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Congratulations on your new 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 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.

Thermal Dynamics is a Global Brand of manual and automation

Plasma Cutting Products for Thermadyne Industries Inc.

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 ad-

vanced products to achieve a safer working environment within

the welding industry.

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Summary of Contents for A-08950

Page 1: ...Art A 08950 380V 400V 415V 40 PLASMA CUTTING SYSTEM 12mm CUTMASTER Rev AH Date April 25 2012 Manual 0 5077 Operating Features Service Manual ...

Page 2: ...e 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 Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves ...

Page 3: ...rporation 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 Original Publication Date January 9 2009 Revis...

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

Page 5: ...ons 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 Connections 3 1 3 04 Gas Connections 3 2 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 P...

Page 6: ...n 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 Major External Replacement Parts 6 2 6 05 Front Panel Replacement Parts 6 3 6 06 Left Side Replacement Parts 6 4 6 07 Right Side Replacement Parts 6 5 6 08 Options and Accessories 6 6 6 09 Replacement Parts for Hand Torch 6 7 6 10 Rep...

Page 7: ...RAM 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 380 400 415V UNITS A 6 APPENDIX 6 Publication History A 8 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Rear Cover ...

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Page 9: ...cesses 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 ...

Page 10: ...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 WEL...

Page 11: ... 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 dépen dent 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 pou...

Page 12: ...urs des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon état Remplacez toute lentille sale ou comportant fissure ou rognure Protégez l...

Page 13: ...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 Asso ciation Batterymarch Park Quincy MA 02269 9 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL dis...

Page 14: ...ory 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 associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when used in conjunction with ...

Page 15: ...mm 3 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 ...

Page 16: ...CUTMASTER 12mm GENERAL INFORMATION 1 8 Manual 0 5077 This Page Intentionally Blank ...

Page 17: ...nt 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 thermal dynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear on...

Page 18: ...perature Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C IEC Rating All Units Duty Cycle 40 60 100 Ratings Non CE CE Non CE CE Non CE CE Current 40A 35A 40A 25A 25A DC Voltage 96 96 94 96 90 90 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 NOTE IEC Rating is determined as specified by the International Elec...

Page 19: ... kVA I max I eff Fuse amps Flexible Cord AWG 3 Phase 380 50 60 5 3 8 5 10 16 400 50 60 5 3 8 5 10 16 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE 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 ...

Page 20: ...nual 0 5077 2 06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 07942 Work Cable and Clamp Art A 08544 Input Power Cord Port for Optional Automation Interface Cable Gas Inlet Port Filter Assembly ...

Page 21: ...rom a 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 to Section 2T 01 Scope of Manual on page 2T 1 for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional speci fications as related to the Power Supply us...

Page 22: ... 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 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 plas...

Page 23: ...c 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 nected 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 ...

Page 24: ...CUTMASTER 12mm INTRODUCTION 2T 4 Manual 0 5077 This Page Intentionally Blank ...

Page 25: ... transporting with a fork lift or other vehicle 3 03 Primary Input Power Connections CAUTION Check your power source for correct voltage 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 speci fied in Section 2 Connections for Three Phase Input ...

Page 26: ...in structions found in section 5 8 Connect the opposite end of individual wires to a customer supplied plug and plug into an appropriate input power receptacle or connect directly to main disconnect 9 Close the main disconnect switch to supply power to the unit 3 04 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders Refer to the f...

Page 27: ...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 th...

Page 28: ... 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 thr...

Page 29: ...Do 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 switch in the ON up position 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn ON the air Do not start an arc Any oil or moisture in the a...

Page 30: ...077 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 Section 4T 07 Torch Parts Selection for details ...

Page 31: ... 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 Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is in pro tective interlock mode Shut unit OFF shut OFF or disconnect input power correct the fault and restar...

Page 32: ...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 do not connect to the part to be cut off Art A 04509 Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator turns ON Gas indicator turns ON if there is sufficient gas pressure...

Page 33: ...rk 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 metal or gratings or in gouging or trimming operations when an uninter rupted restart is desired And with the knob in the LATCH position the main cutting arc will be main tained after the torch switch is released Typica...

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Page 35: ...t into the torch head until it clicks 4 Install the starter cartridge and desired tip for the operation into the torch head 5 Hand tighten the shield cup assembly until it is seated on the torch head If resistance is felt when installing the cup check the threads before proceeding 4T 02 Cut Quality NOTE Cut quality depends heavily on setup and parameters such as torch standoff align ment with the ...

Page 36: ...nd metal NOTE Handle torch leads with care and protect them from damage Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect t...

Page 37: ... with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the holding technique that feels most comfort able and allows good control and move ment NOTE The tip should never come in contact with the workpiece except during drag cutting o...

Page 38: ... can be used with a non conduc tive straight edge to make straight cuts by hand WARNING The straight edge must be non conductive A 03539 Non Conductive Straight Edge Cutting Guide Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 ...

Page 39: ...ne hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the technique that feels most comfortable and allows good control and movement NOTE The tip should never come in contact with the workpiece except during drag ...

Page 40: ...Be sure the operator is equipped with proper gloves clothing eye and ear protection and that all safety precautions at the front of this manual have been followed Make sure no part of the operator s body comes in con tact with the workpiece when the torch is activated Disconnect primary power to the system be fore disassembling the torch leads or power supply CAUTION Sparks from plasma gouging can...

Page 41: ... Slag Buildup Slag generated by gouging on materials such as 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 build up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc The build up is most o...

Page 42: ...e Control Module Operating Manual for any Corner Slowdown adjustments that may be required Piercing With Machine Torch To pierce with a machine torch the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the front end of the torch When operating with a cuttin...

Page 43: ... 70 120A 50 60A 40A Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Tip Tips Tips Tips DRAG TIP CUTTING 40 120A GOUGING CUTTING CUTTING CUTTING Art A 08951 DRAG SHIELD CUTTING Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 O Ring No 8 3488 Standoff Guide 9 8281 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 O Ring No 8 3488 STANDOFF ...

Page 44: ...40 355 9 02 0 125 3 2 70 4 8 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 98 40 310 7 87 0 125 3 2 70 4 8 55 170 0 00 0 2 5 1 0 06 1 5 9 8208 98 40 240 6 10 0 125 3 2 70 4 8 55 170 0 10 0 2 5 1 0 078 2 0 9 8208 100 40 125 3 18 0 125 3 2 70 4 8 55 170 0 30 0 2 5 1 0 135 3 4 9 8208 120 40 30 0 76 0 187 4 8 70 4 8 55 170 0 40 0 2 5 1 0 188 4 8 9 8208 124 40 20 0 51 0 187 4 8 70 4 8 55 170 0 60 0 2 5 1 0 25 6 ...

Page 45: ...0 180 4 57 0 125 3 2 70 4 8 55 170 0 00 0 2 5 1 0 05 1 3 9 8208 105 40 165 4 19 0 125 3 2 70 4 8 55 170 0 00 0 2 5 1 0 06 1 5 9 8208 115 40 120 3 05 0 125 3 2 70 4 8 55 170 0 10 0 2 5 1 0 078 2 0 9 8208 120 40 65 1 65 0 187 4 8 70 4 8 55 170 0 30 0 2 5 1 0 135 3 4 9 8208 125 40 25 0 64 0 187 4 8 70 4 8 55 170 0 40 0 2 5 1 0 188 4 8 9 8208 132 40 20 0 51 0 187 4 8 70 4 8 55 170 0 60 0 2 5 1 0 25 6 ...

Page 46: ... US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8226 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8227 T...

Page 47: ...ield Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237 Shield Cup 9 8238 Shield Cap 9 8239 Shield Cap 9 8244 Shield Cap 9 8245 Shield Cap ...

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Page 49: ...heck 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 ...

Page 50: ... blow air into the 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 Common Cause Insufficient Penetration 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics part...

Page 51: ...hat operating pres sure is set too low and power supply output power will be disabled PART IN PLACE Indicates that the shield cup is not properly installed or tightened START ERROR Indicates that the START SIGNAL was active ie Torch Trigger depressed hand held pendant switch ON or CNC signal for torch ON during one of three conditions 1 During initial power up when ON OFF switch is turned to ON po...

Page 52: ... clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacement GAS indicator OFF FAULT and MIN pressure indicators flashing 1 Gas supply not connected to unit 2 Gas supply not turned ON 3 Gas supply pressure too low 4 AIR PRESSURE CONTROL regulator set too low 5 Failed components in unit 1 Connect gas supply to unit 2 Turn gas supply ON 3 S...

Page 53: ...pper O Ring position correct if necessary 2 Turn OFF power supply Bleed down system pressure Remove shield cup tip and start cartridge Check start cartridge lower end fitting for free movement Replace if fitting does not move freely 3 Inspect torch consumable parts Replace if necessary 4 Replace torch and leads or return to an authorized service center for repair FAULT indicator flashing and 85 PS...

Page 54: ...ngage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws C Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Subsection 5 02 and either cleaned or replaced 1 Remove power from the power supply turn OFF the gas supply and bleed down the sys...

Page 55: ...ent can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system be fore disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Filter Housing Cover counter clockwise and remove it The Filter El...

Page 56: ...bs 2 3 3 4 Nm Improper torque may damage the gasket 8 Slowly apply air pressure to the assembly check ing for leaks NOTE A small amount of air leakage from the bottom fitting is normal This completes the parts replacement procedures 5 07 Circuit Fault Isolation WARNING The following procedures should not be attempted by anyone who has not had proper training or authorized to do so A Cover Removal ...

Page 57: ...erating pressure per pressure setting label on power supply 3 Set the Power Supply controls as follows ON OFF SWITCH to OFF position Turn FUNCTION CONTROLSWITCH to SET position CURRENT CONTROLPOTENTIOMETER to MAXIMUM position fully clockwise E Main Input and Internal Power Test 1 Connect Primary Line power to the unit 2 Turn the ON OFF SWITCH SW1 to ON position and observe the following Software v...

Page 58: ...3 Set the CURRENT CONTROL POTENTIOM ETER to maximum position Current adjusts from 20 amps up to 40 amps 4 While cutting keep the torch switch closed bring the torch OFF the edge of the material Cutting arc extinguishes Gas solenoid closes Gas flow stops momentarily then restarts when solenoid opens Pilot arc ignites 5 Open the torch switch DC LED turns OFF After 20 second post flow time Gas soleno...

Page 59: ...ctor with jumper installed between pins 2 and 3 ARC VOLTS divided by 16 Measure the voltage between these points while piloting Open Circuit Voltage and while cutting The voltages should approximately as listed below Open Circuit Voltage Cutting Voltage a 300 VDC 100 VDC b 6 VDC 2 VDC c 19 VDC 6 VDC This completes the CNC Interface Test If the above are all correct then the unit is functioning cor...

Page 60: ...er turning SW1 to ON 3 Open or improperly connected ribbon cable to J2 connector on Main PCB 1 a Inspect connection and check continuity Re place if open 4 Defective Main PCB 1 a Replace Main PCB 1 F UNDER PRESSURE FAULT AC LED ON FAULT Indicator and 60 PSI LED flashing 1 Air pressure source to unit is too low a Set input pressure source to 90 100 PSI 2 Regulator set too low a Adjust unit regulato...

Page 61: ...ch circuit a Check continuity of torch switch circuit atATC pins 3 4 See previous illustration 3 Short in CNC cable a Check continuity 4 Defective Logic PCB PCB 3 a Measure voltage at Main PCB between J2 16 to test point GND1 for 12VDC If voltage is present replace Logic PCB 5 Defective Main PCB a Replace Main PCB J TIP MISSING FAULT The FAULT Indicator and 80 PSI LED is flashing Gas solenoid cycl...

Page 62: ...to J8 2 on Main PCB for 12VDC If voltage is missing at either recep tacle replace Main PCB 5 Defective Logic PCB a Replace Logic PCB L AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing Gas is not flowing 1 Gas supply not connected to unit a Connect gas supply to unit 2 Gas supply not turned ON a Turn gas supply ON 3 Gas supply pressure too low a Set gas s...

Page 63: ... Measure on Main PCB between J2 11 to GND1 for less than 2VDC If voltage is 12VDC re place Logic PCB Q Cannot adjust gas pressure in the SET mode 1 Inlet gas pressure is too low a Increase inlet gas pressure to 95 120 psi 2 Faulty regulator a Replace Regulator 5 09 Pilot Arc Problems A AC LED ON TEMP LED OFF GAS LED ON Nothing happens when torch switch or remote switch is closed Or CNC START signa...

Page 64: ...ng DC LED OFF Fault Indicators OFF No arc in torch 1 Defective Logic PCB 3 a Measure voltage at Main PCB between test point GND1 to J2 10 Voltage is normally 12VDC and should drop to less than 2VDC two 2 seconds after torch switch is de pressed If voltage does not drop replace Logic PCB b While pilot arc is established measure voltage on Main PCB 1 between test points GND1 to I_DMD1 for 1 4 VDC If...

Page 65: ...ch switch closed the pilot does not start immediately when the cutting arc extinguishes 1 Defective Logic PCB 3 a Replace Logic PCB 3 E INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to clear the error 5 11 CNC Interface Problems A Nothing happens when jumper is installed betwe...

Page 66: ...e chart Input Diode Module Meter Meter Indication AC1 MTH 2 Forward Bias AC2 MTH 2 Forward Bias AC3 MTH 2 Forward Bias MTH 2 AC1 Reverse Bias MTH 2 AC2 Reverse Bias MTH 2 AC3 Reverse Bias MTH 5 AC1 Forward Bias MTH 5 AC2 Forward Bias MTH 5 AC3 Forward Bias AC1 MTH 5 Reverse Bias AC2 MTH 5 Reverse Bias AC3 MTH 5 Reverse Bias 2 If the test reveals a failed component replace Main PCB and perform main...

Page 67: ... transformer wires from Main PCB terminal SEC 1 2 Using an ohmmeter perform the tests in the chart Output Diode Module Meter Meter Indication SEC 1 WORK 1 Forward Bias SEC 1 CHOKE 1 Reverse Bias WORK 1 SEC 1 Reverse Bias CHOKE 1 SEC 1 Forward Bias SEC 2 WORK 1 Forward Bias SEC2 CHOKE 1 Reverse Bias WORK 1 SEC2 Reverse Bias CHOKE 1 SEC 2 Forward Bias 3 If the test reveals a failed component replace...

Page 68: ...2 LAYOUT A CAPACITOR PCB SIGNALS Signal Source Destination J1 1 Capacitor bank A J1 5 Capacitor bank A J2 1 Capacitor Bank B J2 5 Capacitor Bank B J3 1 12 VDC M C J3 2 460 Active low for 460VAC input M C J3 3 230 Active low for 230VAC input M C B CAPACITOR PCB TEST POINTS MTH 1 2 Capacitor bank A MTH 3 4 Capacitor bank A MTH 6 8 Capacitor Bank B MTH 5 7 Capacitor Bank B ...

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Page 70: ... A 08504_AB D1 TP3 J3 A LOGIC PCB SIGNALS Same for MAIN PCB J2 Signal Source Destination J1 1 VOUT OUTPUT VOLTAGE M L J1 2 TIP VOLTS Active high when tip is installed M L J1 3 TIP_SEN Approx 100VDC while cutting with tip not in M L contact w work piece Active low when tip contact work during cut Drag Mode J1 4 400V_IN Active low with 400VAC primary input voltage L M ...

Page 71: ...w when Latch mode is active during cut L M J1 16 TRCH_SW Active low START is active Torch switch CNC M L J1 17 PIP Active low PARTS IN PLACE satisfied M L J1 18 AC_ON Pulse signal M L J1 19 CSR Active high during main transfer M L J1 20 TORCH_SOL_DETECTED Active low for torch with remote solenoid M L J1 21 OVERTEMP Active low when over temperature M L J1 22 V_IN Input Voltage signal M L 2 6VDC 400...

Page 72: ... Shorted torch D5 80 PSI X 4 Tip Missing D6 75 PSI X 3 Start Signal active during power up D7 70 PSI X 2 Parts In Place Fault PIP D8 65 PSI X 1 Input Power Fault D9 MIN PRESSURE X 0 Low Pressure D10 AC 1 X D11 OVERTEMP 2 X D12 GAS 3 X D13 DC 4 X D14 ERROR 5 X C LOGIC PCB TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 3DCV TP5 0 5 to 5 VDC 0 100 psi TP6 1 8VDC TP7 Potentiometer Current Demand 0 3 ...

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Page 74: ... J4 J3 J2 TP8 TP7 J13 J12 TP2 TP1 J1 TP3 I_DMD1 GND1 12V1 12V2 48V2 TP6 PRI_2 TP5 AC3 AC1 AC2 WORK_1 PRI_1 PRI_4 TP4 J11 Art A 08518_AB 1 39 40 2 J2 PINOUT MAIN PCB LAYOUT A MAIN PCB SIGNALS J1 1 L1 Primary AC Line J1 2 Not used J1 3 Not used J1 4 Not used J1 5 L2 Primary AC Line J2 Signal info is the same as Logic PCB 3 connector J1 J3 1 230VAC J3 2 Common ...

Page 75: ... supply J9 6 Not Used J9 7 Torch solenoid 24VAC return J10 1 OK TO MOVE J10 2 Not used J10 3 OK TO MOVE J10 4 Not used J10 5 Common J10 6 Common J10 7 Not used J10 8 START Torch Switch J11 1 Jumper installed J11 2 Jumper installed J12 1 12VDC J12 2 460VAC J12 3 230VAC B LED INDICATORS D59 PCRIndicates Pilot IGBT gate signal is ON D78 CSRIndicates cutting arc has been established C MAIN PCB TEST PO...

Page 76: ... Work Cable J2 To Logic Pcb J12 To PCB2 J1 To SW1 J10 To Automation Interface Pcb J9 To ATC connector J8 To Fan J5 To SOL1 J6 To W1 J3 To SW2 J11 CM52 Jumper CM82 TS2 J7 To Fan SEC2 SEC2 SEC1 SEC1 7 7A 8 9 ELEC 1 CHOKE1 J4 N A E64 A B E35 D C Art A 08902 MAIN PCB WIRING DIAGRAM ...

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Page 79: ...rch 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 scheduled basis This will allow the o rings to remain pliable and provide a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to ...

Page 80: ...re 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 indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 03406 Example of Tip Wear 5 Remove the starter cartridge Check for excessive wear plugged gas h...

Page 81: ...t shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial n...

Page 82: ...ernal Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 0220 2 1 Base Enclosure Assembly 9 0118 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0226 5 1 Rear Panel 9 0101 Art A 08120 3 2 4 5 1 3 NOTE Illustration may vary slightly from unit ...

Page 83: ...ion Ref Catalog 1 1 Output Current Control and Function Control Knobs 9 8527 2 1 Toggle On Off Switch SW1 9 0109 3 1 Work Cable with Clamp 20 Ft 6 1 m 9 0184 Not Shown 1 Wire harness from SW1 w EMI Choke CE Power Supplies Only 9 0247 Art A 08123 1 2 3 NOTE Illustration may vary slightly from unit ...

Page 84: ...08 2 1 Logic PCB PCB 3 9 0214 3 1 Center Chassis Molded Plastic 9 0102 4 1 Fan MOT 1 MOT 2 9 0104 5 1 Transformer Main T1 9 0106 6 1 Inductor Output L1 9 0105 Not Shown 1 Power Cable Strain Relief for all units 9 0111 1 Input Power Cord for 380 400 415V Power Supply 9 0218 1 2 3 4 5 6 Art A 08122 NOTE Illustration may vary slightly from unit ...

Page 85: ...Input Capacitors PCB 2 9 0475 8 1 Filter Auto Drain 9 0116 NOTE 9 0115 regulator If the serial number of the power supply is prior to 05078755 then kit number 9 0201 will be needed to replace not only the regulator 9 0115 but the logic PCB as well Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting If there is a transducer ...

Page 86: ...rst 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 1008 1 35 10 7 m CNC Cable for Automation Interface Kit 9 1010 1 50 15 2 m CNC Cable for Automation Interface Kit 9 1011 1 Nylon Dust Cover 9 7071 Art A 02476 Filter Element ...

Page 87: ...t Kit includes items No 5 6 9 8219 5 1 Large O ring 8 3487 6 1 Small O ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 SL60 20 foot Leads Assembly with ATC connector 4 7834 1 SL60 50 foot Leads Assembly with ATC connector 4 7835 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 9 7031 10 ...

Page 88: ...ot 15 2 m Leads Assembly with ATC connector 4 7853 6 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 foot 1 5 m Leads Assembly with ATC connector 4 7842 1 10 foot 3 05 m Leads Assembly with ATC connector 4 7843 1 25 foot 7 6 m Leads Assembly with ATC connector 4 7844 1 50 foot 15 2 m Leads Assembly with ATC connector 4 7845 7 1 11 279 mm Rack 9 7041 8 1 11 279 mm Mounting Tube 9 704...

Page 89: ...CUTMASTER 12mm Manual 0 5077 6 9 PARTS LIST A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13 ...

Page 90: ...0 120A 50 60A 40A Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Tip Tips Tips Tips DRAG TIP CUTTING 40 120A GOUGING CUTTING CUTTING CUTTING Art A 08951 DRAG SHIELD CUTTING Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 O Ring No 8 3488 Standoff Guide 9 8281 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 O Ring No 8 3488 STANDOFF CU...

Page 91: ...wrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to a convenient and ex posed electrical ground 4 Connect the equipment primary cable ground to the same electrical ground as the wrist strap 5 Open the equipment enclosure and remove the failed PC boa...

Page 92: ... the screws securing the tube handles to the base of the unit NOTE Some of the earliest manufactured units have Tube Handles that are joined together under the base of the unit Later versions are not joined together 4 Remove the power supply from the Tube Han dles 5 Replace the Tube Handles by reversing the above steps 6 Reinstall the power supply cover D Disconnecting Front and Rear Panels from t...

Page 93: ...section 7 04 A 2 Remove the three 3 air hoses from the regulator per subsection 7 05 C 3 Pull the Air Regulator adjusting knob from the shaft 4 Loosen and remove the locking nut securing the Air Regulator to the front Panel then remove the regulator 5 Install replacement Air Regulator by reversing the above steps 6 Reinstall the power supply cover E Gas Solenoid Replacement Tools required T20 Torx...

Page 94: ... the replacement fan s note the direction of air flow as labeled on the fan housing and orient so fan will blow air into the unit 6 Install replacement fan by reversing the above steps 7 Reinstall the power supply cover B Main Transformer T1 Replacement Tools required T20 Torx Driver Nut Driver 1 Remove the Cover per subsection 7 04 A 2 Remove the Tube Handle per subsection 7 04 C 3 Remove the two...

Page 95: ...move the two screws securing the Output Inductor to the base 15 Remove the Output Inductor carefully guiding its wires through from the right side of the unit 16 Install replacement Output Inductor by reversing the above steps 17 Reinstall the power supply cover 7 07 Rear Panel Parts Replacement A Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better syste...

Page 96: ...er Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Ele ment 3 Disconnect gas supply hose 4 Turn the Filter Housing Cover counter clockwise and remove it The Fi...

Page 97: ...he PCB noting the location and orientation of each wire and connector 6 Remove the four 4 mounting screws securing the PCB to the center chassis 7 Carefully guide the PCB assembly up and out of the unit 8 Install the replacement PCB by reversing the above steps 9 Reinstall the power supply cover C Main Contactor W1 Replacement Tools required T20 Torx Driver 1 Remove the Cover per subsection 7 04 A...

Page 98: ...CUTMASTER 12mm PARTS REPLACEMENT 7 8 Manual 0 5077 This Page Intentionally Blank ...

Page 99: ...ET RESULT Gas flows 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 specific applications torch switch can be released after main arc transfer RESULT Gas flow stops ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will...

Page 100: ...anufacturer 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 Dat e of M f r 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 Revis...

Page 101: ...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 MACHINE TORCH 3 Switch 4 Switch Art A 08576 Negative Plasma Pilot 1 2 3 4 5 6 7 8 5 6 8 1 2 3 4 7 C Automation Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Co...

Page 102: ...7 1 2 5 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 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 103: ...id on Positioning Tube Torch Lead with ATC Connector Power Supply PIP Switch ATC Male Torch Leads Connector ATC Female Torch Receptacle Negative Plasma Lead Pilot Lead Art A 07115 Pin No s Socket No s 1 2 5 4 3 7 6 8 Main PC Board 1 2 5 4 3 7 6 8 White Black Orange Green Main PC Board Solenoid Torch Leads Torch Head Not Connected Not Connected Main PC Board Main PC Board ...

Page 104: ... AC INPUT PCB1 40 PIN RIBBON CABLE SIGNALS LATCH SET RUN RAR 40 CIRCUIT RIBBON CABLE MAX 90 85 80 75 70 65 MIN J2 7 D1 L1 L2 L3 GND D C AIR INLET FILTER REGULATOR SOLENOID VALVE TP1 TP2 TP3 TP4 TP5 TP6 TP7 ATC MAIN PCB ASSY LOGIC PCB INPUT CAPACITOR PCB GAS CONTROL GND 12 VDC 5 VDC 3 3 VDC 0 v 5 0 VDC 0 100PSI 1 8 VDC POT DEMAND TEST POINTS GND1 GND2 GND3 12V1 48V1 I_DMD_1 TIP_SEN COMMON COMMON CO...

Page 105: ... or Distribution without Written Consent NOTE UNLESS OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC 42X1329 Wednesday May 06 2009 1 1 16052 Swingley Ridre Road Suite 300 St Louis MO 63017 USA CM52 82 12mm 20mm 25mm A40 A60 380 400 415 600V Thursday March 27 2008 13 16 29 THERMADYNE C 8...

Page 106: ...in section 6 per ECOB1637 Aug 31 2010 AD Correct Logic PCB part numbers and information in section 6 per ECOB1800 Delete Note information for Logic PCB Feb 8 2011 AE Per ECOB1859 corrected Schematics with art number A 09131 and A 09133 to show proper ARC Volts for Automation Interface PCB Mar 20 2012 AF Changed COO text per ECOB2149 Mar 26 2012 AG Updated CAP PCB catalog number per ECOB1502 April ...

Page 107: ...This Page Intentionally Blank ...

Page 108: ... Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 64072626 Fax 86 21 64483032 Singapore Sales Office Ph 65 6832 8066 Fax 65 6763 5812 Form ...

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