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Tweco 152 User Manual

120
CUTMASTER™ 152
PLASMA CUTTING SYSTEM
208-
230V
460V
600V
Operating Manual
Art # A-08619_AC
VictorThermalDynamics.com
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.thermal-dynamics.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.
!
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™ 152 SL100 1Torch™ Operating Manual Number 0-4987
Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711
www.victortechnologies.com
Copyright 2008, 2009, 2010, 2012, 2013 by Victor Technologies International, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Original Publication Date: May 30, 2008 Revision Date: February 11, 2014
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ________________
Purchase Date:__________________________________ ________________
Power Supply Serial #:___________________________ ________________
Torch Serial #:___________________________________ ________________
i
This Page Intentionally Blank
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................. 1-1
1.01 Notes, Cautions and Warnings ...................................................................1-1
1.02 Important Safety Precautions .....................................................................1-1
1.03 Publications ................................................................................................1-2
1.04 Note, Attention et Avertissement ................................................................1-3
1.05 Precautions De Securite Importantes .........................................................1-3
1.06 Documents De Reference ..........................................................................1-6
1.07 Statement of Warranty ................................................................................ 1-7
SECTION 2 SYSTEM:
INTRODUCTION ............................................................................................................2-1
2.01 How To Use This Manual ...........................................................................2-1
2.02 Equipment Identification .............................................................................2-1
2.03 Receipt Of Equipment ................................................................................. 2-1
2.04 Power Supply Specifications ......................................................................2-2
2.05 Input Wiring Specifications .........................................................................2-3
2.06 Power Supply Features ..............................................................................2-4
SECTION 2 TORCH:
INTRODUCTION ..........................................................................................................2T-1
2T.01 Scope of Manual .......................................................................................2T-1
2T.02 General Description ..................................................................................2T-1
2T.03 Specifications ...........................................................................................2T-1
2T.04 Options And Accessories ..........................................................................2T-2
2T.05 Introduction to Plasma ..............................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION .............................................................................................................3-1
3.01 Unpacking ................................................................................................... 3-1
3.02 Lifting Options ............................................................................................. 3-1
3.03 Opening the Contactor Cover .....................................................................3-1
3.04 Primary Input Power Connections ..............................................................3-1
3.05 Gas Connections ........................................................................................3-3
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
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-8
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ........4T-9
4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-14
PATENT INFORMATION .....................................................................................................4T-20
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
CUTMASTER 152
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SECTION 1:
GENERAL INFORMATION
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.

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:
Gases and fumes produced during the plasma cutting
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.
WARNING
Gives information regarding possible electri­cal shock injury. Warnings will be enclosed in a box such as this.
process can be dangerous and hazardous to your health.

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.
Manual 0-4987 GENERAL INFORMATION
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.
GASES AND FUMES
• 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.
• 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.
Wash hands after handling.
ELECTRIC SHOCK
• Nevertouchanypartsthatareelectrically“live” or“hot.”
1-1
CUTMASTER 152
• Weardryglovesandclothing.Insulateyourself
from the work piece or other parts of the welding circuit.
• Repairorreplaceallwornordamagedparts.
• Extracaremustbetakenwhentheworkplaceis
moist or damp.
• InstallandmaintainequipmentaccordingtoNEC
code, refer to item 9 in Subsection 1.03, Publica­tions.
• Disconnectpowersourcebeforeperformingany
service or repairs.
• ReadandfollowalltheinstructionsintheOperat­ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Besurethereisnocombustibleor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.
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.
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.
GENERAL INFORMATION Manual 0-4987
1-2

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 OC-
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CUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFE­TY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CON- TAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO­CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, REC­OMMENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONTAIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et Avertissement

CUTMASTER 152
ATTENTION
Touteprocédurepouvantrésulterl’endom­magementdumatérielencasdenon-respect delaprocédureenquestion.
AVERTISSEMENT
Touteprocédurepouvantprovoquerdesbles­suresdel’opérateuroudesautrespersonnes
se trouvant dans la zone de travail en cas de
non-respectdelaprocédureenquestion.
AVERTISSEMENT
Fournit l'information concernant des dom-
mages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.
Danscemanuel,lesmots“note,”“attention,”et“aver­tissement”sontutiliséspourmettreenreliefdesinfor-
mations à caractère important. Ces mises en relief sont
classiéescommesuit:
NOTE
Toute opération,procédureourenseigne­mentgénéralsurlequelilimported’insister davantageouquicontribueàl’efcacitéde
fonctionnement du système.
Manuel 0-4987 INFORMATIONS GÉNÉRALES
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.
1-3
CUTMASTER 152
FUMÉE et GAZ
Lafumée etles gazproduitsparle procédéde jetde plasmapeuvent présenterdes risqueset desdangers desanté.
• Eloigneztoutefuméeetgazdevotrezonederespi­ration.Gardezvotretêtehorsdelaplumedefumée
provenant du chalumeau.
• Utilisezunappareilrespiratoireàalimentation en airsil’aérationfournienepermetpasd’éliminerla fuméeetlesgaz.
• 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.
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’opéra-
teur et les autres personnes sur le lieu de travail.
• Netouchezjamaisunepièce“soustension”ou“vive”;
portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendom­magée.
• Prenezdessoinsparticulierslorsquelazonedetravail
est humide ou moite.
• Montezetmaintenez lematérielconformémentau CodeélectriquenationaldesEtats-Unis.(Voirlapage
5, article 9.)
• Débranchezl’alimentationélectriqueavanttouttra­vaild’entretienouderéparation.
• LisezetrespecteztouteslesconsignesduManuelde
consignes.
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ammablenesetrouvesurlelieudetravail.Proté-
gez 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.
• AVERTISSEMENT: Ce produit contient des produits chimiques, notamment du plomb, reconnu par l'État delaCaliforniepourcauserdesmalformationscongé­nitales et d'autres dommages touchant le système reproductif.
INFORMATIONS GÉNÉRALES Manuel 0-4987
1-4
Se laver les mains après manipulation.
• 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.
RAYONS D’ARC DE PLASMA
CUTMASTER 152
• Ilfautmesurerlesniveauxsonoresand’assurerque lesdécibels(le bruit)nedépassentpasles niveaux
sûrs.
Les rayons provenant de l’arc de plasma peuvent bles-
ser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compor-
tant 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ltresmoinsfoncéspeuventêtre utilisésquandl’arcestcachéparmoiceaude
travail.
• Pourdesrenseignementssurlamanièredetesterle
bruit, consultez l’article 1, page 5.
!
AVERTISSEMENT
AVERTISSEMENT: Ce produit contient des produits chimiques, 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and’éviteruneperte
permanente de l’ouïe.
• Pourprotégervotreouïecontrelesbruitsforts,portez
des tampons protecteurs et/ou des protections auri-
culaires.Protégezégalementlesautrespersonnesse
trouvant sur le lieu de travail.
Manuel 0-4987 INFORMATIONS GÉNÉRALES
1-5
CUTMASTER 152

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’AssociationdesGazComprimés(CompressedGasAssociation),1235JeffersonDavisHighway,Suite
501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Asso­ciation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103
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 0-4987
1-6
CUTMASTER 152

1.07 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or tness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER™ 39 4 Years 1 Year
CUTMASTER™ 52 4 Years 1 Year
CUTMASTER™ 82 4 Years 1 Year
CUTMASTER™ 102 4 Years 1 Year
CUTMASTER™ 152 4 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o-rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized 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: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer
ofdistributors(hereinafter“Purchaser”)forserviceinterruption.TheremediesofthePurchasersetforthhereinareexclusive
and the liability of Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007
Manual 0-4987 GENERAL INFORMATION
1-7
CUTMASTER 152
This Page Intentionally Blank
GENERAL INFORMATION Manual 0-4987
1-8
CUTMASTER 152
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.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
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.
!
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 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 0-4987 INTRODUCTION
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CUTMASTER 152
2.04 Power Supply Specifications
CutMaster 152 Power Supply Specifications
Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 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 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable. Output Current 30 - 120 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. **60% at 208/230V 1 Phase input ONLY
Particulates to 5 Microns
CutMaster 152 Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Current 120 120 100
DC Voltage 128 128 120
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
6"
150 mm
Art # A-07925_AB
150 mm
6"
150 mm
6"
INTRODUCTION Manual 0-4987
2-2
2.05 Input Wiring Specifications
CutMaster 152 Power Supply Input Cable Wiring Requirements
Input voltage
Volts Hz kVA I max I eff Fuse
1 Phase 208 60 26.2 126 98 150 4 Type W
230 60 27.6 118 95 125 4 Type W 460 60 35 76 68 100 4
3 Phase 208 60 21.6 60 55 60 4
230 60 22.3 56 50 60 4 380 50 23 35 32 40 8 400 50 23.6 34 31 40 8 460 60 29.5 37 33 40 8 600 60 29.0 28 25 30 10
Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code
Freq Power
Input
Suggested Sizes
Flexible Cord
(amps)
(Min. AWG)
CUTMASTER 152
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 0-4987 INTRODUCTION
2-3
CUTMASTER 152
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 0-4987
2-4
CUTMASTER 152
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.
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.
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
0.625" / 16 mm
4.95" / 126 mm
Art # A-03322_AB
1.175" / 30 mm
Art # A-02998
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 Introduction to Plasma" on page 2T-2, for a more detailed description of plasma torch operation.
Refer to the Appendix Pages for additional specifications as related to the Power Sup­ply used.
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20ft/6.1m,withATCconnectors
• 50ft/15.2m,withATCconnectors
Machine Torches are available as follows:
• 5foot/1.5m,withATCconnectors
• 10foot/3.05m,withATCconnectors
• 25foot/7.6m,withATCconnectors
• 50foot/15.2m,withATCconnectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream through torch.
Manual 0-4987 INTRODUCTION
2T-1
CUTMASTER 152
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (V
Arc Striking Voltage
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (V
Arc Striking Voltage
G. Gas Requirements
Manual and Mechanized Torch Gas
)
peak
Mechanized Torch Ratings
)
peak
Specications
104° F
40° C
100% @ 100 Amps @ 400 scfh
120 Amps
500V
7kV
104° F
40° C
100% @ 100 Amps @ 400 scfh
120 Amps
500V
7kV

2T.04 Options And Accessories

Foroptionsandaccessories,seesection6.

2T.05 Introduction to Plasma

A. Plasma Gas Flow
Plasma is a gas which has been heated to an ex­tremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to gas pressure settings charts for each model.
H. Direct Contact Hazard
Forstandofftiptherecommendedstandoffis3/16
inches / 4.7 mm.
60 - 95 psi
4.1 - 6.5 bar
300 - 500 scfh
142 - 235 lpm
_
Power
Supply
A
+
B
Workpiece
C
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.
A-00002
Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.
INTRODUCTION Manual 0-4987
2T-2
CUTMASTER 152
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
Sh ield Cup
CNC Start
To AT C
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
Manual 0-4987 INTRODUCTION
2T-3
CUTMASTER 152
This Page Intentionally Blank
INTRODUCTION Manual 0-4987
2T-4
SECTION 3 SYSTEM:
CUTMASTER 152
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

1
2
1
2
Art# A-11478
Contactor cover

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
L1
L2
L3 L4
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)
L1
L2
L3 L4
GND
Art # A-08493
The input power cord is connected to the main contactor,
A. Connections to Single Phase Input Power
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.
Manual 0-4987 INSTALLATION
WARNING
Disconnect input power from the power supply and input cable before attempting this procedure.
3-1
CUTMASTER 152
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).
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.
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.
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.
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.
INSTALLATION Manual 0-4987
3-2

3.05 Gas Connections

Regulator/Filter
Regulator/Filter
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
Hose Clamp
Gas Supply Hose
OptionalSingle-StageFilterInstallation
CUTMASTER 152
Assembly
Inlet Port
Art # A-07944
1/4 NPT to 1/4"
(6mm) Fitting
Inlet Port
Hose Clamp
1/4 NPT or ISO-R
Gas Supply Hose
Art # A-07943
to 1/4” (6mm) Fitting
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.
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly.
NOTE
For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air pas­sages in the torch.
2. Connect the two stage filter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied fittings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose barbed fitting is shown as an example.
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:
Manual 0-4987 INSTALLATION
3-3
CUTMASTER 152
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 0-4987
3-4
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