Thermal Dynamics CUTMASTER 102 Service Manual

PLASMA CUTTING SYSTEM
102
CUTMASTER
™
Rev. AA Date: September 25, 2008 Manual # 0-4998
Operating Features:
Service Manual

Thermal Dynamics CUTMASTER 102 Specifications

General

Input Frequency	50/60 Hz
Output Current Range	20-100 A
Rated Output Current	100 A
Duty Cycle	60% @ 100 A
Input Phase	1 or 3-Phase
Rated Output Voltage	120 V
Cutting Capacity (Maximum)	1-1/2" (38 mm)
Max Cutting Thickness	1.5 in (38 mm)
Pierce Capacity	0.75 in (19 mm)
Gas Type	Air
Dimensions	18 x 10 x 14 in

Summary

Section 1: General Information

Notes, Cautions, and Warnings

Explains how notes, cautions, and warnings highlight important information in the manual.

Important Safety Precautions

Details critical safety measures regarding gases, fumes, electric shock, fire, noise, and plasma arc rays.

Publications

Lists relevant safety standards and publications for further reference.

Declaration of Conformity

States the equipment's compliance with applicable directives and regulations.

Statement of Warranty

Outlines the limited warranty period, terms, conditions, and exclusions for the product.

Section 2: System Introduction

How To Use This Manual

Guides users on how to effectively use the owner's manual, including understanding annotations.

Equipment Identification

Explains how to identify the unit's specification, model, and serial number for reference.

Power Supply Specifications

Provides detailed technical specifications for the power supply unit.

Input Wiring Specifications

Details the input voltage, frequency, power input, and cable requirements for the unit.

Power Supply Features

Identifies and illustrates the key features of the power supply unit.

Section 2: Torch Introduction

Scope of Manual

Defines the scope of the manual, covering operating instructions and maintenance for specific torch models.

General Description

Provides a general overview of plasma torch design and operation principles.

Specifications

Details torch configurations, lead lengths, parts, and cooling types.

Introduction to Plasma

Explains the process of plasma gas flow and its role in cutting and gouging.

Section 3: System Installation

Unpacking

Provides instructions for unpacking the equipment and inspecting for damage.

Lifting Options

Details safe procedures for lifting and handling the power supply unit.

Primary Input Power Connections

Guides on connecting the primary input power, including phase changes.

Gas Connections

Explains how to connect the compressed air supply to the unit.

Section 3: Torch Installation

Torch Connections

Describes how to connect the torch to the power supply unit.

Setting Up Mechanical Torch

Provides instructions for setting up the mechanical torch for operation.

Section 4: System Operation

Front Panel Controls / Features

Identifies and explains the functions of the front panel controls and indicators.

Preparations for Operation

Outlines the necessary steps before starting operation, including connections and settings.

Section 4: Torch Operation

Torch Parts Selection

Guides on selecting the correct torch parts based on the type of operation.

Cut Quality

Explains factors affecting cut quality and defines key characteristics.

General Cutting Information

Provides general information and safety advice for cutting operations.

Hand Torch Operation

Details how to perform cutting operations using a hand torch.

Section 4: Torch Operation (Continued)

Gouging

Explains gouging parameters, lead angle, standoff, and slag buildup.

Mechanized Torch Operation

Covers cutting and piercing operations using a mechanized torch.

Parts Selection for Manual and Mechanized Torch Cutting

Illustrates consumable parts selection for manual and mechanized cutting.

Recommended Cutting Speeds for Mechanized Torch With Exposed Tip

Provides recommended cutting speeds for various materials with an exposed tip.

Recommended Cutting Speeds for Mechanized Torch With Shielded Tip

Provides recommended cutting speeds for various materials with a shielded tip.

Patent Information

Section 5: System Service

General Maintenance

Outlines general maintenance tasks to be performed on the system.

Maintenance Schedule

Provides a schedule for daily, weekly, and six-month maintenance checks.

Common Faults

Lists common problems, their symptoms, and potential causes.

Fault Indicator

Explains the fault indicators and their meanings.

Basic Troubleshooting Guide

Offers a guide to diagnose and resolve common operational problems.

Circuit Fault Isolation

Provides procedures for isolating circuit faults and performing pre-power up tests.

Main Input and Internal Power Problems

Addresses issues related to primary input power and internal power supply problems.

Pilot Arc Problems

Troubleshoots issues related to the pilot arc function.

CNC Interface Problems

Addresses problems specific to CNC interface connectivity and signals.

Test Procedures

Details specific test procedures for various components and circuits.

Section 5: Torch Service

General Maintenance

Covers cleaning procedures and O-ring lubrication for the torch.

Inspection and Replacement of Consumable Torch Parts

Guides on inspecting and replacing consumable parts of the torch.

Section 6: Parts Lists

Introduction

Introduces the parts list breakdown and ordering information.

Power Supply Replacement

Lists items included with a replacement power supply unit.

Major External Replacement Parts

Identifies major external replaceable parts of the power supply.

Front Panel Replacement Parts

Lists replaceable parts for the front panel assembly.

Left Side Replacement Parts

Identifies replaceable components located on the left side of the unit.

Right Side Replacement Parts

Lists replaceable components located on the right side of the unit.

Replacement Power Supply Parts

Lists replacement parts specific to the power supply unit.

Options and Accessories

Details available options and accessories for the system.

Replacement Parts for Hand Torch

Lists replacement parts for the hand torch assembly.

Replacement Parts - for Machine Torches with Unshielded Leads

Lists replacement parts for machine torches with unshielded leads.

Torch Consumable Parts (SL100 SV)

Details consumable parts for the SL100 SV torch, categorized by cutting type.

Section 7: Replacement Procedures

Scope

Defines the scope of replacement procedures covered in this section.

Anti-Static Handling Procedures

Provides essential procedures for safely handling electronic components.

Parts Replacement - General Information

Offers general information regarding parts replacement and disassembly.

Major External Parts

Details procedures for replacing major external parts of the unit.

Front Panel Parts Replacement

Provides step-by-step instructions for replacing front panel components.

Left Side Internal Parts Replacement

Covers procedures for replacing internal parts on the left side of the unit.

Right Side Internal Parts Replacement

Details procedures for replacing internal parts on the right side of the unit.

Appendix 1: Sequence of Operation (Block Diagram)

Appendix 2: Data Tag Information

Appendix 3: Torch Pin - Out Diagrams

Appendix 4: Torch Connection Diagrams

Appendix 5: System Schematic, 208/460V Units

Appendix 6: Publication History

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