CutMaster 12+ is a plasma cutting system that can be used to cut a variety of metals, including steel, aluminum, and stainless steel. It uses a high-frequency, high-voltage electrical arc to create a plasma stream that melts and removes material. The CutMaster 12+ has a number of features that make it a versatile and reliable cutting tool, including a compact design, a built-in air compressor, and a variety of cutting settings.
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12+
CUTMASTER
™ plASMA CUTTing SySTEM
115V 16A
115V 32A
230V 16A
30
24
20
20
27
40
CUTMASTER
®
12+
Art # A-10556
Service Manual
Revision: AC
Operating Features:
Issue Date: September 3, 2012 Manual No.: 0-5198
40
AMP
DC
1
PHASE
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service provider visit us on the web at www.
thermal-dynamics.com (Americas and Europe).
This Service Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may exist when working with this product. We have made every effort to provide you with accurate instructions, drawings, and photographs of the product(s) we used when writing this manual. However errors do occur and we apologize if there are any contained in this manual.
Due to our constant effort to bring you the best products, we may make an improvement that does not get reflected in the manual. If you are ever in doubt about what you see or read in this manual with the product you received, then check for a newer version of the manual on our website or contact our customer support for assistance.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma
Cutting Products for Victor Technologies Inc.
We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster™ 12+
SL40 Torch™
Service Manual l Number 0-5198
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711 www.thermal-dynamics.com
Copyright 2011, 2012 by
Victor Technologies
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: October 31, 2011
Revision AC Date: September 3, 2012
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ____________
Purchase Date:__________________________________ ____________
Power Supply Serial #:___________________________ _____________
Torch Serial #:___________________________________ ___________
i
TABLE OF CONTENTS
GENERAL INFORMATION ........................................................................... 1-1
THEORY OF OPERATION ............................................................................ 5-1
TABLE OF CONTENTS
TROUBLESHOOTING ................................................................................ 6-1
6.02 Inspection and Replacement of Consumable Torch Parts ............................... 6-4
6.04 Tools Needed for Troubleshooting and Servicing ............................................ 6-6
6.08 Preliminary DC Bus Measurement of the Main Inverter Board ........................ 6-7
DISASSEMBLY PROCEDURE ....................................................................... 7-1
7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal ....................... 7-5
7.06 Power Switch S1 and Power Cord Removal ................................................... 7-7
ASSEMBLY PROCEDURES .......................................................................... 8-1
8.04 Installing Main Control Panel and Clear Cover Sheet ...................................... 8-5
REPLACEMENT PARTS .............................................................................. 9-1
GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.
CUTMASTER 12+
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony
Cobalt
Barium
Cadmium
Chromium
Copper
Lead
Manganese
Mercury
Selenium
Vanadium
Silver
• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These
MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
Manual 0-5198 1-1 General information
CUTMASTER 12+ GENERAL INFORMATION
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infrared light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels
(sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following chart.
NOTE
These values apply where the actual arc is clearly seen.
Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
(From AWS F2.2, Lens Shade Selector)
Shade numbers are given as a guide only and may be varied to suit individual needs.
Process
Shielded Metal Arc Welding (SMAW)
Gas Metal Arc Welding (GMAW) and
Flux Cored Arc Welding (FCAW)
Electrode Size in. (mm)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Arc Current
(Amperes)
Less than 60
60-160
160-250
250-550
Less than 60
60-160
160-250
250-550
Minimum
Protective
Shade
7
8
10
11
7
10
10
10
Suggested*
Shade No.
(Comfort)
-
10
12
14
-
11
12
14
Gas Tungsten arc Welding (GTAW)
Air Carbon Arc Cutting (CAC-A)
Plasma Arc Welding (PAW)
Plasma Arc Cutting (PAC)
(Light)
(Heavy)
Less than 50
50-150
150-500
Less than 500
500-1000
Less than 20
20-100
100-400
400-800
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
8
8
10
10
11
6
8
10
11
8
9
10
4
5
6
8
10
12
14
12
14
6 to 8
10
12
14
9
12
14
4
5
6
8
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding, cutting, or brazing where the torch and/or the flux produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line of the visible light spectrum.
Table 1-1
General information 1-2 Manual 0-5198
GENERAL INFORMATION
1.03 Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS
WHICH HAVE HELD COMBUSTIBLES, obtainable from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELD-
ING, CUTTING AND ALLIED PROCESSES, obtainable from the
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
CUTMASTER 12+
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES
IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND
CUTTING, obtainable from the Canadian Standards Association,
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED
SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTEC-
TION, obtainable from American National Standards Institute,
1430 Broadway, New York, NY 10018
Manual 0-5198 1-3 General information
CUTMASTER 12+ GENERAL INFORMATION
1.04 Servicing Hazards
!
WARNING
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard.
Only qualified persons should test, maintain, and repair this unit.
Only qualified persons should test, maintain, and repair this unit.
WARNING
FLYING METAL or DIRT can injure eyes.
• Wear safety glasses with side shields or face shield during servicing.
• Be careful not to short metal tools, parts, or wires together during testing and servicing.
WARNING
HOT PARTS can cause sever burns.
• Do not touch hot parts bare handed.
• Allow cooling period before working on equipment.
• To handle not parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Turn Off cutting power source and disconnect and lockout input power using line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
• Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
• Do not leave live unit unattended.
• If this procedure requires and energized unit, have only personnel familiar with and following standard safety practices do the job.
• When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free.
• Disconnect input power conductors from de-energized supply line BEFORE moving a cutting power source.
SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.
• Turn Off inverters, disconnect input power, and discharge input capacitors according to instructions in Troubleshooting
Section before touching any parts.
WARNING
EXPLODING PARTS can cause injury.
• Failed parts can explode or cause other parts to explode when power is applied to inverters.
• Always wear a face shield and long sleeves when servicing inverters.
WARNING
SHOCK HAZARD from testing.
• Turn Off cutting power source or stop engine before making or changing meter lead connections.
• Use at least one meter lead that has a self-retaining spring clip such as an alligator clip.
• Read instructions for test equipment.
WARNING
STATIC (ESD) can damage PC boards.
• Put on grounded wrist strap BEFORE handling boards or parts.
• Use proper static-proof bags and boxes to store, move, or ship PC boards.
WARNING
FALLING UNIT can cause injury.
• Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
WARNING
FIRE OR EXPLOSION hazard.
• Do not place unit on, over, or near combustible surfaces.
• Do not service unit near flammables.
WARNING
MOVING PARTS can cause injury,
• Keep away from moving parts such as fans.
• Keep away from pinch points such as drive rolls.
• Have only qualified persons remove panels, covers, or guards for maintenance as necessary.
• Keep hands, hair, loose clothing, and tools away from moving parts.
General information 1-4 Manual 0-5198
GENERAL INFORMATION
• Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
WARNING
MAGNETIC FIELDS can affect Implanted Medical
Devices.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away from servicing areas until consulting their doctor and the device manufacturer.
WARNING
OVERUSE can cause OVERHEATING.
• Allow cooling period; follow rated duty cycle.
• Reduce current or reduce duty cycle before starting to cut again.
• Do not block or filter airflow to unit.
WARNING
H.F. RADIATION can cause interference.
• High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
• Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.
!
WARNING
READ INSTRUCTIONS.
• Use Testing Booklet (Part No. 150 853) when servicing this unit.
• Consult the Owner’s Manual for cutting safety precautions.
• Use only genuine replacement parts from the manufacturer.
1.05 EMF Information
CUTMASTER 12+
Considerations About Cutting And The Effects Of Low Frequency
Electric And Magnetic Fields
Cutting current, as it flows through cutting cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the
National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep cutting power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.
Manual 0-5198 1-5 General information
CUTMASTER 12+ GENERAL INFORMATION
1.06 Note, Attention et Avertissement
• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :
NOTE
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:
Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
antimoine argent chrome nickel arsenic cobalt baryum
béryllium
plomb
sélénium manganèse vanadium
ATTENTION
Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.
• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.
!
AVERTISSEMENT
• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.
Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.
• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.
1.07 Precautions De Securite
Importantes
• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.
• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un
“pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de consignes.
General information 1-6 Manual 0-5198
GENERAL INFORMATION CUTMASTER 12+
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez
également les autres personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un
écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon
état. Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent tableau.
NOTE
Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.
Manual 0-5198 1-7 General information
CUTMASTER 12+ GENERAL INFORMATION
1.08 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de la National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE
DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas
Association), 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE
COUPE ET DE SOUDAGE, disponible auprès de la Société
Américaine de Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE
SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada, M9W 1R3
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS
DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU
SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply
Association), 1900 Arch Street, Philadelphia, PA 19103
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET
DANS LES ECOLES, disponible de l’Institut Américain des
Normes Nationales (American National Standards Institute),
1430 Broadway, New York, NY 10018
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR
LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE
CONTENEURS ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES
PROTECTRICES, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS
DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute,
1430 Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS),
LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT
RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC
ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA
COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
General information 1-8 Manual 0-5198
GENERAL INFORMATION
1.09 Declaration of Conformity
Manufacturer: Victor Technologies
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
CUTMASTER 12+
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council
Directive 2006/95/EC) and to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive
2004/108/EC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* 2002/95/EC RoHS directive.
* AS60974.1 Arc Welding Equipment Welding Power Sources.
For environments with increased hazard of electrical shock, Power Supplies bearing the
S
mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
!
WARNING
This equipment does not comply with IEC 61000-3-12. If it is connected to a public low voltage system, it is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment may be connected.
Victor Technologies has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative in Europe: Steve Ward
Operations Director
Victor Technologies Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Manual 0-5198 1-9 General information
CUTMASTER 12+ GENERAL INFORMATION
1.10 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER® plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Victor Technologies shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Victor
Technologies’s specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Victor Technologies will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Victor Technologies must be notified within 30 days of any failure, at which time
Victor Technologies will provide instructions on the warranty procedures to be implemented.
Victor Technologies will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Distributor.
LIMITED WARRANTY PERIOD
Product
CUTMASTER 12+
Power Supply Components
(Parts and Labor)
3 Years
Torch and Leads
(Parts and Labor)
1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Victor Technologies:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Victor Technologies.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Victor Technologies and are FOB West Lebanon, NH or an authorized Victor Technologies service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Victor Technologies shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service interruption.
The remedies of the Purchaser set forth herein are exclusive and the liability of Victor Technologies with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Victor Technologies whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor
Technologies product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective March 14,2011
General information 1-10 Manual 0-5198
INTRODUCTION CUTMASTER 12+
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How to Use This Manual 2.02 Equipment Identification
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
Throughout this manual, the word WARNING, CAU-
TION and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:
The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the machine. Equipment which does not have a nameplate attached to the machine is identified only by the specification or part number printed on the shipping container. Record these numbers for future reference.
!
WARNING
Gives information regarding possible personal injury. Warnings will be enclosed in a box such as this.
CAUTION
Refers to possible equipment damage. Cautions will be shown in bold type.
NOTE
Offers helpful information concerning certain operating procedures. Notes will be shown in italics
You will also notice icons from the safety section appearing throughout the manual. These are to advise you of specific types of hazards or cautions related to the portion of information that follows. Some may have multiple hazards that apply and would look something like this:
2.03 Receipt of Equipment
When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual. Include all equipment identification numbers as described above along with a full description of the parts in error.
2.04 Transportation Methods
!
Disconnect input power conductors from de-energized supply line before moving the cutting power source.
Lift unit with handle on top of case. Use handcart or similar device of adequate capacity. If using a fork lift vehicle, secure the unit on a proper skid before transporting.
2.05 Working Principle
Rectifier
Inverter Transformer Rectifier
Compressed air
Reduce pressure, filter Gas valve Cutting torch
Workpiece
Art # A-09204_AB
Manual 0-5198 2-1 Introduction
CUTMASTER 12+ INTRODUCTION
2.06 Power Supply Features
On/Off
Switch
Power Cord
Air Inlet
Art# A-09335
Introduction 2-2 Manual 0-5198
INTRODUCTION CUTMASTER 12+
SECTION 2TORCH:
INTRODUCTION
2T.01 Scope of Manual
F. Torch Ratings
Ambient
Temperature
Duty Cycle
SL40 Torch Ratings
104° F
40° C
100% @ 40 Amps @ 250 scfh
This manual contains descriptions, operating instructions and maintenance procedures for the SL40 Plasma
Cutting Torch. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.
Maximum Current
Voltage (V peak
)
Arc Striking Voltage
G. Current Ratings
SL40 Current Ratings
SL40 Torch & Leads
40 Amps
500V
500V
Up to 40 Amps, DC,
Straight Polarity
2T.02 Specifications
A. Torch Configurations
1. Hand Torch, Model SL40
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch trigger assembly.
8.3" (210.82mm)
NOTE
Power Supply characteristics will determine material thickness range.
H. Gas Requirements
SL40 Torch Gas Specifications
Gas (Plasma and Secondary)
Minimum Input Pressure
Compressed Air
85 psi
5.9 bar
Art # A-09336
Maximum Input Pressure 125 psi / 8.6 bar
2.6"
(66.04mm)
.96" (24.38mm)
B. Torch Leads Lengths
Hand Torches are available as follows:
• 15 ft / 4.6 m.
C. Torch Parts
Gas Flow
193 scfh
91 lpm
!
WARNING
This torch is not to be used with oxygen
(O
2
). This torch is not to be use with high frequency starting systems.
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch has built-in switch.
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through torch.
Manual 0-5198 2T-1 Introduction
CUTMASTER 12+ INTRODUCTION
2T.03 Introduction to Plasma
B. Gas Distribution
A. Plasma Gas Flow
The single gas used is internally split into plasma and secondary gases.
Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.
The plasma gas flows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orifice.
The secondary gas flows down around the outside of the torch starter cartridge, and out between the tip and shield cup around the plasma arc.
While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
C. Pilot Arc
In a Plasma Cutting Torch a cool gas enters Zone
B, where a arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.
When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.
D. Main Cutting Arc
By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.
DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.
E. Parts - In - Place (PIP)
Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.
The torch includes a 'Parts - In - Place' (PIP) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.
Torch Switch Torch Trigger
To Control
Cable Wiring
PIP Switch
Shield Cup
A-09595
Parts - In - Place Circuit Diagram for Hand Torch
_
Power
Supply
+
A
B
Workpiece
A-00002
C
Typical Torch Head Detail
Introduction 2T-2 Manual 0-5198
INSTALLATION CUTMASTER 12+
SECTION 3:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
A. Contents List
Description
CM12+ Power source
10ft power input cable (installed)
Work cable and clamp (installed)
SL40 Torch (15ft(4.6m)) w/consumables
Carry case
40A Tip Drag
20A Tip Drag
40A Tip, Standoff
Electrode
Gloves
Cutting Glasses
Quantity
1
1
1
1
1
2
2
2
2
1
1
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
WARNING
!
WARNING
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-5198 3-1 Installation
CUTMASTER 12+ INSTALLATION
3.03 Primary Input Power Connections
Power Cord and Plug
This power supply comes installed with a input power cable with no plug, single-phase input power.
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.
Input Voltage (VAC)
115V, 16A Circuit
115V, 32A Circuit
230V, 16A Circuit
Rated Output
20A, 88V
27A, 91V
40A, 96V
Amps (RMS) input at rated output, 60 Hz, single-phase
21.3
21.3
23-21.4
KVA
2.5
3.5
4.8
3.04 Air Supply Connections
A. Connecting Air Supply to Unit
The connection is the same for compressed air or industrial compressed air in gas cylinders.
1. Connect the gas line to the compressed air inlet port at the appropriate pressure.
On/Off
Switch
Air Inlet
Art# A-09337
Figure 3-2 Gas Connection to Compressed Air input
Installation 3-2 Manual 0-5198
INSTALLATION CUTMASTER 12+
B. Using Industrial Compressed Air In Gas Cylinders
When using Industrial compressed air in gas cylinders as the gas supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to
100 psi (6.9 bar) maximum and flows of at least 250 scfh (120 lpm).
4. Connect gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the torch.
3.05 Power Supply Specifications
Input Power
Output Current
Ambient Temperature
Duty Cycle
Rated Current
CUTMASTER 12+ Power Supply Specifications
115 VAC (+-10%), 1Phase, 50/60Hz
230 VAC (+-10%), 1Phase, 50/60Hz
20-27 Amps @ 115VAC
20-40 Amps @ 230VAC
CUTMASTER 12+ Power Supply Duty Cycle (Note 1)
104° F (40° C)
30% @ 115VAC, 40% @ 230VAC
27 Amps @ 115VAC, 40 Amps @ 230V
SL40 Torch Gas Requirements (see section 2T.03)
Notes
1. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is reduced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.
2. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear. Optional filters provide increased filtering capabilities.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications include calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, and actual cutting operation.
Manual 0-5198 3-3 Installation
CUTMASTER 12+ INSTALLATION
Figure 2-1 Power Supply Dimensions & Weight
NOTE
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit proper cooling and reduce duty cycle.
3.06 Input Wiring Specifications
CUTMASTER 12+ Input Power Requirements
Voltage
(Volts-AC)
115
230
Input
Freq.
(Hz)
50/60
50/60
Power Input Current Input Current Input Suggested Sizes (See Note)
(kVA) Max (Amps) Ieff (Amps) Fuse (Amps)
1-Ph
3.3
5.0
240 50/60 5.0
Line Voltages with Suggested Circuit Protection
1-Ph
28.5
21.4
20.8
1-Ph
15
13.5
13
1-Ph
32
16
16
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is 167° F (75° C).
Installation 3-4 Manual 0-5198
OPERATION CUTMASTER 12+
SECTION 4 SYSTEM:
OPERATION
4.01 Control Panel
1. ON / OFF Switch (Power Switch/Lamp)
Controls input power to the power supply. I is ON (Red Lamp), O is OFF.
2. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit opens frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate input power. Note: For 120V input power, the unit will automatically limit the output current to a maximum of 27A. For 230V input power, the maximum output is 40 Amps. Refer to Section 2 for input power requirements.
3. AC Indicator
Steady light indicates power supply is ready for operation.
4. OVERHEAT Indicator (TEMP Indicator)
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Allow the unit to run with the fan on until the temp indicator turns off.
5. AIR Indicator
AIR light should be ON when there is sufficient gas pressure.
6. READY (DC Indicator)
Indicator is ON when DC output circuit is active.
NOTE
All consumables must be correctly installed and maintained to ensure correct operation.
Manual 0-5198 4-1 Operation
CUTMASTER 12+ OPERATION
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this power supply (40 amps maximum). Use only genuine
Thermal Dynamics parts with this torch.
Art # A-09340-AG
Electrode, Cat. No. 9-0096
40 Amp Drag Tip, Cat. No. 9-0093
Shield Cup, Cat. No. 9-0098
Start Cartridge,
Cat. No. 9-0097
40 Amp
Standoff Tip,
Cat. No. 9-0094
Worn Electrode
Worn Tip
NOTE
When operating the torch in a normal condition, some gas vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
B. Torch Connection
Check that the torch is properly connected.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Operation 4-2 Manual 0-5198
OPERATION CUTMASTER 12+
D. Gas Selection
Ensure gas source meets requirements listed in section 2T. Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.
Art # A-03387
F. Power On
Place the power supply ON / OFF switch to the ON (I) position. Power indicator
On/Off
Switch
Power Cord
Air Inlet
turns on.
120V 15A
120V 20A
230V 20A
30
24
Art# A-09335
Art# A-09339_AD
20
20
27
40
A
Rear Panel with ON/OFF Switch Front Panel With Power ON/OFF Indicator
Manual 0-5198 4-3 Operation
CUTMASTER 12+ OPERATION
G. Select Current Output Level
Set the desired current output level.
115V 16A
115V 32A
230V 16A
A#09937
115V, 16A
A
30
24
20
115V, 32A
27
A
30
20
230V, 16A
40
A
4.03 Sequence of Operation
The following is a typical sequence of operation for this power supply.
1. Place the ON / OFF switch on the power supply to ON (up) position (Red indicator lamp is illuminated).
a. AC indicator turns on; fan turns on.
NOTE
During initial power up, there will be a delay of about 2 seconds before the AC Indicator light will illuminate and the pre-flow gas and fan starts. The gas will automatically flow from torch for approximately
10 seconds (only after the AC Indicator lamp is illuminated) (The AC Indicator lamp and fan turns on approximately 2 seconds after the ON/OFF switch is enabled), this is a process that makes sure all inputs (gas, input power, torch connection, and torch parts) are acknowledged for proper operation.
2. Wear protective clothing, including welding gloves and appropriate eye protection (see table 1-1). Place tip on work piece and pull trigger. Arc will initiate and start cutting material.
• Standoff Cutting With Hand Torch
NOTE
For best performance and parts life, always use the correct parts for the type of operation.
Operation 4-4 Manual 0-5198
OPERATION CUTMASTER 12+
A. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.
NOTE
Trigger
Trigger Release
1
2
3
The tip should never come in contact with the workpiece except during drag cutting operations.
B. Depending on the cutting operation, do one of the following:
a). For drag cutting, place the tip on the plate holding the torch at a angle to the plate so that only one edge of the tip is in contact with the plate. This prevents damage to the tip during the piercing process.
b). For standoff cutting, hold the torch tip on the work piece, pull the trigger. After the arc is initiated lift the tip to 1/8" -
3/8" (3-4mm) off the work.
Torch
4
NOTE
Art# A-11462
When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.
• Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4"(6 mm) thick or less.
NOTE
Shield Cup
A-00024_AB
Standoff Distance
1/8" - 3/8" (3 - 9mm)
Standoff Distance
Art # A-09342
For best parts performance and life, always use the correct parts for the type of operation.
A. Install the drag cutting tip and set the output current.
B. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.
C. Keep the torch in contact with the workpiece during the cutting cycle.
D. Hold the torch away from your body.
Trigger
Trigger Release
Manual 0-5198 4-5 Operation
CUTMASTER 12+ OPERATION
E. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The arc will start.
4.04 Cut Quality
NOTE
Trigger Release
Art # A-09342
Trigger
F. Place the torch tip on the work. The main arc will transfer to the work.
NOTE
The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.
Trigger
Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.
Refer to appendix pages for additional information as related to the power supply used.
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following figure:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
1
2
Trigger Release
Top Edge
Rounding
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
3
Cut Quality Characteristics
4
Art# A-09341
G. Cut as usual. Simply release the trigger assembly to stop cutting.
H. Follow normal recommended cutting practices as provided herein.
3. Complete cutting operation.
NOTE
If the torch is lifted too far from the workpiece while cutting, the main arc will stop and the pilot arc will automatically restart.
4. Release the torch trigger. a. Main arc stops.
5. Set the power supply ON / OFF switch to OFF
(down position).
a. AC indicator turns OFF.
6. Set the main power disconnect to OFF, or unplug input power cord.
a. Input power is removed from the system.
Cut Surface
The desired or specified condition (smooth or rough) of the face of the cut.
Nitride Build - Up
Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material is to be welded after the cutting process.
Bevel Angle
The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0° bevel angle.
Top - Edge Rounding
Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.
Operation 4-6 Manual 0-5198
OPERATION CUTMASTER 12+
Bottom Dross Buildup Edge Starting
Molten material which is not blown out of the cut area and resolidifies on the plate. Excessive dross may require secondary cleanup operations after cutting.
Kerf Width
The width of the cut (or the width of material removed during the cut).
Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice has become elongated.
4.05 General Cutting Information
WARNING
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.\
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.
Direction of Cut
In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
Left Side
Cut Angle
Right Side
Cut Angle
Side Characteristics Of Cut
A-00512
CAUTION
Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.
NOTE
Handle torch leads with care and protect them from damage.
Torch Standoff
Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally result in a more square cut.
To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.
Dross
When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.
Manual 0-5198 4-7 Operation
CUTMASTER 12+ OPERATION
Notes
Operation 4-8 Manual 0-5198
THEORY OF OPERATION
5.01 Inverter Design
What does the word inverter mean?
SECTION 5:
THEORY OF OPERATION
CUTMASTER 12+
The term inverter refers to the ability to change DC power into AC. Inverter power supplies immediately rectify the incoming AC to DC, and then the transistors create a higher frequency AC. The higher frequency AC then goes on to a much smaller main transformer than in a conventional power supply. The AC is then rectified to extremely smooth DC. The diagram to the below shows the basic electrical wiring of a DC output inverter power supply.
Inverter Technology - Summary
Rectifier Filter IGBT Transformer Rectifier Inductor
AC-50/60Hz DC-Rippled DC-Smooth AC-23KHz AC-23KHz DC- Rippled DC-Smooth
High Voltage High Voltage High voltage High Voltage Low Voltage Low Voltage Low Voltage
Low Amperage Low Amperage Low Amperage Low Amperage High Amperage High Amperage High Amperage
Art # A-09846
Manual 0-5198 5-1 Theory of operation
CUTMASTER 12+ THEORY OF OPERATION
Notes
Theory of operation 5-2 Manual 0-5198
TROUBLESHOOTING
SECTION 6:
TROUBLESHOOTING
6.01 Basic Troubleshooting-Power Source Faults
CUTMASTER 12+
!
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair it unless you are an accredited service provider and you have had training in power electronics measurement and troubleshooting techniques.
Common Faults symptom LED Indicators
A. AC indicator OFF
1. Main input power cord does not connect to power distribution net.
a. Connect the power cord.
2. Power ON/OFF switch in OFF (down) position.
a. Turn switch to ON (up) position.
3. Actual input voltage does not correspond to voltage of unit.
a. Verify that the input line voltage is correct.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
B. AC indicator blinking
1. Indicator blinking (1 sec ON/1 Sec OFF, Gas may also pulse 3 times).
a. Check for missing torch parts or not properly installed. Turn ON/OFF switch to OFF position and restart the machine by turning the power switch to ON.
2. Indicator blinking (1 sec ON/3 Sec OFF).
a. Check for worn or sticking torch parts. Replace if necessary.
3. Indicator blinking (3 sec ON/3 Sec OFF).
a. Torch switch was depressed before machine was completely powered up. Turn ON/OFF switch to
OFF position and the restart the machine by turning the power switch to ON.
C. Air indicator OFF
1. Gas pressure too low. Check supply pressure.
D. TEMP indicator ON, (AC indicator
1. Unit air flow obstructed.
ON)
a. Check for blocked air flow around the unit and correct condition.
2. Fan blocked.
a. Check for blocked status and correct condition.
3. Unit is overheated.
a. Keep the machine plugged in and turned on for five minutes. This will allow the fan to run and cool the machine.
Manual 0-5198 6-1 Troubleshooting
CUTMASTER 12+
4. Faulty components in unit
TROUBLESHOOTING
a. Return for repair or have qualified technician repair per service manual.
E. Torch will not pilot, when torch trigger is activated.
1. Faulty parts in torch
a. Check torch parts per section 4.02; replace as needed.
2. Gas pressure too low
a. Adjust supply pressure to proper setting value.
NOTE
The pressure should be set at (100 PSI).
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
F. No cutting output when torch is activated; AC indicator
1. Torch is not connected properly to power supply.
a. Check torch connection to power supply.
ON, gas flows, fan turns.
2. Working cable not connected to work piece, or connection is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
4. Faulty torch
a. Return for repair or have qualified technician repair.
G. Torch cuts but not adequately
1. Incorrect setting of output current control
a. Check and adjust to proper setting.
2. Working cable connection to work piece is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair.
H. Output is restricted, and can not be controlled.
1. Input or output connection is poor.
a. Check all input and output connection leads.
2. Working cable connection to work piece is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
I. Cutting output is unstable or inadequate at 120V operation.
1. Low or fluctuating input voltage a. Turn output current to minimum (20 amps) and suggest using 20A Drag tip.
b. Connect to a dedicated input line voltage.
c. Have electrician check input line voltage under load.
Troubleshooting 6-2 Manual 0-5198
TROUBLESHOOTING
2. Input or output connection is poor
a. Check all input and output connection leads.
CUTMASTER 12+
3. Working cable connection is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
J. Hard to startup
1. Torch parts worn (consumables)
a. Turn off input power, remove shield cup, tip, start cartridge, and electrode and check them all. If the electrode or cutting tip is worn out, replace them. If the start cartridge does not move freely, replace it. If there is too much spatter on shield cup, replace it.
K. Arc goes out while operating. Arc can’t be restarted when torch trigger is activated.
1. Power Supply is overheated (TEMP indicator ON).
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond duty cycle limit.
2. Fan blades blocked (TEMP indicator ON).
a. Check and clear blades.
3. Air flow blocked
a. Check for blocked air flow around the unit and correct condition.
4. Gas pressure is too low. (Air indicator ON when torch trigger is activated.)
a. Check gas source. Adjust to proper setting value.
5. Torch parts worn
a. Check torch shield cup, cutting tip, start cartridge and electrode. Replace as needed.
6. Faulty component in unit
a. Return for repair or have qualified technician repair per service manual.
L. Torch cuts but not well.
1. Current control is set too low.
a. Increase the current setting.
2. Torch is being moved too fast across work piece
a. Reduce cutting speed.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup
(do not activate torch). If there are contaminants in the gas, additional filtering may be needed.
4. Torch parts worn
a. Check torch shield cup, cutting tip, start cartridge and electrode. Replace as needed.
M. Gas in torch pulsates 3 times and then stops. AC indicator light blinking.
1. Torch parts not properly installed in torch. There may have been an attempt to remove torch parts without turning off ON/OFF power switch to OFF on unit.
a. Check to make sure torch parts are properly installed.
b. Turn ON/OFF switch to OFF and then back to ON.
Manual 0-5198 6-3 Troubleshooting
CUTMASTER 12+ TROUBLESHOOTING
6.02 Inspection and Replacement of Consumable Torch Parts
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE
The shield cup holds the tip and starter cartridge shield cup in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE
Slag built up on the shield cup that cannot be removed may effect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace if damaged.
Art# A-09345
Torch Head
Electrode
Start Cartridge
Tip
Shield Cup
Consumable Parts
3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary.
Good Tip
Worn Tip
Tip Wear
A-09791
Troubleshooting 6-4 Manual 0-5198
TROUBLESHOOTING CUTMASTER 12+
4. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion. Replace if necessary.
Art A-09792
5. Pull the electrode straight out of the torch head. Check the face of the electrode for excessive wear. Refer to the following figure.
New Electrode
Art # A-09346_AB
Worn Electrode
Electrode Wear
6
. Reinstall the electrode by pushing it straight into the torch head until it clicks.
7 . Reinstall the desired starter cartridge and tip into the torch head.
8. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.
SL40 Replacement Parts
Item # Description
1 Electrode
Cat. No
9-0096
2 Cartridge 9-0097
3 Tip, 20A Drag
Tip, 40A Drag
Tip, 40A Standoff
9-0091
9-0093
9-0094
4 Shield Cup 9-0098
N/S SL40 Torch w/ 15ft (4.6m) leads 7-0040
Art# A-09817
Torch Head
Electrode
Start Cartridge
Tip
Shield Cup
1
2
3
4
Manual 0-5198 6-5 Troubleshooting
CUTMASTER 12+ TROUBLESHOOTING
6.03 Checking Unit Before Applying Power
!
!
Turn SW1 to OFF position, and disconnect unit from primary line voltage before working on unit.
!
Significant DC voltage can remain on capacitors after unit is Off. Wait until all front panel LED’s are off before removing case.
!
Check DC bus voltage according to Section 6.08 after removing case.
!
Before troubleshooting or applying power to unit, complete the following checks to avoid causing further damage.
6.04 Tools Needed for Troubleshooting and Servicing
6.05 Case Removal
!
Read and follow safety information in Section 6.03 before proceeding.
Remove the ten screws from the cover and remove the cover panel.
Art # A-09849
Art # A-10242
Troubleshooting 6-6 Manual 0-5198
TROUBLESHOOTING
6.06 Clear Cover Sheet Removal
!
Read and follow safety information in Section 6.03 before proceeding.
1. Clear protective sheet
Take out clear protective sheet.
CUTMASTER 12+
Art # A-10243
1
6.07 Visually Inspect
Visually inspect the inside of the Power Source. The levels of current present in these units can cause burning or arcing of PCB, transformers, switches, or rectifier when a failure occurs. Carefully inspect all components within these units.
Look in particular for the following: a) Loose or broken wires or connectors.
b) Burned or scorched parts or wires or evidence of arcing.
c) Any accumulation of metal dust or filings that may have caused shorting or arcing.
If any parts are damaged, they must be replaced. Refer to the Spare Parts section for a complete list of components used in the Power Source.
Locate the faulty component(s) then replace where necessary.
6.08 Preliminary DC Bus Measurement of the Main Inverter Board
!
Read and follow safety information in Section 6.03 before proceeding.
DC Bus Testing
Upper capacitor bank
Lower capacitor bank
Multimeter Lead Placement
Positive meter lead to testpoint 30
Negative meter lead to testpoint 29
Positive meter lead to testpoint 32
Negative meter lead to testpoint 31
Voltage with Supply voltage OFF
Table 6-1 DC BUS, Multimeter set to measure DC volts
0 VDC
0 VDC
Manual 0-5198 6-7 Troubleshooting
CUTMASTER 12+ TROUBLESHOOTING
6.09 Preliminary Check of the Main Inverter Board
!
Read and follow safety information in Section 6.03 before proceeding.
Troubleshooting 6-8 Manual 0-5198
TROUBLESHOOTING
IGBT Testing
IGBT 1
IGBT 2
IGBT 3
VIGBT 4
PFC IGBT 1
PFC IGBT2
PILOT IGBT1
CUTMASTER 12+
Multimeter Lead Placement
Positive meter lead to test point 3
Negative meter lead to test point 2
Positive meter lead to test point 5
Negative meter lead to test point 4
Positive meter lead to test point 8
Negative meter lead to test point 7
Positive meter lead to test point 10
Negative meter lead to test point 9
Positive meter lead to test point 14
Negative meter lead to test point 13
Positive meter lead to test point 12
Negative meter lead to test point 11
Positive meter lead to test point 26
Negative meter lead to test point 25
Diode Voltage
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
0.2000 to 0.8000 VDC
Table 6-2 IGBT’s, Multimeter set to measure Diode Voltage
6.10 Check Main On / Off Switch
!
Read and follow safety information in Section 6.03 before proceeding.
1 3
2 4
Art # A-10245
Power Switch Testing
Switch ON
Switch ON
Switch OFF
Switch OFF
Multimeter Lead Placement
Positive meter lead to testpoint 1
Negative meter lead to testpoint 2
Positive meter lead to testpoint 3
Negative meter lead to testpoint 4
Positive meter lead to testpoint 1
Negative meter lead to testpoint 2
Positive meter lead to testpoint 3
Negative meter lead to testpoint 4
Table 6-3 Power Switch, Multimeter set to measure ohms (Ω)
Impedance
0 to 1 Ω
0 to 1 Ω
> 1k Ω
> 1k Ω
Manual 0-5198 6-9 Troubleshooting
CUTMASTER 12+
6.11 Check Pressure Switch
TROUBLESHOOTING
1
Art # A-10292
2
1. Pressure switch open
When the pressure is up to 3.5kgf/cm
2
(49.78 PSI), the pressure switch turns off.
2. Pressure switch closed
When the pressure is less than 2.4kgf/cm
2
(34.13 PSI), the pressure switch turns on and the resistance between
1 and 2 is about 0.1Ω.
6.12 Check Regulator
1
Art # A-10293
When solenoid valve is on,adjusts the knob 1. If the pressure is continuously adjustable, the regulator is ok.
Troubleshooting 6-10 Manual 0-5198
TROUBLESHOOTING
6.13 Check Main Input Rectifier
AC1 DC—
CUTMASTER 12+
AC2
DC+
Art # A-10291
Input Rectifier Testing
AC1 to DC+
AC2 to DC+
AC1 to DC-
AC2 to DC-
Multimeter Lead Placement
Positive meter lead to AC1
Negative meter lead to testpoint DC+
Positive meter lead to AC2
Negative meter lead to testpoint DC+
Positive meter lead to testpoint DC-
Negative meter lead to testpoint AC1
Positive meter lead to testpoint DC-
Negative meter lead to testpoint AC2
Table 6-4 IGBT’s, Multimeter set to measure Diode Voltage
Diode Voltage
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
0.2 – 0.8 VDC
Measurements may be made directly onto the main input rectifier. AC1 and AC2 may be measured from the pins on the mains supply plug with the main power switch set to the ON position.
6.14 DC Bus Voltage Measurement
Apply voltage to the Power Source.
There are extremely dangerous voltage and power levels present inside these Power Sources.
Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.
Once power is applied to the Power Source, there are extremely hazardous voltage and power levels present.
Do not touch any live parts.
Manual 0-5198 6-11 Troubleshooting
CUTMASTER 12+ TROUBLESHOOTING
Troubleshooting 6-12 Manual 0-5198
TROUBLESHOOTING CUTMASTER 12+
DC Bus Testing
Upper capacitor bank
Lower capacitor bank
Overall capacitor bank
Multimeter Lead Placement Voltage with Supply voltage ON
Positive meter lead to testpoint 30
Negative meter lead to testpoint 29
Positive meter lead to testpoint 31
Negative meter lead to testpoint 32
Positive meter lead to testpoint 29
Negative meter lead to testpoint 32
Table 6-5 DC BUS, Multimeter set to measure DC volts
192 VDC +/-10%
192 VDC +/-10%
384 VDC +/-10%
Note: These DC voltages are at nominal mains supply voltage of 240VAC.
Manual 0-5198 6-13 Troubleshooting
CUTMASTER 12+
6.15 Check of Control PCB
TROUBLESHOOTING
!
Read and follow safety information in Section 6.03 before proceeding.
Troubleshooting 6-14 Manual 0-5198
1
2
2
J7
3
4
J8
3
4
5
6
1
2
3
4
5
J5
7
J6
1
8
9
6
7
4
5
2
3
10
J3
J4
1
2
2
3
J1
1
4
J2
1
TROUBLESHOOTING
Pin function
GND
Control circuit power source
Negative of solenoid control signal
Positive of solenoid control signal
Current control potentiometer
N/A
Fault indicator signal
N/A
Control circuit power supply
GND
Power indication signal
N/A
Work indication signal
Power indication signal
N/A
Positive of TIP test signal
TIP test signal
Control circuit power source
GND
Control circuit power source
Drive circuit power
IGBT 1 pwm drive signal
IGBT 2 pwm drive signal
IGBT 2 pwm drive signal
IGBT 1 pwm drive signal
Overcurrent signal
GND
Feedback of input voltage
GND
Power source of current sensor
Power source of current sensor
Output current feedback
GND
Signal
0VDC
27VDC
0VDC (when solenoid is on)
27VDC
CUTMASTER 12+
0—4VDC
N/A
2vdc (when indication lights up)
N/A
5VDC
0VDC
2VDC
N/A
2VDC
2VDC
N/A
5VDC
5VDC (when the machine dose no work);0VDC
(when the machine is woking)
24VDC
0VDC
-24VDC
+15VDC
15V p-p square wave
15V p-p square wave
15V p-p square wave
15V p-p square wave
>7VDC (when over primary current protection)
0VDC
41VDC(input 230vac)
23VDC(input 115vac)
0VDC
15VDC
-15VDC
0VDC
Manual 0-5198 6-15 Troubleshooting
3
4
J14
1
2
1
2
3
J13
CUTMASTER 12+
1
2
J9
1
Power source of fan
0VDC(fan negative)when fan is on
Pilot ARC current feedback signal
1
2
2
J11
2
3
J10
1
J12
1
2
GND
N/A
Positive of voltage feedback
Negative of voltage feedback
+12VDC
Pilot ARC IGBT drive signal
N/A
Thermostat (0VDC when thermostat closed)
GND
Pressure switch signal
GND
GND
Gun switch signal
Cup test signal
Cup test signal
TROUBLESHOOTING
24VDC
0VDC
-0.8VDC
+5VDC( A main cutting arc is established)
0VDC
N/A
Machine output +
Machine output _
+12VDC
N/A
0VDC
0VDC (when switch closed otherwise 4VDC)
0VDC
0VDC
0VDC (when switch on otherwise 27VDC)
0VDC
0VDC (when the cup is fixed otherwise 27VDC)
Troubleshooting 6-16 Manual 0-5198
TROUBLESHOOTING
6.16 Waveforms
CUTMASTER 12+
1. Vds of inverter IGBT at no load
Test point C1: 4 and 5 C2: 9 and 10 (Testpoints refer to inverter PCB diagram in Sec. 6.13).
Timebase Trigger
Stop
Art # A-10247
2. Vds of inverter IGBT at full load
Test point C1: 4 and 5 C2: 9 and 10 (Testpoints refer to inverter PCB diagram in Sec. 6.13 ).
Positive
Timebase Trigger
Stop
Art # A-10248
Positive
Manual 0-5198 6-17 Troubleshooting
CUTMASTER 12+
6.17 Main Circuit Description
TROUBLESHOOTING
!
Turn off power and disconnect mains supply plug from receptacle before working on the unit. Allow two minutes for capacitors to discharge after disconnection from mains supply voltage.
U1
AC V+
AC V-
DC+
DC-
DC+ dc+
PFC Control Chip
DCdc+
Art # A-10249
Troubleshooting 6-18 Manual 0-5198
TROUBLESHOOTING CUTMASTER 12+
The mains supply voltage is connected via a double pole switch to the input rectifier U1 through an EMC filter.
Overvoltage protection is provided by varistor CY1.
The rectifier circuit converts the input AC voltage to DC voltage. The input current is controlled by comparing with a reference waveform which is a pure sine wave derived from the source voltage. The PFC control chip will be used to generate suitable gate signal to drive V8,V8-1, ensuring the current is sinusoidal.
The boostdiode output charges the main capacitor bank (C16, C17, C18, C19, C20 and C21) to high voltage. Inrush current limiting is provided by a high power resistor which is then bypassed by relay J1 after a few seconds.
The primary igbt transistors (T1, T2, T4, and T5) switch the transformer primary at high frequency and varying duty cycle. The transformer return wire is taken from the junction of the capacitors C20 and C21 (the voltage at this point is approximately half the DC bus voltage).
Secondary output voltage from the transformer is rectified by the output diodes (T14-1 & T16-1) to DC. This DC is controlled by the PWM of the primary side igbt transistors, and is filtered by an inductor before connecting to the output terminals.
A thermal overload device (thermistor) is fixed to the rectifier heatsink. When an over temperature occurs, the control circuit inhibits the trigger and the output. The thermal overload indicator LED on the front panel is illuminated.
The current transformer TR8 provides a signal to the control circuit to indicate both transformer primary current, and also detect transformer saturation. The Hall effect current sensor is powered from regulated + & - 15VDC supplies and provides a voltage signal proportional to the output DC cutting current to allow the control circuit to regulate cutting current.
Manual 0-5198 6-19 Troubleshooting
CUTMASTER 12+
6.18 Circuit Diagram
TROUBLESHOOTING
T O R C H
1 2 3 4 1 2 1 2 3
7 DR
1 2
D
1 2
1 2
Art # A-09396_AE
Troubleshooting 6-20 Manual 0-5198
DISASSEMBLY PROCEDURE
SECTION 7:
DISASSEMBLY PROCEDURE
7.01 Safety Precautions for Disassembly
!
!
Read and follow safety information in Section 6.03 before proceeding.
Unplug unit before beginning Disassembly procedure.
CUTMASTER 12+
Manual 0-5198 7-1 Disassembly Procedure
CUTMASTER 12+
7.02 Control Board Removal
DISASSEMBLY PROCEDURE
!
Read and follow safety information in Section 6.03 before proceeding with disassembly
Remove case (refer to 6.05) before remove control board.
Refer to graphics on page 7-3.
1. M4 Screw. Remove 4 screws from Control panel.
2. Disconnect HF/QF harness from HF/QF connector.
3. Disconnect MB harness from MB connector.
4. Disconnect SOURCE&TIP harness from SOURCE&TIP connector.
5. Disconnect DRIVE harness from DRIVE connector.
6. Disconnect U-D harness from U-D connector.
7. Disconnect WA harness from WA connector.
8. Disconnect FAN harness from FAN connector.
9. Disconnect TRANF-IFB harness from TRANF-IFB connector.
10. Disconnect WV harness from WV connector.
11. Disconnect D-PORT harness from D-PORT connector.
12. Disconnect OT harness from OT connector.
13. Disconnect PRESSURE harness from PRESSURE connector.
14. Disconnect GUN&TEST harness from GUN&TEST connector.
Disassembly Procedure 7-2 Manual 0-5198
DISASSEMBLY PROCEDURE CUTMASTER 12+
Manual 0-5198 7-3 Disassembly Procedure
CUTMASTER 12+ DISASSEMBLY PROCEDURE
7.03 Front Panel Assembly Removal
!
Read and follow safety information in Section 6.03 before proceeding with disassembly
1. Case removal
Remove the ten screws from the cover panel and remove the cover panel
2. Remove the screws on front panel
3. Unplug the three harnesses from control PCB as shown in photo on following page.
4. Remove the two screws.
Disassembly Procedure 7-4 Manual 0-5198
DISASSEMBLY PROCEDURE
7.04 Front Panel (Operator Interface) Circuit Board PCB3 Removal
CUTMASTER 12+
!
Read and follow safety information in Section 6.03 before proceeding with disassembly.
1. Remove the screw on the potentiometer knob.
2. Remove the nut.
3. Remove the front panel PCB.
Manual 0-5198 7-5 Disassembly Procedure
CUTMASTER 12+
7.05 Back Panel Removal
DISASSEMBLY PROCEDURE
!
Read and follow safety information in Section 6.03 before proceeding with disassembly
1. Remove screws on back panel
2. Remove the three screws
3. Terminals from supply cable.
Disconnect two terminals from switch.
4. Wires from main PCB1 .
Disconnect the two terminals from switch.
5. Goung wire terminal.
Remove the nut.
Disassembly Procedure 7-6 Manual 0-5198
DISASSEMBLY PROCEDURE
7.06 Power Switch S1 and Power Cord Removal
CUTMASTER 12+
!
Read and follow safety information in Section 6.03 before proceeding with disassembly
1. Gas inlet. Remove gas inlet from rear panel.
2. SW locking tabs
Squeeze the locking tabs and push SW out from the rear panel.
3. Loose the cable anchorage
4. Remove fan
5 Pull the Input Power Cord out.
Manual 0-5198 7-7 Disassembly Procedure
CUTMASTER 12+
7.07 Base Panel Removal
DISASSEMBLY PROCEDURE
!
Read and follow safety information in Section 6.03 before proceeding with disassembly
1. Remove Central Panel Screws.
2. Remove Main PCB assembly Screws.
Disassembly Procedure 7-8 Manual 0-5198
ASSEMBLY PROCEDURE
SECTION 8:
ASSEMBLY PROCEDURES
8.01 Installing Base Board
1. Main Power PCB assembly
2. Install main PCB assembly screws
3. Install central Panel Screws.
CUTMASTER 12+
1
3
2
Manual 0-5198 8-1
Art # A-10256
Assembly Procedures
CUTMASTER 12+
8.02 Installing Back Panel
ASSEMBLY PROCEDURES
1. Install gas inlet.
2. Install ON/OFF switch
3. Install wire cord.
4. Reconnect Input Wire on the ON/OFF switch.
5. Install fan.
6. Install ground wire.
7. Reconnect AC input wire on Main Power PCB to power ON/OFF switch.
8. Reconnect the three screws.
9. Reconnect Rear Panel screws.
1
2
3
5
9
6
4
Art # A-10257
Assembly Procedures 8-2 Manual 0-5198
ASSEMBLY PROCEDURE CUTMASTER 12+
7
8
Manual 0-5198 8-3
Art # A-10258
Assembly Procedures
CUTMASTER 12+
8.03 Installing Front Panel
ASSEMBLY PROCEDURES
1. Place front panel PCB assembly into front panel. Install the nut and screw.
2. Reconnect three harnesses to control PCB.
3. Reconnect two red wires and install the screws.
4. Install the front panel screws.
1
2
4
3
Art # A-10558
Assembly Procedures 8-4 Manual 0-5198
ASSEMBLY PROCEDURE
8.04 Installing Main Control Panel and Clear Cover Sheet
1. Install 4 screws.
2. Plug harness into HF/QF connector
3. Plug harness into MB connector
4. Plug harness into SOURCE&TIP connector
5. Plug harness into DRIVE connector
6. Plug harness into U-D connector
7. Plug harness into WA connector
8. Plug harness into FAN connector
9. Plug harness into TRANF-IFB connector
10. Plug harness into WV connector
11. Plug harness into D-PORT connector
12. Plug harness into OT connector
13. Plug harness into PRESSURE connector
14. Plug harness into GUN&TEST connector
15. Install clear protective sheet.
CUTMASTER 12+
Manual 0-5198 8-5 Assembly Procedures
CUTMASTER 12+
1
6
5
ASSEMBLY PROCEDURES
4
3
2
14
13
12
7 8 9 10 11 Art # A-10250
15
Art # A-10260
Assembly Procedures 8-6 Manual 0-5198
ASSEMBLY PROCEDURE CUTMASTER 12+
Manual 0-5198 8-7 Assembly Procedures
CUTMASTER 12+
8.05 Installing Case
1. Install Case.
2. Install Screws. Tighten screws.
1
ASSEMBLY PROCEDURES
2
Art # A-10261
Assembly Procedures 8-8 Manual 0-5198
REPLACEMENT PARTS CUTMASTER 12+
SECTION 9:
REPLACEMENT PARTS
9.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable components.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.
C. Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor.
Manual 0-5198 9-1 Replacement Parts
CUTMASTER 12+
9.02 Power Supply Replacement Parts
Item
1 1 Control
REPLACEMENT PARTS
2 1 Front Control PCB assembly
3 1 Main
9-0076
4 1 Regulator 9-0081
5 1 Solenoid
6 1 Pressure
7 1 Front
8 1 Rear
9 1 Cover
10
11 1
Current 9-0088
CM12+ Cutting Control Knob 9-0073
12 9-0074
13
14
15
16
17
18
19
20
1
1
CM12+ Carry Case (not shown)
Replacement Torch (not shown)
9-0084
7-0040
9
Art# A-09387-AE
16
8
12
15
6
4
5
1
2
11
13
14
10
3
7
Replacement Parts 9-2 Manual 0-5198
THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph: 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada
Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph: +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph: 6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph: +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812
T E C H N O L O G I E S
™
I N N O V A T I O N T O S H A P E T H E W O R L D ™
U.S. Customer Care: 800-426-1888
•
Canada Customer Care: 905-827-4515
•
International Customer Care: 940-381-1212
Form No. 0-5198 (09/03/12) © 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in USA
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Key Features
- Plasma cutting
- Compact design
- Built-in air compressor
- Variety of cutting settings
- Cutting capacity up to 3/8 inch steel
- Single-phase power
- Lightweight and portable
