Thermal Dynamics Cutmaster 82 Service Manual Download Page 49

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cutmaster 82

Manual 0-4980

4T-13

OPERATION

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded

Tip

Type Torch: Mechanized With Shielded Tip

Type Material: Mild Steel

Type Plasma Gas: Air

Type Secondary Gas: Single Gas Torch

Thickness

Tip

Output

Amperage Speed (Per Minute)

Standoff

Plasma Gas Press

Flow (CFH)

Pierce

Pierce Height

Inches mm (Cat. No.) Volts(VDC)

(Amps)

Inches

Meters

Inches mm

psi*

bar

Plasma Total** Delay (Sec) Inches mm

0.060 1.5

9-8210

124

250

6.35

0.19 4.8

4.8

245

0.00

0.2

5.1

0.075 1.9

9-8210

126

237

6.02

0.19 4.8

4.8

245

0.10

0.2

5.1

0.120 3.0

9-8210

126

230

5.84

0.19 4.8

4.8

245

0.10

0.2

5.1

0.135 3.4

9-8210

128

142

3.61

0.19 4.8

4.8

245

0.10

0.2

5.1

0.188 4.8

9-8210

128

125

3.18

0.19 4.8

4.8

245

0.20

0.2

5.1

0.250 6.4

9-8210

123

2.03

0.19 4.8

4.8

245

0.30

0.2

5.1

0.375 9.5

9-8210

132

0.86

0.19 4.8

4.8

245

0.50

0.2

5.1

0.500 12.7 9-8210

137

0.58

0.19 4.8

4.8

245

0.75

0.2

5.1

0.625 15.9 9-8210

139

0.36

0.19 4.8

4.8

245

0.750 19.1 9-8210

145

0.36

0.19 4.8

4.8

245

1.000 25.4 9-8210

156

0.10

0.19 4.8

4.8

245

Type Torch: Mechanized With Shielded Tip

Type Material: Stainless Steel

Type Plasma Gas: Air

Type Secondary Gas: Single Gas Torch

Thickness

Tip

Output

Amperage Speed (Per Minute)

Standoff

Plasma Gas Press

Flow (CFH)

Pierce

Pierce Height

Inches mm (Cat. No.) Volts(VDC)

(Amps)

Inches

Meters

Inches mm

psi*

bar

Plasma Total** Delay (Sec) Inches mm

0.06

1.5 9-8210

110

165

4.19

0.13 3.2

4.8

245

0.00

0.20 5.1

0.075 1.9 9-8210

116

155

3.94

0.13 3.2

4.8

245

0.10

0.20 5.1

0.120 3.0 9-8210

115

125

3.18

0.13 3.2

4.8

245

0.10

0.20 5.1

0.135 3.4 9-8210

118

2.03

0.13 3.2

4.8

245

0.10

0.20 5.1

0.188 4.8 9-8210

120

1.91

0.13 3.2

4.8

245

0.20

0.20 5.1

0.250 6.4 9-8210

121

1.52

0.13 3.2

4.8

245

0.30

0.20 5.1

0.375 9.5 9-8210

129

0.71

0.13 3.2

4.8

245

0.50

0.20 5.1

0.500 12.7 9-8210

135

0.43

0.19 4.8

4.8

245

0.75

0.20 5.1

0.625 15.9 9-8210

135

0.36

0.19 4.8

4.8

245

0.750 19.1 9-8210

142

0.25

0.19 4.8

4.8

245

Type Torch: Mechanized With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air

Type Secondary Gas: Single Gas Torch

Thickness

Tip

Output

Amperage Speed (Per Minute)

Standoff

Plasma Gas Press

Flow (CFH)

Pierce

Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps)

Inches

Meters

Inches mm

psi*

bar

Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210

105

350

8.89

0.13 3.2

4.8

245

0.00

0.20

5.1

0.075 1.9 9-8210

110

350

8.89

0.13 3.2

4.8

245

0.10

0.20

5.1

0.120 3.0 9-8210

110

275

6.99

0.13 3.2

4.8

245

0.10

0.20

5.1

0.188 3.4 9-8210

122

140

3.56

0.13 3.2

4.8

245

0.20

5.1

0.250 6.4 9-8210

134

2.03

0.19 4.8

4.8

245

0.30

0.20

5.1

0.375 9.5 9-8210

140

1.14

0.19 4.8

4.8

245

0.50

0.20

5.1

0.500 12.7 9-8210

144

0.66

0.19 4.8

4.8

245

0.80

0.20

5.1

0.625 15.9 9-8210

145

0.48

0.19 4.8

4.8

245

0.750 19.1 9-8210

150

0.38

0.19 4.8

4.8

245

Summary of Contents for Cutmaster 82

Page 1: ...Art A 08839_AB 600 v 460 400 v v PLASMA CUTTING SYSTEM 82 CUTMASTER Rev AH Date May 29 2009 Manual 0 4980 Operating Features Service Manual...

Page 2: ......

Page 3: ...ts 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 an...

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

Page 5: ...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 2 3 04 Gas...

Page 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 Par...

Page 7: ...AG INFORMATION A 2 APPENDIX 3 TORCH PIN OUT DIAGRAMS A 3 APPENDIX 4 TORCH CONNECTION DIAGRAMS A 4 APPENDIX 5 SYSTEM SCHEMATIC 208 460V UNITS A 6 APPENDIX 6 SYSTEM SCHEMATIC 600V UNITS A 8 APPENDIX 7 P...

Page 8: ...TABLE OF CONTENTS...

Page 9: ...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 shou...

Page 10: ...atest 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 Z...

Page 11: ...ouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent c...

Page 12: ...peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres pers...

Page 13: ...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 POUR...

Page 14: ...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 15: ...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 16: ...cutmaster 82 GENERAL INFORMATION 1 8 Manual 0 4980...

Page 17: ...he 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...

Page 18: ...Power Supply Duty Cycle Ambient Temperature Duty Cycle Ratings 40 C 104 F Opperating Range 0 50 C IEC Rating IEC Rating IEC Rating All Units Duty Cycle 40 60 100 Current 80 Amps 65 Amps 50 Amps DC Vo...

Page 19: ...2 46 100 6 460 60 20 44 28 50 10 3 Phase 208 60 16 40 26 50 8 230 50 60 16 39 25 50 10 380 50 60 11 8 18 12 20 12 400 50 60 11 8 18 12 20 12 460 60 17 21 14 25 12 600 60 9 6 16 10 20 12 Line Voltages...

Page 20: ...06 Power Supply Features Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 07942 Work Cable and Clamp Art A 07981 Input Power Cord Port for Optional Automation Interface Cable Gas Inle...

Page 21: ...from 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 R...

Page 22: ...s 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 tr...

Page 23: ...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 nect...

Page 24: ...CutMaster 82 INTRODUCTION 2T 4 Manual 0 4980 This Page Intentionally Blank...

Page 25: ...3 02 Lifting Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNING Do not touch live electrical parts Disconnect input po...

Page 26: ...L4 Single Phase Input Power Wiring Art A 07983_AB Three Phase 3 and Jumper Settings L1 L2 L3 L4 Jumper L1 L4 L1 L2 L3 GND L4 Store copper jumper in spare parts box Three Phase Input Power Wiring NOTE...

Page 27: ...ctions are for changing the input power and or cable on the 208 230 400 460 VAC Power Supply to Three Phase input power 1 Remove the Power Supply cover per instructions found in section 5 2 Disconnect...

Page 28: ...the air line to the inlet port The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do not...

Page 29: ...filter hose 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 inst...

Page 30: ...egulator Filter Assembly 2 Stage Filter Inlet Port IN Outlet Port OUT Two Stage Filter Assembly Art A 07945_AC Optional Two Stage Filter Installation Using High Pressure Air Cylinders When using high...

Page 31: ...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...

Page 32: ...0 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 Secti...

Page 33: ...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 34: ...ections 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...

Page 35: ...ece 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...

Page 36: ...CutMaster 82 OPERATION 4 4 Manual 0 4980 This Page Intentionally Blank...

Page 37: ...ies NOTE The shield cup holds the tip and starter cartridge 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 rem...

Page 38: ...bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece Bottom Dross Buildup Molten material which is not blown out...

Page 39: ...in a clockwise direction Dross When dross is present on carbon steel it is com monly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by to...

Page 40: ...and postflow are a characteristic of the power supply and not a function of the torch 3 4 Art A 03383 Trigger 2 1 Trigger Release 6 Cut as usual Simply release the trigger assembly to stop cutting 7...

Page 41: ...rotection Choose the holding technique that feels most comfort able and allows good control and move ment 4 Keep the torch in contact with the work piece during the cutting cycle 5 Hold the torch away...

Page 42: ...toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start A 02986 Trigger Trigger Release 6 Bring the torch within transfer distance to the work The main...

Page 43: ...el speed mode of operation hand or machine torch and the amount of material to be removed Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel sp...

Page 44: ...the leading edge of the arc column produces the cut If the travel speed is too slow a rough cut will be produced as the arc moves from side to side in search of metal for transfer Travel speed also a...

Page 45: ...Cup Body 9 8237 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 08065_AC DRAG...

Page 46: ...m psi bar Plasma Total Delay Sec Inches 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 1...

Page 47: ...9 8211 133 80 10 0 25 0 19 4 8 70 4 8 115 340 NR NR NR 1 000 25 4 9 8211 132 80 9 0 23 0 19 4 8 70 4 8 115 340 NR NR NR Type Torch Mechanized With Exposed Tip Type Material Stainless Steel Type Plasma...

Page 48: ...4 8 9 8211 124 80 180 4 57 0 25 6 4 70 4 8 115 340 0 20 0 25 6 4 0 250 6 4 9 8211 128 80 110 2 79 0 25 6 4 70 4 8 115 340 0 30 0 25 6 4 0 375 9 5 9 8211 136 80 55 1 40 0 25 6 4 70 4 8 115 340 0 40 0...

Page 49: ...psi bar Plasma Total Delay Sec Inches 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 11...

Page 50: ...149 80 11 0 28 0 19 4 8 70 4 8 115 340 NR NR NR 1 000 25 4 9 8211 162 80 8 0 20 0 19 4 8 70 4 8 115 340 NR NR NR Type Torch Mechanized With Shielded Tip Type Material Stainless Steel Type Plasma Gas...

Page 51: ...8 4 8 9 8211 120 80 165 4 19 0 13 3 2 70 4 8 115 340 0 20 0 25 6 4 0 250 6 4 9 8211 124 80 100 2 54 0 13 3 2 70 4 8 115 340 0 30 0 25 6 4 0 375 9 5 9 8211 138 80 60 1 52 0 19 4 8 70 4 8 115 340 0 40 0...

Page 52: ...S 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: ...ld 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 82 OPERATION 4T 18 Manual 0 4980 This Page Intentionally Blank...

Page 55: ...cutmaster 82 Manual 0 4980 5 1 SERVICE SECTION 5 SYSTEM SERVICE 5 01 General Maintenance...

Page 56: ...low air into the power supply during cleaning 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 Prob...

Page 57: ...voltage is outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit Low is 208 230 VAC and high is 460 VAC S LO HI Art A 08...

Page 58: ...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 replacement GAS indicator off FAULT and MIN pressure indicator...

Page 59: ...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 posi...

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 Elemen...

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: ...ement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 above 7 Hand tighten the two bolts evenly then torque each bolt to 20 30 in lbs 2 3 3 4 Nm Improper torque m...

Page 63: ...ditions This section is to help isolate the defective circuit before troubleshooting identify symptoms and test the unit for proper operation Follow the instructions as given to identify the possible...

Page 64: ...s stated above then note the symptom and proceed to Section 5 08 Pilot Arc Problems G Main Arc and Controls Test Connect work Cable to the work piece Close torch switch Pendant switch or activate CNC...

Page 65: ...al Position the torch to pilot Check the OK TO MOVE signal by connecting a jumper between J2 3 and J2 4 START signal Pilot arc is established 2 Bring the torch to the work piece and transfer to cuttin...

Page 66: ...rimary input cable is defective a Check cable for shorts B Primary line fuses blow immediately after ON OFF SWITCH SW1 is turned to ON position 1 Shorted Input Diode Module a Check per section 5 11B 2...

Page 67: ...AULT The FAULT Indicator and 70 PSI LED is flashing 1 Shield Cup loose a Hand tighten the shield cup to close the PIP switch 2 Torch not properly connected to power supply a Insure torch ATC is secure...

Page 68: ...at idle with fan running to cool power supply See Power Sup ply Specifications section 2 04 for duty cylcle information 3 Fan s not turning a Measure voltage at plug between J7 1 to J7 2 and between J...

Page 69: ...OL2 for 24vac If present re place SOL2 5 Defective Main PCB a Measure on Main PCB between J2 20 to GND1 for less than 2VDC If voltage is 12VDC replace Main PCB b Measure on Main PCB between J2 11 to G...

Page 70: ...umables removed from the torch Check continuity of torch at ATC between negative plasma lead connection to pilot lead connection Negative Plasma Lead 4 Torch Switch 3 Torch Switch 2 PIP 1 PIP Pilot Le...

Page 71: ...ace Main PCB C In LATCH mode when the torch switch is released the arc shuts off immediately 1 Defective Logic PCB a Replace Logic PCB D With CURRENT CONTROL POTENTIOMETER set at maximum output curren...

Page 72: ...Test 1 Using an ohmmeter perform the tests in the 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...

Page 73: ...Forward Bias PRI 4 D MTH 5 Reverse Bias MTH 6 PRI 4 D Reverse Bias MTH 5 PRI 4 D Forward Bias 3 If the test reveals a failed component replace Main Pcb and perform main contactor test Sec tion 5 11A I...

Page 74: ...ire to Main PCB Signal Information Many of the signal listed will be low voltage signals that will be in one of two states 12VDC High or 0VDC Low with respect to pcb common When a signal name is prece...

Page 75: ...on 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 MTH1 2 Capa...

Page 76: ...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 460V_IN Act...

Page 77: ...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...

Page 78: ...horted 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...

Page 79: ...cutmaster 82 Manual 0 4980 5 25 SERVICE This Page Intentionally Blank...

Page 80: ...HOKE1 SEC2 SEC1 TIP1 PRI_3 ELECTRODE1 V_OUT1 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...

Page 81: ...oid 24VAC 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...

Page 82: ...CutMaster 82 SERVICE 5 28 Manual 0 4980 This Page Intentionally Blank...

Page 83: ...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 84: ...ield cup body In shielded drag cutting operations only there 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 34...

Page 85: ...be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authoriza tion will not be accepted 6 02 Ordering...

Page 86: ...nal Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 0128 2 1 Base Enclosure Assembly 9 0118 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0127 5 1 Rear Panel 9 0101 Art A 08120...

Page 87: ...Replacement Parts Item Qty Description 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 Art A...

Page 88: ...111 1 Input Power Cable 230 V with plug 9 8596 1 Input Power Cable 460 600V 9 8593 1 Hi Lo voltage selection switch 9 0110 NOTE 9 0107 Logic PCB If the serial number of the power supply is prior to 05...

Page 89: ...put Capacitors 9 0126 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 reg...

Page 90: ...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 C...

Page 91: ...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 78...

Page 92: ...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 6 1 1...

Page 93: ...cutmaster 82 Manual 0 4980 6 9 PARTS LIST A 07994 6 1 4 2 3 5 7 8 9 10 12 11 10...

Page 94: ...up Body 9 8237 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 08065_AC DRAG S...

Page 95: ...rap 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 t...

Page 96: ...the screws securing the tube handles to the base of the unit NOTE Some of the earliest manufactured units have Tube Handles tha are joined together under the base of the unit Later versions are not jo...

Page 97: ...required T20 Torx Driver 1 Remove the cover per subsection 7 04A 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 Loose...

Page 98: ...ain PCB 3 Carefully feed the fan wires through the center chassis wire slot 4 Remove the fan by pushing the fan retaining clips apart and pulling the fan out of the center chassis 5 On the replacement...

Page 99: ...to disengage the bottom locking tabs securing the Chassis to the base 13 Carefully guide the Center Chassis up far enough to lay the Chassis down towards the right side of the unit 14 Remove the two s...

Page 100: ...wdriver 1 Remove the Cover per subsection 7 04A 2 Disconnect the input cable wires from the W1 contactor terminals and ground lug 3 Loosen the two screws in the cable strain relief 4 Remove cable thro...

Page 101: ...hoses per subsection 7 05 C 3 Remove the Gas Solenoid per subsection 5 05E 4 Remove Capacitor PCB per subsection 7 08 A 5 Disconnect the wires and connectors from the PCB noting the location and orien...

Page 102: ...CutMaster 82 PARTS REPLACEMENT 7 8 Manual 0 4980 This Page Intentionally Blank...

Page 103: ...ows 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 spe...

Page 104: ...ufacturer 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 0...

Page 105: ...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 106: ...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 Re...

Page 107: ...cutmaster 82 Manual 0 4980 A 5 APPENDIX This Page Intentionally Blank...

Page 108: ...3 C5 not installed PCB2 SOLENOID Q1 PRIMARY AC INPUT PCB1 40 PIN RIBBON CABLE SIGNALS 460_IN LATCH SET RUN RAR 40 CIRCUIT RIBBON CABLE MAX 90 85 80 75 70 65 MIN 460 230 J2 7 JUMPER D1 L1 L2 L3 GND D C...

Page 109: ...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 42X1298 Monday March 30 2009 1 1 16052 Swingley...

Page 110: ...CutMaster 82 APPENDIX A 8 Manual 0 4980 APPENDIX 6 SYSTEM SCHEMATIC 600V UNITS...

Page 111: ...cutmaster 82 Manual 0 4980 A 9 APPENDIX...

Page 112: ...ing chart per ECOB880 for CSA approval May 16 2008 AD Added information to section 6 about regulator logic PCB kit upgrade for older systems per ECOB908 July 17 2008 AE Updated input power and cable c...

Page 113: ...hanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Wes...

Page 114: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com...

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