Summary of Contents for Thermal Dynamics Cutmaster
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25mm CUTMASTER ™ PLASMA CUTTING SYSTEM Operating Manual Rev. AB Date: September 19, 2008 Manual # 0-5080 Operating Features: 380-...
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1888, or visit us on the web at www.thermal-dynamics.com. This 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.
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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™ 25mm SL60 1Torch™ Operating Manual Number 0-5080 Published by: Thermal Dynamics Corporation...
CUTMASTER 25mm 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...
CUTMASTER 25mm • 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.
CUTMASTER 25mm 14. American Welding Society Standard AWSF4.1, RECOM- MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT FUMÉE et GAZ HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the La fumée et les gaz produits par le procédé de jet de plasma peuvent American Welding Society, 550 N.W.
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CUTMASTER 25mm • Utilisez la nuance de lentille qui est suggèrée dans le recommenda- • Montez et maintenez le matériel conformément au Code électrique tion qui suivent ANSI/ASC Z49.1: national des Etats-Unis. (Voir la page 5, article 9.) Nuance Minimum Nuance Suggerée...
CUTMASTER 25mm 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...
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.
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CUTMASTER 25mm This Page Intentionally Blank GENERAL INFORMATION Manual 0-5080...
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 0-5080...
Output Current 20 - 80 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster 25mm Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Rating...
CUTMASTER 25mm 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 Filter Assembly Gas Inlet Port Art # A-08544 Input Power Cord INTRODUCTION...
CUTMASTER 25mm 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.
CUTMASTER 25mm 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...
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CUTMASTER 25mm 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.
CUTMASTER 25mm 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.
CUTMASTER 25mm 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 specified in Section 2.
CUTMASTER 25mm 8. Reinstall the Power Supply cover. 9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect. 10. Connect the input power cable (or close the main disconnect switch) to supply power. 3.04 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders.
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CUTMASTER 25mm 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.
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CUTMASTER 25mm 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.
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CUTMASTER 25mm Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign mate- rial.
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.
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CUTMASTER 25mm 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.
CUTMASTER 25mm 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.
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.
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CUTMASTER 25mm Typical Cutting Speeds STANDOFF CutMaster 25mm 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...
CUTMASTER 25MM 2. Remove the Electrode by pulling it straight SECTION 4 TORCH: out of the Torch Head. OPERATION 4T.01 Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used. Type of operation:...
CUTMASTER 25MM 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.
CUTMASTER 25MM 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.
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CUTMASTER 25MM 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.
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CUTMASTER 25MM 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.
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CUTMASTER 25MM 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.
CUTMASTER 25MM 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...
CUTMASTER 25MM 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...
9-8241 9-8237 Tips: 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_AB...
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CUTMASTER 25MM 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Type Torch: SL60 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...
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CUTMASTER 25MM Type Torch: SL60 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)
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CUTMASTER 25MM Type Torch: SL60 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)
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CUTMASTER 25MM Type Torch: SL60 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)
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CUTMASTER 25MM 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Type Torch: SL60 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...
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CUTMASTER 25MM Type Torch: SL60 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 (Cat. No.) Volts (VDC)
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CUTMASTER 25MM Type Torch: SL60 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.)
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CUTMASTER 25MM Type Torch: SL60 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)
CUTMASTER 25MM 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;...
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CUTMASTER 25MM 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...
CUTMASTER 25mm SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed...
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 damaged 7. Incorrect gas pressure or worn. Main Arc 1.
CUTMASTER 25mm 5.04 Fault Indicator At initial power up, two lights will temporarily illu- minate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7.
CUTMASTER 25mm 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...
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CUTMASTER 25mm 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.
CUTMASTER 25mm 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.
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CUTMASTER 25mm Optional Single-Stage Filter Element 5. Remove the fitting from the filter element as- sembly by inserting a 6 mm hex wrench into Replacement the internal hex fitting and turning it counter These instructions apply to power supplies where the clock-wise (left).
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CUTMASTER 25mm 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 continue to operate but cut quality may become unac- ceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.
CUTMASTER 25mm 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.
CUTMASTER 25mm 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.
Catalog # CutMaster 25mm 400V CE Power Supply with 400/415VAC, 3 Phase, 50 Hz, with input power cable 3-1130-4 CutMaster 25 400V Non CE Power Supply with 400/415VAC, 3 Phase, 50 Hz, with input power cable 3-1130-3 Manual 0-5080 PARTS LIST...
CUTMASTER 25mm 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115* Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 8-4384 Input Power Cord for 400 V Power Supply 9-8562 NOTE: *9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well.
CUTMASTER 25mm 6.07 Replacement Parts - for Machine 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...
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CUTMASTER 25mm A-07994 Manual 0-5080 PARTS LIST...
9-8241 9-8237 Tips: 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_AB...
CUTMASTER 25mm 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...
CUTMASTER 25mm 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)
CUTMASTER 25mm 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 /...
CUTMASTER 25mm 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...
CUTMASTER 25mm APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS J3 J3 K5-K6 K5-K6 J1 J1 PRI 2 PRI 2 PRI 1 PRI 1 PRI 4 PRI 4 PRI 3 PRI 3 +12VDC INRUSH MTH2 MTH2 MTH1 MTH1 RESISTORS /INRUSH C1-C4* C1-C4*...
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Last Modified: Last Modified: Tuesday, July 01, 2008 Tuesday, July 01, 2008 Tuesday, July 01, 2008 CutMaster 12mm / 20mm / 25mm 400vac CutMaster 12mm / 20mm / 25mm 400vac CutMaster 12mm / 20mm / 25mm 400vac 10:27:48 10:27:48 10:27:48...
CUTMASTER 25mm APPENDIX 6: Publication History Cover Date Rev. Change(s) July 30, 2008 Manual released. Sept. 19, 2008 Added CE information per ECOB886 APPENDIX Manual 0-5080...
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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...
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Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...
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Quali sono i codici di ricambio degli elementi della torcia?