cutmaster 102
Manual 0-4998 5-9 SERVICE
If all of the Pre Power-Up Tests are ok, proceed with
the trouble shooting guide.
CAUTION
Due to the close proximity of the Main Pcb to the
Capacitor Pcb, It is recommended to use an insu-
lated meter probe when making measurements on
the J2 connector on the Main Pcb. Do not short
between the pins. Do not short to the Capacitor
Pcb connections.
D. Initial Set up Conditions
This section is to help isolate the defective circuit
before troubleshooting, identify symptoms, and test
the unit for proper operation. Follow the instructions
as given to identify the possible symptom(s) and the
defective circuit. After repairs are complete, run the
following tests again to verify that the unit is fully
operational.
1. Connect gas supply to rear of Power Supply.
2. Turn on gas supply and set operating pressure
per pressure setting label on power supply.
3. Set the Power Supply controls as follows:
• ON/OFF SWITCH to OFF position
• Turn FUNCTION CONTROL SWITCH to SET
position
• CURRENT CONTROL POTENTIOMETER to
MAXIMUM position, fully clockwise.
E. Main Input and Internal Power Test
1. Connect Primary Line power to the unit.
2. Turn the ON/OFF SWITCH ( SW1) to ON position
and observe the following:
• Software version is displayed (See section 5.04
Fault Indicators)
After approx. three (3) seconds
• Inrush relay on PCB1 energizes, starting pre-
charging of working capacitors.
• W1 energizes
• AC and GAS Indicators come on
• Gas flows
• For earlier units, Fan MOT1 turns on for one
(1) second then shuts off.
3. Adjust the pressure regulator to set the gas pres-
sure as specified in charts.
STANDOFF
CutMaster 102 Gas Pressure Settings
Leads
Length
SL100
(Hand Torch)
SL100
(Mechanized Torch)
Up to 25'
(7.6 m)
75 psi
5.2 bar
75 psi
5.2 bar
Each
additional
25'
(7.6 m)
Add 5 psi
0.4 bar
Add 5 psi
0.4 bar
DRAG
CutMaster 102 Gas Pressure Settings
Leads
Length
SL100
(Mechanized Torch)
Up to 25'
(7.6 m)
80 psi
5.5 bar
Each additional
25'
(7.6 m)
Add 5 psi
0.4 bar
4. Turn FUNCTION CONTROL SWITCH to RUN
position
• Solenoid turns off, gas stops flowing (pressure
display may increase slightly when gas is not
flowing)
This completes the Main Input and Internal Power Test.
If the above are all correct then proceed to the next section
"F. Pilot Arc Test". If the unit does not function as stated
above, then note the symptom and proceed to Section
"5.07, Main Input and Internal Power Problems".
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