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Thermal Dynamics Cutmaster 82 User Manual

Thermal Dynamics Cutmaster 82
114 pages
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Art # A-08839_AB
600
v
460
400
v
v
PLASMA CUTTING SYSTEM
82
CUTMASTER
Rev. AH Date: May 29, 2009 Manual # 0-4980
Operating Features:
Service Manual

Table of Contents

Questions and Answers:

Thermal Dynamics Cutmaster 82 Specifications

General IconGeneral
BrandThermal Dynamics
ModelCutmaster 82
CategoryWelding System
LanguageEnglish

Summary

Section 1: General Information

1.02 Important Safety Precautions

Details critical safety measures for operating plasma cutting equipment, covering hazards like electric shock and fumes.

1.04 Note, Attention et Avertissement

1.05 Precautions De Securite Importantes

Covers essential safety precautions for plasma cutting, including health and environmental hazards.

1.08 Statement of Warranty

2.04 Power Supply Specifications

2.05 Input Wiring Specifications

3.03 Primary Input Power Connections

A. Connections to Single Phase Input Power

Provides step-by-step instructions for connecting single-phase input power.

B. Connections to Three Phase Input Power

3.04 Gas Connections

Section 4 System: Operation

4.01 Front Panel Controls / Features

Identifies and describes the function of each control and indicator on the front panel.

4.02 Preparations for Operation

Section 4 Torch: Operation

4T.01 Torch Parts Selection

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

4T.02 Cut Quality

4T.03 General Cutting Information

4T.04 Hand Torch Operation

4T.05 Gouging

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

Explains how to control the mechanized torch for automated cutting processes.

4T.07 Parts Selection for Manual and Mechanized Torch Cutting

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip

Section 5 System: Service

5.01 General Maintenance

Provides general maintenance guidelines and a schedule for the power supply unit.

5.02 Maintenance Schedule

5.03 Common Faults

5.04 Fault Indicator

5.05 Basic Troubleshooting Guide

5.06 Power Supply Basic Parts Replacement

5.07 Circuit Fault Isolation

B. Cover Installation

C. Pre Power Up Tests

D. Initial Set up Conditions

E. Main Input and Internal Power Test

F. Pilot Arc Test

G. Main Arc and Controls Test

H. CNC Interface Test

5.08 Main Input and Internal Power Problems

A. Primary input line fuse blows as soon as primary disconnect is closed.

Diagnoses and resolves issues where the primary input fuse blows upon connection.

B. Primary line fuses blow immediately after ON/OFF SWITCH (SW1) is turned to ON position.

Troubleshoots immediate blowing of primary fuses after the unit is powered on.

D. All front panel indicators are off, fans do not run. Main Contactor W1 does not close.

Diagnoses why all front panel indicators are off and fans/contactor are not operating.

E. INPUT POWER FAULT.

F. PARTS-IN-PLACE (PIP) FAULT.

G. TRIGGER LOCKED DURING POWER UP FAULT.

H. TIP MISSING FAULT.

I. AC LED on, yellow TEMP LED is on, red FAULT Indicator is flashing.

J. AC LED on, TEMP, GAS, DC LED's are off, FAULT Indicator is flashing. MIN PRESSURE LED is flashing. Gas is not flowing

K. INTERNAL ERROR

L. MAX PRESSURE ERROR

M. AC LED on, TEMP LED off, GAS LED on, Gas does not flow in SET mode using a hand torch or a machine torch without remote solenoid.

N. AC LED on, TEMP LED off, GAS LED on, Gas does not flow in SET mode using a machine torch with remote solenoid.

O. Cannot adjust gas pressure in the SET mode

5.09 Pilot Arc Problems

B. SHORTED TORCH FAULT

Describes the shorted torch fault indicated by flashing FAULT and PSI LEDs, with gas flow interruptions.

C. AC LED on, TEMP LED off, GAS LED on, gas flowing, DC LED off, Fault Indicators off, No arc in torch

D. AC LED on, TEMP LED off, GAS LED on, gas flowing, DC LED on, Fault Indicators off, No arc in torch.

5.10 Main Arc and Controls Problems

A. Main arc will not establish, LED D59 on Main PCB remains on while pilot arc is striking the work piece.

Troubleshoots failure of the main arc to establish while the pilot arc is active.

B. Main arc transfers but current cannot be adjusted

Addresses issues where the main arc transfers but the output current is not adjustable.

C. In LATCH mode, when the torch switch is released the arc shuts off immediately.

Troubleshoots immediate arc shutdown in LATCH mode upon switch release.

D. With CURRENT CONTROL POTENTIOMETER set at maximum, output current is only 60 amps.

Diagnoses low output current when the control potentiometer is at maximum.

F. INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING

Explains the internal error fault indicated by flashing FAULT and 90 PSI LEDs.

5.11 CNC Interface Problems

5.12 Test Procedures

A. Main Contactor (W1) Test

Details the procedure for testing the main contactor (W1) using an ohmmeter.

B. Input Diode Module Test

C. Input Capacitor PCB Test

D. IGBT Modules Test

E. Output Diode Module Test

F. Pilot IGBT Test

Section 5 Torch: Service

5T.01 General Maintenance

Covers general maintenance procedures for the plasma torch, including cleaning and lubrication.

Cleaning Torch

5T.02 Inspection and Replacement of Consumable Torch Parts

6.04 Major External Replacement Parts

6.05 Front Panel Replacement Parts

6.09 Replacement Parts for Hand Torch

6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads

7.04 Major External Parts

7.05 Front Panel Parts Replacement

G. ON/OFF Switch (SW1) Replacement

H. Work Cable Replacement

7.06 Left Side Internal Parts Replacement

7.07 Rear Panel Parts Replacement

7.08 Right Side Internal Parts Replacement

B. Main PCB (PCB1) Replacement

Guides on removing and installing the main PCB (PCB1).

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

APPENDIX 4: TORCH CONNECTION DIAGRAMS

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS

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