch and inexpensive operation.

NOTE

Refer to Section "2T.05 I ntrod ucti on t o Plasma" on page 2T-2, for a more detailed description of plasma torch operation.

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

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

2. Mechanized Torch, Model

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

15.875" / 403 mm

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 mm

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20ft/6.1m,withATCconnectors

• 50ft/15.2m,withATCconnectors

Machine Torches are available as follows:

• 5foot/1.5m,withATCconnectors

• 10foot/3.05m,withATCconnectors

• 25foot/7.6m,withATCconnectors

• 50foot/15.2m,withATCconnectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

0.625" / 16 mm

4.95" / 126 mm

Art # A-03322_AB

1.175" / 30 mm

Art # A-02998

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.

Manual 0-4997 INTRODUCTION

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

F. Torch Ratings

Temperature

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Duty Cycle

peak

Manual Torch Ratings

104° F

40° C

100% @ 100 Amps @ 400 scfh

120 Amps

)

500V

7kV

2T-1

Page 20

CUTMASTER 102

Mechanized Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

G. Gas Requirements

Gas (Plasma and Secondary) Compressed Air

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and

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

Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to gas pressure settings charts for each model.

peak

Manual and Mechanized Torch Gas

Operating Pressure

Refer to NOTE

Gouging)

100% @ 100 Amps @ 400 scfh

)

Specications

WARNING

NOTE

104° F

40° C

120 Amps

500V

7kV

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

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.

Power

Supply

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.

Workpiece

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.

A-00002

INTRODUCTION Manual 0-4997

2T-2

Page 21

CUTMASTER 102

Remote Pendant

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 starter cartridge, around the electrode, and out through the tip oriﬁce.

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

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.

To Control

Torch Switch

Cable Wiring

PIP Switch

A-02997

Torch Trigger

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

To AT C

PIP Sw itch

CNC Start

Sh ield Cup

To AT C

PIP Sw itch

Automation To rch

PIP Sw itch

Sh ield Cup

Art # A-08168

Sh ield Cup

Parts - In - Place Circuit Diagram for Machine Torch

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CUTMASTER 102

This Page Intentionally Blank

INTRODUCTION Manual 0-4997

2T-4

Page 23

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.

3.03 Opening the Contactor Cover

The input power cord is connected to the main contactor, the contactor is located inside a box with a snap on cover. The cover is held in place with two or more snap lock tabs. To remove the cover release the front latch and tilt the cover up about ½ inch. Then squeeze both sides of the cover and lift it straight up. See the Primary Input Power Connections section for the necessary changes to the Contactor. Remember to replace the Contactor Cover when the changes are complete.

Art# A-11478

Contactor cover

Manual 0-4997 INSTALLATION

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CUTMASTER 102

3.04 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.

Input Power Cable Connections

Single-Phase (1ø) and Jumper Settings

Store copper jumpers on base plate

GND

Single and Three Phase Input Power Wiring

NOTE

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

Three-Phase (3ø)

GND

Art # A-08493

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. Refer to Section 2 for power cable speciﬁcations.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2).

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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 per instructions found in section 5.

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

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

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. Refer to Section 2 for power cable speciﬁcations.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2).

6. Connect the wires as follows.

• 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 per instructions found in section 5.

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

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

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CUTMASTER 102

Regulator/Filter

3.05 Gas Connections

ConnectingGasSupplytoUnit

The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line ﬁlter is to be installed.

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

NOTE

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

Assembly

Inlet Port

Hose Clamp

1/4 NPT or ISO-R

Gas Supply Hose

to 1/4” (6mm) Fitting

Art # A-07943

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter An optional ﬁlter kit is recommended for improved ﬁltering with compressed air, to keep moisture and debris out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet Port.

2. Attach the Filter Assembly to the ﬁlter hose.

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

NOTE

For a secure seal, apply thread sealant to the ﬁtting threads, according to the maker'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. Connect as follows:

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3-4

Page 27

Hose Clamp

Regulator/Filter

CUTMASTER 102

Assembly

Inlet Port

Art # A-07944

Gas Supply Hose

1/4 NPT to 1/4"

(6mm) Fitting

Optional Single - Stage Filter Installation

Installing Optional Two - Stage Air Filter Kit This optional two - stage air line ﬁlter is also for use on compressed air shop systems. Filter removes moisture and contami-

nants to at least 5 microns.

Connect the air supply as follows:

1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the ﬁlter assembly.

NOTE

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

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

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

Manual 0-4997 INSTALLATION

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CUTMASTER 102

Regulator/Filter

Assembly

Regulator Input

Hose Clamp

Gas Supply Hose

1/4 NPT to 1/4” (6mm) Fitting

2-Stage Filter Inlet Port (IN)

Outlet Port (OUT)

Two Stage Filter Assembly

Art # A-07945_AC

Optional Two - Stage Filter Installation

Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s speciﬁcations for installation and maintenance procedures for high pressure regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Brieﬂy open each cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and ﬂows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator. Supply hose must be at least 1/4 inch (6 mm) I.D. For a secure seal, apply thread sealant to the ﬁtting threads, according to manufacturer's instructions. Do Not use

Teﬂon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

INSTALLATION Manual 0-4997

3-6

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CUTMASTER 102

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 locking 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 ﬁlter lens in front of the torch and turn ON the air. Do not start an arc!

Any oil or moisture in the air will be visible on the lens.

3T.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.

Art # A-07885

Connecting the Torch to the Power Supply

3. The system is ready for operation.

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.

Manual 0-4997 INSTALLATION

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CUTMASTER 102

Workpiece

Mechanical Torch Set - Up

Pinch Block Assembly

Square

A-02585

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 Manual 0-4997

3T-2

Page 31

CUTMASTER 102

SECTION 4 SYSTEM:

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identiﬁcation

1. Output Current Control

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

2. Function Control

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

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

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster restart-

ing of the Pilot Arc for uninterrupted cutting.

MAX

MIN

PSI BAR

MAXMAX

MINMIN

6. Temp Indicator

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

Art# A-07886

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 mode to adjust the air/gas pressure. Pull the knob out to adjust and push in to lock.

5. AC Indicator

Steady light indicates power supply is ready for operation.

Blinking light indicates unit is in protective interlock mode. Shut unit OFF, shut OFF or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details.

Control is used in the "SET"

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

PSI BAR

MAX MAX

90 6.3

85 5.9

MINMIN

5.5

5.2

4.8

4.5

Art # A-08170

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

Manual 0-4997 OPERATION

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CUTMASTER 102

Art # A-04509

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.

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.

The cooling fans will turn ON as soon as the unit is turned ON. After the unit is idle for ten (10) minutes the fans will turn OFF. The fans will come back ON as soon as the torch switch (Start Signal) is activated or if the unit is turned OFF, then turned ON again. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period once the condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control knob to the

SET position. Gas will ﬂow.

Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Speciﬁcations.

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

Air Source

Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.

Connect Work Cable

Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.

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.

MIN

MAX

PSI BAR

MAXMAX

MINMIN

Art# A-07946

OPERATION Manual 0-4997

4-2

Page 33

CUTMASTER 102

STANDOFF

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

3. For Drag cutting (60 Amps and below), adjust gas pressure from 75 - 95 psi / 5.2 - 6.5 bar (LED's in center of control panel). Refer to the Drag Cutting chart for pressure setting details.

CutMaster 102 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

SL100

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

DRAG

(Mechanized Torch)

Add 5 psi

SL100

(Mechanized Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

SL100

80 psi

5.5 bar

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 ﬂow stops.

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

Cutting Operation

When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART 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.

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This Page Intentionally Blank

OPERATION Manual 0-4997

4-4

Page 35

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

CUTMASTER 102

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

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

Torch Head

Electrode

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter 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 starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

Start Cartridge

Tip

Shield Cup

A-03510_AB

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 starter cartridge and desired tip for the

operation into the torch head.

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

Manual 0-4997 OPERATION

4T-1

Page 36

CUTMASTER 102

Kerf Width

4T.02 Cut Quality

NOTE

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 cutting is important when ﬁnish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following ﬁgure:

Cut Surface Bevel Angle

Top

Spatter

Top Edge

Rounding

Dross

Build-Up

Cut Surface

Drag Lines

Cut Quality Characteristics

Cut Surface

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

Nitride Build - Up

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

Bevel Angle

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

Top - Edge Rounding

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

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.

A-00007

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

WARNING

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

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.

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.

OPERATION Manual 0-4997

4T-2

Page 37

CUTMASTER 102

Left Side

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.

Cut Angle

Right Side

Cut Angle

A-00512

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "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.

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.

2. Depending on the cutting operation, do one of the following:

a) For edge starts, hold the torch perpendicular

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.

Torch

Manual 0-4997 OPERATION

Shield Cup

Standoff Distance

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

Standoff Distance

3. Hold the torch away from your body.

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

4T-3

Page 38

CUTMASTER 102

Tr igger

Trigger

Trigger Release

A-02986

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

NOTE

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

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Art # A-04034

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 - conductive.

Tr igger Release

Art # A-03383

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

7. Follow normal recommended cutting practices as provided in the power supply operator's manual.

NOTE

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

8. For a consistent standoff height from 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.

Non-Conductive

Straight Edge Cutting Guide

A-03539

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 1/4" (6 mm) thick or less.

NOTE

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

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

OPERATION Manual 0-4997

4T-4

Page 39

CUTMASTER 102

Tr igger

3. Keep the torch in contact with the workpiece during the cutting cycle.

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.

Trigger

Trigger Release

A-02986

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

NOTE

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

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.

Tr igger Release

Art # A-03383

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

8. Follow normal recommended cutting practices as provided in the power supply operator's manual.

NOTE

Trigger

Trigger Release

A-02986

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

NOTE

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

Manual 0-4997 OPERATION

4T-5

Page 40

CUTMASTER 102

A-00941_AB

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

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.

• Linevoltageuctuations

• Torchstandoffheight

• Properworkcableconnection

4T.05 Gouging

WARNING

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

Disconnect primary power to the system 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.

Gouging Parameters

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.

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.

Torch Head

35°

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).

Standoff Height

Workpiece

Gouging Angle and Standoff Distance

OPERATION Manual 0-4997

4T-6

Page 41

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.

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

CUTMASTER 102

Direction of Torch Travel

Standoff Distance

Straight Arc

Trailing Arc

A-02586

Leading Arc

Mechanized Torch Operation

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.

Manual 0-4997 OPERATION

4T-7

Page 42

CUTMASTER 102

This Page Intentionally Blank

OPERATION Manual 0-4997

4T-8

Page 43

4T.07 Parts Selection for SL100 Torch Cutting

Ohmic Clip

Manual Torch

9-8259

CUTMASTER 102

Ohmic Clip

Automation To rch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205 30A 9-8206 40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine 40A 9-8245

Shield Cap, Deflector 9-8243

Drag Shield Cup 9-8235

Shield Cap, Machine 50-60A 9-8238

Shield Cap, Deflector 9-8243

Drag Shield Cup 70-100A 9-8236

Drag Shield Cup 120A 9-8258

Shield Cap, Machine 70-100A 9-8239

Shield Cap, Machine 120A 9-8256

Shield Cap, Deflector 9-8243

40-120A

GOUGING

Tips:

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)

Art # A-08066_AG

Manual 0-4997 OPERATION

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

4T-9

Page 44

CUTMASTER 102

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip

TypeTorch:SL100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

0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 65 4.5 55 170 NR NR NR

0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR

0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR

TypeTorch:SL100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

0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

TypeTorch:SL100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

0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 65 4.5 55 170 NR NR NR

OPERATION Manual 0-4997

4T-10

Page 45

CUTMASTER 102

TypeTorch:SL100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:SL100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:SL100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

Manual 0-4997 OPERATION

4T-11

Page 46

CUTMASTER 102

TypeTorch:SL100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 65 4.5 115 340 0.00 0.19 4.8

0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8

0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 65 4.5 115 340 0.10 0.19 4.8

0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 65 4.5 115 340 0.20 0.19 4.8

0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.19 4.8

0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 65 4.5 115 340 0.40 0.19 4.8

0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 65 4.5 115 340 0.60 0.19 4.8

0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 65 4.5 115 340 0.75 0.19 4.8

0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 65 4.5 115 340 NR NR NR

TypeTorch:SL100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 65 4.5 115 340 0.00 0.25 6.4

0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 65 4.5 115 340 0.80 0.25 6.4

0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 65 4.5 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 65 4.5 115 340 NR NR NR

TypeTorch:SL100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 65 4.5 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 65 4.5 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 65 4.5 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 65 4.5 115 340 NR NR NR

OPERATION Manual 0-4997

4T-12

Page 47

CUTMASTER 102

TypeTorch:SL100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

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

1.000 25.4

9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390 9-8212 117 100 70 1.75 0.190 4.8 75 5.2 130 390 9-8212 120 100 50 1.25 0.190 4.8 75 5.2 130 390 9-8212 125 100 35 0.90 0.190 4.8 75 5.2 130 390 9-8212 131 100 18 0.45 0.190 4.8 75 5.2 130 390 9-8212

135

100

0.25

4.8 75 5.2 130 390

0.190

NR NR NR

0.200 5.1

0.4

0.200 5.1

0.5

0.200 5.1

0.6

1.0 0.200

2.0 0.250

5.1

6.4

TypeTorch:SL100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

0.250

0.375

0.500

0.625

0.750

1.000

6.4 9-8212

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

118 122 126 133 138

139

100 100 100 100 100 100

90 55 30 20 15

2.30

1.40

0.75

0.50

0.40

0.25

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

4.8 75 5.2 130 390

0.190

0.5 0.250

0.8 0.250

1.0 0.250

1.5 0.250

NR NR

6.4

6.4 NR NR

TypeTorch:SL100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

0.250 6.4 9-8212 108 100 120 3.05 0.190 4.8 65 4.5 120 360 0.2 0.225 5.7

0.375 9.5 9-8212 117 100 65 1.65 0.190 4.8 65 4.5 120 360 0.4 0.225 5.7

0.500 12.7 9-8212 120 100 45 1.15 0.190 4.8 65 4.5 120 360 0.5 0.225 5.7

0.625 15.9 9-8212 125 100 30 0.75 0.190 4.8 65 4.5 120 360 0.8 0.225 5.7

0.750 19.0 9-8212 131 100 25 0.65 0.190 4.8 65 4.5 120 360 1.0 0.225 5.7

25.4 9-8212

1.000

140

* 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.

100

0.25

0.190

NOTE

4.8 65 4.5 120 360

NR NR

Manual 0-4997 OPERATION

4T-13

Page 48

CUTMASTER 102

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip

TypeTorch:SL100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

0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 65 4.5 55 170 0.10 0.2 5.1

0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 65 4.5 55 170 NR NR NR

0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 65 4.5 55 170 NR NR NR

0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 65 4.5 55 170 NR NR NR

TypeTorch:SL100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

0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 65 4.5 55 170 0.00 0.2 5.1

0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 65 4.5 55 170 0.10 0.2 5.1

0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 65 4.5 55 170 0.30 0.2 5.1

0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 65 4.5 55 170 NR NR NR

TypeTorch:SL100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

0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1

0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 65 4.5 55 170 0.10 0.2 5.1

0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 65 4.5 55 170 0.30 0.2 5.1

0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 65 4.5 55 170 0.40 0.2 5.1

0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 65 4.5 55 170 0.60 0.2 5.1

0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 65 4.5 55 170 1.00 0.2 5.1

0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 65 4.5 55 170 NR NR NR

OPERATION Manual 0-4997

4T-14

Page 49

CUTMASTER 102

TypeTorch:SL100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:SL100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:SL100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 0-4997 OPERATION

4T-15

Page 50

CUTMASTER 102

TypeTorch:SL100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 65 4.5 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 65 4.5 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 65 4.5 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 65 4.5 115 340 0.50 0.2 5.1

0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.2 5.1

0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 65 4.5 115 340 0.75 0.2 5.1

0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

TypeTorch:SL100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 65 4.5 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 65 4.5 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 65 4.5 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 65 4.5 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 65 4.5 115 340 0.75 0.25 6.4

0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 65 4.5 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 65 4.5 115 340 NR NR NR

TypeTorch:SL100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 65 4.5 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 65 4.5 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 65 4.5 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 65 4.5 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 65 4.5 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 65 4.5 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 65 4.5 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 65 4.5 115 340 NR NR NR

0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 65 4.5 115 340 NR NR NR

1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 65 4.5 115 340 NR NR NR

OPERATION Manual 0-4997

4T-16

Page 51

CUTMASTER 102

TypeTorch:SL100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

0.250 6.4

0.375 9.5

0.500 12.7

0.625 15.9

0.750 19.0

1.000 25.4

9-8212 9-8212 9-8212 9-8212 9-8212 9-8212

124 127 132 136 140 147

TypeTorch:SL100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

6.4 9-8212

0.250

0.375

0.500

0.625

0.750

1.000

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

121 100 110 125 100 60 132 100 35 137 100 20 144 100 15 154 100 8

100 100 100 100 100 100

110

75 50 30 18

2.80

1.90

1.30

0.75

0.45

0.25

2.80

1.50

0.90

0.50

0.40

0.20

0.180

0.190

0.125

0.150

0.190

4.6 75 5.2 130 390

4.8 75 5.2 130 390

4.8 75 5.2

3.2 75 5.2 130 390

3.8 75 5.2 130 390

4.8 75 5.2 130 390

130

390

0.4 0.200

0.5 0.200

0.6 0.200

0.8 0.200

2.0 0.225

NR NR

0.5 0.200

0.8 0.200

1.0 0.200

2.0 0.225

NR NR

5.1

5.7 NR

5.1

5.7 NR NR

TypeTorch:SL100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

6.4 9-8212

0.250

0.375

0.500

0.625

0.750

1.000

9.5 9-8212

12.7 9-8212

15.9 9-8212

19.0 9-8212

25.4 9-8212

120 128 130 135

140

148

* 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.

100 100 100 100 100 100

120

65 45 30 25

3.05

1.65

1.15

0.75

0.65

0.25

0.180

0.190

NOTE

65 4.5 105 360 65 4.5 105 360 65 4.5 105 360 65 4.5 105 360 65 4.5 105 360 65 4.5

105 360 NR NR

0.2 0.225

0.4 0.225

0.5 0.225

0.8 0.225

1.0 0.225

5.7

5.7 NR

Manual 0-4997 OPERATION

4T-17

Page 52

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 Manual 0-4997

4T-18

Page 53

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 0-4997 OPERATION

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Page 54

CUTMASTER 102

This Page Intentionally Blank

OPERATION Manual 0-4997

4T-20

Page 55

5.01 General Maintenance

CUTMASTER 102

SECTION 5 SYSTEM:

SERVICE

Warning! Disconnect input power before maintaining.

Visual check of torch tip and electrode

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

Maintain more often if used under severe conditions

Each Use

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Clean exterior of power supply

6 Months

Visually check and Carefully clean the interior

Art # A-07938_AB

Manual 0-4997 SERVICE

5-1

Page 56

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 or worn.

2. Check plasma and secondary supply and pressure/ ﬂow.

3. Purge plasma gas line to remove any moisture buildup.

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.

5.03 Common Faults

Problem - Symptom Common Cause

Insufﬁcient Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics parts used

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

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

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

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

CAUTION

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

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

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

Difﬁcult Starting 1. Worn torch parts.

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

SERVICE Manual 0-4997

5-2

Page 57

CUTMASTER 102

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.

7 6

5 4

3 2 1

MAX

MIN

PSI BAR

MAXMAX

MINMIN

When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is. The following table explains each of those Faults.

Pressure

Fault

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

NOTE

Fault explanations are covered in the following tables.

Art# A-07988

Manual 0-4997 SERVICE

5-3

Page 58

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

Fault indicator ﬂashing, 65 PSI indicator ﬂashing

1. Primary power disconnect is in OFF position.

2. Primary fuses / breakers are blown or tripped.

3. Units internal fuse blown.

4. Faulty components in unit.

1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage.

2. Primary input voltage problem.

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. a) Replace fuse. b) If fuse blows again, return to authorized service center for repair or replacement.

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

1. 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 2.05.

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

TEMPERATURE indicator ON. FAULT indicator ﬂashing.

GAS LED OFF, FAULT and MIN pressure indicators ﬂashing.

FAULT and 70 PSI indicators ﬂashing.

FAULT and 75 PSI indicators ﬂashing.

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

2. Duty cycle of the unit has been exceeded

3. Failed components in unit

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

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

2. Problem in the torch and leads switch circuit.

3. Failed components in unit.

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.

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.

SERVICE Manual 0-4997

5-4

Page 59

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.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter cartridge missing.

3. Torch starter cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads switch circuit.

6. Failed components in unit.

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

2. CNC Contoller device not providing Start signal.

3. Failed components in unit.

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

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

3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter 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.

CUTMASTER 102

FAULT and 85 PSI indicators ﬂashing.

No Fault lights ON, no arc in torch.

Fault and 90 PSI indicators ﬂashing

Pilot arc is ON but cutting arc will not establish

Torch cutting is diminished

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

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5 blinks per second.

6. Power Supply Failure (Standard rate of blinking)

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. 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 starter cartridge. Check starter cartridge lower end ﬁtting for free movement. Replace if ﬁtting does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

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

5. Release torch switch and reactivate.

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

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 0-4997 SERVICE

5-5

Page 60

CUTMASTER 102

5.06 Power Supply Basic Parts Replacement

WARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.

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.

Upper Screws

Lower Screws

C. Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel. For better

system performance, the ﬁlter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced.

1. Remove power from the power supply; turn OFF the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Removal" in this section.

3. Locate the internal air line and the ﬁtting from the ﬁlter assembly. Number 1 in the following illustration.

4. Hold a wrench or similar tool against the locking ring on the ﬁlter assembly ﬁtting, then pull on the hose to release it. (Numbers 2 and 3 in the following illustration).

Slots

Lower Screws

Art # A-08429

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

B. Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.

Art # A-07989

6mm

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.

SERVICE Manual 0-4997

5-6

Page 61

CUTMASTER 102

5. Remove the ﬁtting from the ﬁlter element assembly by inserting a 6 mm hex wrench into the internal hex ﬁtting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous illustration.

6. Disconnect the input line from the ﬁlter element assembly.

7. Remove the ﬁlter element assembly through the rear opening.

NOTE

If replacing or cleaning just the ﬁlter element refer to the following illustration for disassembly.

Filter Element

1. Remove power from power supply.

2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter Element Replacement

Art # A-07990

8. Install the new or cleaned assembly by reversing these procedures.

9. Turn ON the air supply and check for leaks before reinstalling the cover.

Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional

Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter

Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement ﬁlter element catalog number.

5. Remove the Filter Element from the Housing and set Element aside to dry.

6. Wipe inside of housing clean, then insert the replacement Filter Element open side ﬁrst.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE

If unit leaks between housing and cover, inspect the O-Ring for cuts or other damage.

Manual 0-4997 SERVICE

5-7

Page 62

CUTMASTER 102

Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the

Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement ﬁlter element catalog number.

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket.

1. Shut OFF primary input power.

2. Shut OFF air supply and bleed down system.

WARNING

Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE

A small amount of air leakage from the bottom ﬁtting is normal.

This completes the parts replacement procedures.

First & Second Stage Cartridges (as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

SERVICE Manual 0-4997

5-8

Page 63

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

NOTE

Refer to Previous "Section 5 System" for common and fault indicator descriptions.

CUTMASTER 102

Upper Groove with Vent Holes Must Remain Open

Upper O-Ring in Correct Groove

Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNING

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with 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.

Lower O-Ring

Torch Head O-Ring

Gas Fitting

Threads

Art # A-03725

ATC Male Connector

O-Ring Lubrication

An o-ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal. The o-rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems.

It is recommended to apply a very light ﬁlm of o-ring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis.

Manual 0-4997 SERVICE

Art #A-03791

O-Ring

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.

5T-1

Page 64

CUTMASTER 102

Drag Shield Cap

Good Tip

Worn Tip

Spring-Loaded

5T.02 Inspection and Replacement of

Consumable Torch Parts

WARNING

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE

The shield cup holds the tip and starter cartridge 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.

A-03406

Example of Tip Wear

5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end ﬁtting for free motion. Replace if necessary.

Lower End Fitting Full Compression

Lower End Fitting at Reset / Full Extension

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

Art # A-08067

Shield Cups

3. 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.

Shield

Cup Body

Art # A-08064_AC

6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following ﬁgure.

New Electrode

Art # A-03284

Worn Electrode

Electrode Wear

7. Reinstall the Electrode by pushing it straight into the

torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into the

torch head.

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

This completes the parts replacement procedures.

4. Remove the tip. Check for excessive wear (indicated

O-Ring No. 8-3488

Art # A-03878

by an elongated or oversized oriﬁce). Clean or replace the tip if necessary.

SERVICE Manual 0-4997

5T-2

Page 65

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 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"

Section "6.05 Options and Accessories"

Section "6.06 Replacement Parts for Hand Torch"

Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads"

Section "6.08 Replacement Shielded Machine Torch Leads Assemblies"

Section "6.09 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 208/230V single phase input power cable and plug 3-1330-1 with 460V single phase input power cable 3-1330-2 1 CutMaster 102 Power Supply 600VAC, 3 Phase, 60Hz, with 600V, 3 phase input power cable and plug 3-1330-5

Manual 0-4997 PARTS LIST

6-1

Page 66

CUTMASTER 102

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 208 / 230 V Power Supply 9-0191 1 460/600V Power Supply 9-0209

6.05 Options and Accessories

Qty Description 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 & Mounting Screws) 1 Bracket, Filter Mounting (not shown) 1 Two - Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529 1 Automation Interface Kit 9-8311 1 Automation Harness 9-9385 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008 1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second Stage Cartridges (as marked)

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

Art # A-02942

PARTS LIST Manual 0-4997

6-2

Page 67

CUTMASTER 102

6.06 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 9-7031 10 1 Torch Control Cable Adapter (includes item # 11) 7-3447 11 1 Through - Hole Protector 9-8103

Manual 0-4997 PARTS LIST

Art # A-07993_AB

6-3

Page 68

CUTMASTER 102

6.07 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 Automated Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845 7 1 11” / 279 mm Rack 9-7041 8 1 11” / 279 mm Mounting Tube 9-7043 9 1 End Cap Assembly 9-7044 10 2 Body, Mounting, Pinch Block 9-4513 11 1 Pin, Mounting, Pinch Block 9-4521 12 1 Torch Holder Sleeve 7-2896 13 1 PIP Plunger and Return Spring Kit 9-7045 1 Pinion Assembly (Not shown) 7-2827 1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE

* Does not include Control Cable Adapter or Through - Hole Protector. Refer to Section 6.09 for Replacement Shielded Leads Assemblies.

PARTS LIST Manual 0-4997

6-4

Page 69

CUTMASTER 102

5 & 6

A-07994_AB

Manual 0-4997 PARTS LIST

6-5

Page 70

CUTMASTER 102

6.08 Replacement Shielded Machine Torch Leads Assemblies

Item No. Qty Description Catalog No.

1 Mechanized Shielded Leads Assemblies with ATC Connectors 1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848 1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849

Remote Pendant Adapter is present on Mechanized leads only.

Torch Continuity ('PIP') Switch

A-03684

PARTS LIST Manual 0-4997

6-6

Page 71

6.09 Torch Consumable Parts (SL100)

Ohmic Clip

Manual Torch

9-8259

CUTMASTER 102

Ohmic Clip

Automation To rch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

20A 9-8205 30A 9-8206 40A 9-8208

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine 40A 9-8245

Shield Cap, Deflector 9-8243

Drag Shield Cup 9-8235

Shield Cap, Machine 50-60A 9-8238

Shield Cap, Deflector 9-8243

Drag Shield Cup 70-100A 9-8236

Drag Shield Cup 120A 9-8258

Shield Cap, Machine 70-100A 9-8239

Shield Cap, Machine 120A 9-8256

Shield Cap, Deflector 9-8243

40-120A

GOUGING

Tips:

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)

Art # A-08066_AG

Manual 0-4997 PARTS LIST

Tip E 9-8254 (60 - 120 Amps)

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

6-7

Page 72

CUTMASTER 102

This Page Intentionally Blank

PARTS LIST Manual 0-4997

6-8

Page 73

CUTMASTER 102

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

when input

Power circuit ready.

ACTION:

RUN / Rapid Auto Restart / SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

Torch moved away from work (while

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate

Torch switch (START)

RESULT:

Fans turn on. Gas flows briefly,

then stops.Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release Torch switch.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

(Fans will continue to run for

10 minutes after the Torch switch

[START] is removed)

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fans shut off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-07979_AB

Manual 0-4997 APPENDIX

A-1

Page 74

CUTMASTER 102

APPENDIX 2: DATA TAG INFORMATION

Type of Power Supply (Note 1)

Plasma Cutting Symbol

Input Power Symbol

Input Power Specifications (Phase, AC or DC Hertz Rating)

Mo de l:

Da te of Mf r:

1/ 3

Rated NoLoad Voltage

Degree of Protection

Output Current Type

Conventional Load Voltage

Rated Supply Voltage (Note 2)

West Lebanon, NH USA 03784

S/N

Duty Cycle Factor

Rated Maximum Supply Current

1max 1eff

1Ø

3Ø

Made in USA

3Ø1Ø

Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code

Regulatory Standard Covering This Type of Power Supply

Output Range (Amperage/ Voltage)

Duty Cycle Data (Note 3)

Maximum Effective Supply Current

Manufacturer's Electrical Schematic File Number and Revision Level

NOTES:

1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.

3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. TDC duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas of the power supply.

Standard Symbols

Phase

Art # A-03288_AB

APPENDIX Manual 0-4997

A-2

Page 75

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

CUTMASTER 102

ATC Male Connector

Negative / Plasma

4 - Green / Switch

3 - White / Switch

2- Orange / PIP

1 - Black / PIP

4 3

2 1

Pilot

Front View

8 7

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black Pendant Connector

3 - White Pendant Connector

2 - Orange / PIP

Front View

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green Pendant Connector Ground

8 7

7 - Green / Not Used

6 - Open

8 - Open

7 - Open

6 - Open

5 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

8 - Ground

7 - Open

6 - Open

ATC Female Receptacle

Front View

8 7

Pilot

ATC Female Receptacle

8 7

6 5

2 1

Front View

2 1

Negative / Plasma

4 - Switch

3 - Switch

4 3

2 - PIP

1 - PIP

A-03701

Negative / Plasma

4 - Switch

3 - Switch

2 - PIP

1 - Black / PIP

Art # A-03799

Pilot

5 - White / Not Used

5 - Open

1 - PIP

Pilot

Manual 0-4997 APPENDIX

A-3

Page 76

CUTMASTER 102

APPENDIX 4: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

To rch: SL60 / SL100 Hand Torch Leads: To rch Leads with ATC Connector Power Supply: with ATC Receptacle

Torch

Head

PIP

Switch

Torch

Switch

Torch Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

AT C Female

Receptacle

Power Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03797

B. Mechanized Torch Connection Diagram

To rch: Unshielded Mechanized SL100 Machine To rch Leads: Leads with ATC Connector and Remote Pendant Connector Power Supply: with ATC Female Receptacle

Male

AT C Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote

Pendant

Connector

Black

White

Green

AT C Female

Receptacle

Power Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

APPENDIX Manual 0-4997

A-4

Page 77

CUTMASTER 102

This Page Intentionally Blank

Manual 0-4997 APPENDIX

A-5

Page 78

CUTMASTER 102

T1T1

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

SW1SW1

PRIMARY AC INPUT

GND

BUSS BARS/JUMPERS

PRIMARY POWER CONNECTIONS:

FOR 3 PH: REMOVE BUSS BARS/JUMPERS BETWEEN L1 TO L4 & L2 TO L3 CONNECT PRIMARY INPUT CABLE TO L1,L2,L3 & GND

FOR 1PH: INSTALL BUSS BARS/JUMPERS BETWEEN L1 TO L4 & L2 TO L3 CONNECT PRIMARY INPUT CABLE TO BUSS BARS (L1/L4) & (L2/L3)

W1W1

SW2SW2

INPUT VOLTAGE SELECTOR (Closed for 230VAC input)

MOT1MOT1

FAN

SOL 1SOL 1

W1W1

SERIAL PORT

MOT2MOT2

FAN

MOT3MOT3

FAN

PRI 4 PRI 4

J1J1

1 2 3 4 5

+12VDC

K1K1

/INRUSH

J3J3

460_IN

1 2

+12VDC

J7J7

1 2

J5J5

1 2 3

24VAC

J6J6

1 2

J4J4

3.3VDC

TXD

RXD

3 4

FERRITE FILTER

J4J4

+12VDC

J1J1

1 2

J2J2

1 2

/FAN

/SOLENOID

24VAC RET

1 /OVERTEMP 2 /FAN_ON 3 /CSR 4 CUR_SET 5 MAIN_PCB_ID 6 COMMON

J13J13

12345

123456789

/FAN

INRUSH RESISTORS

SYNC

BIAS SUPPLY

TP2TP2

J14J14

SYNC

+12VDC

J9J9

MTH1MTH1

+12VDC

/460

/230

J12J12

J3J3

+12VDC BIAS SUPPLY

C16-17+C16-17

* CM102 & A80 C7 & C10 not installed

K1K1

K2K2

K3K3

MTH7MTH7

TP8TP8

AC1AC1

80A_AC180A_AC1

80A_AC280A_AC2

AC2AC2

AC3AC3

80A_AC380A_AC3

K1,K2K1,K2

K5,K6K5,K6

123

K3,K4K3,K4

J1J1

1 2 3

+12VDC

J2J2

1 2

AC1AC1

40A_AC140A_AC1

AC2AC2

40A_AC240A_AC2

AC3AC3

40A_AC340A_AC3

PMTH1PMTH1

PCB2

INPUT CAPACITOR PCB

C3,C4,C7,C8*+C3,C4,C7,C8*

K4K4

C5,C6,C9,C10*+C5,C6,C9,C10*

C12-13+C12-13

PRI 2PRI 2

PRI 1PRI 1

MTH2MTH2

TP1TP1

MTH4MTH4

TP5TP5

K6K6

K5K5

TP4TP4

MTH8MTH8

TP3TP3

MTH6MTH6

MAIN PCB ASSY

PCB1

PRI 1 PRI 1

PMTH2PMTH2

PMTH3PMTH3

PRI 3PRI 3

T2T2

PRI 3PRI 3

PRI 2 PRI 2

PRI 4PRI 4

PMTH4PMTH4

40/50 AMP PCB

PCB5

A-09132_AC

APPENDIX Manual 0-4997

A-6

Page 79

CUTMASTER 102

A120 ONLY

TS1TS1

J11J11

D59 PCRD59 PCR

D78 CSRD78 CSR

+12VDC

SEC2SEC2

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

GND1 GND2 +12V1 48V1 I_DMD_1 TIP_SEN

TEST POINTS

COMMON COMMON +12 VDC SUPPLY +48 VDC SUPPLY CURRENT DEMAND TIP DRAG SENSE

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

(5A @ 250VAC / 30VDC)

SEC1SEC1

CHOKE1CHOKE1

/START

/PIP

PILOT IGBTQ5PILOT IGBT

+12VDC

L1L1

ELECTRODE1ELECTRODE1

L2L2

-V OUT 1-V OUT 1

WORK1WORK1

ATC CONNECTOR

J1J1

1 2 3 4 5 6 7 8

E64

E35

TIP1TIP1

J9J9

5 6

P10P10

J10J10

1 2

3 4

7 8

40 PIN RIBBON CABLE SIGNALS

FERRITE FILTER

-V_OUT_SIGNAL

/TIP_VOLTS

/TIP_SENSE

/460V_IN

/230V_IN

CUR_SET

/RAR (RAPID AUTO RESTART)

/INRUSH

/W1_ON

SHDN

/TORCH_SOLENOID

/SOLENOID_ON

/OK_TO_MOVE

/FAN_ON

/LATCH_ACTIVE

/TORCH_SWITCH

/PIP

AC_ON

CSR

/TORCH_SOLENOID_DETECT

/OVERTEMP

V_IN

+12VDC

COMMON

MAIN_PCB_ID

460_IN

+3.3VDC

TXD

RXD

COMMON

M-L M-L M-L L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L L-M M-L M-L L-M M-L

CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1 on PCB1

P10P10

1 2 3 4 5 6 7 8

P2P2

1 2 3 4 5 6 7 8

J2J2

14 13 12 11 10 9 8 7 6 5 4 3 2 1

P1P1

E1E1

+12VDC

K1K1

PCB4

AUTOMATION INTERFACE PCB

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION TORCH SOLENOID

WORKWORK

OK TO MOVE

}

/START / STOP

}

To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS / 16.67 Jumper pins 1 & 2 for ARC VOLTS / 30

123

Jumper pins 2 & 3 for ARC VOLTS / 50

J1J1

1 2 3 4 5 6 7 8 9 10 11 12 13 14

CNC PINOUT

/START / STOP

}

(-)

DIVIDED ARC VOLTS

}

(+) (-)

ARC VOLTS

}

(W/ 100K IN SERIES (2))

(+)

OK-TO-MOVE

}

811

1214

Current ControlCurrent Control

LATCH

SET

RUN

RAR

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

FAULT

ERROR IND

MAX 90 85 80 75 70 65 MIN

TEST POINTS

TP1 TP2 TP3 TP4 TP5 TP6 TP7

+12VDC

OVER PRESSURE INTERNAL ERROR SHORTED TORCH CONSUMABLES MISSING START ERROR PARTS IN PLACE INPUT POWER UNDER PRESSURE

GND +12 VDC +5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC CURRENT DEMAND

D1D1

LOGIC PCB

PCB3

0-100PSI / 0-4.5VDC

+5VDC

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

J3J3

3 2 1

GAS CONTROL

REGULATOR

SOLENOID

ATC

FILTER AIR INLET

VALVE

PRESSURE TRANSDUCER

123

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

NTCNTC

TEMP CIRCUIT

/OVERTEMP

+OUT_1+OUT_1

A-09132_AC

Rev

INTRO ECO-B935

AA AB

ECO B1192

ECO B1357

AD AD

ECO B1611

Last Modified:

6111B OCE

Friday, December 11, 2009

DateByRevisions

MNC

05/21/08

80/11/

MNC

11/01/08

MNC

RWH

Information Proprietary to THERMAL DYNAMICS CORPORATION.

03/31/09

Not For Release, Reproduction, or Distribution without Written Consent.

RWH

12/11/09

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF)

TITLE:

SCHEMATIC,

09:02:19

SCHEMATIC,

CUTMASTER 102/152/A80/A120 230/460V

VICTOR TECHNOLOGIESVICTOR TECHNOLOGIESVICTOR TECHNOLOGIES 16052 Swingley Ridge Road

16052 Swingley Ridge Road

16052 Swingley Ridge Road Suite 300

Suite 300

Suite 300 St Louis, MO 63017 USA

St Louis, MO 63017 USA

PCB No:

Assy No:

SupersedesScale

Date:

JANUARY 31, 2008

Drawn: References

MNC

Chk: App:

Sheet

Size

DWG No:

42X1315

Manual 0-4997 APPENDIX

A-7

Page 80

CUTMASTER 102

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS

GND

380/400/415V OR 600V 3 PH AC INPUT

PRIMARY POWER CONNECTIONS: USE L1, L2, L3 & GND

CE UNITS ONLY

J1J1

SW1SW1

1 3

1 2 3 4

2 4

+12VDC

K1K1

EMI

CHOKE

EMI FILTER

MOT1MOT1

FAN

+ -

SOL 1SOL 1

W1W1

SERIAL PORT

/INRUSH

W1W1

+12VDC

J7J7

1 2

J5J5

1 2 3

24VAC

J6J6

24VAC RET

J4J4

3.3VDC

TXD

RXD

3 4

J13J13

/FAN

/SOLENOID

1 /OVERTEMP 2 /FAN_ON 3 /CSR 4 CUR_SET 5 MAIN_PCB_ID 6 COMMON

12345

INRUSH RESISTORS

BIAS SUPPLY

TP2TP2

J14J14

SYNC

MTH1MTH1

+12VDC BIAS SUPPLY

MTH7MTH7

TP8TP8

AC1AC1

80A_AC180A_AC1

80A_AC280A_AC2

AC2AC2

AC3AC3

80A_AC380A_AC3

PRI 3PRI 3

PRI 2PRI 2

PRI 1PRI 1

C3,C4,C7,C8*+C3,C4,C7,C8*

C5,C6,C9,C10*+C5,C6,C9,C10*

PRI 1PRI 1

MTH2MTH2

TP1TP1

MTH4MTH4

TP5TP5

MTH8MTH8

TP4TP4

TP3TP3

MTH6MTH6

T1T1

PRI 4 PRI 4

MAIN PCB ASSY

PCB1

T2T2

FERRITE

MOT2MOT2

FAN

MOT3MOT3

FAN

FILTER

J4J4

123456789

+12VDC

J1J1

/FAN

J2J2

1 2

+12VDC

J9J9

SYNC

40/50 AMP PCB

PCB5

A-09130_AD

+12VDC

J2J2

1 2

J3J3

PRI 1 PRI 1

PRI 3PRI 3

PRI 2 PRI 2

PRI 4PRI 4

AC1AC1

AC2AC2

AC3AC3

PMTH1PMTH1

PMTH4PMTH4

40A_AC140A_AC1

40A_AC240A_AC2

40A_AC340A_AC3

PMTH1PMTH1

PMTH4PMTH4

PCB2

INPUT CAPACITOR PCB

*CM102/35mm/A80 C7 & C10 may not be installed

C16-17+C16-17

C12-13+C12-13

PMTH2PMTH2

PMTH3PMTH3

PMTH2PMTH2

PMTH3PMTH3

APPENDIX Manual 0-4997

A-8

Page 81

CUTMASTER 102

TS1TS1

/START

/PIP

PILOT IGBTQ5PILOT IGBT

+12VDC

L1L1

ELECTRODE1ELECTRODE1

L2L2

-V OUT 1-V OUT 1

WORK1WORK1

TIP1TIP1

J10J10

1 2 3 4 5 6 7 8

J11J11

D59 PCRD59 PCR

D78 CSRD78 CSR

+12VDC

TEMP

/OVERTEMP

CIRCUIT

NTCNTC

TEST POINTS

GND1

COMMON

GND2

COMMON

+12V1

+12 VDC SUPPLY

48V1

+48 VDC SUPPLY

I_DMD_1

CURRENT DEMAND

TIP_SEN

TIP DRAG SENSE

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

24VAC RETURN

24VAC SUPPLY

OK-TO-MOVE

(5A @ 250VAC / 30VDC)

ATC CONNECTOR

J1J1

E64

E35

J9J9

5 6

P10P10

1 2 3 4 5 6 7 8

40 PIN RIBBON CABLE SIGNALS

FERRITE FILTER

-V_OUT_SIGNAL

/TIP_VOLTS

/TIP_SENSE

/460V_IN

/230V_IN

CUR_SET

/RAR (RAPID AUTO RESTART)

/INRUSH

/W1_ON

SHDN

/TORCH_SOLENOID

/SOLENOID_ON

/OK_TO_MOVE

/FAN_ON

/LATCH_ACTIVE

/TORCH_SWITCH

/PIP

AC_ON

CSR

/TORCH_SOLENOID_DETECT

/OVERTEMP

V_IN

+12VDC

COMMON

MAIN_PCB_ID

460_IN

+3.3VDC

TXD

RXD

COMMON

M-L M-L M-L L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L L-M M-L M-L L-M M-L

CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1 on PCB1

E1E1

P2P2

P10P10

+12VDC

AUTOMATION INTERFACE PCB

1TORCH

PIP SWITCHPIP SWITCH

TORCH SWITCHTORCH SWITCH

AUTOMATION TORCH SOLENOID

WORKWORK

J2J2

OK TO MOVE

}

12 11 10 9 8 7 6 5 4

/START / STOP

}

3 2 1

123

P1P1

K1K1

PCB4

CNC PINOUT

To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS / 16.67 Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50

J1J1

1 2 3

/START / STOP

}

(-)

DIVIDED ARC VOLTS

}

(+)

(-)

ARC VOLTS

}

(W/ 100K IN SERIES (2))

(+)

9 10 11 12

OK-TO-MOVE

}

811

1214

Current ControlCurrent Control

LATCH

SET

RUN

RAR

ACAC

OVERTEMPOVERTEMP

GASGAS

DCDC

ERRORERROR

FAULT

ERROR IND

MAX 90 85 80 75 70 65 MIN

TEST POINTS

TP1 TP2 TP3 TP4 TP5 TP6 TP7

+12VDC

OVER PRESSURE INTERNAL ERROR SHORTED TORCH CONSUMABLES MISSING START ERROR PARTS IN PLACE INPUT POWER UNDER PRESSURE

GND +12 VDC +5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC CURRENT DEMAND

D1D1

LOGIC PCB

PCB3

INTRO ECO B1357

ECO B1399RWH

ECO B1611 RWH

Last Modified:

Friday, December 11, 2009

0-100PSI / 0-4.5VDC

MAXMAX

9090

8585

8080

7575

7070

6565

MINMIN

J3J3

+5VDC

3 2 1

DateByRevisionsRev

03/31/09

RWH

05/05/09

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

TITLE:

09:02:19

REGULATOR

FILTER AIR INLET

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF)

SCHEMATIC,

CM102/152/35mm/40mm/A80/A120 380/400/415/600V

GAS CONTROL

PRESSURE TRANSDUCER

SOLENOID VALVE

123

VICTOR TECHNOLOGIESVICTOR TECHNOLOGIESVICTOR TECHNOLOGIES 16052 Swingley Ridge Road

16052 Swingley Ridge Road

16052 Swingley Ridge Road Suite 300

Suite 300

Suite 300 St Louis MO 63017 USA

St Louis MO 63017 USA

ATC

A-09130_AD

PCB No:

Assy No:

SupersedesScale

Date:

MARCH 30, 2009

Drawn: References

RWH

Chk: App:

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1330

Sheet

SEC1SEC1

SEC2SEC2

CHOKE1CHOKE1

NTCNTC

TEMP CIRCUIT

/OVERTEMP

+OUT_1+OUT_1

Manual 0-4997 APPENDIX

A-9

Page 82

CUTMASTER 102

APPENDIX 7: Publication History

Cover Date Rev. Change(s)

May 30, 2008 AA Manual released. June 23, 2008 AB Updated with new Cut Charts, updated system schematic per ECOB935 and added 460V

version per ECOB939 Nov. 19, 2008 AC Updated system schematic. Jan 27, 2009 AD Corrected art sizing in section 3 to show missing information per ECOB1248. Updated power supply specs and input wiring charts in section 2 per ECOB1197. Apr. 1, 2009 AE Updated cover, system specs and input wiring specs in section 2, system catalog number in

section 6 and added 600V schematic to Appendix per ECOB1346. May 29, 2009 AF Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V sche matic per

ECOB1357. Corrected part numbers in section 6 per ECOB1201. Feb. 25, 2010 AG Updated CNC cable part numbers in section 6 per ECOB1637. Sept. 14, 2010 AH Updated sections 4T and 6 consumables art per ECOB1819. Mar. 20, 2012 AI Updated ART A-08066 and changed COO text, per ECOB2149 April 25, 2012 AJ Updated ART A-07994 per ECOB2136. Aug. 20, 2012 AK Added Opening the Contactor Cover text per ECOB2122. Inserted Victor Technologies branding text. Nov. 30, 2012 AL Revised frequencies speciﬁed in power supply and input wiring speciﬁcations per ECO B2334 Oct. 16, 2013 AM Updated Declaration of Conformity; Made the following changes per ECO B2527: updated

cover to show new Victor Thermal Dynamics trade dress, updated thank you text, changed headers and footers, changed logo on art on pages A-2, A-7, A-9, updated rear cover.

APPENDIX Manual 0-4997

A-10

Page 83

This Page Intentionally Blank

Page 84

THE AMERICAS

Denton, TX USA U.S. Customer Care

Ph 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree)

International Customer Care

Ph 1-940-381-1212 Fax: 1-940-483-8178

Miami, FL USA Sales Office, Latin America

Ph 1-954-727-8371 Fax: 1-954-727-8376

Oakville, Ontario, Canada Canada Customer Care

Ph 1-905-827-4515 Fax: 1-800-588-1714 (tollfree)

EUROPE

Chorley, United Kingdom Customer Care

Ph +44 1257-261755 Fax: +44 1257-224800

Milan, Italy Customer Care

Ph +39 0236546801 Fax: +39 0236546840

ASIA/PACIFIC

Cikarang, Indonesia Customer Care

Ph 6221-8990-6095 Fax: 6221-8990-6096

Rawang, Malaysia Customer Care

Ph +603 6092-2988 Fax: +603 6092-1085

Melbourne, Australia Australia Customer Care

Ph 1300-654-674 (tollfree) Ph 61-3-9474-7400 Fax: 61-3-9474-7391

International

Ph 61-3-9474-7508 Fax: 61-3-9474-7488

Shanghai, China Sales Office

Ph +86 21-64072626 Fax: +86 21-64483032

Singapore Sales Office

Ph +65 6832-8066 Fax: +65 6763-5812

INNOVATION TO SHAPE THE WORLD™

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178

Tweco 102 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.04 Note, Attention et Avertissement

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.01 How To Use This Manual

2.03 Receipt Of Equipment

2.06 Power Supply Features

2T.01 Scope of Manual

2T.02 General Description

2T.05 Introduction to Plasma

2T.04 Options And Accessories

3.01 Unpacking

3.02 Lifting Options

3.03 Opening the Contactor Cover

3.04 Primary Input Power Connections

3.05 Gas Connections

3T.01 Torch Connections

3T.02 Setting Up Mechanical Torch

4.01 Front Panel Controls / Features

4.02 Preparations for Operation

4T.01 Torch Parts Selection

4T.02 Cut Quality

4T.03 General Cutting Information

4T.04 Hand Torch Operation

4T.05 Gouging

4T.06 Mechanized Torch Operation

4T.07 Parts Selection for SL100 Torch Cutting

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip

PATENT INFORMATION

5.01 General Maintenance

5.02 Maintenance Schedule

5.03 Common Faults

5.04 Fault Indicator

5.05 Basic Troubleshooting Guide

5.06 Power Supply Basic Parts Replacement

5T.01 General Maintenance

6.01 Introduction

6.02 Ordering Information

6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts

6.05 Options and Accessories

6.06 Replacement Parts for Hand Torch

6.07 Replacement Parts - for Machine Torches with Unshielded Leads

6.08 Replacement Shielded Machine Torch Leads Assemblies

6.09 Torch Consumable Parts (SL100)

APPENDIX 2: DATA TAG INFORMATION

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

APPENDIX 4: TORCH CONNECTION DIAGRAMS

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS

APPENDIX 7: Publication History