Thermal Dynamics CUTMASTER 12 Operating Manual Download Page 1

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380-

400

Art # A-09205

PLASMA CUTTING SYSTEM

12mm

CUTMASTER

™

Rev. AG Date:

March 20, 2012

Manual #

0-5076

Operating Features:

Operating Manual

ARC WELDING SUPPLIES - 07 847 7870

Summary of Contents for CUTMASTER 12

Page 1: ...380 400 Art A 09205 PLASMA CUTTING SYSTEM 12mm CUTMASTER Rev AG Date March 20 2012 Manual 0 5076 Operating Features Operating Manual A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 2: ...ad 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 Contr...

Page 3: ...eserved 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 lo...

Page 4: ...This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 5: ...ccessories 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 SECTIO...

Page 6: ...Replacement Power Supply Parts 6 2 6 05 Options and Accessories 6 2 6 06 Replacement Parts for Hand Torch 6 3 6 07 Replacement Parts for Machine Torches with Unshielded Leads 6 4 6 08 Replacement Shi...

Page 7: ...on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Bar...

Page 8: ...et seq 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U...

Page 9: ...nt pr senter des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respira...

Page 10: ...us ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protec...

Page 11: ...ociety 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 POUR LE SOUDAGE LA COUPE ET L...

Page 12: ...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 equipme...

Page 13: ...nty 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 impro...

Page 14: ...CUTMASTER 12mm GENERAL INFORMATION 1 8 Manual 0 5076 This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 15: ...ctronic 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 Literatu...

Page 16: ...0 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 re...

Page 17: ...lexible 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...

Page 18: ...y 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 A...

Page 19: ...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 05 Introducti...

Page 20: ...ch 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 t...

Page 21: ...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 th...

Page 22: ...CUTMASTER 12mm INTRODUCTION 2T 4 Manual 0 5076 This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 23: ...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 u...

Page 24: ...cable 8 Reinstall the Power Supply cover per in structions found in section 5 9 Connect the opposite end of individual wires to a customer supplied plug or main disconnect 10 Connect the input power c...

Page 25: ...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 At...

Page 26: ...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 th...

Page 27: ...he 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...

Page 28: ...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 Selec...

Page 29: ...s 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...

Page 30: ...y 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 t...

Page 31: ...rts 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 ope...

Page 32: ...CUTMASTER 12mm OPERATION 4 4 Manual 0 5076 This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 33: ...out of the Torch Head A 03510_AB Electrode Start Cartridge Tip Shield Cup Torch Head Torch Parts Drag Shield Cap Shield Cup Body Shown 3 Install the replacement Electrode by push ing it straight into...

Page 34: ...utions at the front of this manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the workpiece wh...

Page 35: ...ting With Hand Torch NOTE For best performance and parts life always use the correct parts for the type of opera tion 1 The torch can be comfortably held in one hand or steadied with two hands Positio...

Page 36: ...g it onto the torch shield cup Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc During operation posi tion the legs of the standoff gu...

Page 37: ...eld cup is properly installed there is a slight gap between the shield 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 t...

Page 38: ...Proper work cable connection 4T 05Gouging WARNING 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 b...

Page 39: ...els 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 inconsiste...

Page 40: ...ired 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 Th...

Page 41: ...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 08065_AE DRAG SHIELD CUTTING Shield Cap...

Page 42: ...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 7...

Page 43: ...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...

Page 44: ...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 714509...

Page 45: ...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 C...

Page 46: ...CUTMASTER 12mm OPERATION 4T 14 Manual 0 5076 This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 47: ...ode 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...

Page 48: ...ng Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 5 03 Common Faults Problem Symptom Common Cause Insufficient Penet...

Page 49: ...75 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 blinking it will be accompanied...

Page 50: ...ponents in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacement GAS LED OFF FAULT and MIN pressure indicators flashin...

Page 51: ...ts 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 position correct if necessary 2...

Page 52: ...er 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 Element Assembly Replacement Th...

Page 53: ...ally 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 Section 6 Parts List for replac...

Page 54: ...ts 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 Filter Elements First Second...

Page 55: ...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...

Page 56: ...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...

Page 57: ...ber 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...

Page 58: ...cludes Filter Hose 7 7507 1 Replacement Filter Body 9 7740 1 Replacement Filter Hose not shown 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose Mounting Screws 9 9387 1...

Page 59: ...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 As...

Page 60: ...d 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...

Page 61: ...CUTMASTER 12mm Manual 0 5076 6 5 PARTS LIST A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 62: ...nectors 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 7848 1 50 foot 15 2 m Lead...

Page 63: ...d 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 08065_AE DRAG SHIELD CUTTING Shield Cap Deflector 9 82...

Page 64: ...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 Shield Cup 120A 9 8258 Shield Ca...

Page 65: ...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 s...

Page 66: ...econd 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 Ra...

Page 67: ...e 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 Connec...

Page 68: ...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 Pow...

Page 69: ...CUTMASTER 12mm Manual 0 5076 A 5 APPENDIX This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 70: ...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 LOGI...

Page 71: ...tten 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 Wednes...

Page 72: ...CUTMASTER 12mm APPENDIX A 8 Manual 0 5076 This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 73: ...CUTMASTER 12mm Manual 0 5076 A 9 APPENDIX This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 74: ...mbers in section 6 per ECOB1637 Sept 14 2010 AD Updated SL 100 consumables art in section 6 per ECOB1819 Feb 8 2011 AE Per ECOB1859 corrected Schematics with art number A 09131 and A 09133 to show pro...

Page 75: ...This Page Intentionally Blank A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0...

Page 76: ...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 224800 Milan Italy Customer...

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