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CUTMASTER
Thermal Dynamics CUTMASTER Service Manual
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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
2
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
25
Gas Connections
26
Section 3 Torch: Installation
29
01 Torch Connections
29
02 Setting up Mechanical Torch
29
Section 4 System: Operation
31
Front Panel Controls / Features
31
Preparations for Operation
32
Section 4 Torch: Operation
35
01 Torch Parts Selection
35
02 Cut Quality
36
03 General Cutting Information
36
04 Hand Torch Operation
37
05 Gouging
41
06 Mechanized Torch Operation
42
07 Parts Selection for SL100 Torch Cutting
43
08 Recommended Cutting Speeds for SL100 Torch with Exposed Tip
44
09 Recommended Cutting Speeds for SL100 Torch with Shielded Tip
49
Patent Information
54
Section 5 System: Service
57
General Maintenance
57
Maintenance Schedule
58
Common Faults
58
Fault Indicator
59
Basic Troubleshooting Guide
62
Circuit Fault Isolation
64
Main Input and Internal Power Problems
68
Pilot Arc Problems
72
Main Arc and Controls Problems
75
CNC Interface Problems
76
Test Procedures
76
Main PCB Layout & Signals
82
Capacitor PCB Layout & Signals
86
Logic PCB Layout & Signals
88
40AMP Logic PCB Layout & Signals
90
Right Side Wiring Diagram
92
Section 5 Torch: Service
95
01 General Maintenance
95
02 Inspection and Replacement of Consumable Torch Parts
96
Section 6: Parts Lists
97
Introduction
97
Ordering Information
97
Power Supply Replacement
97
Major External Replacement Parts
98
Front Panel Replacement Parts
99
Left Side Replacement Parts
100
Right Side Replacement Parts
101
Options and Accessories
102
Replacement Parts for Hand Torch
103
Replacement Parts - for Machine Torches with Unshielded Leads
104
Replacement Shielded Machine Torch Leads Assemblies
106
Torch Consumable Parts (SL100 SV)
107
Section 7: Replacement Procedures
109
Scope
109
Anti-Static Handling Procedures
109
Parts Replacement - General Information
109
Major External Parts
110
Front Panel Parts Replacement
111
Left Side Internal Parts Replacement
112
Rear Panel Parts Replacement
114
Right Side Internal Parts Replacement
116
Appendix 1: Sequence of Operation (Block Diagram
119
Appendix 2: Data Tag Information
120
Appendix 3: Torch Pin - out Diagrams
121
Appendix 4: Torch Connection Diagrams
122
Appendix 5: System Schematic, 380-415V Units
124
Appendix 6: Publication History
126
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Thermal Dynamics CUTMASTER Specifications
General
Brand
Thermal Dynamics
Model
CUTMASTER
Category
Welding System
Language
English
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