Thermal Dynamics CUTMASTER 151 - User Manual

151
Rev. AF.01 Date: April 2, 2007 Manual # 0-4691
Operating Features:
Operating Manual
AUTOMATED
PLASMA CUTTING SYSTEM
CUTMASTER
™
Art # A-04611
SL100SV
PLASMA CUTTING
MACHINE TORCH

Summary

Cutmaster Automated Plasma Cutting System

Operating Manual

Instructions for correct use and safe operation.

Section 1: General Information

1.01 Notes, Cautions and Warnings

Highlights important information using notes, cautions, and warnings.

1.02 Important Safety Precautions

Details dangers and necessary precautions for operation and maintenance.

1.03 Publications

Lists relevant standards and reference documents for more information.

1.04 Note, Attention et Avertissement

Explains the usage of "note", "attention", and "warning" terms in the manual.

1.05 Precautions De Securite Importantes

Outlines critical safety measures regarding fumes, gases, and electric shock.

1.06 Documents De Reference

Lists references for further safety and operational guidance.

1.07 Declaration of Conformity

States conformity to applicable European directives and national legislation.

1.08 Statement of Warranty

Details the limited warranty terms, conditions, and exclusions for the product.

Section 2: Specifications

2.01 Scope of Manual

Defines the manual's purpose, scope, and servicing restrictions.

2.02 Power Supply Specifications

Provides detailed technical specifications for the power supply unit.

2.03 Input Wiring Specifications

Details input voltage, frequency, current, and wiring requirements.

2.04 Power Supply Features

Identifies and illustrates the main components and features of the power supply.

2.05 Power Supply Options and Accessories

Lists available options and accessories to enhance system performance or portability.

2.06 Torch Specifications

Provides technical specifications for the SL100SV machine torch.

2.07 Torch Options and Accessories

Lists optional items for torch customization and performance enhancement.

2.08 Introduction to Plasma

Explains the basic principles of plasma gas flow and distribution in cutting.

Section 3: Installation

3.01 Unpacking

Instructions for unpacking the equipment and recording serial numbers.

3.02 Lifting Options

Guidelines and warnings for safely lifting and handling the power supply unit.

3.03 Primary Input Power Connections

Details how to connect the power supply to different voltage and phase power sources.

3.04 Gas Connections

Instructions for connecting the compressed air supply to the power unit.

3.05 Torch Connections

Steps for connecting the SL100 torch to the power supply correctly.

3.06 Torch Installation

Guidance on mounting the machine torch assembly and ensuring proper alignment.

3.07 Torch Parts Selection

Information on selecting appropriate consumable torch parts for different operations.

3.08 Power Supply Connection to SC-11 Standoff Control

Instructions for connecting the power supply to the SC-11 standoff control.

3.09 Power Supply Connection to Alternate Standoff Control

Steps for connecting the power supply to alternative CNC controls.

3.10 Automation Interface PC Board Set-up

How to set switches on the Automation Interface PC Board for system compatibility.

3.11 Optional Remote Current Control Harness Installation

Procedure for installing the optional remote current control harness.

Section 4: Operation

4.01 Product Features

Overview of the power supply's front panel controls and indicators.

4.02 Preparations For Operating

Step-by-step guide for preparing the system before each operating session.

G. Set Operating Pressure

Instructions for setting the correct gas pressure for optimal cutting performance.

H. Select Current Output Level

How to set the desired output current level for the cutting operation.

I. Cutting Operation

Details on performing cutting operations with different switch settings.

4.03 Selection, Inspection and Replacement of Consumable Torch Parts

Guides on choosing, inspecting, and replacing torch consumable parts.

4.04 Cut Quality

Explains factors affecting cut quality and characteristics of a good cut.

4.05 General Cutting Information

Provides essential information on piloting, torch standoff, and cut direction.

4.06 Torch Operation

Step-by-step instructions for operating the torch for cutting.

B. Travel Speed

Discusses the importance of proper travel speed for cut quality.

C. Piercing With Machine Torch

Guidance on how to properly pierce material using a machine torch.

4.08 Cutting Specifications

Defines cut quality for various materials and thicknesses.

4.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip

Provides recommended cutting speeds for mild steel with an exposed tip torch.

4.10 Cutting Speed Chart: Stainless Steel, SL100 Torch with Exposed Tip

Provides recommended cutting speeds for stainless steel with an exposed tip torch.

4.11 Cutting Speed Chart: Aluminum, SL100 Torch with Exposed Tip

Provides recommended cutting speeds for aluminum with an exposed tip torch.

4.12 Cutting Speed Chart: Mild Steel, SL100 Torch with Shielded Tip

Provides recommended cutting speeds for mild steel with a shielded tip torch.

4.13 Cutting Speed Chart: Stainless Steel, SL100 Torch with Shielded Tip

Provides recommended cutting speeds for stainless steel with a shielded tip torch.

4.14 Cutting Speed Chart: Aluminum, SL100 Torch with Shielded Tip

Provides recommended cutting speeds for aluminum with a shielded tip torch.

4.15 Operators Custom Cutting Speed Charts

Blank charts for operators to record their own cutting parameters and speeds.

Section 5: Service

5.01 General Maintenance

Routine maintenance procedures for ensuring optimal system performance.

B. Single-Stage Filter Element Replacement

Instructions for replacing the filter element in a single-stage air filter system.

C. Optional Two-Stage Filter Element Replacement

Steps for replacing filter elements in an optional two-stage air filter assembly.

5.02 Common Faults

Lists common operational issues and their potential causes.

5.03 Basic Troubleshooting

Guide for diagnosing and resolving common symptoms and problems.

5.04 Advanced Troubleshooting Guide - General Information

Overview of advanced troubleshooting requiring disassembly and live measurements.

C. Main Input and Internal Power Tests

Procedures for testing main input power and internal system operations.

D. Pilot Arc Test

Steps to verify the establishment and function of the pilot arc.

E. Main Arc Test

Procedure to test the main cutting arc initiation and transfer.

5.05 Main Input and Internal Power Problems

Troubleshooting guide for issues related to main power input and internal components.

A. Main power line fuses blow as soon as main disconnect is closed

Addresses issues where main power fuses blow upon closing the disconnect switch.

D. AC and TEMP indicators ON, fans do not run

Troubleshooting steps when AC and TEMP indicators are on, but fans are not running.

5.06 Pilot Arc Problems

Diagnosing and resolving issues related to pilot arc initiation and function.

5.07 Main Arc Problems

Troubleshooting guide for problems affecting the main cutting arc.

B. Tube Handle Replacement

Instructions for replacing the tube handle assembly on the power supply.

5.10 Front Panel Parts Replacement

Procedures for replacing components on the front panel of the power supply.

5.11 Left Side Internal Parts Replacement

Guides for replacing internal components located on the left side of the unit.

B. Main Input Contactor (W1) Replacement

Steps for replacing the main input contactor assembly.

C. Logic PC Board Replacement

Procedure for replacing the logic PC board.

D. Input Diode Bridge Replacement

Instructions for replacing the input diode bridge component.

E. IGBT Replacement

Steps for safely removing and replacing IGBT modules.

E. Main PC Board Replacement

Procedure for replacing the main PC board.

F. Input Power Cable Replacement

Instructions for replacing the unit's input power cable.

5.12 Right Side Internal Parts Replacement

Guides for replacing internal components located on the right side of the unit.

A. Fan Replacement (M1, M2)

Steps for removing and replacing the unit's cooling fans.

C. Pilot PC Board Replacement

Procedure for replacing the pilot PC board.

D. Pressure Switch;Solenoid Assembly Replacement

Steps for replacing the pressure switch and solenoid valve assembly.

E. Output Diode PC Board Replacement

Instructions for replacing the output diode PC board.

F. Heatsink Shroud Assembly Removal

Procedure for removing the heatsink shroud for component access.

G. Main Transformer Removal and Replacement

Steps for removing and replacing the main transformer.

H. Output Inductor Assembly Removal and Replacement

Procedure for removing and replacing the output inductor assembly.

Section 6: Parts Lists

6.01 Introduction

Explains the breakdown and arrangement of the parts lists within the manual.

6.02 Ordering Information

Guidance on how to order replacement parts and necessary information to provide.

6.03 Complete Power Supply Replacement

Lists items included with a complete replacement power supply unit.

6.04 Power Supply Options and Accessories

Lists available options and accessories for the power supply.

6.05 Power Supply Major External Replacement Parts

Identifies major external parts available for power supply replacement.

6.06 Power Supply Front Panel Replacement Parts

Lists replacement parts specifically for the front panel of the power supply.

6.07 Rear Panel Replacement Parts

Lists replacement parts for the rear panel of the power supply.

6.08 Power Supply Left Side Internal Replacement Parts

Lists internal replacement parts for the left side of the power supply.

6.09 Right Side Internal Replacement Parts

Lists internal replacement parts for the right side of the power supply.

6.10 Torch Replacement Parts

Details replacement parts specifically for the SL100 Torch.

6.11 Torch Replacement Parts

Details replacement parts for the SL100SV Torch with solenoid.

6.12 Torch Consumables

Illustrates and lists consumable parts for the SL100 torch.

6.13 Torch Spare Parts Kits

Lists contents of spare parts kits for automation torches.

6.14 Complete Torch Assembly Replacement

Lists complete torch assemblies for replacement.

6.15 Torch Options & Accessories

Lists optional accessories for the torch.

PATENT INFORMATION

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)

APPENDIX 2: DATA TAG INFORMATION

APPENDIX 3: MAINTENANCE SCHEDULE

APPENDIX 4: TORCH PIN - OUT DIAGRAM

A. Power Supply and SL100 Torch without Solenoid

Pin-out diagram for SL100 torch connection without solenoid.

B. Power Supply and SL100 SV Torch [withSolenoid]

Pin-out diagram for SL100SV torch connection with solenoid.

APPENDIX 5: TORCH CONNECTION DIAGRAM

A. Power Supply and SL100 Torch without Solenoid

Wiring diagram for connecting SL100 torch without solenoid.

B. Power Supply and SL100 SV Torch [withSolenoid]

Wiring diagram for connecting SL100SV torch with solenoid.

APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM

APPENDIX 7: INTERFACE PCB SWITCH SETTINGS (MOST COMMON SETTINGS)

APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24)

APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30)

APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33)

APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36)

APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43)

APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50)

APPENDIX 14: AUTOMATION INTERFACE PC BOARD WIRING LAYOUT

APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS

APPENDIX 16: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO OEM CNC HARNESS

APPENDIX 17: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO ALTERNATE CNC HARNESS

APPENDIX 18: MAIN PC BOARD LAYOUT

APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208;230-Volt POWER SUPPLIES)

APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-V, 415-V, 460-V, 600-V POWER SUPPLIES)

APPENDIX 21: LOGIC BOARD LAYOUT

APPENDIX 22: POT; LED BOARD LAYOUT

APPENDIX 23: OUTPUT DIODE LAYOUT

APPENDIX 24: OUTPUT DIODE WIRING DIAGRAM

APPENDIX 25: PILOT BOARD LAYOUT

APPENDIX 26: 28 VAC CIRCUIT DIAGRAM

APPENDIX 27: 208;230 V SYSTEM SCHEMATIC

APPENDIX 29: 400; 415; 460 V SYSTEM SCHEMATIC

APPENDIX 31: 600 V SYSTEM SCHEMATIC

APPENDIX 33: Manual Publication History

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Corporate Headquarters

Thermal Dynamics CUTMASTER 151 Specifications

General

Input Frequency	50/60 Hz
Open Circuit Voltage (OCV)	300 VDC
Input Phase	1 or 3-Phase
Output Current Range	20 - 150 A
Rated Output Current	150 Amps
Output Voltage	120 VDC
Duty Cycle	60% @ 150 Amps
Gas Type	Air or Nitrogen
Pilot Arc Current	20 Amps