Thermal Dynamics Cutmaster 82 Service Manual
  1. Manuals
  2. Brands
  3. Thermal Dynamics Manuals
  4. Welding System
  5. Cutmaster 82
  6. Service manual

Thermal Dynamics Cutmaster 82 Service Manual

Plasma cutting system
Hide thumbs
Table of Contents

Advertisement

Quick Links

82
CUTMASTER
™
PLASMA CUTTING SYSTEM
Art # A-08839_AB

Service Manual

Rev. AH
Date: May 29, 2009
Manual # 0-4980
Operating Features:
460
400
600
v
v
v

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Cutmaster 82 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Thermal Dynamics Cutmaster 82

Summary of Contents for Thermal Dynamics Cutmaster 82

  • Page 1: Service Manual

    CUTMASTER ™ PLASMA CUTTING SYSTEM Art # A-08839_AB Service Manual Rev. AH Date: May 29, 2009 Manual # 0-4980 Operating Features:...
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ 82 SL100 1Torch™ Operating Manual Number 0-4980 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2007, 2008, 2009 by Thermadyne Corporation All rights reserved.
  • Page 4 This Page Intentionally Blank...

  • Page 5: Table Of Contents

    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...
  • Page 6 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 ..............5-4 5.06 Power Supply Basic Parts Replacement.............5-6 5.07 Circuit Fault Isolation ..................5-8 5.08 Main Input and Internal Power Problems ..........5-12 5.09 Pilot Arc Problems ..................5-15...
  • Page 7 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: SYSTEM SCHEMATIC, 600V UNITS ..............
  • Page 8 TABLE OF CONTENTS...

  • Page 9: Section 1:General Information

    82 SECTION 1: • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the GENERAL INFORMATION different processes. You must be very careful when cutting...

  • Page 10: Publications

    82 • Do not cut or weld on containers that may have held combus- 1.03 Publications tibles. Refer to the following standards or their latest revisions for more • Provide a fire watch when working in an area where fire hazards information: may exist.

  • Page 11: Note, Attention Et Avertissement

    82 1.04 Note, Attention et Avertissement • Les sortes de gaz et de fumée provenant de l’arc de plasma dépen- dent du genre de métal utilisé, des revêtements se trouvant sur le Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont métal et des différents procédés.
  • Page 12 82 produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables. BRUIT • Soyez certain qu’aucune matière combustible ou inflammable ne Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés se trouve sur le lieu de travail.

  • Page 13: Documents De Reference

    82 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT été...

  • Page 14: Declaration Of Conformity

    Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 15: Statement Of Warranty

    This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose. Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below.
  • Page 16 82 GENERAL INFORMATION Manual 0-4980...

  • Page 17: Section 2 System:introduction

    Electronic 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 Literature link: http://www.thermal-dynamics.com Manual 0-4980...

  • Page 18: Power Supply Specifications

    Output Current 20 - 80 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster 82 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Rating...

  • Page 19: Input Wiring Specifications

    82 2.05 Input Wiring Specifications CutMaster 82 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts I max Fuse (amps) (Min. AWG) 1 Phase 50/60 50/60 11.8 3 Phase 50/60 11.8 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 20: Power Supply Features

    82 2.06 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-07942 Work Cable and Clamp Port for Optional Automation Interface Cable Input Power Selection Filter Assembly Gas Inlet Port Art # A-07981 Input Power Cord...

  • Page 21: Section 2 Torch:introduction

    82 SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Hand/Manual Torch, Models 2T.01 Scope of Manual The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch This manual contains descriptions, operating trigger assembly.

  • Page 22: 04 Options And Accessories

    82 2T.05 Introduction to Plasma F. Torch Ratings Manual Torch Ratings A. Plasma Gas Flow Ambient 104° F Plasma is a gas which has been heated to an ex- Temperature 40° C tremely high temperature and ionized so that it...
  • Page 23 82 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) circuit. and secondary gases. When the shield cup is properly installed, it closes a switch.
  • Page 24 82 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4980...

  • Page 25: Section 3 System: Installation

    82 SECTION 3 SYSTEM: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account 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.

  • Page 26: Primary Input Power Connections

    82 3.03 Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting 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 specified in Section 2.
  • Page 27 82 4. If the power cable being used is not the factory - supplied cable, use a three - conductor input power cable for the voltage desired and strip back the insulation on the individual wires. 5. Pass the cable being used through the access opening in the back panel of the power supply. Re- fer to Section 2 for power cable specifications.

  • Page 28: Gas Connections

    82 3.04 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed. 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example.
  • Page 29 82 Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port.
  • Page 30 82 Installing Optional 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.

  • Page 31: Section 3 Torch: Installation

    3T.01 Torch Connections 2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- ply. Connect only the Thermal Dynamics model position. SL60 / Manual or SL100 / Mechanical Torch to 3. Place a welding filter lens in front of the this power supply.
  • Page 32 82 Pinch Block Assembly Square Workpiece A-02585 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 Selection for details.

  • Page 33: Section 4 System: Operation

    82 SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

  • Page 34: Preparations For Operation

    Set Operating Pressure Check that the torch is properly connected. Only 1. Place the Power Supply Function Control Thermal Dynamics model SL60 / Manual or SL100 / knob to the SET position. Gas will Mechanical Torches may be connected to this Power Supply.
  • Page 35 82 Typical Cutting Speeds STANDOFF CutMaster 82 Gas Pressure Settings Cutting speeds vary according to torch output am- perage, the type of material being cut, and opera- Leads SL60 SL100 tor skill. Refer to Section 4T.08 and following for...
  • Page 36 82 This Page Intentionally Blank OPERATION Manual 0-4980...

  • Page 37: Section 4 Torch:operation

    82 2. Remove the Electrode by pulling it straight SECTION 4 TORCH: out of the Torch Head. OPERATION Torch Head 4T.01 Torch Parts Selection Electrode Depending on the type of operation to be done determines the torch parts to be used.

  • Page 38: 02 Cut Quality

    82 4T.02 Cut Quality Bottom Dross Buildup Molten material which is not blown out of the cut NOTES area and resolidifies on the plate. Excessive dross Cut quality depends heavily on setup and may require secondary cleanup operations after parameters such as torch standoff, alignment with cutting.

  • Page 39: 04 Hand Torch Operation

    82 Torch Standoff Dross Improper standoff (the distance between the torch When dross is present on carbon steel, it is com- tip and workpiece) can adversely affect tip life as monly referred to as either “high speed, slow speed, well as shield cup life.
  • Page 40 82 2. Depending on the cutting operation, do one Trigger of the following: a. For edge starts, hold the torch perpen- dicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.
  • Page 41 82 6. Slide the trigger release toward the back Shield Cup With Straight Edge of the torch handle while simultaneously The drag shield cup can be used with a non conduc- squeezing the trigger. The pilot arc will tive straight edge to make straight cuts by hand.
  • Page 42 82 6. Bring the torch within transfer distance to Piercing With Hand Torch the work. The main arc will transfer to the 1. The torch can be comfortably held in one work, and the pilot arc will shut off.

  • Page 43: 05 Gouging

    82 4T.05 Gouging Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle WARNINGS greater than 45° the molten metal will not be blown...

  • Page 44: 06 Mechanized Torch Operation

    82 4T.06 Mechanized Torch Operation For optimum smooth surface quality, the travel speed should be adjusted so that only the leading Cutting With Mechanized Torch edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as...

  • Page 45: 07 Parts Selection For Manual And Mechanized Torch Cutting

    Tip Gouging A 9-8225 (40 Amps Max.) NOTE CutMaster 52 uses 60A and less Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less Art # A-08065_AC Tip Gouging C 9-8227 (60 - 120 Amps)

  • Page 46: T.08 Recommended Cutting Speeds For Mechanized Torch With Exposed Tip

    82 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press...
  • Page 47 82 Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)
  • Page 48 82 Type Torch: Mechanized With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)

  • Page 49: T.09 Recommended Cutting Speeds For Mechanized Torch With Shielded Tip

    82 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press...
  • Page 50 82 Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.)
  • Page 51 82 Type Torch: Mechanized With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC)

  • Page 52: Patent Information

    82 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;...
  • Page 53 82 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...
  • Page 54 82 This Page Intentionally Blank OPERATION 4T-18 Manual 0-4980...

  • Page 55: Section 5 System:service

    82 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Manual 0-4980 SERVICE...

  • Page 56: Maintenance Schedule

    4. Worn torch parts Daily Operational Checks or Every Six Cutting 5. Cutting current too low. Hours: 6. Non - Genuine Thermal Dynamics parts used Check torch consumable parts, replace if dam- 7. Incorrect gas pressure aged, worn or when cut performance has demi- Main Arc 1.

  • Page 57: Fault Indicator

    82 5.04 Fault Indicator Explanation of Faults " UNDER PRESSURE: Indicates that operating pres- At initial power up, two lights will temporarily illu- sure is set too low and power supply output minate for 2-3 seconds to show the version of software power will be disabled.

  • Page 58: Basic Troubleshooting Guide

    82 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause...
  • Page 59 82 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn off power supply. Remove shield cup. Install missing Gas flow is cycling on cartridge missing.

  • Page 60: Power Supply Basic Parts Replacement

    82 5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced.
  • Page 61 82 5. Remove the fitting from the filter element as- 4. Turn the Filter Housing Cover counter-clockwise sembly by inserting a 6 mm hex wrench into and remove it. The Filter Element is located inside the internal hex fitting and turning it counter the Housing.

  • Page 62: Circuit Fault Isolation

    82 5.07 Circuit Fault Isolation 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 WARNING continue to operate but cut quality may become unac- The following procedures should not be attempted ceptable.
  • Page 63 3. Adjust the pressure regulator to set the gas pres- sure as specified in charts. Pilot IGBT Test – Section 5.11 F STANDOFF If all of the Pre Power-Up Tests are ok, proceed with CutMaster 82 Gas Pressure Settings the trouble shooting guide. Leads SL60 SL100...
  • Page 64 82 G. Main Arc and Controls Test Turn FUNCTION CONTROL SWITCH to RUN position Connect work Cable to the work piece, Close torch • Solenoid turns off, gas stops flowing (pressure switch (Pendant switch or activate CNC Start) to es- display may increase slightly when gas is not tablish a pilot arc.
  • Page 65 82 9. Close torch switch (Pendant switch or activate 3. Remove jumper from J6. CNC Start) to establish a pilot arc. Bring torch to • OK-TO-MOVE signal off (Meter shows no within 1/8” – 3/8” of the work piece to establish continuity) main cutting arc.

  • Page 66: Main Input And Internal Power Problems

    82 5.08 Main Input and Internal Power B. Primary line fuses blow immediately after ON/OFF SWITCH (SW1) is turned to ON Problems position. A. Primary input line fuse blows as soon as Shorted Input Diode Module primary disconnect is closed.
  • Page 67 82 E. INPUT POWER FAULT. Negative / Plasma Lead AC LED on, FAULT Indicator and 65 PSI LED is flashing. 1. INPUT VOLTAGE SELECTOR SWITCH (SW2) 4 Torch Switch set for incorrect voltage 3 Torch Switch a) Set SW2 to correspond to the primary line volt- 2 PIP age.
  • Page 68 82 H. TIP MISSING FAULT. The FAULT Indicator 3. Fan(s) not turning and 80 PSI LED is flashing. Gas solenoid a) Measure voltage at plug between J7-1 to J7- cycles on and off. 2 and between J81 to J8-2 on Main Pcb for 12VDC If voltage is present replace fan.

  • Page 69: Pilot Arc Problems

    82 M. AC LED on, TEMP LED off, GAS LED on, 6. Defective Logic PCB Gas does not flow in SET mode using a a) Measure on Main PCB between J2-11 to GND1 hand torch or a machine torch without for less than 2VDC.
  • Page 70 82 Defective Main PCB 4. Shorted Torch a) With Torch Switch closed, measure voltage a) Disconnect torch from unit. With consumables on Main PCB between test points GND1 to removed from the torch, Check continuity of I_DMD1 for 1.4 VDC. Replace Main PCB if torch at ATC, between negative/plasma lead voltage is present.

  • Page 71: Main Arc And Controls Problems

    82 E. AC LED on, TEMP LED off, GAS LED on, D. With CURRENT CONTROL gas flowing, DC LED on, Fault Indicators POTENTIOMETER set at maximum, output off, Pilot Arc is intermittent. current is only 60 amps. 1. Defective Logic PCB 1.

  • Page 72: Test Procedures

    82 C. ARC VOLTS signals are low or not present B. Input Diode Module Test Defective Automation Interface PCB (PCB4) 1. Using an ohmmeter perform the tests in the chart a) Replace PCB4 Input Diode Module 5.12 Test Procedures...
  • Page 73 82 D. IGBT Modules Test 1. Disconnect transformer wires from Main PCB terminals PRI 1 (A) and PRI 4 (D). 2. Using an ohmmeter perform the following checks IGBT A Meter (+) Meter (-) Indication PRI 1 (A) MTH 2...
  • Page 74 82 F. Pilot IGBT Test Disconnect wire from Main PCB terminal TIP1 Measure continuity on Main PCB between test point GND1 to terminal TIP1 If the test reveals a failed component, replace Main PCB. If no problem is found, reconnect wire to Main PCB.
  • Page 75 82 CAPACITOR PCB SIGNALS Signal Source-Destination J1-1 Capacitor bank A+ J1-5 Capacitor bank A- J2-1 Capacitor Bank B+ J2-5 Capacitor Bank B- J3-1 +12 VDC J3-2 /460 Active low for 460VAC input J3-3 /230 Active low for 230VAC input...
  • Page 76 82 LOGIC PCB LAYOUT PCB3 D1 TP3 T P5 *J1 Pinout Art # A-08179 LOGIC PCB SIGNALS (Same for MAIN PCB J2) Signal Source/Destination J1-1 -VOUT (-) OUTPUT VOLTAGE J1-2 /TIP VOLTS Active high when tip is installed J1-3 TIP_SEN Approx.
  • Page 77 82 J1-9 /W1_ON Active low to enable W1 contactor J1-10 SHDN Active low enables PWM circuit J1-11 /TRCH_SOL Active low to enable Torch Solenoid J1-12 /SOL_ON Active low to enable Power Supply solenoid J1-13 /OK_TO_MOVE Active low to enable OK_TO_MOVE (CNC)
  • Page 78 82 LED INDICATORS NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE +12VDC MAX PRESSURE Over Pressure 90 PSI Internal Error 85 PSI Shorted torch 80 PSI Tip Missing 75 PSI Start Signal active during power up 70 PSI Parts-In-Place Fault (PIP)
  • Page 79 82 This Page Intentionally Blank Manual 0-4980 5-25 SERVICE...
  • Page 80 82 *J2 PINOUT PRI_4 J4 J3 I_DMD1 PRI_1 GND1 PRI_3 PRI_2 TIP1 SEC1 ELECTRODE1 +48V2 +12V2 -V_OUT1 +48V1 J8 J7 J6 J5 Art # A-08518_AB CHOKE1 SEC2 WORK_1 GND2 +12V1 MAIN PCB SIGNALS J1-1 L1 Primary AC Line J1-2...
  • Page 81 82 J1-5 L2 Primary AC Line GND2 Common GND3 Common J3-1 /230VAC +12V1 +12VDC J3-2 Common +48V1 +48VDC For factory use I_DMD1 0-4VDC Current Demand Signal J5-1 +12VDC J5-2 Not used J5-3 /SOLENOID J6-1 24VAC Supply for W1 J6-2...
  • Page 82 82 This Page Intentionally Blank SERVICE 5-28 Manual 0-4980...

  • Page 83: Section 5 Torch:service

    82 SECTION 5 TORCH: It is recommended to apply a very light film of o- ring lubricant (Catalog # 8-4025) to the o-rings on a SERVICE weekly basis. 5T.01 General Maintenance NOTE Upper Groove with Vent Holes Refer to Previous "Section 5 System" for common Must Remain Open and fault indicator descriptions.

  • Page 84: 02 Inspection And Replacement Of Consumable Torch Parts

    82 5T.02 Inspection and Replacement 4. Remove the tip. Check for excessive wear (indi- cated by an elongated or oversized orifice). Clean of Consumable Torch Parts or replace the tip if necessary. Good Tip Worn Tip WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 85: Section 6:Parts Lists

    The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # CutMaster 82 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with input power cable and plug 3-1130-1...

  • Page 86: Major External Replacement Parts

    82 6.04 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-0128 Base Enclosure Assembly 9-0118 Tube, roll handle 9-0121 Front Panel 9-0127 Rear Panel 9-0101 Art # A-08120 NOTE Illustration may vary slightly from unit.

  • Page 87: Front Panel Replacement Parts

    82 6.05 Front Panel Replacement Parts Item# Description Ref. Catalog # Output Current Control and Function Control Knobs 9-8527 Toggle - On/Off Switch 9-0109 Work Cable with Clamp, 20 Ft / 6.1 m 9-0184 Art # A-08123 NOTE Illustration may vary slightly from unit.

  • Page 88: Left Side Replacement Parts

    82 6.06 Left Side Replacement Parts Item # Description Catalog # Main PCB Assembly PCB1 9-0125 Logic PCB PCB3 9-0107* Center Chassis Molded Plastic 9-0102 Fan, MOT1,MOT2 9-0104 Transformer, Main Non 600V 9-0199 Transformer, Main 600V Only 9-0170 Inductor, Output...

  • Page 89: Right Side Replacement Parts

    82 6.07 Right Side Replacement Parts Item # Description Catalog # Contactor, 4 Pole 9-8587 Solenoid, 12V 9-0114 Spare Parts Box 7-3267 Spare Parts Box Cover 7-3266 Console Quick Disconnect 9-0161 Regulator, with knob and mounting nut 9-0115* Assembly, PCB, Input Capacitors...

  • Page 90: Options And Accessories

    82 6.08 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Two - Stage Filter Kit (includes Hose & Mounting Screws)

  • Page 91: Replacement Parts For Hand Torch

    82 6.09 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.

  • Page 92: Replacement Parts - For Mechanized Torches With Unshielded Leads

    82 6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads Item No. Qty Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486...
  • Page 93 82 A-07994 Manual 0-4980 PARTS LIST...

  • Page 94: Torch Consumable Parts Manual And Mechanized Torches

    Tip Gouging A 9-8225 (40 Amps Max.) NOTE CutMaster 52 uses 60A and less Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less Art # A-08065_AC Tip Gouging C 9-8227 (60 - 120 Amps)

  • Page 95: Section 7: Replacement Procedures

    82 SECTION 7: REPLACEMENT B. Procedure PROCEDURES 1. Open the wrist strap and unwrap the first two folds of the band. Wrap the adhesive side firmly around your wrist. 7.01 Scope 2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

  • Page 96: Major External Parts

    82 7.04 Major External Parts C. Tube Handle Replacement Tools required: T20 Torx Driver A. Cover Removal 1. Disconnect the Torch and Leads from the unit. Tools required: T20 Torx Driver 2. Remove the cover per subsection 7.04 A.

  • Page 97: Front Panel Parts Replacement

    82 7.05 Front Panel Parts Replacement D. Air Regulator Replacement Tools required: T20 Torx Driver Refer to section 6.05 for Front Panel Replacement Parts and overall detailed drawing. 1. Remove the cover per subsection 7.04A A. Current Control Potentiometer (A) Knob 2.

  • Page 98: Left Side Internal Parts Replacement

    82 7.06 Left Side Internal Parts 7. Install the replacement Logic PCB by reversing the above steps. Replacement 8. Reinstall the power supply cover. A. Fan Replacement G. ON/OFF Switch (SW1) Replacement Tools required: T20 Torx Driver Tools required: T20 Torx Driver 1.

  • Page 99: Rear Panel Parts Replacement

    82 7.07 Rear Panel Parts Replacement 13. Remove the two screws securing the Main Trans- former to the base. A. Filter Element Assembly Replacement 14. Remove the Main Transformer, carefully guiding all its wires through from the right side of the The Filter Element Assembly is in the rear panel.
  • Page 100 82 C. Input Power Cable Replacement the internal hex fitting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous Tools required: T20 Torx Driver, Phillips Head Screw- illustration. driver, Flathead Screwdriver, 6. Disconnect the input line from the filter element 1.

  • Page 101: Right Side Internal Parts Replacement

    82 5. Remove the Filter Element from the Housing and 3. Loosen the two (2) Torx head screws securing the set Element aside to dry. Main Contactor to the base. 6. Wipe inside of housing clean, then insert the 4.
  • Page 102 82 This Page Intentionally Blank PARTS REPLACEMENT Manual 0-4980...

  • Page 103: Appendix 1: Sequence Of Operation(Block Diagram

    82 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN...

  • Page 104: Appendix 2: Data Tag Information

    82 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1)

  • Page 105: Appendix 3: Torch Pin - Out Diagrams

    82 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green /...

  • Page 106: Appendix 4: Torch Connection Diagrams

    82 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Torch Torch Supply...
  • Page 107 82 This Page Intentionally Blank Manual 0-4980 APPENDIX...

  • Page 108: Appendix 5: System Schematic, 208/460V Units

    82 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS K1-K4 K1-K4 K5, K6 K5, K6 PRI 2 PRI 2 PRI 1 PRI 1 PRI 4 PRI 4 PRI 3 PRI 3 +12VDC BIAS SUPPLY MTH2 MTH2 MTH1 MTH1 C1-C4* C1-C4* /INRUSH...
  • Page 109 05/09/08 Date: Date: Date: ECO B1159 10/03/08 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, March 27, 2008 Thursday, March 27, 2008 Thursday, March 27, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 110: Appendix 6: System Schematic, 600V Units

    82 APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS APPENDIX Manual 0-4980...
  • Page 111 82 Manual 0-4980 APPENDIX...

  • Page 112: Appendix 7: Publication History

    82 APPENDIX 7: Publication History Cover Date Rev. Change(s) Oct. 1, 2007 Manual released. Apr. 15, 2008 Per ECOB752 updated firmware changes to pgs. 4-1 and 5-5. Per ECOB845 correct ed drag cutting statement to ¼” pg. 4T-5. Per ECOB803 releasing 400 – 460V sys tems.
  • Page 113 GLOBAL CUSTOMER SERVICE CONTACT Thermadyne USA Thermadyne Asia Sdn Bhd Lot 151, Jalan Industri 3/5A 2800 Airport Road Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Telephone: 603+ 6092 2988 Fax: 800-535-0557 Fax : 603+ 6092 1085...
  • Page 114 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

Table of Contents

Save PDF