Thermal Dynamics CUTMASTER 102 Service Manual

Name: Thermal Dynamics CUTMASTER 102
Brand: Thermal Dynamics
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120 pages

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cutmaster 102

Manual 0-4997 6-3 PARTS LIST

6.05 Front Panel Replacement Parts

Item# Qty Description Ref. Catalog #

1 1 Output Current Control and Function Control Knobs 9-8527

2 1 Toggle - On/Off Switch SW1 9-0109

3 1 Work Cable with Clamp, 20 Ft / 6.1 m 9-0189

Art # A-08123

NOTE

Illustration may vary slightly from unit.

Service Manual1
Table of Contents5
Section 1:General Information9
- Notes, Cautions and Warnings9
- Important Safety Precautions9
- Publications10
- Note, Attention Et Avertissement11
- Precautions de Securite Importantes11
- Documents de Reference13
- Declaration of Conformity14
- Statement of Warranty15
Section 2 System:introduction17
- How to Use this Manual17
- Equipment Identification17
- Receipt of Equipment17
- Power Supply Specifications18
- Input Wiring Specifications19
- Power Supply Features20
Section 2 Torch:introduction21
- 01 Scope of Manual21
- 02 General Description21
- 03 Specifications21
- 04 Options and Accessories22
- 05 Introduction to Plasma22
Section 3 System: Installation25
- Unpacking25
- Lifting Options25
- Primary Input Power Connections26
- Gas Connections28
Section 3 Torch: Installation31
- 01 Torch Connections31
- 02 Setting up Mechanical Torch31
Section 4 System: Operation33
- Front Panel Controls / Features33
- Preparations for Operation34
Section 4 Torch:operation37
- 01 Torch Parts Selection37
- 02 Cut Quality38
- 03 General Cutting Information38
- 04 Hand Torch Operation39
- 05 Gouging43
- 06 Mechanized Torch Operation44
- 07 Parts Selection for Manual and Mechanized Torch Cutting45
Patent Information52
Section 5 System:service55
- General Maintenance55
- Maintenance Schedule56
- Common Faults56
- Fault Indicator57
- Basic Troubleshooting Guide60
- Circuit Fault Isolation62
- Main Input and Internal Power Problems66
- Pilot Arc Problems70
- Main Arc and Controls Problems73
- CNC Interface Problems74
- Test Procedures74
Section 5 Torch:service89
- 01 General Maintenance89
- 02 Inspection and Replacement of Consumable Torch Parts90
Section 6:Parts Lists91
- Introduction91
- Ordering Information91
- Power Supply Replacement91
- Major External Replacement Parts92
- Front Panel Replacement Parts93
- Left Side Replacement Parts94
- Right Side Replacement Parts95
- Replacement Power Supply Parts96
- Options and Accessories96
- Replacement Parts for Hand Torch97
- Replacement Parts - for Machine Torches with Unshielded Leads98
- Torch Consumable Parts (SL100 SV)100
Section 7: Replacement Procedures101
- Scope101
- Anti-Static Handling Procedures101
- Parts Replacement - General Information101
- Major External Parts102
- Front Panel Parts Replacement103
- Left Side Internal Parts Replacement104
- Rear Panel Parts Replacement106
- Right Side Internal Parts Replacement109
Appendix 1: Sequence of Operation(Block Diagram111
Appendix 2: Data Tag Information112
Appendix 3: Torch Pin - out Diagrams113
Appendix 4: Torch Connection Diagrams114
Appendix 5: System Schematic, 208/460V Units116
APPENDIX 6: Publication History118

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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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Thermal Dynamics CUTMASTER 102 Service Manual

Table of Contents

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Thermal Dynamics CUTMASTER 102 Specifications

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