Thermal Dynamics CUTMASTER Service Manual
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Thermal Dynamics CUTMASTER Service Manual

Plasma cutting system
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40mm

Service Manual

CUTMASTER
PLASMA CUTTING SYSTEM
Rev. AK
Date: April 25, 2012
Operating Features:
™
Art # A-08797_AB
Manual # 0-5085
380V
400V
415V

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Summary of Contents for Thermal Dynamics CUTMASTER

  • Page 1: Service Manual

    40mm CUTMASTER ™ PLASMA CUTTING SYSTEM Art # A-08797_AB Service Manual Rev. AK Date: April 25, 2012 Manual # 0-5085 Operating Features: 380V 400V 415V...
  • Page 2 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.
  • 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 Supply CutMaster™ 40mm SL100 1Torch™ Service Manual Number 0-5085 Published by: Thermal Dynamics Corporation...
  • 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...
  • Page 6 TABLE OF CONTENTS PATENT INFORMATION .....................4T-20 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...
  • 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, 380-415V UNITS ............A-6 APPENDIX 6: PUBLICATION HISTORY ................
  • Page 8 This Page Intentionally Blank...

  • Page 9: Section 1: General Information

    CUTMASTER 40mm SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Keep your Throughout this manual, notes, cautions, and warnings are used to head out of the welding fume plume.

  • Page 10: Publications

    CUTMASTER 40mm • Be sure there is no combustible or flammable material in the 1.03 Publications workplace. Any material that cannot be removed must be protected. Refer to the following standards or their latest revisions for more information: • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combus- 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, tibles.

  • Page 11: Note, Attention Et Avertissement

    CUTMASTER 40mm 1.04 Note, Attention et Avertissement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont FUMÉE et GAZ utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit : La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé. NOTE • Eloignez toute fumée et gaz de votre zone de respiration. Gardez Toute opération, procédure ou renseignement...
  • Page 12 CUTMASTER 40mm • Montez et maintenez le matériel conformément au Code électrique * Ces valeurs s’appliquent ou l’arc actuel est national des Etats-Unis. (Voir la page 5, article 9.) observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand • Débranchez l’alimentation électrique avant tout travail d’entretien l’arc est caché par moiceau de travail. ou de réparation.

  • Page 13: Documents De Reference

    CUTMASTER 40mm 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À of Documents, U.S. Government Printing Office, Washington, D.C. LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT 20402 RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE 33126 ET DE SOUDAGE, disponible auprès de la Société Américaine de...

  • Page 14: Declaration Of Conformity

    * ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories. * For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park...

  • 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. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation...
  • Page 16 CUTMASTER 40mm This Page Intentionally Blank GENERAL INFORMATION Manual 0-5085...

  • Page 17: Section 2 System: Introduction

    Acrobat PDF format INTRODUCTION by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the 2.01 How To Use This Manual Literature link: This Service Manual applies to just specification http://www.thermal-dynamics.com...

  • Page 18: Power Supply Specifications

    30 - 120 Amps, Continuously Adjustable Power Supply Gas Filtering Particulates to 5 Microns Ability CutMaster 40mm Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Operating Range 0° - 50° C Duty Cycle...

  • Page 19: Input Wiring Specifications

    CUTMASTER 40mm 2.05 Input Wiring Specifications CutMaster 40mm Power Supply Input Cable Wiring Requirements Power Input voltage Freq Suggested Sizes Input Flexible Fuse Flexible Cord Volts I max I eff Cord (Min. (amps) (Min. mm AWG) Phase 400/415 23.6 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 20: Power Supply Features

    CUTMASTER 40mm 2.06 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-08359 Work Cable and Clamp Port for Optional Automation Interface Cable Filter Assembly Gas Inlet Port Art # A-08547 Input Power Cord INTRODUCTION...

  • Page 21: Section 2 Torch: Introduction

    CUTMASTER 40mm 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

    CUTMASTER 40mm 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 CUTMASTER 40mm 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 CUTMASTER 40mm This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-5085...

  • Page 25: Section 3 System: Installation

    CUTMASTER 40mm SECTION 3 SYSTEM: 3.03 Primary Input Power Connections INSTALLATION 3.01 Unpacking CAUTION 1. Use the packing lists to identify and ac- Check your power source for correct voltage count for each item. before plugging in or connecting the unit. The 2.

  • Page 26: Gas Connections

    CUTMASTER 40mm 5. Connect the wires as follows. 3.04 Gas Connections For non CE units: 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.
  • Page 27 CUTMASTER 40mm Installing Optional Single - Stage Air Filter Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter is also An optional filter kit is recommended for im- for use on compressed air shop systems. Filter...
  • Page 28 CUTMASTER 40mm 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 proce- dures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material.

  • Page 29: Section 3 Torch: Installation

    2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- position. ply. Connect only the Thermal Dynamics model 3. Place a welding filter lens in front of the SL100 / Manual or SL100 / Mechanical Torch to torch and turn on the air.
  • Page 30 CUTMASTER 40mm 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 31: Section 4 System: Operation

    CUTMASTER 40mm 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 32: Preparations For Operation

    Check that the torch is properly connected. Only Set Operating Pressure Thermal Dynamics model SL100 / Manual or SL100 1. Place the Power Supply Function Control / Mechanical Torches may be connected to this Power Supply.
  • Page 33 CUTMASTER 40mm Typical Cutting Speeds STANDOFF CutMaster 40mm Gas Pressure Settings Cutting speeds vary according to torch output am- perage, the type of material being cut, and operator SL100 skill. Refer to Section 4T.08 and following for greater Leads SL100 (Mechanized Torch) details.
  • Page 34 CUTMASTER 40mm This Page Intentionally Blank OPERATION Manual 0-5085...

  • Page 35: Section 4 Torch: Operation

    CUTMASTER 40mm 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 36: 02 Cut Quality

    CUTMASTER 40mm 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 may require secondary cleanup operations after Cut quality depends heavily on setup and cutting.

  • Page 37: 04 Hand Torch Operation

    CUTMASTER 40mm 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 38 CUTMASTER 40mm 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 39 CUTMASTER 40mm 4. Keep the torch in contact with the work- Shield Cup With Straight Edge piece during the cutting cycle. The drag shield cup can be used with a non conduc- 5. Hold the torch away from your body.
  • Page 40 CUTMASTER 40mm NOTE 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 Trigger not attempt to force the shield cup to close this gap.

  • Page 41: 05 Gouging

    CUTMASTER 40mm 4T.05 Gouging Pressure Setting Even though the setting is within the specified range, if the torch does not pilot well the pressure may need to be reduced. WARNING Lead Angle Be sure the operator is equipped with proper...

  • Page 42: 06 Mechanized Torch Operation

    CUTMASTER 40mm 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 43: 07 Parts Selection For Sl100 Torch Cutting

    CUTMASTER 40mm 4T.07 Parts Selection for SL100 Torch Cutting Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243...

  • Page 44: 08 Recommended Cutting Speeds For Sl100 Torch With Exposed Tip

    CUTMASTER 40mm 4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip Type Torch: SL100 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 45 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters...
  • Page 46 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters...
  • Page 47 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters...
  • Page 48 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters...

  • Page 49: 09 Recommended Cutting Speeds For Sl100 Torch With Shielded Tip

    CUTMASTER 40mm 4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip Type Torch: SL100 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 CUTMASTER 40mm Type Torch: SL100 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.) Volts(VDC) (Amps) Inches Meters...
  • Page 51 CUTMASTER 40mm Type Torch: SL100 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.) Volts(VDC) (Amps) Inches Meters...
  • Page 52 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters Inches...
  • Page 53 CUTMASTER 40mm Type Torch: SL100 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) (Amps) Inches Meters Inches...

  • Page 54: Patent Information

    CUTMASTER 40mm 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 55 CUTMASTER 40mm 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 56 CUTMASTER 40mm This Page Intentionally Blank OPERATION 4T-22 Manual 0-5085...

  • Page 57: Section 5 System: Service

    CUTMASTER 40MM 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...

  • Page 58: Maintenance Schedule

    3. Metal too thick. ment. 4. Worn torch parts 5. Cutting current too low. Daily Operational Checks or Every Six Cutting 6. Non - Genuine Thermal Dynamics Hours: parts used 7. Incorrect gas pressure Check torch consumable parts, replace if dam-...

  • Page 59: Fault Indicator

    CUTMASTER 40MM 5.04 Fault Indicator Explanation of Faults UNDER PRESSURE: Indicates that operating pres- At initial power up, two lights will temporarily illumi- sure is set too low and power supply output nate for 2-3 seconds to show the version of software used.
  • Page 60 CUTMASTER 40MM OVER PRESSURE: Indicates that operating pressure is set too high. The Error Indicator will not flash when the pressure is above 95 PSI. This LED will remain ON and the system will operate but pilot starting and cut performance may be affected.
  • Page 61 CUTMASTER 40MM This Page Intentionally Blank Manual 0-5085 SERVICE...

  • Page 62: Basic Troubleshooting Guide

    CUTMASTER 40MM 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 63 CUTMASTER 40MM 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 start 2. Turn OFF power supply. Remove shield cup. Install missing Gas flow is cycling cartridge missing. parts. ON and OFF. 3. Torch start cartridge is stuck.

  • Page 64: Circuit Fault Isolation

    CUTMASTER 40MM 5.06 Circuit Fault Isolation C. Pre Power Up Tests Prior to applying primary line power to the unit, perform the following checks to prevent component failure or blowing primary fuses. The troubleshoot- WARNING ing guide will assume these tests were done and no...
  • Page 65 This section is to help isolate the defective circuit before troubleshooting, identify symptoms, and test STANDOFF the unit for proper operation. Follow the instructions CutMaster 102 Gas Pressure Settings as given to identify the possible symptom(s) and the Leads SL100 SL100 defective circuit.
  • Page 66 CUTMASTER 40MM F. Pilot Arc Test 2. While cutting, adjust the CURRENT CONTROL POTENTIOMETER from maximum setting to There are three types of START signals which can be minimum setting. used to begin system operation: • Current adjusts from 120 amps down to 30 1.
  • Page 67 CUTMASTER 40MM 11. Open the torch switch 3. Remove jumper from the CNC connector. • DC LED turns OFF • OK-TO-MOVE signal OFF (Meter shows no continuity) After 20 second post flow time • Gas continues to flow • Gas solenoid closes •...

  • Page 68: Main Input And Internal Power Problems

    CUTMASTER 40MM 5.07 Main Input and Internal Power C. Gas flows with ON/OFF SWITCH in OFF position Problems 1. Foreign debris has lodged in gas solenoid. A. Primary input line fuse blows as soon as a) Replace gas solenoid. This is a problem caused primary disconnect is closed.
  • Page 69 CUTMASTER 40MM H. PARTS-IN-PLACE (PIP) FAULT. The 3. Open or improperly connected ribbon cable to J2 connector on Main PCB 1 FAULT Indicator and 70 PSI LED flashing, After 20 seconds fan MOT 1 turns ON. a) Inspect connection and check continuity. Re- place if open.
  • Page 70 CUTMASTER 40MM START ERROR FAULT. The FAULT 4. Open conductor in torch leads Indicator and 75 PSI LED flashing. a) Check continuity Start signal is active when SW1 is turned to ON 5. Defective Main PCB 1. position. b) Measure voltage between J2-2 connector on a) START can be active for one of the following: Main PCB 1 to test point GND1 for 12VDC.
  • Page 71 CUTMASTER 40MM L. AC LED ON, TEMP, GAS, DC LED's are O. AC LED ON, TEMP LED OFF, GAS LED OFF, FAULT Indicator is flashing. ON, Gas flows. DC LED & FAULT indictor PRESSURE LED is flashing. OFF. W1 contactor does not energize.

  • Page 72: Pilot Arc Problems

    CUTMASTER 40MM S. AC LED ON, TEMP LED is OFF, GAS LED If gas DOES flow out of SOL1 when the unit is in SET mode, reconnect SOL1 to the ATC connector. is ON. Fan MOT 1 turns ON, plasma gas not flowing.
  • Page 73 CUTMASTER 40MM a) Jumper on Main PCB 1 between J2-16 and a) Inspect torch consumables parts. Replace if test point GND1. If gas does not flow, replace necessary. Logic PCB 3. 4. Shorted Torch/leads b) With START signal active, measure voltage a) Disconnect torch from unit.
  • Page 74 CUTMASTER 40MM D. AC LED ON, TEMP LED OFF, GAS LED b) Measure Logic PCB 3 for SHDN signal be- tween J1-10 to TP1. Normally 12VDC signal ON, gas flowing, DC LED ON, Fault should drop to less than 1VDC when START Indicator OFF, No arc in torch.

  • Page 75: Main Arc And Controls Problems

    CUTMASTER 40MM 5.09 Main Arc and Controls 2. Measure for 12VDC on the Logic PCB 3 between J7-1 to J7-1 after the START signal is activated. If Problems voltage is not present replace Main PCB 1. A. Main arc will not establish, LED D59 on H.

  • Page 76: Cnc Interface Problems

    CUTMASTER 40MM E. With CURRENT CONTROL B. No OK-TO-MOVE signal while cutting. POTENTIOMETER set at maximum, output 1. Defective Main PCB `1 current is only 60 amps. a) Measure voltage on PCB 4 between J1-1 to J1-3 Tip is touching the work piece, Drag mode.
  • Page 77 CUTMASTER 40MM Retest continuity between terminals while engag- C. PCB 5 Input Diode D1 Test ing the contacts manually. This can be done by 1. Using an ohmmeter perform the tests in the pushing down on the recessed actuator button on...
  • Page 78 CUTMASTER 40MM E. PCB 1 IGBT Test F. PCB 5 IGBT Test Disconnect transformer wire from PCB 2 Terminal 1. Disconnect transformer wires from 40 Amp PCB PRI1 (A). 5 terminal PRI 1 (A). 2. Using an ohmmeter check continuity between the 2.
  • Page 79 CUTMASTER 40MM H. PCB 5 Output Diode D2 Test K. PCB 1 Input Diode Test. (With PCB 2 removed form unit) 1. Disconnect transformer wires from Main PCB 5 terminal SEC1. 1. Using an ohmmeter perform the following checks: 2. Using an ohmmeter perform the following checks:...
  • Page 80 CUTMASTER 40MM M. PCB 1 IGBT Test. (With PCB 2 removed PCB 5 – Q2 from unit) Test points located on PCB 5 Meter (+) Meter (-) Indication Using an ohmmeter perform the following checks: PRI 4 PMTH 3 Forward Biased Diode...
  • Page 81 CUTMASTER 40MM This Page Intentionally Blank Manual 0-5085 5-25 SERVICE...

  • Page 82: Main Pcb Layout & Signals

    CUTMASTER 40MM 5.12 Main PCB Layout & Signals *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 GND2 +12V1 WORK_1 MAIN PCB 1 LAYOUT A.
  • Page 83 CUTMASTER 40MM Signal Source/Destination J2-1 -VOUT (-) OUTPUT VOLTAGE J2-2 /TIP VOLTS Active high when tip is installed J2-3 TIP_SEN Approx. 100VDC while cutting w/ tip OFF work, Active low in Drag Mode J2-4 /400V_IN Active low with 400VAC primary input voltage...
  • Page 84 CUTMASTER 40MM J3-1 J3-2 Common J13-1 /OVERTEMP J4-1 3.3VDC J13-2 /FAN_ON J4-2 J13-3 /CSR J4-3 J13-4 CUR_SET J4-4 Common J13-5 MAIN_PCB_ID J4-5 J13-6 Common J5-1 +12VDC B. MAIN PCB 1 LED INDICATORS J5-2 Not used J5-3 /SOLENOID D59 PCR Indicates Pilot IGBT gate signal is ON...
  • Page 85 CUTMASTER 40MM This Page Intentionally Blank Manual 0-5085 5-29 SERVICE...

  • Page 86: Capacitor Pcb Layout & Signals

    CUTMASTER 40MM 5.13 Capacitor PCB Layout & Signals PRI1 MTH8 MTH6 MTH1 MTH2 PMTH4 PMTH3 MTH7 PRI2 MTH4 80A_AC1 80A_AC3 80A_AC2 PMTH1 PMTH2 40A_AC1 40A_AC3 40A_AC2 Art # A-08505AB CAPACITOR PCB 2 LAYOUT A. CAPACITOR PCB 2 SIGNALS J1-1 +12VDC...
  • Page 87 CUTMASTER 40MM B. CAPACITOR PCB 2 TEST POINTS MTH 1 CAP BANK A+ MTH 2 CAP BANK A+ MTH 4 CAP BANK A- MTH 6 CAP BANK B+ MTH 7 CAP BANK B- MTH 8 CAP BANK B+ PMTH 1...

  • Page 88: Logic Pcb Layout & Signals

    CUTMASTER 40MM 5.14 Logic PCB Layout & Signals *J1 Pinout Art # A-08504_AB LOGIC PCB 3 LAYOUT A. LOGIC PCB 3 SIGNALS Signal info is the same as MAIN PCB 1 J2 connector. J3-1 +5VDC J3-2 Pressure Transducer output 0.5 to 5 VDC / 0 - 100 psi...
  • Page 89 CUTMASTER 40MM B. LOGIC PCB 3 LED INDICATORS NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE +12VDC MAX PRESSURE Over Pressure 90 PSI Internal Error 85 PSI Shorted torch (Output Fault) 80 PSI Tip Missing 75 PSI Start Signal active during power up...

  • Page 90: 40Amp Logic Pcb Layout & Signals

    CUTMASTER 40MM 5.15 40AMP Logic PCB Layout & Signals SEC1 CHOKE1 +OUT_1 SEC2 PMTH3 PMTH4 PRI3 PRI4 I_OUT1 GND1 I_DMD1 PRI2 PRI1 PMTH2 PMTH1 Art # A-08506 40AMP PCB 5 LAYOUT SERVICE 5-34 Manual 0-5085...
  • Page 91 CUTMASTER 40MM A. 40AMP PCB 5 SIGNALS J1-1 +12VDC Supply for Fan MOT 2 J1-2 /FAN Active Low to enable Fan MOT 2 J2-1 +12VDC Supply for Fan MOT 3 J2-2 /FAN Active Low to enable Fan MOT 3 Signal Source/Destination...

  • Page 92: Right Side Wiring Diagram

    CUTMASTER 40MM 5.16 Right Side Wiring Diagram RIGHT SIDE WIRING DIAGRAM (MAIN PCB J12) (MAIN PCB J4) TO SW2 NOT USED TO PCB 3 (MAIN PCB J4) NOT USED CHOKE TO ATC (-) TO ATC (+) WORK CABLE USED TO T1...
  • Page 93 CUTMASTER 40MM (40A/50A PCB J2) (40A/50A PCB J4) (40A/50A PCB J1) (40A/50A PCB J3) TO MOT3 TO MOT2 TO T2 CHOKE NOT USED TO T2 Art # A-08620_AB Manual 0-5085 5-37 SERVICE...
  • Page 94 CUTMASTER 40MM This Page Intentionally Blank SERVICE 5-38 Manual 0-5085...

  • Page 95: Section 5 Torch: Service

    CUTMASTER 40mm SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System" for com- mon and fault indicator descriptions. Threads Cleaning Torch Lower O-Ring...

  • Page 96: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER 40mm 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 WARNING Disconnect primary power to the system be- fore disassembling the torch or torch leads.

  • Page 97: Section 6: Parts Lists

    / filter, and operating manual. Description Catalog # CutMaster 40mm CE Power Supply with 380/400/415VAC, 3 phase input power cable 3-1930-3 CutMaster 40mm Non CE Power Supply with 380/400/415VAC, 3 phase input power cable 3-1930-4 Manual 0-5085 PARTS LIST...

  • Page 98: Major External Replacement Parts

    CUTMASTER 40mm 6.04 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-0224 Base Enclosure Assembly 9-0186 Tube, roll handle 9-0121 Front Panel 9-0230 Rear Panel 9-0101 Art # A-08564 NOTE Illustration may vary slightly from unit.

  • Page 99: Front Panel Replacement Parts

    CUTMASTER 40mm 6.05 Front Panel Replacement Parts Item# Description Ref. Catalog # Output Current Control and Function Control Knobs 9-8527 Toggle - On/Off Switch SW1 9-0109 Work Cable with Clamp, 20 Ft / 6.1 m 9-0189 Not Shown: Wire harness (from SW1) w/EMI Choke (CE Power Supplies Only) 9-0247 Art # A-08123 NOTE Illustration may vary slightly from unit. Manual 0-5085...

  • Page 100: Left Side Replacement Parts

    CUTMASTER 40mm 6.06 Left Side Replacement Parts Item # Description Catalog # Main PCB Assembly PCB 1 9-0123 Main PCB Assembly 50 Amp PCB 5 9-0122 Logic PCB PCB 3 9-0107 Center Chassis Molded Plastic 9-0190 Fan, (3 total) MOT 1-3...

  • Page 101: Right Side Replacement Parts

    CUTMASTER 40mm 6.07 Right Side Replacement Parts Item # Description Catalog # Contactor, 4 Pole 9-8587 Solenoid, 12V SOL1 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 PCB 2 9-0202 Filter, Auto Drain 9-0116 3 Phase Input Line EMI Filter (CE Power Supplies Only)) 9-0253...

  • Page 102: Options And Accessories

    CUTMASTER 40mm 6.08 Options and Accessories Description Ref. 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, Bracket & Mounting Screws) 9-9387 Bracket, Filter Mounting (not shown) 9-9386 Two - Stage Air Filter Assembly 9-7527 First Stage Cartridge 9-1021 Second Stage Cartridge 9-1022 Extended Work Cable (50 ft / 15.2 m) with Clamp...

  • Page 103: Replacement Parts For Hand Torch

    CUTMASTER 40mm 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. 5 & 6) 9-8219 Large O-Ring 8-3487 Small O-Ring 8-3486 Leads Assemblies with ATC connectors (includes switch assemblies) SL100, 20 - foot Leads Assembly with ATC connector 4-7836...

  • Page 104: Replacement Parts - For Machine Torches With Unshielded Leads

    CUTMASTER 40mm 6.10 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 PIP Switch Kit 9-7036 Unshielded Automated Leads Assemblies with ATC connectors 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852 50 - foot / 15.2 m Leads Assembly with ATC connector...
  • Page 105 CUTMASTER 40mm 5 & 6 A-07994_AB Manual 0-5085 PARTS LIST...

  • Page 106: Replacement Shielded Machine Torch Leads Assemblies

    CUTMASTER 40mm 6.11 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. Mechanized Shielded Leads Assemblies with ATC Connectors 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849 Remote Pendant Adapter is Torch Continuity present on Mechanized leads only.

  • Page 107: Torch Consumable Parts (Sl100 Sv)

    CUTMASTER 40mm 6.12 Torch Consumable Parts (SL100 SV) Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218...
  • Page 108 CUTMASTER 40mm This Page Intentionally Blank PARTS LIST 6-12 Manual 0-5085...

  • Page 109: Section 7: Replacement Procedures

    This section describes parts replacement procedures 3. Attach the copper foil to a convenient and ex- which may be performed on the CutMaster 40mm posed electrical ground. Power Supply. 4. Connect the equipment primary cable ground to Under no circumstances are field repairs to be attempted the same electrical ground as the wrist strap.

  • Page 110: Major External Parts

    CUTMASTER 40mm 7.04 Major External Parts C. Tube Handle Replacement Tools required: T20 Torx Driver A. Cover Removal 1. Remove the cover per subsection 7.04-A. Tools required: T20 Torx Driver 2. Remove the screws securing the tube handles to 1. Remove the upper and lower screws which the base of the unit.

  • Page 111: Front Panel Parts Replacement

    CUTMASTER 40mm 7.05 Front Panel Parts Replacement D. Air Regulator Replacement Tools required: T20 Torx Driver, 11/16" Open End Wrench Refer to section 6.05 for Front Panel Replacement Parts and overall detailed drawing. 1. Remove the cover per subsection 7.04-A.

  • Page 112: Left Side Internal Parts Replacement

    CUTMASTER 40mm G. Logic PCB (PCB 3) Replacement Work Cable Replacement Tools required: T20 Torx Driver Flat Screw Driver, ½” Tools required: T20 Torx Driver wrench 1. Remove the Cover per subsection 7.04-A. 1. Remove the cover per subsection 7.04-A.
  • Page 113 CUTMASTER 40mm B. Main Transformer (T1) Replacement 8. Disengage the Front and Rear panel from the base per section 7.04-D. Tools required: T20 Torx Driver 9. Guide the Center Chassis towards the center of 1. Remove the Cover per subsection 7.04-A.

  • Page 114: Rear Panel Parts Replacement

    CUTMASTER 40mm 7.07 Rear Panel Parts Replacement E. Output Inductor (L2) Tools required: T20 Torx Driver A. Filter Element Assembly Replacement 1. Remove the Cover per subsection 7.04-A. The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be 2 Remove the two large and one small gas hoses checked per the Maintenance Schedule (Subsection 5.02),...
  • Page 115 CUTMASTER 40mm D. Optional Single-Stage Filter Element 6. Disconnect the input line from the filter element assembly. Replacement 7. Remove the filter element assembly through the These instructions apply to power supplies where the rear opening. optional Single-Stage Filter has been installed.

  • Page 116: Right Side Internal Parts Replacement

    CUTMASTER 40mm 7.08 Right Side Internal Parts Optional Two-Stage Filter Element Replacement Replacement The Two-Stage Air Filter has two Filter Elements. When A. Capacitor PCB (PCB 2) Replacement the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unac- Tools required: T20 Torx Driver, #2 Phillips Head Driver ceptable.
  • Page 117 CUTMASTER 40mm C. Main Contactor (W1) Replacement Tools required: T20 Torx Driver 1. Remove the Cover per subsection 7.04-A. 2. Remove all wires from W1, noting the location and orientation of each wire 3. Loosen the two (2) Torx head screws securing the Main Contactor to the base.
  • Page 118 CUTMASTER 40mm This Page Intentionally Blank PARTS REPLACEMENT 7-10 Manual 0-5085...

  • Page 119: Appendix 1: Sequence Of Operation (Block Diagram

    CUTMASTER 40MM 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 120: Appendix 2: Data Tag Information

    CUTMASTER 40MM APPENDIX 2: DATA TAG INFORMATION Manufacturer's Name and/or West Lebanon, NH USA 03784 Logo, Location, Model and Revision Level, Serial Number M odel : and Production Code Dat e of M f r : Made in USA Type of Power...

  • Page 121: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER 40MM 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 122: Appendix 4: Torch Connection Diagrams

    CUTMASTER 40MM 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 Receptacle Power Connector Torch Torch Supply...
  • Page 123 CUTMASTER 40MM C. Automation Torch Connection Diagram Automated CutMaster Power Supply with ATC Torch Receptacle, Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector ATC Female ATC Male Torch Receptacle Torch Leads Connector Power Supply Torch Head...

  • Page 124: Appendix 5: System Schematic, 380-415V Units

    CUTMASTER 40MM APPENDIX 5: SYSTEM SCHEMATIC, 380-415V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2...
  • Page 125 ECO B1611 05/05/09 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. MARCH 30, 2009 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 126: Appendix 6: Publication History

    CUTMASTER 40MM APPENDIX 6: PUBLICATION HISTORY Cover Date Rev. Change(s) Dec. 10, 2008 Manual released. Dec. 23, 2008 Revised to correct Section 6 catalog numbers, Corrected Section 3 Art size, Added art for Logic PCB to section 5. May 29, 2009 Updated 400V/600V schematic in appendix per ECOB1399.
  • Page 127 This Page Intentionally Blank...
  • Page 128 Printed in: Mexico U.S. Customer Care: 800-426-1888 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 www.thermal-dynamics.com • A Global Cutting & Welding Market Leader ™ W O R L D H E A D Q U A R T E R S : 1 6 0 5 2 S w i n g l e y R i d g e R o a d , S u i t e 3 0 0 •...

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