Thermal Dynamics CUTMASTER 102 Manuel utilisateur

PLASMA CUTTING SYSTEM

102 CUTMASTER™

Rev. AA Date: September 25, 2008 Manual # 0-4998

Operating Features:

Service Manual

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat-

ing, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

CutMaster™ 102

SL100 1Torch™

Service Manual Number 0-4998

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermadyne Corporation

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

loss or damage caused by any error or omission in this Manual, whether such error

results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: September 25, 2008

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION...................................................................................1-1

1.01 Notes, Cautions and Warnings ...................................................................1-1

1.02 Important Safety Precautions .....................................................................1-1

1.03 Publications.................................................................................................1-2

1.04 Note, Attention et Avertissement ................................................................1-3

1.05 Precautions De Securite Importantes.........................................................1-3

1.06 Documents De Reference...........................................................................1-5

1.07 Declaration of Conformity ...........................................................................1-6

1.08 Statement of Warranty ................................................................................1-7

SECTION 2 SYSTEM:INTRODUCTION .................................................................................2-1

2.01 How To Use This Manual ............................................................................2-1

2.02 Equipment Identiﬁcation .............................................................................2-1

2.03 Receipt Of Equipment.................................................................................2-1

2.04 Power 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 Speciﬁcations ........................................................................................... 2T-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 Connections ........................................................................................3-4

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 Operation..........................................................................4-2

SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1

4T.01 Torch Parts Selection................................................................................ 4T-1

4T.02 Cut Quality ................................................................................................ 4T-2

4T.03 General Cutting Information...................................................................... 4T-2

4T.04 Hand Torch Operation............................................................................... 4T-3

4T.05 Gouging .................................................................................................... 4T-7

4T.06 Mechanized Torch Operation .................................................................... 4T-8

4T.07 Parts Selection for Manual and Mechanized Torch Cutting ...................... 4T-9

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip4T-10

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip4T-13

PATENT INFORMATION ...................................................................................................... 4T-16

TABLE OF CONTENTS

SECTION 5 SYSTEM:SERVICE ..............................................................................................5-1

5.01 General Maintenance .................................................................................5-1

5.02 Maintenance Schedule ...............................................................................5-2

5.03 Common Faults...........................................................................................5-2

5.04 Fault Indicator .............................................................................................5-3

5.05 Basic Troubleshooting Guide ......................................................................5-6

5.06 Circuit Fault Isolation ..................................................................................5-8

5.07 Main Input and Internal Power Problems..................................................5-12

5.08 Pilot Arc Problems ....................................................................................5-16

5.09 Main Arc and Controls Problems ..............................................................5-19

5.10 CNC Interface Problems ...........................................................................5-20

5.11 Test Procedures........................................................................................5-20

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

6.02 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 Parts .....................................................................6-4

6.07 Right Side Replacement Parts ...................................................................6-5

6.08 Replacement Power Supply Parts ..............................................................6-6

6.09 Options and Accessories ............................................................................6-6

6.10 Replacement Parts for Hand Torch ............................................................6-7

6.11 Replacement Parts - for Machine Torches with Unshielded Leads.............6-8

6.12 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 Information ..................................................7-1

7.04 Major External Parts ..................................................................................7-2

7.05 Front Panel Parts Replacement ..................................................................7-3

7.06 Left Side Internal Parts Replacement .........................................................7-4

7.07 Rear Panel Parts Replacement ..................................................................7-6

7.08 Right Side Internal Parts Replacement.......................................................7-9

TABLE OF CONTENTS

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) ........................................ A-1

APPENDIX 2: DATA TAG 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: Publication History........................................................................................... A-8

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

TABLE OF CONTENTS

cutmaster 102

Manual 0-4998 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to

highlight important information. These highlights are categorized as

follows:

NOTE

An operation, procedure, or background information

which requires additional emphasis or is helpful in ef-

ﬁcient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause

damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause

injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC

EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS

TO YOUR HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the proper

function of cardiac pacemakers, hearing aids, or other

electronic health equipment. Persons who work near

plasma arc cutting applications should consult their

medical health professional and the manufacturer of

the health equipment to determine whether a hazard

exists.

To prevent possible injury, read, understand and follow

all warnings, safety precautions and instructions before

using the equipment. Call 1-603-298-5711 or your local

distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma 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 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 Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should

be supplied with the material you are using. These MSDSs

will give you the information regarding the kind and amount of

fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your

workplace, refer to item 1 in Subsection 1.03, Publications in

this manual.

• Use special equipment, such as water or down draft cutting

tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or

explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlo-

rinated solvents and cleansers. Remove all sources of these

vapors.

• This product, when used for welding or cutting, produces

fumes or gases which contain chemicals known to the State

of California to cause birth defects and, in some cases, cancer.

(California Health & Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and

produces high voltage electrical energy. This electric energy can cause

severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work

piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or

damp.

• Install and maintain equipment according to NEC code, refer

to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or

repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma

arc.

• Be sure there is no combustible or ﬂammable material in the

workplace. Any material that cannot be removed must be

protected.

• Ventilate all ﬂammable or explosive vapors from the work-

place.

cutmaster 102

GENERAL INFORMATION 1-2 Manual 0-4998

• Do not cut or weld on containers that may have held combus-

tibles.

• Provide a ﬁre watch when working in an area where ﬁre hazards

may exist.

• Hydrogen gas may be formed and trapped under aluminum

workpieces when they are cut underwater or while using a water

table. DO NOT cut aluminum alloys underwater or on a water

table unless the hydrogen gas can be eliminated or dissipated.

Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can

cause noise levels to exceed safe limits. You must protect your ears

from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear

plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound)

do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsec-

tion 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 will damage your eyes and burn your skin if you are not

properly protected.

• To protect your eyes, always wear a welding helmet or shield.

Also always wear safety glasses with side shields, goggles or

other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin

from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace

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 seen.

Experience has shown that lighter ﬁlters may be used

when the arc is hidden by the workpiece.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces

chemicals known to the State of California to cause cancer, birth defects

and other reproductive harm.Wash hands after handling. (California

Health & Safety Code § 25249.5 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.S.

Government Printing Ofﬁce, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,

obtainable from the American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS

WELDING AND CUTTING, obtainable from the Superintendent

of Documents, U.S. Government Printing Ofﬁce, Washington,

D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION

AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable

from American National Standards Institute, 1430 Broadway,

New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE

FOOTWEAR, obtainable from the American National Standards

Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-

TING AND WELDING PROCESSES, obtainable from American

National Standards Institute, 1430 Broadway, New York, NY

10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-

ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from

American Welding Society, 550 N.W. LeJeune Rd, Miami, FL

33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR

WELDING, CUTTING AND ALLIED PROCESSES, obtainable

from the National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable

from the National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,

obtainable from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED

GASES IN CYLINDERS, obtainable from the Compressed

Gas Association, 1235 Jefferson Davis Highway, Suite 501,

Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING

AND CUTTING, obtainable from the Canadian Standards As-

sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable

from the National Welding Supply Association, 1900 Arch

Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARATION FOR

WELDING AND CUTTING OF CONTAINERS AND PIPING THAT

HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the

American Welding Society, 550 N.W. LeJeune Rd, Miami, FL

33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-

TECTION, obtainable from American National Standards

Institute, 1430 Broadway, New York, NY 10018

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