Thermal Dynamics 1-4200-6 Page 39 Operating Manual Download

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CUTMASTER 10MM, 12MM

Manual 0-5197AC 6-1 PART LIST

SECTION 6:

PARTS LIST

C. Ordering Information

Order replacement parts by part 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 torch. Address all

inquiries to your authorized distributor.

6.02 Power Source Replacement Parts

Item

Qty

Description

Catalog

Logic PCB assembly 10mm & 12mm

9-0076

Control PCB assembly 10mm

9-7555

Control PCB assembly 12mm

9-0077

Main PCB assembly 10mm

9-7556

Main PCB assembly 12mm

9-0079

Air Regulator 10mm & 12mm

9-0081

Solenoid assembly 10mm & 12mm

9-0082

Pressure Switch 10mm & 12mm

9-0075

Hall Current Sensor 10mm & 12mm

9-0088

ON/OFF Switch 10mm & 12mm

9-0074

Cooling Fan 10mm & 12mm

9-0042

Input Rectifier 10mm & 12mm

9-0049

Parts 6-1 - Power Source

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable

components.

B. Returns

If a product must be returned for service, contact

your distributor. Materials returned without proper

authorization will not be accepted.

Summary of Contents for 1-4200-6

Page 1: ...30 20 40 Art A 10399 30 AMP 40 AMP 1 DC PHASE 240 PLASMA CUTTING SYSTEM 10mm 12mm CUTMASTER Rev AE Date September 3 2012 Manual 0 5197AE Operating Features Operating Manual ...

Page 2: ...ereforepleasetakethetimetoreadtheentire manual especiallytheSafetyPrecautions Theywillhelpyoutoavoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies Inc We distinguish ourselves from our com...

Page 3: ... com Copyright 2011 2012 by Victor Technologies All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negli gence accident or any other cause Publicat...

Page 4: ... SECTION 3 INSTALLATION 3 1 3 01 Unpacking 3 1 3 02 Lifting Options 3 1 3 03 Air Supply Connections 3 2 SECTION 4 SYSTEM OPERATION 4 1 4 01 Control Panel 4 1 4 02 Preparations for Operating 4 2 4 03 Sequence of Operation 4 4 4 04 Cut Quality 4 6 4 05 General Cutting Information 4 7 SECTION 5 SYSTEM SERVICE 5 1 5 01 General Maintenance 5 1 5 02 Basic Troubleshooting Guide 5 2 SECTION 5 TORCH SERVIC...

Page 5: ...Panel 4 1 Figure 4 2 Rear Controls 4 1 Figure 4 3 SL60 Torch Parts 4 2 Figure 4 4 Work Cable Connection 4 3 Figure 4 5 Rear Panel with ON OFF Switch 4 3 Figure 4 6 Front Panel with Power ON OFF Indicator 4 3 Figure 4 7 Torch Trigger Release 4 4 Figure 4 8 Standoff Distance 4 4 Figure 4 9 Standoff Cutting 4 4 Figure 4 10 Torch Trigger Release 4 5 Figure 4 11 Drag Cutting 4 5 Figure 4 12 Cut Quality...

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Page 7: ... 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 do...

Page 8: ... 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...

Page 9: ...to 100 10 100 to 400 12 400 to 800 14 Plasma Arc Spraying 15 Plasma Arc Welding Less than or equal to 20 8 20 to 100 10 100 to 400 12 400 to 800 14 Submerged Arc Welding 2 5 Resistance Welding Safety Spectacles or eye shield Refer to standard AS NZS 1338 1 1992 for comprehensive information regarding the above table Table 1 1 Protective Filters FLYING SPARKS AND HOT METAL Chipping and grinding cau...

Page 10: ...source and cables as far away from body as practical ABOUT PACEMAKERS The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for complete information 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtain able from the Superintendent of Documents U S Gov...

Page 11: ...g 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories IEC 60974 10 applicable to Industrial Equipment generic emissions and regulations AS 1674 Safety in welding and allied processes 2002 95 EC RoHS direct...

Page 12: ...CUTMASTER 10MM 12MM GENERAL INFORMATION 1 6 Manual 0 5197AD This Page Intentionally Blank ...

Page 13: ...hermal Dynamics and then on the Literature link http www thermal dynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on a data tag attached to the rear panel Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely...

Page 14: ... Current 20 40 Amps 240VAC CUTMASTER 12mm Power Source Duty Cycle Note 1 Ambient Temperature 104 F 40 C Duty Cycle 40 240VAC Rated Current 40 Amps 240V SL60 Torch Gas Requirements See Section 2T 02 Note 1 Duty Cycle is the percentage of time the system can be operated without overheating Duty cycle is reduced if primary input voltage AC is low or the DC voltage is higher than shown in this chart 2...

Page 15: ...CUTMASTER A 40 20 30 Art A 10216 Figure 2 1 Power Source Dimensions Weight NOTE Weight includes torch leads input power cord and work cable with clamp CAUTION Provide clearance for proper air flow through the Power Source Operation without proper air flow will inhibit proper cooling and reduce duty cycle ...

Page 16: ...ASTER 12mm Input Power Requirements Input Power Input Current Input Current Input Suggested Sizes See Note Voltage Frequency kVA Max Amps I1 eff Amps Fuse Amps Volts AC Hz 1 Ph 1 Ph 1 Ph 1 Ph 240 50 60 5 0 20 8 13 16 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this ...

Page 17: ...ource Feature Locations Air Inlet Control Panel Torch Lead 240 VAC Power Source Work Cable and Clamp CUTMASTER 40 20 30 Art A 10217 To Air Supply clean dry Figure 2 2 Power Source Setup Art A 10225 Air Inlet 1 4 NPT On Off Switch Power Cord Figure 2 3 Power Source Rear View ...

Page 18: ...CUTMASTER 10MM 12MM SYSTEM INTRODUCTION 2 6 Manual 0 5197AD This Page Intentionally Blank ...

Page 19: ... available as follows 20 ft 6 2m C Torch Parts Starter Cartridge Electrode Tip Shield Cup See Figure 4 3 SL60 Torch Parts on page 4 2 D Parts In Place PIP Torch has built in switch 12 vdc circuit rating E Type Cooling Combination of ambient air and gas stream through torch F Torch Ratings SL60 Torch Ratings Ambient Temperature 104 F 40 C Duty Cycle 100 60 Amps 400 scfh Maximum Current 60 Amps Volt...

Page 20: ...his 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 Workpiece Power Supply _ C B A Figure 2T 2 Typical Torch Head Detail 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 el...

Page 21: ...le shipping damage If damage is evident contact your distributor and or shipping company before proceeding with the installation 3 Record Power Source 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 Source includes a handle for hand lifting only Be sure unit is lifted and transported safely and sec...

Page 22: ...s specifications for installation and maintenance procedures for high pressure gas regulators 2 Examine the cylinder valves to be sure they are clean and free of oil grease or any foreign mate rial Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjust able high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar m...

Page 23: ...utting output reduce the cutting time or connect the unit to more adequate input power For 240V input power the maximum output is 40 Amps Refer to Section 2 05 Power Source Specifications on page 2 2 for input power requirements 3 AC Indicator Steady light indicates Power Source is ready for operation 4 OVERHEAT Indicator TEMP Indicator Indicator is normally OFF Indicator is ON when internal tempe...

Page 24: ...st correspond with the type of operation and with the amperage output of this Power Source 40 amps maximum Use only genuine Thermal Dynamics parts with this torch See 6 03 SL60 Replacement Parts on page 6 2 Art A 10224 Start Cartridge Part No OTD9 8213 Electrode OTD9 8215 Worn Electrode Worn Tip 40 Amp Drag Tip Part No OTD9 8207 fitted Shield Cup Part No OTD9 8218 40 Amp Standoff Tip Part No OTD9 ...

Page 25: ...s source meets requirements listed in Section H Gas Requirements on page 2T 1 Check connec tions and turn gas supply on E Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 03387 Figure 4 4 Work Cable Connection F Power On Place the Powe...

Page 26: ...th Hand Torch NOTE For best performance and parts life always use the correct parts for the type of operation A 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 protec tion Choose the hold...

Page 27: ...ble and allows good control and movement C Keep the torch in contact with the workpiece during the cutting cycle D Hold the torch away from your body E Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The arc will start Art A 03962 Trigger Trigger Release Figure 4 10 Torch Trigger Release F Place the torch tip on the work The main arc will tr...

Page 28: ...s 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 su...

Page 29: ...sh the cutting arc as quickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Right Side Cut Angle Left Side Cut Angle A 00512 Figure 4 13 Side C...

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Page 31: ... subassemblies are faulty then the Cutting Power Source must be returned to an Accredited Thermal Dynamics Service Provider for repair Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months 6 Months Replace all broken parts Visually check and Carefully clea...

Page 32: ... measurement and troubleshooting techniques Common Faults symptom LED Indicators A AC indicator OFF 1 Main input power cord does not connect to power distribution net a Connect the power cord 2 Power ON OFF switch in OFF down position a Turn switch to ON up position 3 Actual input voltage does not correspond to voltage of unit a Verify that the input line voltage is correct 4 Faulty components in ...

Page 33: ...ue 3 Faulty components in unit a Have an Accredited CIGWELD service provider repair or replace as required F No cutting output when torch is activated AC indicator ON gas flows fan turns 1 Torch is not connected properly to Power Source a Check torch connection to Power Source 2 Working cable not connected to workpiece or connection is poor a Make sure that work cable has a proper connection to a ...

Page 34: ... parts worn consumables a Turn OFF input power remove shield cup tip start cartridge and electrode and check them all If the electrode or cutting tip is worn out replace them If the start cartridge does not move freely replace it If there is too much spatter on shield cup replace it K Arc goes out while operating Arc can t be restarted when torch trigger is activated 1 Power Source is overheated T...

Page 35: ... NOT activate torch If there are contaminants in the gas additional filtering may be needed 4 Torch parts worn a Check torch shield cup cutting tip start cartridge and electrode Replace as needed M When torch trigger is activated gas in torch flows and then stops but will not pilot AC indicator light blinking 1 Torch parts not properly installed in torch There may have been an attempt to remove to...

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Page 37: ...This buildup can affect the 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 Source is ON The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the...

Page 38: ...d Art A 09345 Electrode Start Cartridge Tip Shield Cup Torch Head Figure 5 3 Consumable Parts 3 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 09791 Figure 5 4 Tip Wear 4 Remove the starter cartridge Check for excessive wear plugged gas holes or discoloration Check the lower end fitting for free moti...

Page 39: ...assembly 10mm 9 7555 2 1 Control PCB assembly 12mm 9 0077 3 1 Main PCB assembly 10mm 9 7556 3 1 Main PCB assembly 12mm 9 0079 4 1 Air Regulator 10mm 12mm 9 0081 5 1 Solenoid assembly 10mm 12mm 9 0082 6 1 Pressure Switch 10mm 12mm 9 0075 7 1 Hall Current Sensor 10mm 12mm 9 0088 8 1 ON OFF Switch 10mm 12mm 9 0074 9 1 Cooling Fan 10mm 12mm 9 0042 10 1 Input Rectifier 10mm 12mm 9 0049 Parts 6 1 Power ...

Page 40: ... 1 Tip 40A Drag fitted OTD9 8207 1 Tip 40A Standoff OTD9 8208 4 1 Shield Cup OTD9 8218 N S 1 SL60 Torch w 20 ft 6 2m leads not shown OTD7 5204 Parts 6 2 Electrode Parts 6 04 Options and Accessories Qty Description Part No 1 Single Stage Filter Kit 7 7507 1 Circle cutting guide OTD7 3291 1 Roller radius cutting guide OTD7 7501 1 ATC 7 6m Torch torch lead extension OTD7 7545 ...

Page 41: ...11 G D S G D S G D S 1 3 4 5 6 2 7 1 2 3 4 5 6 7 DRIVE SIGNAL DRIVE SIGNAL 1 2 3 4 5 1 2 3 4 5 HF QF 1 2 3 1 2 1 2 3 4 TEST WV OUTPUT 1 2 3 1 2 3 WV OUTPUT 1 2 1 2 3 4 FEEDBACK SIGNAL WORK T O R C H AC 240 VAC INPUT 50 60Hz 1 2 3 4 A GAS SOLENOID 1 2 DC 24V PILOT SOURCE TIP 1 2 U_D AC 1 V 2 AC 3 V 4 AC 1 V 2 AC 3 V 4 1 2 L G D S OVER TEMPERATURE PRESSURE SW TORCH SW OT POWER DC CURRENT CONTROL AIR...

Page 42: ...s 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 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasona...

Page 43: ... 1257 224800 PT Victor Technologies Utama Indonesia Jl Angsana II Blok AE No 28 Delta Silicon I Cikarang Sukaresmi Bekasi 17550 Indonesia Tel 62 21 8990 6095 Fax 62 21 8990 6096 1867 http www Victortechnologies com Victor Technologies China No 100 Lao Hongjing Rd Minhang District Shanghai PR 200235 Telephone 86 21 64072626 Fax 86 21 64483032 Victor Technologies Asia Sdn Bhd Lot 151 Jalan Industri ...

Page 44: ...Asia Pacific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 FAX 61 3 9474 7391 Email enquiries cigweld com au www cigweld com ...

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