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CUTMASTER 12mm

Manual 0-5076

3-1 INSTALLATION

SECTION 3 SYSTEM:

INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and ac-

count for each item.

2. Inspect each item for possible shipping

damage. If damage is evident, contact

your distributor and / or shipping company

before proceeding with the installation.

3. Record Power Supply and Torch model

and serial numbers, purchase date and ven-

dor name, in the information block at the

front of this manual.

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 power cord before moving

unit.

FALLING EQUIPMENT

can cause serious

personal injury and can damage equipment.

HANDLE

is not for mechanical lifting.

• Only persons of adequate physical strength

should lift the unit.

• Lift unit by the handles, using two hands.

Do not use straps for lifting.

• Use optional cart or similar device of ad-

equate capacity to move unit.

• Place unit on a proper skid and secure in

place before transporting with a fork lift or

other vehicle.

3.03 Primary Input Power

Connections

CAUTION

Check your power source for correct voltage

before plugging in or connecting the unit.

The primary power source, fuse, and any

extension cords used must conform to local

electrical code and the recommended circuit

protection and wiring requirements as speci-

fied in Section 2.

All units are shipped from the factory with a

380/400Volt input power cable wired to the input

contactor in the three - phase configuration. The

following illustration and directions are for re-

placing the input power cable.

Art # A-08546

Three-Phase (3ø) and Jumper Settings

L3
L4

Jumper L1 -L4

L1
L2
L3

GND

Three Phase Input Power Wiring

A. Connections to Three Phase Input Power

WARNING

Disconnect input power from the power sup-

ply and input cable before attempting this

procedure.

These instructions are for replacing a 380/400V

input power cable to the Power Supply for Three -

Phase input power.

1. Remove the Power Supply cover per in-

structions found in section 5.

2. Disconnect the original input power cable

from the main input contactor and the

chassis ground connection.

3. Loosen the through - hole protector on the

back panel of the power supply. Pull the

original power cable out of the power sup-

ply.

ARC WELDING SUPPLIES - 07 847 7870

Содержание CUTMASTER 12

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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