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Manual 0-2992

5-11

SERVICE

5.04 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 screws which secure the cover to the main assembly.

NOTE

There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there
is a need for more room to work.

Art # A-03792

Lower
screws

Upper screws

Ground wire

Lower
screws

2.

Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit.

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Summary of Contents for 101 CUTMASTER

Page 1: ...Plasma Cutting Power Supply CE CutMaster 101 Operating Manual January 6 2004 Manual No 0 2992 A 03661 ...

Page 2: ......

Page 3: ...Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United State...

Page 4: ...pe of Manual 2 1 2 02 Power Supply Specifications 2 1 2 03 Input Wiring Specifications 2 2 2 04 Power Supply Features 2 3 2 05 Power Supply Options and Accessories 2 4 SECTION 3 INSTALLATION 3 1 3 1 Unpacking 3 1 3 2 Lifting Options 3 1 3 3 Primary Input Power Connections 3 2 3 4 Air Connections 3 3 3 5 Torch Connections 3 7 SECTION 4 OPERATION 4 1 4 01 Product Features 4 1 4 02 Preparations For O...

Page 5: ...wer Supply Replacement Parts 6 1 6 05 Options and Accessories 6 2 6 06 Torch Parts 6 3 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 DATA TAG INFORMATION A 2 APPENDIX 3 MAINTENANCE SCHEDULE A 3 APPENDIX 4 TORCH PIN OUT DIAGRAMS A 4 APPENDIX 5 CONNECTION DIAGRAMS A 5 APPENDIX 6 SYSTEM SCHEMATIC A 6 ...

Page 6: ......

Page 7: ...p 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 met als which may contain one or more of the follow ing Antimony Chromium M...

Page 8: ...ons in this manual PLASMAARC RAYS PlasmaArc 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 hel met or shield Also always wear safety glasses with side shields goggles or other protective eye w...

Page 9: ...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 NOTE Toute opération procédure ou renseignement général sur lequel il importe d insister davantage ou qui contribu...

Page 10: ...lesser 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 s...

Page 11: ...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 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 TRAVAILET DE PROTECTION DE LA SANTÉ 29CFR 1910 disponible auprès d...

Page 12: ...ÉCURITÉ POUR LE SOUDAGE ET LA COUPE disponible auprès de l Association des Normes Canadiennes Stan dards 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 ...

Page 13: ...welding equipment UL Underwriters Laboratory rating 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 associ ated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform...

Page 14: ...e as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster Series shall be as ...

Page 15: ... Cycle Current 80A n a 68A n a 45A n a DC Voltage 112V n a 107V n a 98V n a CE CutMaster 101 Power Supply Specifications 400 VAC 360 440 VAC Three Phase 50 Hz CE CutMaster 101 Particulates to 20 Microns CE CutMaster 101 Power Supply Duty Cycle Power Supply includes Input Power Cable with Filtering Beads 20 80 Amps Continuously Adjustable Power Supply uses Compressed Air Only Ambient Temperature 40...

Page 16: ...adian Electric Code CE CutMaster 101 Input Wiring Specifications NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated based on the Duty Cycle of the equipment The suggested sizes are based on flexible power cable with power plug installations For hard wired installations refer to local or national codes Cable conductor...

Page 17: ...Cable and Clamp Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 03738 Input Power Cord Ports for Optional Automation Interface Cable Gas Inlet Port Gas Pressure Regulator Filter Assembly Gas Pressure Gauge 2 04 Power Supply Features ...

Page 18: ...be installed with In Line Air Filters D Extended Work Cable with Clamp As an alternative to the standard 20 ft 6 1 m work cable clamp on the power supply a 50 ft 15 2 m work cable with clamp is available E Multi Purpose Cart Rugged steel cart on easy rolling rear wheels and front mounted swivel casters Provides maximum mobility for the power supply and can also serve as a display cart Top shelf is...

Page 19: ...ing Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNINGS 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 Lif...

Page 20: ... the free end of the cable 2 Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows 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 All the input cable wires must be connected for three phase operation Green Yellow wire to Gro...

Page 21: ...lled 1 Connect the air line to the inlet port The illustration shows typical fittings as an example Other fittings can be used 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 Art A 02999 Hose Clamp 1 4 NPT t...

Page 22: ...ose 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 Art A 03000 Regulator Filter Assembly Inlet Port...

Page 23: ...tting 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 b Connect the two stage filter outlet hose to the inlet port of the Regulator Filter Assembly c Use customer supplied fittings to connect the air line to the Filter A 1 4 NPT to 1 4 hose barbed fitting is shown a...

Page 24: ... 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 500 scfh 236 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 sea...

Page 25: ...e 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 3 The system is ready for operation A...

Page 26: ...e ON OFF switch in the ON up position 2 Put the RUN RAPID AUTO RESTART SET switch in the SET down position 3 Place a welding filter lens in front of the torch and turn on the air Any oil or moisture in the air will be visible on the lens Do not start an arc Art A 03577 A 40 60 20 80 1 2 ...

Page 27: ...T middle position is for an uninterrupted restart when cutting expanded metal or in gouging or trimming operations SET down position is for setting air pressure and purging lines 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...

Page 28: ...h is properly connected Only Thermal Dynamics model SL60 or SL100 Torches may be connected to this Power Supply C Check Primary Input Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power re quirements 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 ...

Page 29: ...y ON OFF switch to the ON up position AC indicator turns on Gas indicator turns on if there is sufficient air pressure for power supply operation NOTE Minimum pressure for power supply operation is lower than minimum for torch operation Art A 03580 A 40 60 20 80 ...

Page 30: ...position Air will flow Art A 03577 A 40 60 20 80 1 2 2 Adjust air pressure per the settings chart Leads Length SL100 Hand Torch or Machine Torch Up to 25 7 6 m 70 psi 4 8 bar Over 25 7 6 m 75 psi 5 2 bar CE CutMaster 101 Air Pressure Settings Art A 03793 70 75 psi 4 5 5 2 bar Pressure Control Knob Bouton De Contrôle de Pression ...

Page 31: ... switch in the Rapid Auto Restart middle 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 NOTE When the shield cup is properly installed...

Page 32: ...e 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 L 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 Art A 03584 A 40 60 20 80 ...

Page 33: ...the o ring 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 ring on a weekly basis 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...

Page 34: ...hed to the main body of the Regulator Filter 3 Grasp the filter element and unscrew it from the Regulator Filter body The filter element will come off with a spool and some additional pieces 4 Note the correct assembly of the filter spool then remove the filter from the spool and either clean it or replace it 5 The filter element and spool with the baffle ring in place teeth facing downward can be...

Page 35: ...off air supply and bleed down system before disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Cover counter clockwise and remove it from the Filter Housing The Filter Element is located inside the Housing Art A 02476 Filter Element Cat No 9 7741 Housing Cover Barbed Fitting Spring Assembled Filter O ring Optional Single Stage Filter Element Replacement 5 Remove ...

Page 36: ...bly as injury could result 3 Loosen the two bolts on the top of the FilterAssembly 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 First Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the sam...

Page 37: ...Worn torch parts f Non Genuine Thermal Dynamics parts used 3 Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cutting current e Non Genuine Thermal Dynamics parts used f Incorrect gas pressure 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d...

Page 38: ...e most likely causes for various symptoms Follow all instructions as listed and complete each section in the order presented This guide is set up in the following manner X Symptom Bold Type Any Special Instructions 1 Cause a Check Remedy Locate your symptom check the causes easiest listed first then remedies Repair as needed being sure to verify that unit operates properly after any repairs C Comm...

Page 39: ...rch will not pilot when torch switch is activated AC indicator ON 1 System is in SET mode a Change RUN Rapid Auto Restart SET switch to RUN up D No gas flow RUN Rapid Auto Restart SET switch in SET position Fans operate AC indicator ON GAS indicator OFF 1 Gas not connected a Check gas connections 2 Gas pressure too low for power supply operation a Adjust gas pressure per torch manual 3 Faulty comp...

Page 40: ...nternal components may result 3 Upper O ring on torch head is in wrong position a Remove shield cup from torch check position of upper O ring Correct if necessary Lower O Ring Upper O Ring in Correct Groove Upper Groove with Vent Holes Must Remain Open Threads Art A 03640 H Torch will not pilot AC GAS and TEMP indicators ON DC indicator OFF 1 Air flow blocked a Check for blocked air flow around th...

Page 41: ...switch to ON up K No cutting output Torch pilots Gas flows Fans operate AC Gas and DC indicator ON TEMP indicator OFF 1 Work cable not connected to work piece or connection is poor a Make sure that work cable has a proper connection to a clean dry area of the workpiece 2 Faulty Torch a Return for repair or have qualified technician repair 3 Faulty components in unit a Return for repair or have qua...

Page 42: ...ast 5 minutes Make sure the unit has not been operated beyond Duty Cycle limit Refer to Section 2 for duty cycle specifications 2 Fan blades blocked TEMP indicator ON a Check and clear blades 3 Air flow obstructed TEMP indicator ON a Check for obstructed air flow around the unit and correct condition 4 Gas pressure too low GAS indicator OFF when torch switch is activated a Check source for at leas...

Page 43: ...ement procedures refer to the Power Supply Service Manual A Cover Removal 1 Remove the upper screws which secure the cover to the main assembly NOTE There is a ground wire connection to the inside of the unit There is no need to disconnect the ground wire unless there is a need for more room to work Art A 03792 Lower screws Upper screws Ground wire Lower screws 2 Loosen but do not remove the lower...

Page 44: ...he upper screws C Fuse Replacement 1 Remove the unit cover per paragraph A above 2 Locate the internal fuse on the left side of the center chassis 3 Replace the fuse A replacement fuse is located inside the power supply Refer to Section 6 Parts Lists for replacement fuse catalog number 4 Reinstall the cover by reversing the steps in paragraph B above Art A 03002 Fuse Location Internal Fuse Locatio...

Page 45: ...ll 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 c...

Page 46: ...35 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 Automation Interface Kit 9 8310 1 25 7 6 m CNC Cable for Automation Interface Kit 9 8312 1 50 15 2 m CNC Cable for Automation Interface Kit 9 8313 Art A 02476 Filter Element Cat No 9 7741 Housing Cover Barbed Fit...

Page 47: ...arter Cartridge 9 8213 9 8241 9 8218 9 8237 8 3487 O Ring 8 3486 O Ring 9 8243 9 8236 70 100A 9 8218 9 8237 Art A 03796 Electrode 9 8215 Shield Cup Shield Cup Shield Cap Drag Shield Cap Deflector Shield Cap Gouging Shield Cup Body Shield Cup Body Art A 03801 Electrode Starter Cartridge Tip Shield Cup Torch Head ...

Page 48: ...PARTS LISTS 6 4 Manual 0 2852 ...

Page 49: ...stem is ready for operation ACTION RUN Rapid Auto Restart SET switch to SET RESULT Gas flows to set pressure ACTION RUN Rapid Auto Restart SET switch to RUN for most applications or to Rapid Auto Restart for gouging trimming or expanded metal applications RESULT Gas flow stops ACTION Release torch trigger RESULT Main arc stops Gas flow stops after post flow ACTION ON OFF switch to OFF RESULT All i...

Page 50: ...acturer 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 I Art A 03288 Date of Mfr Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltage Plasma Cutting Symbol Manufacturer s Name and or Logo Location Model and Revision Lev...

Page 51: ... supply and pressure flow 4 Purge plasma gas line to remove any moisture build up 5 Inspect input power cable for damage or exposed wires replace if necessary Weekly or Every 30 Cutting Hours 1 Check fan for proper operation and adequate air flow 2 Blow or 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 caus...

Page 52: ... 1 Black PIP Negative Plasma 8 Ground ATC Male Connector Front View A 03701 B Mechanized Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma 3 White Pendant Connector 4 Black Pendant Connector 2 Orange PIP 1 Black PIP Pilot 2 PIP 1 PIP 6 Open 7 Open 5 Open 8 Ground 8 Green Pendant Connector Ground 5 White Not Used 7 Green Not Used 6 Open UNS...

Page 53: ... 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector Power Supply with ATC Female Receptacle Pilot Negative Plasma Power Supply To Remote Control Remote Pendant Connector PIP Switch Not Used Male ATC Leads Connector ATC Female Recept...

Page 54: ...20 17 18 11 8 1 2 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 7 D33 ASSY 19X1913 CM101 DC COM W1 ON D25 GAS ON DC COM DC COM P13 J12 J43 P1 INV ON DRAG ON SW ON ASSY 19X1775 LOGIC ASSY 19X1932 CM81 8 3 5 2 7 1 4 6 8 6 7 4 1 5 2 3 DC COM TIP VOLTS 12VDC I SENSE OUT SENSE CSR TIP SENSE 71 70 77 75 74 73 72 8 3 5 2 7 1 4 6 8 6 7 1 4 5 2 3 PIP 3 5 2 1 4 6 6 1 4 5 2 3 8 TORCH SW TORCH SW RTN PIP PI...

Page 55: ...AC PRESSURE SWITCH GAS SOLENOID SWITCH ON OFF SWITCH RUN SET FAN 4 5 220VAC F4 D7 B2 B1 C1 F4 F4 C1 C1 D4 E1 F3 D1 1 5 J28 7 2 3 P40 2 18 PILOT BOARD 8 4 E62 17 8 1 E58 15 ASSY 19X1905 14 6 5 DC COM ISENSE 12VDC J40 5 3 7 6 4 8 2 1 CSR E35 WORK T O R C H E64 E64 DLL E50B E48B E53B E54B E34B E39B E56B E60B E36 E57 E49 E45 E62 E35 E43 E64 E32 E61 E58 E37 E50A E48A E53A E54A E56A E60A E34A E39A E63 E...

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