Thermal Dynamics 1-4730-6 Operating Manual
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Thermal Dynamics 1-4730-6 Operating Manual

Thermal Dynamics 1-4730-6 Operating Manual

Cutmaster 10mm, cutmaster 12mm plasma cutting system
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10mm
12mm
Operating Manual
CUTMASTER
PLASMA CUTTING SYSTEM
Rev. AE
Operating Features:
™
Date: September 3, 2012
30
40
DC
AMP
AMP
Art A-10399
Manual # 0-5197AE
1
240
PHASE

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Summary of Contents for Thermal Dynamics 1-4730-6

  • Page 1 10mm 12mm CUTMASTER ™ PLASMA CUTTING SYSTEM Art A-10399 Operating Manual Rev. AE Date: September 3, 2012 Manual # 0-5197AE Operating Features: PHASE...
  • Page 2 Technologies.com on the web. This Installation/Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Source CutMaster™ 10mm Plant - Part Number 1-4730-6 Cutmaster™ 12mm Plant - Part Number 1-4200-6 SL60 Torch™...

  • Page 4: 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 ......................1-4 1.04 Declaration of Conformity..................1-5 SECTION 2 SYSTEM: INTRODUCTION ................2-1 2.01 How To Use This Manual ..................2-1 2.02 Equipment Identification ...................
  • Page 5 Figures and Tables SECTION 1: GENERAL INFORMATION ................1-1 Table 1-1 - Protective Filters ....................1-3 SECTION 2 SYSTEM: INTRODUCTION ................2-1 Figure 2-1 - Power Source Dimensions & Weight..............2-3 Figure 2-2 - Power Source Setup ..................... 2-5 Figure 2-3 - Power Source Rear View ..................2-5 SECTION 2 TORCH: INTRODUCTION................
  • Page 6 This Page Intentionally Blank...

  • Page 7: Section 1: General Information

    CUTMASTER 10MM, 12MM SECTION 1: GENERAL INFORMATION WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEAR- ERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT. Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions. Safe practices have developed from past experience in the use of welding and cutting.
  • Page 8 CUTMASTER 10MM, 12MM ELECTRIC SHOCK PLASMA ARC RAYS Electric Shock can injure or kill. The plasma arc process uses and Plasma Arc Rays can injure your eyes and burn your skin. The plasma produces high voltage electrical energy. This electric energy can arc process produces very bright ultra violet and infrared light.

  • Page 9: Table 1-1 - Protective Filters

    CUTMASTER 10MM, 12MM Recommended Protective Filters for Electric Welding Approximate Range of Welding Current Description of Process Minimum Shade Number of Filter(s) in Amps Less than or equal to 100 100 to 200 Manual Metal Arc Welding - covered 200 to 300 electrodes (MMAW) 300 to 400 Greater than 400...

  • Page 10: Publications

    CUTMASTER 10MM, 12MM 1.03 Publications CYLINDERS CAN EXPLODE Refer to the following standards or their latest revisions for more Shielding gas cylinders contain gas under high pressure. If dam- information: aged, a cylinder can explode. Since gas cylinders are normally part 1.

  • Page 11: Declaration Of Conformity

    CUTMASTER 10MM, 12MM 1.04 Declaration of Conformity Manufacturer: Victor Technologies Address: 82 Benning Street West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 2006/95/EC) and to the National legislation for the enforcement of this Directive.
  • Page 12 CUTMASTER 10MM, 12MM This Page Intentionally Blank GENERAL INFORMATION Manual 0-5197AD...

  • Page 13: Section 2 System: Introduction

    Operating Manual number and equipment identification numbers. 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...

  • Page 14: Power Source Specifications

    CUTMASTER 10MM, 12MM 2.05 Power Source Specifications CutMaster 10mm Plant Part No. 1-4730-6 CUTMASTER 10mm Power Source Specifications Input Power 240 VAC (+/-15%), 1 Phase, 50/60Hz Output Current 20-30 Amps @ 240VAC CUTMASTER 10mm Power Source Duty Cycle (Note 1) Ambient Temperature 104°...

  • Page 15: Figure 2-1 - Power Source Dimensions & Weight

    CUTMASTER 10MM, 12MM 9" (228.6mm) 18.5" (469.9mm) Art # A-10216 7" (177mm) 26lb / 11.8kg Figure 2-1 - Power Source Dimensions & Weight NOTE Weight includes torch & leads, input power cord, and work cable with clamp. CAUTION Provide clearance for proper air flow through the Power Source. Operation without proper air flow will inhibit proper cooling and reduce duty cycle. Manual 0-5197AD SYSTEM INTRODUCTION...

  • Page 16: Input Wiring Specifications

    CUTMASTER 10MM, 12MM 2.06 Input Wiring Specifications CUTMASTER 10mm Input Power Requirements Input Power Input Current Input Current Input Suggested Sizes (See Note) Voltage Frequency (kVA) Max (Amps) eff (Amps) Fuse (Amps) (Volts-AC) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 50/60 15.6 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application.

  • Page 17: Power Source Feature Locations

    CUTMASTER 10MM, 12MM 2.07 Power Source Feature Locations 240 VAC Power Source Air Inlet To Air Supply (clean/dry) Control Panel Art # A-10217 Torch Lead Work Cable and Clamp Figure 2-2 - Power Source Setup On/Off Switch Air Inlet, 1/4” NPT Power Cord Art# A-10225 Figure 2-3 - Power Source Rear View...
  • Page 18 CUTMASTER 10MM, 12MM This Page Intentionally Blank SYSTEM INTRODUCTION Manual 0-5197AD...

  • Page 19: Section 2 Torch: Introduction

    CUTMASTER 10MM, 12MM SECTION 2 TORCH: INTRODUCTION 2T.01 Scope of Operating Manual This manual contains descriptions, operating instructions F. Torch Ratings and maintenance procedures for the SL60 Plasma Cutting SL60 Torch Ratings Torch. Service of this equipment is restricted to properly Ambient 104°...

  • Page 20: 03 Introduction To Plasma

    CUTMASTER 10MM, 12MM 2T.03 Introduction to Plasma A. Plasma Gas Flow B. Gas Distribution Plasma is a gas which has been heated to an extreme- The single gas used is internally split into plasma and ly high temperature and ionized so that it becomes secondary gases.

  • Page 21: Section 3: Installation

    SECTION 3: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account for each item. A. Contents List for CutMaster 10mm Plant Part No. 1-4730-6 Description Quantity CM 10mm Power Source Work cable and clamp 5m (installed) Carry bag SL60 Torch (Including SL60 Torch 20 ft/6.2m w/ATC, consumables set, spare parts kit)

  • Page 22: Air Supply Connections

    CUTMASTER 10MM, 12MM 3.03 Air Supply Connections A. Connecting Air Supply to Unit B. Using Industrial Compressed Air In Gas Cylinders The connection is the same for compressed air or indus- When using industrial compressed air in gas cylinders trial compressed air in gas cylinders. as the gas supply: 1.

  • Page 23: Section 4 System: Operation

    CUTMASTER 10MM, 12MM SECTION 4 SYSTEM: OPERATION 4.01 Control Panel On/O Air Inlet, Switch 1/4” NPT AC Indicator Power Cord DC Indicator (Ready) Air Indicator Overheat Indicator CUTMASTER 12mm ® Art # A-10218 Figure 4-1 - Front Control Panel Figure 4-2 - Rear Controls 1.

  • Page 24: Preparations For Operating

    CUTMASTER 10MM, 12MM 4.02 Preparations for Operating At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling Power Source, torch parts, or torch and leads assemblies. NOTE All consumables must be correctly installed and maintained to ensure correct operation. A.

  • Page 25: Figure 4-4 - Work Cable Connection

    CUTMASTER 10MM, 12MM B. Torch Connection Check that the torch is properly connected. C. Check Primary Input Power Source 1. Check the power source for proper input voltage. Make sure the input power source meets the power require- ments for the unit per Section "2.05 Power Source Specifications"...

  • Page 26: Sequence Of Operation

    CUTMASTER 10MM, 12MM 4.03 Sequence of Operation The following is a typical sequence of operation for this Power Source. 1. Place the ON/OFF switch on the Power Source to ON (up) position (Red indicator lamp is illuminated). a. AC indicator turns ON;...

  • Page 27: Figure 4-10 - Torch Trigger Release

    CUTMASTER 10MM, 12MM NOTE Trigger When the shield 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 this gap. Forcing Trigger Release the shield cup against the torch head or torch handle can damage components.

  • Page 28: Cut Quality

    CUTMASTER 10MM, 12MM Cut Surface 4.04 Cut Quality The desired or specified condition (smooth or rough) NOTE of the face of the cut. Cut quality depends heavily on setup and Nitride Build-Up parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pres- Nitride deposits can be left on the surface of the cut sures, and operator ability.

  • Page 29: General Cutting Information

    CUTMASTER 10MM, 12MM 4.05 General Cutting Information Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of WARNING gas. This swirl effect results in one side of a cut being more square than the other.
  • Page 30 CUTMASTER 10MM, 12MM This Page Intentionally Blank OPERATION Manual 0-5197AD...

  • Page 31: Section 5 System: Service

    CUTMASTER 10MM, 12MM SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements Maintain more often and troubleshooting techniques.

  • Page 32: Basic Troubleshooting Guide

    CUTMASTER 10MM, 12MM A. Every three months Check external air filter, replace if necessary. 1. Shut OFF input power; turn OFF the gas supply. Bleed down the gas supply. Check air filter and replace if necessary. NOTE Leave internal ground wire in place. B.
  • Page 33 CUTMASTER 10MM, 12MM C. Air indicator OFF. 1. Gas pressure too low. Check supply pressure. D. TEMP indicator ON, (AC indicator ON). 1. Unit air flow obstructed. a. Check for blocked air flow around the unit and correct condition. 2. Fan blocked. Check for blocked status and correct condition. 3. Unit is overheated. a. Keep the machine plugged in and turned ON for five minutes.
  • Page 34 CUTMASTER 10MM, 12MM H. Output is restricted, and can not be controlled. 1. Input or output connection is poor. Check all input and output connection leads. 2. Working cable connection to workpiece is poor. Make sure that work cable has a proper connection to a clean, dry area of the workpiece. 3.
  • Page 35 CUTMASTER 10MM, 12MM L. Torch cuts but not well. 1. Current control is set too low. Increase the current setting. 2. Torch is being moved too fast across workpiece. Reduce cutting speed. 3. Excessive oil or moisture in torch. Hold torch 1/8 inch (3mm) from clean surface while purging and observe oil or moisture buildup (DO NOT activate torch).
  • Page 36 CUTMASTER 10MM, 12MM This page left blank intentionally. SERVICE SYSTEM Manual 0-5197AD...

  • Page 37: 01 General Maintenance

    CUTMASTER 10MM, 12MM SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE Refer to previous "Section 5 System" for com- mon and fault indicator descriptions. Cleaning Torch Upper Groove with Vent Holes Even if precautions are taken to use only clean air with Must Remain Open a torch, eventually the inside of the torch becomes coated with residue.

  • Page 38: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER 10MM, 12MM 3. Remove the tip. Check for excessive wear (indi- 5T.02 Inspection and Replacement of cated by an elongated or oversized orifice). Clean Consumable Torch Parts or replace the tip if necessary. Good Tip Worn Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 39: Section 6: Parts List

    CUTMASTER 10MM, 12MM SECTION 6: PARTS LIST 6.01 Introduction A. Parts List Breakdown C. Ordering Information Order replacement parts by part number and The parts list provides a breakdown of all replaceable complete description of the part or assembly, as components.

  • Page 40: Sl60 Replacement Parts

    CUTMASTER 10MM, 12MM 6.03 SL60 Replacement Parts Item # Description Part No Electrode, 30-120 Amp OTD9/8215 Start Cartridge OTD9/8213 Tip, 40A Drag (fitted) OTD9/8207 Tip, 40A Standoff OTD9/8208 Shield Cup OTD9/8218 SL60 Torch w/20 ft (6,2m) leads (not shown) OTD7/5204 Parts 6-2 - Electrode Parts 6.04 Options and Accessories Description...

  • Page 41: Appendix 1: Circuit Diagram

    CUTMASTER 10MM, 12MM APPENDIX 1: CIRCUIT DIAGRAM Art# A-10222_AB Figure 1 - Appendix: Circuit Diagram Manual 0-5197AD APPENDIX...

  • Page 42: Statement Of Warranty

    This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor Technologies product. This warranty is invalid if the Thermal Dynamics product is sold by non-authorized persons. Effective March 15, 2011...

  • Page 43: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION CIGWELD, Australia Victor Technologies, China 71 Gower Street No 100 Lao Hongjing Rd Preston, Victoria Minhang District Australia, 3072 Shanghai, PR, 200235 Telephone: 61-3-9474-7400 Telephone: 86-21-64072626 Fax: 61-3-9474-7391 Fax: 86-21-64483032 Email: enquiries@cigweld.com.au Victor Technologies Asia Sdn Bhd Lot 151, Jalan Industri 3/5A Victor Technologies USA Rawang Integrated Industrial Park - Jln Batu Arang...
  • Page 44 Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@cigweld.com.au www.cigweld.com...

This manual is also suitable for:

1-4200-6

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