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Victor cutmaster 82, Operating Manual

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Victor cutmaster 82 Operating Manual Download Page 22

CUTMASTER 82

  

INTRODUCTION 

Manual 0-4979

2T-4

This Page Intentionally Blank

Summary of Contents for cutmaster 82

Page 1: ...VictorThermalDynamics com 80 208 230V 460V Art A 08607_AD 600V 400V Operating Manual Revision AR Issue Date February 11 2014 Manual No 0 4979 CUTMASTER 82 PLASMA CUTTING SYSTEM...

Page 2: ...herefore 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 C...

Page 3: ...hnologies International Inc 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 disclai...

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

Page 5: ...r Supply Specifications 2 2 2 05 Input Wiring Specifications 2 3 2 06 Power Supply Features 2 4 SECTION 2 TORCH INTRODUCTION 2T 1 2T 01 Scope of Manual 2T 1 2T 02 General Description 2T 1 2T 03 Specif...

Page 6: ...sic Parts Replacement 5 6 SECTION 5 TORCH SERVICE 5T 1 5T 01 General Maintenance 5T 1 5T 02 Inspection and Replacement of Consumable Torch Parts 5T 2 SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6...

Page 7: ...a cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilat...

Page 8: ...n 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays w...

Page 9: ...rom American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et aver tissement sont utilis s pour mettre en rel...

Page 10: ...ourant descendant pour capter la fum e et les gaz N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique...

Page 11: ...otection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protec teur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre...

Page 12: ...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 13: ...talled standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manu facturing process This is to ensure the product is safe w...

Page 14: ...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 Equipmentthathasbeenmodifiedbyanunauthorizedpa...

Page 15: ...equipment identification numbers Electroniccopiesofthismanualcanalsobedownload edatnochargeinAcrobatPDFformatbygoingtothe Thermal Dynamics web site listed below and clicking on Thermal Dynamics and t...

Page 16: ...ower Supply Duty Cycle Ambient Temperature Duty Cycle Ratings 40 C 104 F Operating 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 Volta...

Page 17: ...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 18: ...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 19: ...single source to be used as both the plasma and secondary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to...

Page 20: ...as 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 t...

Page 21: ...to transfer to the work D Main Cutting Arc DC power is also used for the main cutting arc The negative output is connected to the torch electrode through the torch lead The positive output is con nect...

Page 22: ...CUTMASTER 82 INTRODUCTION Manual 0 4979 2T 4 This Page Intentionally Blank...

Page 23: ...ver The cover is held in place with two or more snap lock tabs To remove the cover release the front latch and tilt the cover up about inch Then squeeze both sides of the cover and lift it straight up...

Page 24: ...ons Green Yellow wire to Ground Remaining wires to L1 and L2 input It does not matter what order these wires are at tached 7 With a little slack in the wires tighten the through hole protector to secu...

Page 25: ...is out of the torch 1 Attach the Single Stage Filter Hose to the Inlet Port 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustration shows typical fittings...

Page 26: ...y are clean and free of oil grease or any foreign mate rial Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjust able high pressure...

Page 27: ...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 switc...

Page 28: ...2 A 02585 Workpiece Square Pinch Block Assembly Mechanical Torch Set Up 3 The proper torch parts shield cup tip start car tridge and electrode must be installed for the type of operation Refer to Sect...

Page 29: ...he 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 Indicat...

Page 30: ...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 31: ...iece 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 32: ...CUTMASTER 82 OPERATION Manual 0 4979 4 4 This Page Intentionally Blank...

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

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

Page 35: ...from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficul...

Page 36: ...head or torch handle can damage components 8 For a consistent standoff height from the work piece install the standoff guide by sliding it onto the torch shield cup Install the guide with the legs at...

Page 37: ...lled 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 at tempt to force the shield cup to close this gap Forcing the shie...

Page 38: ...or power supply CAUTION Sparks from plasma gouging can cause dam age to coated painted or other surfaces such as glass plastic and metal Check torch parts The torch parts must cor respond with the typ...

Page 39: ...cted in the same direction as torch travel Afive degree leading arc is gener ally recommended for air plasma on mild steel 3 Trailing Arc The trailing arc is directed in the opposite direc tion as tor...

Page 40: ...37 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 AE DRAG SHIELD CUTTING Shield Cap...

Page 41: ...mps Inches Meters Inches mm psi bar Plasma Total Delay Sec Inches mm 0 036 0 9 9 8208 103 40 355 9 02 0 125 3 2 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...

Page 42: ...s mm 0 06 1 5 9 8210 119 60 350 8 91 0 19 4 8 75 5 2 90 245 0 00 0 20 5 1 0 075 1 9 9 8210 116 60 300 7 64 0 19 4 8 75 5 2 90 245 0 10 0 20 5 1 0 120 3 0 9 8210 123 60 150 3 82 0 19 4 8 75 5 2 90 245...

Page 43: ...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 SL60 With Exposed Tip Type Material Stainless Steel Type Plasma Gas A...

Page 44: ...ge 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 0 036 0 9 9 8208 114 40 170...

Page 45: ...0 5 84 0 19 4 8 75 5 2 90 245 0 10 0 2 5 1 0 135 3 4 9 8210 128 60 142 3 61 0 19 4 8 75 5 2 90 245 0 10 0 2 5 1 0 188 4 8 9 8210 128 60 125 3 18 0 19 4 8 75 5 2 90 245 0 20 0 2 5 1 0 250 6 4 9 8210 12...

Page 46: ...8210 150 60 15 0 38 0 19 4 8 75 5 2 90 245 NR NR NR Type Torch SL60 With Shielded Tip Type Material Mild Steel Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip Output Amperage Spe...

Page 47: ...R NR NR 1 000 25 4 9 8211 140 80 8 0 20 0 125 3 2 70 4 8 115 340 NR NR NR Type Torch SL60 With Shielded Tip Type Material Aluminum Type Plasma Gas Air Type Secondary Gas Single Gas Torch Thickness Tip...

Page 48: ...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 49: ...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 50: ...CUTMASTER 82 OPERATION Manual 0 4979 4T 18 This Page Intentionally Blank...

Page 51: ...ck of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of pow...

Page 52: ...e 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 Problem Symptom Com...

Page 53: ...ow the Temp indica tor and 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 blinki...

Page 54: ...d 2 Duty cycle of the unit has been exceeded 3 Failed components in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacem...

Page 55: ...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 posit...

Page 56: ...necessary 2 Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws C Filter Eleme...

Page 57: ...ry 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...

Page 58: ...e out the old Filter Elements First Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same o...

Page 59: ...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 andATC Male Connec tor requires lubrication on a sched...

Page 60: ...may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Remove the tip Check for excessive wear ind...

Page 61: ...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...

Page 62: ...talog 1 Single Stage Filter Kit includes 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 inclu...

Page 63: ...ch 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 SL60...

Page 64: ...th ATC connector 4 7852 1 50 foot 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...

Page 65: ...CUTMASTER 82 Manual 0 4979 PARTS LIST 6 5 A 07994_AB 1 4 2 3 5 6 7 8 9 10 12 11 10 13...

Page 66: ...ds Assemblies with ATC Connectors 1 5 foot 1 5 m Leads Assembly with ATC Connector 4 7846 1 10 foot 3 05 m Leads Assembly with ATC Connector 4 7847 1 25 foot 7 6 m Leads Assembly with ATC Connector 4...

Page 67: ...7 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_AE DRAG SHIELD CUTTING...

Page 68: ...up 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...

Page 69: ...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 70: ...acturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 032...

Page 71: ...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 72: ...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 73: ...CUTMASTER 82 Manual 0 4979 APPENDIX A 5 This Page Intentionally Blank...

Page 74: ...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 75: ...nt 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 42X1298 Monday March 30...

Page 76: ...PUT 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...

Page 77: ...r Release Reproduction 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...

Page 78: ...ted 400V 600V schematic in appendix per ECOB1399 Updated 230 460v schematic per ECOB1357 Feb 25 2010 AJ Updated CNC cable part numbers in section 6 per ECOB1637 Sept 14 2010 AK Updated SL 100 consumab...

Page 79: ...This Page Intentionally Blank...

Page 80: ...4800 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...

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