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CUTMASTER 102
Victor CUTMASTER 102 Service Manual
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100
208/230V
460V
600V
400V
VictorThermalDynamics.com
Art # A-08618_AD
Service
Manual
Revision:
AM
Issue Date:
September 4, 2014
Manual No.:
0-4998
CUTMASTER
™
102
PLASMA CUTTING SYSTEM
2
Table of Contents
Table of Contents
5
Section 1: General Information
7
Notes, Cautions and Warnings
7
Important Safety Precautions
7
Publications
8
Note, Attention Et Avertissement
9
Precautions de Securite Importantes
9
Documents de Reference
11
Statement of Warranty
12
Section 2 System: Introduction
13
How to Use this Manual
13
Equipment Identification
13
Receipt of Equipment
13
Power Supply Specifications
14
Input Wiring Specifications
15
Power Supply Features
16
Section 2 Torch: Introduction
17
01 Scope of Manual
17
02 General Description
17
03 Specifications
17
04 Options and Accessories
18
05 Introduction to Plasma
18
Section 3 System: Installation
21
Unpacking
21
Lifting Options
21
Primary Input Power Connections
21
Gas Connections
22
Section 3 Torch: Installation
25
01 Torch Connections
25
02 Setting up Mechanical Torch
25
Section 4 System: Operation
27
Front Panel Controls / Features
27
Preparations for Operation
28
Section 4 Torch: Operation
31
01 Torch Parts Selection
31
02 Cut Quality
31
03 General Cutting Information
32
04 Hand Torch Operation
33
05 Gouging
35
06 Mechanized Torch Operation
36
07 Parts Selection for Manual and Mechanized Torch Cutting
38
Patent Information
44
Section 5 System: Service
47
General Maintenance
47
Maintenance Schedule
48
Common Faults
48
Fault Indicator
49
Basic Troubleshooting Guide
51
Circuit Fault Isolation
53
Main Input and Internal Power Problems
56
Pilot Arc Problems
61
Main Arc and Controls Problems
65
CNC Interface Problems
66
Test Procedures
66
Section 5 Torch: Service
81
01 General Maintenance
81
02 Inspection and Replacement of Consumable Torch Parts
82
Section 6: Parts Lists
83
Introduction
83
Ordering Information
83
Power Supply Replacement
83
Major External Replacement Parts
84
Front Panel Replacement Parts
85
Left Side Replacement Parts
86
Right Side Replacement Parts
87
Options and Accessories
88
Replacement Parts for Hand Torch
89
Replacement Parts - for Machine Torches with Unshielded Leads
90
Torch Consumable Parts (SL100 SV)
92
Section 7: Replacement Procedures
93
Scope
93
Anti-Static Handling Procedures
93
Parts Replacement - General Information
93
Major External Parts
93
Front Panel Parts Replacement
94
Left Side Internal Parts Replacement
96
Rear Panel Parts Replacement
98
Right Side Internal Parts Replacement
100
Appendix 1: Sequence of Operation (Block Diagram
101
Appendix 2: Data Tag Information
102
Appendix 3: Torch Pin - out Diagrams
103
Appendix 4: Torch Connection Diagrams
104
Appendix 5: System Schematic, 208/460V Units
106
Appendix 6: System Schematic, 600V Units
108
Appendix 7: Publication History
110
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Victor CUTMASTER 102 Specifications
General
Process
Plasma Cutting
Open Circuit Voltage (OCV)
300 VDC
Weight
28 kg (62 lbs)
Cutting Capacity (Recommended)
25mm
Gas Supply
Dry, Oil-Free Air or Nitrogen
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