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Welding System
CUTMASTER 102
Thermal Dynamics CUTMASTER 102 Service Manual
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cutmaster 102
SER
VICE
5-32
Manual 0-4998
Art # A-08506
SEC1
CHOKE1
+OUT_1
SEC2
PRI3
PRI4
PRI2
PRI1
PMTH4
AC2
AC3
AC1
PMTH2
PMTH1
PMTH3
J4
J3
J2
J1
J5
I_DMD1
GND1
I_OUT1
J9
1
1
1
1
40AMP PCB 5 LA
YOUT
85
87
Table of Contents
Service Manual
1
Table of Contents
5
Section 1:General Information
9
Notes, Cautions and Warnings
9
Important Safety Precautions
9
Publications
10
Note, Attention Et Avertissement
11
Precautions de Securite Importantes
11
Documents de Reference
13
Declaration of Conformity
14
Statement of Warranty
15
Section 2 System:introduction
17
How to Use this Manual
17
Equipment Identification
17
Receipt of Equipment
17
Power Supply Specifications
18
Input Wiring Specifications
19
Power Supply Features
20
Section 2 Torch:introduction
21
01 Scope of Manual
21
02 General Description
21
03 Specifications
21
04 Options and Accessories
22
05 Introduction to Plasma
22
Section 3 System: Installation
25
Unpacking
25
Lifting Options
25
Primary Input Power Connections
26
Gas Connections
28
Section 3 Torch: Installation
31
01 Torch Connections
31
02 Setting up Mechanical Torch
31
Section 4 System: Operation
33
Front Panel Controls / Features
33
Preparations for Operation
34
Section 4 Torch:operation
37
01 Torch Parts Selection
37
02 Cut Quality
38
03 General Cutting Information
38
04 Hand Torch Operation
39
05 Gouging
43
06 Mechanized Torch Operation
44
07 Parts Selection for Manual and Mechanized Torch Cutting
45
Patent Information
52
Section 5 System:service
55
General Maintenance
55
Maintenance Schedule
56
Common Faults
56
Fault Indicator
57
Basic Troubleshooting Guide
60
Circuit Fault Isolation
62
Main Input and Internal Power Problems
66
Pilot Arc Problems
70
Main Arc and Controls Problems
73
CNC Interface Problems
74
Test Procedures
74
Section 5 Torch:service
89
01 General Maintenance
89
02 Inspection and Replacement of Consumable Torch Parts
90
Section 6:Parts Lists
91
Introduction
91
Ordering Information
91
Power Supply Replacement
91
Major External Replacement Parts
92
Front Panel Replacement Parts
93
Left Side Replacement Parts
94
Right Side Replacement Parts
95
Replacement Power Supply Parts
96
Options and Accessories
96
Replacement Parts for Hand Torch
97
Replacement Parts - for Machine Torches with Unshielded Leads
98
Torch Consumable Parts (SL100 SV)
100
Section 7: Replacement Procedures
101
Scope
101
Anti-Static Handling Procedures
101
Parts Replacement - General Information
101
Major External Parts
102
Front Panel Parts Replacement
103
Left Side Internal Parts Replacement
104
Rear Panel Parts Replacement
106
Right Side Internal Parts Replacement
109
Appendix 1: Sequence of Operation(Block Diagram
111
Appendix 2: Data Tag Information
112
Appendix 3: Torch Pin - out Diagrams
113
Appendix 4: Torch Connection Diagrams
114
Appendix 5: System Schematic, 208/460V Units
116
APPENDIX 6: Publication History
118
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Thermal Dynamics CUTMASTER 102 Specifications
General
Brand
Thermal Dynamics
Model
CUTMASTER 102
Category
Welding System
Language
English
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