Thermal Dynamics CUTMASTER - Service Manual

Thermal Dynamics CUTMASTER

128 pages

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Art # A-08797_AB

380V

400V

415V

PLASMA CUTTING SYSTEM

40mm

CUTMASTER

™

Rev. AK Date: April 25, 2012 Manual # 0-5085

Operating Features:

Service Manual

Table of Contents

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 Connections25
- Gas Connections26
Section 3 Torch: Installation29
- 01 Torch Connections29
- 02 Setting up Mechanical Torch29
Section 4 System: Operation31
- Front Panel Controls / Features31
- Preparations for Operation32
Section 4 Torch: Operation35
- 01 Torch Parts Selection35
- 02 Cut Quality36
- 03 General Cutting Information36
- 04 Hand Torch Operation37
- 05 Gouging41
- 06 Mechanized Torch Operation42
- 07 Parts Selection for SL100 Torch Cutting43
- 08 Recommended Cutting Speeds for SL100 Torch with Exposed Tip44
- 09 Recommended Cutting Speeds for SL100 Torch with Shielded Tip49
Patent Information54
Section 5 System: Service57
- General Maintenance57
- Maintenance Schedule58
- Common Faults58
- Fault Indicator59
- Basic Troubleshooting Guide62
- Circuit Fault Isolation64
- Main Input and Internal Power Problems68
- Pilot Arc Problems72
- Main Arc and Controls Problems75
- CNC Interface Problems76
- Test Procedures76
- Main PCB Layout & Signals82
- Capacitor PCB Layout & Signals86
- Logic PCB Layout & Signals88
- 40AMP Logic PCB Layout & Signals90
- Right Side Wiring Diagram92
Section 5 Torch: Service95
- 01 General Maintenance95
- 02 Inspection and Replacement of Consumable Torch Parts96
Section 6: Parts Lists97
- Introduction97
- Ordering Information97
- Power Supply Replacement97
- Major External Replacement Parts98
- Front Panel Replacement Parts99
- Left Side Replacement Parts100
- Right Side Replacement Parts101
- Options and Accessories102
- Replacement Parts for Hand Torch103
- Replacement Parts - for Machine Torches with Unshielded Leads104
- Replacement Shielded Machine Torch Leads Assemblies106
- Torch Consumable Parts (SL100 SV)107
Section 7: Replacement Procedures109
- Scope109
- Anti-Static Handling Procedures109
- Parts Replacement - General Information109
- Major External Parts110
- Front Panel Parts Replacement111
- Left Side Internal Parts Replacement112
- Rear Panel Parts Replacement114
- Right Side Internal Parts Replacement116
Appendix 1: Sequence of Operation (Block Diagram119
Appendix 2: Data Tag Information120
Appendix 3: Torch Pin - out Diagrams121
Appendix 4: Torch Connection Diagrams122
Appendix 5: System Schematic, 380-415V Units124
Appendix 6: Publication History126

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