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Thermal Dynamics 152 CUTMASTER, Operating Manual

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CUTMASTER 152 

Manual 0-4987 

5-1 

 SERVICE

SECTION 5 SYSTEM: 

SERVICE

5.01  General Maintenance

Warning!

Disconnect input power before maintaining.

Each Use

Visual check of

torch tip and electrode

Weekly

Visually inspect the torch body tip, 

electrode, start cartridge and shield cup

Visually inspect the

cables and leads.

Replace as needed

3 Months

Clean

exterior

of power supply

6 Months

Replace all 

broken parts

Visually check and 

Carefully clean  the 

interior

Maintain more often

if used under severe

conditions

Art # A-07938_AB

Summary of Contents for 152 CUTMASTER

Page 1: ...460 Art A 08619_AB 600 PLASMA CUTTING SYSTEM 152 CUTMASTER Rev AK Date April 25 2012 Manual 0 4987 Operating Features Operating Manual...

Page 2: ...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 Th...

Page 3: ...yne Corporation 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 liabi...

Page 4: ...This Page Intentionally Blank...

Page 5: ...2T 03 Specifications 2T 1 2T 04 Options And Accessories 2T 2 2T 05 Introduction to Plasma 2T 2 SECTION 3 SYSTEM INSTALLATION 3 1 3 01 Unpacking 3 1 3 02 Lifting Options 3 1 3 03 Primary Input Power C...

Page 6: ...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 Uns...

Page 7: ...sses 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 Si...

Page 8: ...he 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 Washi...

Page 9: ...un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pen dent du genre de m tal u...

Page 10: ...des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l ar...

Page 11: ...s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POU...

Page 12: ...ber of standards and technical requirements Among them are UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of ele...

Page 13: ...arranty 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 i...

Page 14: ...CUTMASTER 152 GENERAL INFORMATION 1 8 Manual 0 4987 This Page Intentionally Blank...

Page 15: ...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 Dynami...

Page 16: ...ient Tempera ture Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C All Units Duty Cycle 60 80 100 Current 120 120 100 IEC IEC IEC DC Voltage 128 128 120 NOTE The duty cycle will be reduced if the...

Page 17: ...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 Cod...

Page 18: ...2 06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 08359 Work Cable and Clamp Art A 08360 Input Power Cord Port for Optional Automation Interface Cable Gas Inl...

Page 19: ...single source to be used as both the plasma and second ary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer t...

Page 20: ...Gas Flow Plasma is a gas which has been heated to an ex tremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting and gouging processes use this plasma to...

Page 21: ...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 con nec...

Page 22: ...CUTMASTER 152 INTRODUCTION 2T 4 Manual 0 4987 This Page Intentionally Blank...

Page 23: ...nit Lift unit by the handles using two hands Do not use straps for lifting Use optional cart or similar device of ad equate capacity to move unit Place unit on a proper skid and secure in place before...

Page 24: ...posite 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 A Connections to Single Phase Input P...

Page 25: ...n shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instruc tions Do Not use Teflon tape as a thread sealer as small part...

Page 26: ...hey are clean and free of oil grease or any foreign material Briefly open each cylin der valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjustable high pressur...

Page 27: ...o not use tools to secure the connection 1 2 Art A 07885 Connecting the Torch to the Power Supply 3 The system is ready for operation Check Air Quality To test the quality of air 1 Put the ON OFF swit...

Page 28: ...87 A 02585 Workpiece Square Pinch Block Assembly Mechanical Torch Set Up 3 The proper torch parts shield cup tip start cartridge and electrode must be installed for the type of operation Refer to Sect...

Page 29: ...the power supply Up is ON down is OFF 4 Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock 5 AC Indica...

Page 30: ...nections and turn air supply ON Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece d...

Page 31: ...h leaves the work piece 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 meta...

Page 32: ...CUTMASTER 152 OPERATION 4 4 Manual 0 4987 This Page Intentionally Blank...

Page 33: ...ies NOTE The shield cup holds the tip and starter car tridge in place Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed 1 Unscrew and re...

Page 34: ...he workpiece Bottom Dross Buildup Molten material which is not blown out of the cut area and resolidifies on the plate Excessive dross may require secondary cleanup operations after cutting Kerf Width...

Page 35: ...ve Slow speed dross is normally present on the bot tom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dro...

Page 36: ...cup and the torch handle Gas vents through this gap as part of normal operation Do not attempt to force the shield cup to close this gap Forcing the shield cup against the torch head or torch handle c...

Page 37: ...lot arc will shut OFF NOTE The gas preflow and postflow are a charac teristic of the power supply and not a func tion of the torch 3 4 Art A 03383 Trigger 2 1 Trigger Release 8 Cut as usual Simply rel...

Page 38: ...ollowing factors may have an impact on system performance Torch parts wear Air quality Line voltage fluctuations Torch standoff height Proper work cable connection 4T 05Gouging WARNING Be sure the ope...

Page 39: ...car bon and stainless steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to the side of the gouge path However slag buil...

Page 40: ...justments that may be required Piercing With Machine Torch To pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc...

Page 41: ...ield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 8236 Drag...

Page 42: ...ps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 036 0 9 9 8208 103 40 355 9 02 0 125 3 2 65 4 5 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 98 40 310 7 87 0 125 3 2 65 4 5 55 170 0 00 0...

Page 43: ...es mm 0 06 1 5 9 8210 119 60 350 8 91 0 19 4 8 70 4 8 90 245 0 00 0 20 5 1 0 075 1 9 9 8210 116 60 300 7 64 0 19 4 8 70 4 8 90 245 0 10 0 20 5 1 0 120 3 0 9 8210 123 60 150 3 82 0 19 4 8 70 4 8 90 245...

Page 44: ...0 25 6 4 0 120 3 0 9 8211 120 80 300 7 62 0 25 6 4 65 4 5 115 340 0 10 0 25 6 4 0 135 3 4 9 8211 120 80 280 7 11 0 25 6 4 65 4 5 115 340 0 10 0 25 6 4 0 188 4 8 9 8211 120 80 140 3 56 0 25 6 4 65 4 5...

Page 45: ...Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 250 6 4 9 8212 118 100 90 2 30 0 190 4 8 75 5 2 130 390 0 5 0 250 6 4 0 375 9 5 9 8212 122 100 55 1 40 0 190 4 8 75 5 2 130 390...

Page 46: ...Inches mm psi bar Plasma Total Delay Sec Inches mm 0 250 6 4 9 8253 135 120 180 4 57 0 19 4 8 75 5 2 180 360 0 20 0 25 6 4 0 375 9 5 9 8253 144 120 100 2 54 0 19 4 8 75 5 2 180 360 0 40 0 25 6 4 0 500...

Page 47: ...s Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 036 0 9 9 8208 109 40 180 4 57 0 125 3 2 65 4 5 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 105 40 165 4 19 0 125 3 2 65 4 5 55 170 0 00 0...

Page 48: ...mm 0 06 1 5 9 8210 110 60 165 4 19 0 13 3 2 70 4 8 90 245 0 00 0 20 5 1 0 075 1 9 9 8210 116 60 155 3 94 0 13 3 2 70 4 8 90 245 0 10 0 20 5 1 0 120 3 0 9 8210 115 60 125 3 18 0 13 3 2 70 4 8 90 245 0...

Page 49: ...5 1 0 120 3 0 9 8211 115 80 260 6 50 0 125 3 2 65 4 5 115 340 0 10 0 2 5 1 0 135 3 4 9 8211 113 80 250 6 25 0 125 3 2 65 4 5 115 340 0 10 0 2 5 1 0 188 4 8 9 8211 114 80 170 4 25 0 125 3 2 65 4 5 115...

Page 50: ...No Volts VDC Amps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 250 6 4 9 8212 121 100 110 2 80 0 125 3 2 75 5 2 130 390 0 5 0 200 5 1 0 375 9 5 9 8212 125 100 60 1 50 0 150 3 8 7...

Page 51: ...ters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 250 6 4 9 8253 136 120 180 4 57 0 13 3 2 75 5 2 180 360 0 20 0 20 5 1 0 375 9 5 9 8253 144 120 100 2 54 0 13 3 2 75 5 2 180 360 0 40 0 20 5 1...

Page 52: ...US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip...

Page 53: ...eld Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237...

Page 54: ...CUTMASTER 152 OPERATION 4T 22 Manual 0 4987 This Page Intentionally Blank...

Page 55: ...ck of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of pow...

Page 56: ...power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical com ponents and cause damage to the unit 5 03 Common Faults Problem Symptom Com...

Page 57: ...low the Temp indica tor and 76 psi indicators are ON indicating the version would be 2 3 A PSI BAR MAX MAX MIN MIN 1 2 3 4 Art A 07988 MIN MAX 0 1 2 3 4 5 6 7 5 When the Fault indicator is ON or blink...

Page 58: ...d 2 Duty cycle of the unit has been exceeded 3 Failed components in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacem...

Page 59: ...uck 3 Worn or faulty torch parts 4 Shorted Torch 5 Temporary Short indicated by 5 blinks per second 6 Power Supply Failure Standard rate of blinking 1 Remove shield cup from torch check upper O Ring p...

Page 60: ...necessary 2 Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws C Filter Eleme...

Page 61: ...upply shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Secti...

Page 62: ...esult 3 Loosen the two bolts on the top of the Filter As sembly 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 Fi...

Page 63: ...h and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head andATC Male Connec tor requires lubrication on a schedu...

Page 64: ...may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Remove the tip Check for excessive wear ind...

Page 65: ...e returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete de...

Page 66: ...cludes Hose Mounting Screws 9 9387 Bracket Filter Mounting not shown 9 9386 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable...

Page 67: ...ew and wrench 9 8062 4 1 Torch Head Assembly Replacement Kit includes items No 5 6 9 8219 5 1 Large O ring 8 3487 6 1 Small O ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assembl...

Page 68: ...onnector 4 7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7843 1 25 foot...

Page 69: ...CUTMASTER 152 Manual 0 4987 6 5 PARTS LIST A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13...

Page 70: ...ds Assemblies with ATC Connectors 1 5 foot 1 5 m Leads Assembly with ATC Connector 4 7846 1 10 foot 3 05 m Leads Assembly with ATC Connector 4 7847 1 25 foot 7 6 m Leads Assembly with ATC Connector 4...

Page 71: ...Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 8236 Drag Shiel...

Page 72: ...CUTMASTER 152 PARTS LIST 6 8 Manual 0 4987 This Page Intentionally Blank...

Page 73: ...lows to set pressure ACTION RUN Rapid Auto Restart SET LATCH switch to RUN for most applications or to Rapid Auto Restart for gouging trimming or expanded metal applications or to LATCH is used for sp...

Page 74: ...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 032...

Page 75: ...Switch 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 Pla...

Page 76: ...6 4 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 R...

Page 77: ...CUTMASTER 152 Manual 0 4987 A 5 APPENDIX This Page Intentionally Blank...

Page 78: ...ERS L2 L1 GND L3 FAN BIAS SUPPLY 12VDC BIAS SUPPLY FERRITE FILTER MTH7 MTH7 AC2 AC2 J9 J9 J2 J2 1 2 AC3 AC3 TP3 TP3 MTH4 MTH4 SOL 1 SOL 1 C3 C4 C7 C8 C3 C4 C7 C8 MOT3 MOT3 SW2 SW2 J14 J14 MTH6 MTH6 PM...

Page 79: ...IP DRAG SENSE TEST POINTS A120 ONLY J2 J1 CNC PINOUT 1 3 4 7 8 11 12 14 OK TO MOVE PIP START 24VAC RETURN 24VAC SUPPLY OVERTEMP TEMP CIRCUIT PRESSURE TRANSDUCER AIR INLET FILTER REGULATOR SOLENOID VAL...

Page 80: ...2 35mm A80 C7 C10 may not be installed MTH4 MTH4 TP3 TP3 AC3 AC3 J2 J2 1 2 J9 J9 AC2 AC2 MTH7 MTH7 MOT3 MOT3 C3 C4 C7 C8 C3 C4 C7 C8 SOL 1 SOL 1 MTH6 MTH6 J14 J14 PRI 2 PRI 2 80A_AC2 80A_AC2 J13 J13 1...

Page 81: ...DMD_1 TIP_SEN COMMON COMMON 12 VDC SUPPLY 48 VDC SUPPLY CURRENT DEMAND TIP DRAG SENSE TEST POINTS J2 J1 CNC PINOUT 1 3 4 7 8 11 12 14 OK TO MOVE PIP START 24VAC RETURN 24VAC SUPPLY OVERTEMP TEMP CIRCU...

Page 82: ...ion 2 per ECOB1197 Apr 1 2009 AE Updated cover section 6 system catalog number section 2 system specs and input wiring and appendix with 600V schematic per ECOB1346 Apr 23 2009 AF Fixed 600v schematic...

Page 83: ...This Page Intentionally Blank...

Page 84: ...ica Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 2...

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