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CUTMASTER 102

Manual 0-4998

OPERATION

4T-15

Catalog #

Description

Patent(s)

9-8245

Shield 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

Summary of Contents for CUTMASTER 102

Page 1: ...100 208 230V 460V 600V 400V VictorThermalDynamics com Art A 08618_AD Service Manual Revision AM Issue Date September 4 2014 Manual No 0 4998 CUTMASTER 102 PLASMA CUTTING SYSTEM ...

Page 2: ...erefore please take the time to read the entire manual especially the Safety Pre cautions 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 Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Victor Technologies We distinguish ou...

Page 3: ...nologies International Inc All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Publication Date September 25...

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

Page 5: ...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 Preparations for Operati...

Page 6: ...ent 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 Replacement Parts for Machine Torches with Unshielded Leads 6 8 6 11 Torch Consumable Parts SL100 SV 6 10 SECTION 7 REPLACEMENT PROCEDURES 7 1 7 01 Scope 7 1 7 02 Anti Static Handling Procedures 7 1 7 03 Parts Replacement General I...

Page 7: ...t of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic C...

Page 8: ...and safety glasses in good condition Re place lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly ...

Page 9: ...nts seront enfermés dans une boîte de ce type 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OPÉRATION ET LA MAINTENANCE DU MATÉ RIEL DE SOUDAGE À L ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ Coupant à l arc au jet de plasma produit de l énergie électrique haute tension et des émissions magné tique qui peuvent interférer la fonction propre d un pacemaker ...

Page 10: ... arc de plasma Le procédé à l arc de plasma produit du métal des étincelles des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l explosion de fumées inflammables Soyez certain qu aucune matière combustible ou inflamma ble ne se trouve sur le lieu de travail Protégez toute telle matière qu il est impossible de retirer de la zone de travail Procurez une bonne aération d...

Page 11: ...OLES disponible de l Institut Américain des Normes Nationales American National Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible auprès de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 2 PRÉVENTION DES INCENDIES LORS DE L EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE disponible auprès de...

Page 12: ...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 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 Victor Thermal Dynamics Corporat...

Page 13: ... identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Victor Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link http www victorthermaldynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually...

Page 14: ...ower Supply Duty Cycle Ambient Tempera ture Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C All Units Duty Cycle 60 80 100 Current 100 80 70 IEC IEC IEC DC Voltage 120 112 108 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 Electro Technical Comm...

Page 15: ...17 9 45 36 60 6 380 50 60 18 4 28 22 32 10 400 50 60 18 7 27 22 32 10 460 50 60 23 1 29 22 30 10 600 50 60 22 8 22 17 25 12 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 The suggested sizes are based on flexible pow...

Page 16: ... 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 Inlet Port Filter Assembly Input Power Selection ...

Page 17: ... inexpensive operation NOTE Refer to Section 2T 05 Introduction to Plasma on page 2T 2 for a more detailed descrip tion of plasma torch operation Refer to the Appendix Pages for additional specifi cations as related to the Power Supply used 2T 03 Specifications A Torch Configurations 1 Hand Manual Torch Models The hand torch head is at 75 to the torch handle The hand torches include a torch handle...

Page 18: ...ls to a controlled depth and width In a Plasma Cutting Torch a cool gas enters Zone B where a pilot arc between the electrode and the torch tip heats and ionizes the gas The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C A 00002 Workpiece Power Supply _ C B A Typical Torch Head Detail By forcing the plasma gas and electric arc through a small orifice th...

Page 19: ...ire E Parts In Place PIP The torch includes a Parts In Place PIP circuit When the shield cup is properly installed it closes a switch The torch will not operate if this switch is open A 02997 Torch Trigger PIP Switch Shield Cup To Control Cable Wiring Torch Switch Parts In Place Circuit Diagram for Hand Torch PIPSwitch Shield Cup To ATC CNC Start PIPSwitch Shield Cup PIPSwitch Shield Cup Remote Pe...

Page 20: ...CUTMASTER 102 INTRODUCTION Manual 0 4998 2T 4 This Page Intentionally Blank ...

Page 21: ...sion cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2 The following illustration and directions are for changing phase of the power supply Art A 08493 Input Power Cable Connections Three Phase 3ø Store copper jumpers on base plate Single Phase 1ø and Jumper Settings GND L1 L2 L3 L4 GND L1 L2 L3 L4 Single and T...

Page 22: ...ion on the individual wires 5 Pass the cable being used through the access opening in the back panel of the power supply Refer to Section 2 for power cable specifications CAUTION The primary power source and power cable must conform to local electrical code and the recom mended circuit protection and wiring requirements refer to table in Section 2 6 Connect the wires as follows Wires to L1 L2 and ...

Page 23: ... 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 Permatex PX56521 or equivalent thread se...

Page 24: ...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 regulator 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 Permatex PX56521 o...

Page 25: ...y for operation Check Air Quality To test the quality of air 1 Put the ON OFF switch in the ON up posi tion 2 Put the Function Control switch in the SET posi tion 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 air will be visible on the lens 3T 02 Setting Up Mechanical Torch NOTE An adapter is required to be installed in the p...

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Page 27: ... one of the system interlocks is activated 3 ON OFF Power Switch ON OFF Switch controls input power to 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 Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is i...

Page 28: ... to supply power to the system Air Source Ensure source meets requirements refer to Section 2 Check connections 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...

Page 29: ...ion when the torch leaves the workpiece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded metal or gratings or in gouging or trim ming operations when an uninterrupted restart is desired And with the knob in the LATCH position the main cutting arc will be maintained after the t...

Page 30: ...CUTMASTER 102 OPERATION Manual 0 4998 4 4 This Page Intentionally Blank ...

Page 31: ... opera tion 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 param eters such as torch standoff alignment with the workpiece cutting speed gas pressures and operator ability Cut quality requirements differ d...

Page 32: ...t the bevel angle Reducing standoff will generally result in a more square cut Edge Starting For edge starts hold the torch perpendicular to the work piece with the front of the tip near not touching the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutt...

Page 33: ...ld the torch away from your body 4 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will start A 02986 Trigger Trigger Release 5 Bring the torch within transfer distance to the work The main arc will transfer to the work and the pilot arc will shut OFF NOTE The gas preflow and postflow are a characteristic of the power supply an...

Page 34: ...for maximum control or near the back end for maximum heat protection Choose the holding technique that feels most comfortable and allows good control and movement 3 Keep the torch in contact with the workpiece during the cutting cycle 4 Hold the torch away from your body 5 Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger The pilot arc will st...

Page 35: ...is gap Forcing the shield cup against the torch head or torch handle can damage components 7 Clean spatter and scale from the shield cup and the tip as soon as possible Spraying the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Cutting speed depends on material thickness and the opera tor s ability to accurately follow the desired cut line The fol lowing...

Page 36: ...Standoff distances greater than 1 4 inch 6 mm may result in minimal metal removal or loss of transferred main arc Slag Buildup Slag generated by gouging on materials such as carbon 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 inconsistenc...

Page 37: ...ld be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slow down 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 en...

Page 38: ...GOUGING Shield 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 Shield Cup 120A 9 8258 Shield Cap Machine 70 100A 9 8239 Shield Cap Machine 120A 9 8256 Art A 08066_AG CUTTING STANDOFF 70 120A CUTTING STANDOFF 20 40A Shield Cap Deflector 9 8243 50 60A CUT...

Page 39: ... mm 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 123 60 150 3 82 0 19 4 8 70 4 8 90 245 0 10 0 20 5 1 0 135 3 4 9 8210 118 60 125 3 18 0 19 4 8 70 4 8 90 245 0 10 0 20 5 1 0 188 4 8 9 8210 122 60 90 2 29 0 19 4 8 70 4 8 90 245 0 20 0 20 5 1 0 250 6...

Page 40: ...6 4 0 135 3 4 9 8211 120 80 280 7 11 0 25 6 4 70 4 8 115 340 0 10 0 25 6 4 0 188 4 8 9 8211 120 80 140 3 56 0 25 6 4 70 4 8 115 340 0 20 0 25 6 4 0 250 6 4 9 8211 120 80 100 2 54 0 25 6 4 70 4 8 115 340 0 30 0 25 6 4 0 375 9 5 9 8211 126 80 50 1 27 0 25 6 4 70 4 8 115 340 0 40 0 25 6 4 0 500 12 7 9 8211 129 80 28 0 71 0 25 6 4 70 4 8 115 340 0 80 0 25 6 4 0 625 15 9 9 8211 135 80 20 0 51 0 25 6 4 ...

Page 41: ...mm 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 115 60 125 3 18 0 13 3 2 70 4 8 90 245 0 10 0 20 5 1 0 135 3 4 9 8210 118 60 80 2 03 0 13 3 2 70 4 8 90 245 0 10 0 20 5 1 0 188 4 8 9 8210 120 60 75 1 91 0 13 3 2 70 4 8 90 245 0 20 0 20 5 1 0 250 6 4...

Page 42: ...1 149 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 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 ...

Page 43: ...188 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 25 6 4 0 500 12 7 9 8211 141 80 36 0 91 0 19 4 8 70 4 8 115 340 0 60 0 25 6 4 0 625 15 9 9 8211 142 80 26 0 66 0 19 4 8 70 4 8 115 340 0 75 0 25 6 4 0 750 19 1 9 8211 150 80 18 0 46 0 19 4 8 70 4 8...

Page 44: ... 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 45: ...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 47: ...eck 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 48: ...low 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 parts ...

Page 49: ...basic trouble shooting guide later in this chapter Explanation of Faults UNDER PRESSURE Indicates that operating pressure is set too low and power supply output power will be disabled INPUT POWER Indicates primary line 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 V...

Page 50: ...OVER PRESSURE Indicates that operating pressure is set too high The Error Indicator will not flash when the pressure is above 95 PSI This LED will remain ON and the system will operate but pilot starting and cut performance may be affected NOTE When the unit is turned ON the cooling fans MOT 1 3 will remain OFF In earlier units MOT 1 will turn ON for one 1 second and then turns OFF The fans will t...

Page 51: ...ts 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 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 T...

Page 52: ... 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 PSI indicators flashin...

Page 53: ...he following checks to prevent component failure or blow ing primary fuses The troubleshooting guide will assume these tests were done and no failure was found or that any failures found were corrected 1 Main Contactor W1 Check Section 5 11 A 2 PCB 1 Input Diode D1 Test Section 5 11 B 3 PCB 5 Input Diode D1 Test Section 5 11 C 4 PCB 2 Capacitor Relay Test Section 5 11 D 5 PCB 1 IGBT Test Section 5...

Page 54: ... CutMaster 102 Gas Pressure Settings Leads Length SL100 Hand Torch SL100 Mechanized Torch Up to 25 7 6 m 75 psi 5 2 bar 75 psi 5 2 bar Each additional 25 7 6 m Add 5 psi 0 4 bar Add 5 psi 0 4 bar DRAG CutMaster 102 Gas Pressure Settings Leads Length SL100 Mechanized Torch Up to 25 7 6 m 80 psi 5 5 bar Each additional 25 7 6 m Add 5 psi 0 4 bar 4 Turn FUNCTION CONTROL SWITCH to RUN position Solenoi...

Page 55: ...s Gas flow stops momentarily then restarts when solenoid opens Pilot arc ignites 7 Open the torch switch DC LED turns OFF After 20 second post flow time Gas solenoid closes Gas flow stops 8 Set the FUNCTION CONTROL SWITCH to RAPID AUTO RESTART mode 9 Provide a START signal to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc 10 While cutting keep t...

Page 56: ...VDC c 10 VDC 3 3 VDC d 6 VDC 2 VDC This completes the CNC Interface Test If the above are all correct then the unit is functioning correctly If the unit does not function as stated then note the symptom and proceed to Section 5 10 CNC Interface Problems 5 07 Main Input and Internal Power Problems A Primary input line fuse blows as soon as primary disconnect is closed 1 Primary input cable installe...

Page 57: ...ED 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 regulator to increase pressure 3 Defective Logic PCB 3 a Measure for 5VDC on the Logic PCB 3 between J3 3 to J3 1 Replace Logic PCB 3 if voltage is not present or low b Measure for voltage on the Logic PCB 3 between J3 2 to J3 1 If the voltage is between 3 4 5VDC rep...

Page 58: ...75 PSI LED flashing 1 Start signal is active when SW1 is turned to ON posi tion a START can be active for one of the following Hand torch switch held closed Hand pendant switch held closed CNC START signal is active low Release the START signal source 2 Problem in the torch and leads switch circuit a Check continuity of torch switch circuit at ATC pins 3 4 See previous illustration 3 Short in CNC ...

Page 59: ...B 5 if voltage is not present 4 Defective Main PCB 1 a Measure for 12VDC on Main PCB 1 between J2 21 to TP GND1 Replace Main PCB 1 if voltage is not present 5 Defective Logic PCB 3 a Change Logic PCB 3 L AC LED ON TEMP GAS DC LED s are OFF FAULT Indicator is flashing MIN PRESSURE LED is flashing 1 Gas supply not connected to unit a Connect gas supply to unit 2 Gas supply not turned ON a Turn gas s...

Page 60: ...he unit is in SET mode reconnect SOL1 to the ATC connector 4 Defective torch solenoid a Measure the coil terminals of the torch mounted gas solenoid SOL2 for 24VAC If present replace SOL2 5 Defective Main PCB 1 a Measure on Main PCB 1 between J2 20 to GND1 for less than 2VDC If voltage is 12VDC replace Main PCB 1 b Measure on Main PCB between J2 11 to GND1 for less than 2VDC If voltage is less tha...

Page 61: ...l active measure voltage on Main PCB 1 between test points GND1 to I_DMD1 for 1 4 VDC Replace PCB 1 if voltage is present B SHORTED TORCH OUTPUT FAULT Fault indicator and 85 PSI Indicators are flashing at 1 cycle per second This is a Latched Failure Mode After START signal is ac tivated gas flows After two seconds FAULT INDICATOR flashes and 85 PSI LED flashes To reset the machine turn the unit OF...

Page 62: ...nals to measure less than 2VDC For 230VAC Signal 230_INbetweenJ1 5toTP1 For 460VAC Signal 460_INbetweenJ1 4toTP1 If corresponding signal measures 12 VDC replace the Logic PCB 3 12 Defective Main PCB 1 a Measure for approximately 325VDC on Capacitor PCB 2 between MTH 1 to MTH 7 under load If voltage is not present replace PCB 1 13 Defective Capacitor PCB 2 a Disconnect plug from J2 on Capacitor PCB...

Page 63: ...and remove wire from CHOKE1 terminal Measure Capacitor PCB bias supply between J21 to J2 2 for 12VDC If 40A PCB is at fault the unit will function but with reduced output current Perform Pre power up checks 1 W1 2 Open Input Diode Input rectifier D1 on Main PCB or 40A PCB 3 Shorted Open IGBT s 4 Output Diodes on both Main PCB and 40A PCB 5 Torch parts Power checks 1 Low input voltage or missing ph...

Page 64: ...lashing 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 2 Defective Logic PCB 3 a Replace Logic PCB 3 G Fans MOT 1 3 do not turn ON after a START signal is activated 1 Defective Logic PCB 3 a Measure voltage at J1 14 to J1 25 on Logic PCB 3 for 12VDC The voltage should drop to less than 2VDC after a START signal is acti...

Page 65: ...J13 connector on Main PCB 1 to J4 connector on 40A PCB 5 is broken loose or missing c Wires SEC1 and SEC2 routed too close to component U2 on 40A PCB 5 Re route to space a least 1 inch 25mm away d Older revision 40A PCB 5 Replace if PCB 5 revision is AC or earlier C Main arc transfers but current cannot be adjusted 1 Defective Logic PCB 3 a While main arc is transferred measure voltage on Main PCB...

Page 66: ...4 a Measure voltage on PCB 4 between J1 1 to J1 3 for less than 2VDC while cutting If voltage is less than 2VDC replace PCB 4 C ARC VOLTS signals are low or not present 1 Defective Automation Interface PCB 4 a Replace PCB 4 b Check Voltage Divider Jumper 5 11 Test Procedures A Main Contactor W1 Test 1 Check continuity between L1 to T1 L2 to T2 L3 to T3 L4 to T4 The contacts should be open no conti...

Page 67: ...MTH 4 Reverse Biased Diode PMTH 4 PMTH 1 2 Forward Biased Diodes D PCB 2 Capacitor Relay Test 1 Using an ohmmeter perform the tests in the chart INPUT CAPACITORS PCB 2 Meter Meter Indication MTH 2 MTH 4 Charging MTH 8 MTH 7 Charging Most meters will show a charging action Initially a low resistance will be shown and then the resistance will start to increase If the meter probes are reversed the re...

Page 68: ...Reversed Bias WORK1 SEC2 Reversed Bias SEC1 WORK1 Forward Bias SEC2 WORK1 Forward Bias H PCB 5 Output Diode D2 Test 1 Disconnect transformer wires from Main PCB 5 termi nal SEC1 2 Using an ohmmeter perform the following checks PCB 5 D2 Test points located on PCB 5 Meter Meter Indication CHOKE1 SEC1 Forward Bias CHOKE1 SEC2 Forward Bias SEC1 CHOKE1 Reversed Bias SEC2 CHOKE1 Reversed Bias OUT_1 SEC1...

Page 69: ...d Diode AC2 PMTH 4 Reverse Biased Diode AC3 PMTH 4 Reverse Biased Diode PMTH 4 PMTH 1 2 Forward Biased Diodes 2 If the test reveals a failed component replace 40A PCB 5 M PCB 1 IGBT Test With PCB 2 removed from unit 1 Using an ohmmeter perform the following checks PCB 1 Q1 Test points located on PCB 1 Meter Meter Indication PRI 1 TP1 Forward Biased Diode PRI 1 TP5 Reverse Biased Diode TP1 PRI 1 Re...

Page 70: ...PRI 3 Reverse Biased Diode PMTH 3 PRI 3 Forward Biased Diode 2 If the test reveals a failed component replace 40Amp PCB 5 NOTE Many of the signals listed in the PCB information to follow 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 preceded by the mark it denotes that the signal is an active low For example OV...

Page 71: ...8 J7 J6 J5 D78 J14 D59 GND2 48V1 CHOKE1 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 MAIN PCB 1 LAYOUT ...

Page 72: ... low enables PWM circuit J2 11 TRCH_SOL Active low to enable Torch Solenoid L M J2 12 SOL_ON Active low to enable Power Supply solenoid L M J2 13 OK_TO_MOVE Active low to enable OK_TO_MOVE CNC L M J2 14 FAN_ON Active low to enable fans L M J2 15 LATCH_ACTIVE Active low when Latch mode is active during cut L M J2 16 TRCH_SW Active low START is active Torch switch CNC M L J2 17 PIP Active low PARTS ...

Page 73: ...13 1 OVERTEMP J13 2 FAN_ON J13 3 CSR J13 4 CUR_SET J13 5 MAIN_PCB_ID J13 6 Common MAIN PCB 1 LED INDICATORS D59 PCR Indicates Pilot IGBT gate signal is ON D78 CSR Indicates cutting arc has been established MAIN PCB 1 TEST POINTS 12V1 12VDC 12V2 12VDC 48V1 48VDC 48V2 48VDC AC1 AC Input AC2 AC Input AC3 AC Input CHOKE1 Negative DC output to L1 ELECTRODE1 Negative DC output to torch GND1 Common GND2 ...

Page 74: ...AC2 80A_AC1 PRI2 MTH4 PMTH2 40A_AC1 40A_AC3 40A_AC2 PMTH1 PMTH4 PMTH3 J2 Art A 08505AB CAPACITOR PCB 2 LAYOUT CAPACITOR PCB 2 SIGNALS J1 1 12VDC J1 2 460VAC J1 3 230VAC J2 1 12VDC J2 2 Common CAPACITOR PCB 2 TEST POINTS MTH 1 CAP BANK A MTH 2 CAP BANK A MTH 4 CAP BANK A MTH 6 CAP BANK B ...

Page 75: ... PRESSURE X 7 Over Pressure D3 90 PSI X 6 Internal Error D4 85 PSI X 5 Shorted torch Output Fault 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 D9MIN PRESSURE X 0 Low Pressure D10 AC 1 X D11OVERTEMP 2 X D12 GAS 3 X D13 DC 4 X D14ERROR 5 X LOGIC PCB 3 TEST POINTS TP1 Common TP2 12VDC TP3 5VDC TP4 3 ...

Page 76: ...CUTMASTER 102 SERVICE Manual 0 4998 5 30 Art A 08506 SEC1 CHOKE1 OUT_1 SEC2 PRI3 PRI4 PRI2 PRI1 PMTH4 AC2 AC3 AC1 PMTH2 PMTH1 PMTH3 J4 J3 J2 J1 J5 I_DMD1 GND1 I_OUT1 J9 1 1 1 1 40AMP PCB 5 LAYOUT ...

Page 77: ...4VDC Cut Current Demand M 40A J4 8 MAIN_PCB_ID 825 Ohms to common 40A M J4 9 Not Used J4 10 Common 40A M TEST POINTS 80A_AC1 AC Input Phase 1 80A AC2 AC Input Phase 2 80A_AC3 AC Input Phase 3 40A_AC1 AC Input Phase 1 40A AC2 AC Input Phase 2 40A_AC3 AC Input Phase 3 MTH 1 Capacitor Bank A MTH 2 Capacitor Bank A MTH 4 Capacitor Bank A MTH 6 Capacitor Bank B MTH 7 Capacitor Bank B MTH 8 Capacitor Ba...

Page 78: ... WIRING DIAGRAM TO ATC TO ATC WORK CABLE TO T1 E35 E64 7 TO PCB 3 NOT USED MAIN PCB J4 TO TS1 CM152 ONLY CNC HARNESS OPTIONAL TO ATC NOT USED TO SOL1 NOT USED MAIN PCB J4 TO SW1 MAIN PCB J12 TO SW2 Art A 08620_AB TO W1 TO MOT1 D C C B A 7A 8 CHOKE 9 E35 ...

Page 79: ...CUTMASTER 102 Manual 0 4998 SERVICE 5 33 40A 50A PCB J3 40A 50A PCB J4 D TO T2 CHOKE NOT USED Art A 08620_AB TO T2 C B A TO MOT2 TO MOT3 40A 50A PCB J2 40A 50A PCB J1 ...

Page 80: ...CUTMASTER 102 SERVICE Manual 0 4998 5 34 This Page Intentionally Blank ...

Page 81: ...ch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head and ATC Male Connector 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 p...

Page 82: ...ere 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 indicated 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 start cartridge Check for excessive wear plugged gas hol...

Page 83: ...mber 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 number of the power supply Address all inquir...

Page 84: ...ernal Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 0185 2 1 Base Enclosure Assembly 9 0186 3 1 Tube roll handle 9 0121 4 1 Front Panel 9 0187 5 1 Rear Panel 9 0101 Art A 08564 3 2 4 5 1 3 NOTE Illustration may vary slightly from unit ...

Page 85: ...el 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 0189 Art A 08123 1 2 3 NOTE Illustration may vary slightly from unit ...

Page 86: ...ly T1 9 0170 5b 1 Transformer 60 Amp Non 600V T2 9 0196 5b 1 Transformer 60 Amp 600V Only T2 9 0171 6 1 Inductor Output L1 9 0105 6b 1 Inductor Output 40 Amp L2 9 0195 Not Shown 1 Power Cable Strain Relief all units Kit includes both styles 9 0111 1 Input Power Cable 230 V with plug 9 0191 1 Input Power Cable 460 600 V 9 0209 1 Hi Lo voltage selection switch SW2 9 0213 NOTE 9 0107 Logic PCB 3 If t...

Page 87: ...apacitors non 600V PCB 2 9 0192 7 1 Assembly PCB Input Capacitors 600V Only PCB 2 9 0164 8 1 Filter Auto Drain 9 0116 Not Shown 1 Wire Harness Ferrite Filter Between J13 on PCB 1 to J4 on PCB 5 9 0251 NOTE 9 0115 regulator If the Logic PCB has a PCB mounted pressure transducer with a small hose connecting the transducer to a fitting on the regulator assembly then kit number 9 0201 which includes b...

Page 88: ...Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Automation Interface Kit PCB 4 9 8311 1 Automation Harness 9 9385 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 Art A 02476 Filter Element ...

Page 89: ... Handle Screw Kit 5 each 6 32 x 1 2 cap screw 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 assemblies 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 2 total 9 7031 7 5 6 3 4...

Page 90: ... 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 7043 ...

Page 91: ...CUTMASTER 102 Manual 0 4998 PARTS LIST 6 9 A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13 ...

Page 92: ...ld 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 Shield Cup 120A 9 8258 Shield Cap Machine 70 100A 9 8239 Shield Cap Machine 120A 9 8256 Art A 08066_AG CUTTING STANDOFF 70 120A CUTTING STANDOFF 20 40A Shield Cap Deflector 9 8243 50 60A CUTTING STANDOF...

Page 93: ...xposed 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 board 6 Carefully open the ESD protective bag and remove the replacement PC Board 7 Install the replacement PC Board in the equipment and make all necessary connections 8 Place the failed PC Board in the ESD protective bag an...

Page 94: ...hile grasping the panel close to the base pull the panel directly from the base to release the locking tabs 3 To re engage the panel position the panel so that the locking tabs are above the base then push the panel back onto the base until the locking tabs engage the mating holes in the base 4 For complete removal of panel disconnect any other item still attached to the panel and another componen...

Page 95: ... defective Pressure Transducer from the regulator and install the new Transducer onto the Air Regulator 3 Install the regulator assembly per subsection 7 05 D 4 Reinstall the power supply cover F Gas Solenoid Replacement Tools required T20 Torx Driver Flat Screw Driver 1 Remove the cover per subsection 7 04 A 2 Disconnect J5 connector from the Main PCB 3 Remove the air hose from Gas Solenoid per s...

Page 96: ...ve the Cover per subsection 7 04 A 2 Unplug corresponding J1 or J2 connector from the Main 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 fan s note the direction of air flow as labeled on the fan housing and orient so fan will blow air into the heat...

Page 97: ...o screws securing the W1 contactor to the base Move the contactor out for clearance for the Center Chassis 8 Disengage the Front and Rear panel from the base per section 7 04 D 9 Carefully guide the Center Chassis towards the center of the base to disengage the bottom locking tabs securing the Chassis to the base 10 Carefully guide the Center Chassis up far enough to lay the Chassis down towards t...

Page 98: ...ion 6 Disconnect the input line from the filter element as sembly 7 Remove the filter element assembly through the rear opening NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly Art A 07990 Filter Element 8 Install the new or cleaned assembly by reversing these procedures 9 Turn ON the air supply and check for leaks before reinstalling the co...

Page 99: ...Reinstall the power supply cover NOTE If unit leaks between housing and cover inspect the O ring for cuts or other damage Optional Two Stage Filter Element Replacement The Two Stage Air Filter has two Filter Elements When the Filter Elements become dirty the Power Supply will continue to oper ate but cut quality may become unacceptable Refer to Section 6 Parts List for replacement filter element c...

Page 100: ...nstall 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 2 Remove all wires from W1 noting the location and orientation of each wire 3 Loosen the two 2 Torx head screws securing the Main Contactor to the base 4 Slide the contactor towards the rear of the unit sl...

Page 101: ...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 continue to r...

Page 102: ...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_AB 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 Re...

Page 103: ... White 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 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 Us...

Page 104: ... 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 Recepta...

Page 105: ...CUTMASTER 102 Manual 0 4998 APPENDIX A 5 This Page Intentionally Blank ...

Page 106: ...PERS 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 PMTH2 PMTH2 80A_AC3 80A_AC3 PRI 3 PRI 3 J13 J13 1 2 3 4 5 6 80A_AC2 80A_AC2 PRI 2 PRI 2 J1 J1 1 2 3 K1 K1 K5 K5 PRI 2 PRI 2 AC1 AC1 J4 J4 1 2 3 4 5 MTH8 MTH8 C16 17 C16 17 K1 K1 PRI 4 PRI 4 K6 K6 SW1 S...

Page 107: ...URRENT DEMAND TIP 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 VALVE ATC GAS CONTROL 0 100PSI 0 4 5VDC OVERTEMP D3 5A 250VAC 30VDC 1TORCH AUTOMATION TORCH SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 34 35 36 37 38 ...

Page 108: ...02 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 2 3 4 5 6 PRI 3 PRI 3 80A_AC3 80A_AC3 PMTH2 PMTH2 C16 17 C16 17 MTH8 MTH8 J4 J4 1 2 3 4 5 AC1 AC1 PRI 2 PRI 2 K1 K1 PRI 4 PRI 4 J7 J7 1 2 T1 T1 MTH2 MTH2 SW1 SW1 1 3 2 4 MOT1 MOT1 PMTH1 PMTH1 PRI 1 ...

Page 109: ...D2 12V1 48V1 I_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 CIRCUIT PRESSURE TRANSDUCER AIR INLET FILTER REGULATOR SOLENOID VALVE ATC GAS CONTROL 0 100PSI 0 4 5VDC OVERTEMP D3 5A 250VAC 30VDC 1TORCH AUTOMATION TORCH SOLENOID 1 2 3 4 5 6 7 8 9 10 11 1...

Page 110: ...d part numbers in section 6 per ECOB1201 Sept 2 2009 AF Updated section 6 with 600v PCB numbers per ECOB1520 Feb 25 2010 AG Updated CNC cable part numbers in section 6 per ECOB1637 Sept 14 2010 AH Updated section 4T and 6 consumables art per ECOB1819 Mar 20 2012 AI Updated ART A 08066 and changed COO text per ECOB2149 April 25 2012 AJ Updated ART A 07994 per ECOB2136 Nov 30 2012 AK Revised frequen...

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Page 112: ...24800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 ASIA PACIFIC Cikarang Indonesia 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 ...

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