CutMaster True Service Manual - Victor Technologies - Europe

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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 agency call 1-800-426- 1888, or visit us on the web at www.thermal-dynamics.com. This Operating 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. 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 Thermadyne Industries Inc. We distinguish ourselves from our competition through marketleading, 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 35mm SL100 1Torch Service Manual Number 0-5083 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2008 by Thermadyne Corporation 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: December 9, 2008 Revision AB Date: May 29, 2009 Record the following information for Warranty purposes: Where Purchased:_______________________________ ________________ Purchase Date:__________________________________ ________________ Power Supply Serial #:___________________________ ________________ Torch Serial #:___________________________________ ________________ i
Page 1: 35mm CUTMASTER PLASMA CUTTING SYST
Page 5 and 6: TABLE OF CONTENTS SECTION 1:GENERAL
Page 7 and 8: TABLE OF CONTENTS APPENDIX 1: SEQUE
Page 9 and 10: SECTION 1: GENERAL INFORMATION 1.01
Page 11 and 12: 14. American Welding Society Standa
Page 13 and 14: 1.06 Documents De Reference Consult
Page 15 and 16: 1.08 Statement of Warranty CUTMASTE
Page 17 and 18: SECTION 2 SYSTEM: INTRODUCTION 2.01
Page 19 and 20: 2.05 Input Wiring Specifications 3
Page 21 and 22: SECTION 2 TORCH: INTRODUCTION 2T.01
Page 23 and 24: B. Gas Distribution The single gas
Page 25 and 26: 3.01 Unpacking SECTION 3 SYSTEM: IN
Page 27 and 28: For CE units: EMC Input Power Filte
Page 29 and 30: Installing Optional Single - Stage
Page 31 and 32: SECTION 3 TORCH: INSTALLATION 3T.01
Page 33 and 34: SECTION 4 SYSTEM: OPERATION 4.01 Fr
Page 35 and 36: STANDOFF CutMaster 35mm Gas Pressur
Page 37 and 38: SECTION 4 TORCH: OPERATION 4T.01 To
Page 39 and 40: Torch Standoff Improper standoff (t
Page 41 and 42: Shield Cup With Straight Edge The d
Page 43 and 44: 4T.05 Gouging ! WARNINGS Be sure th
Page 45 and 46: 4T.07 Parts Selection for SL100Torc
Page 47 and 48: CUTMASTER 35mm Type Torch: SL100 Wi
Page 53 and 54:
CUTMASTER 35mm Type Torch: SL100 Wi
Page 55 and 56:
Catalog # Description Patent(s) 9-8
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5.01 General Maintenance SECTION 5
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5.04 Fault Indicator At initial pow
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This Page Intentionally Blank CUTMA
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Problem - Symptom Possible Cause Re
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If all of the Pre Power-Up Tests ar
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11. Open the torch switch • DC LE
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3. Open or improperly connected rib
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L. AC LED on, TEMP, GAS, DC LED's a
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5.08 Pilot Arc Problems A. AC LED o
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should drop to less than 1vdc when
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C. Main arc transfers but current c
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D. PCB 2 Capacitor / Relay Test 1.
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J. PCB 2 Capacitor / Relay Test (wi
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Page 85 and 86:
CUTMASTER 35mm Signal Source/Destin
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Page 89 and 90:
A. CAPACITOR PCB 2 SIGNALS J1-1 +12
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B. LOGIC PCB 3 LED INDICATORS NORMA
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J2-1 +12VDC Supply for Fan MOT3 J2-
Page 95 and 96:
NOT USED TO MOT3 TO MOT2 (40A PCB J
Page 97 and 98:
SECTION 5 TORCH: SERVICE 5T.01 Gene
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6.01 Introduction A. Parts List Bre
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6.05 Front Panel Replacement Parts
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6.07 Right Side Replacement Parts C
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6.09 Replacement Parts for Hand Tor
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1 2 3 12 4 10 10 11 5 9 CUTMASTER 3
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SECTION 7: REPLACEMENT PROCEDURES 7
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7.05 Front Panel Parts Replacement
Page 113 and 114:
B. Main Transformer (T1) Replacemen
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5. Remove the fitting from the filt
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6. Install the replacement Contacto
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ACTION: Close external disconnect s
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APPENDIX 3: TORCH PIN - OUT DIAGRAM
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C. Automation Torch Connection Diag
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3 3 SEC1 SEC1 D2 TS1 +12VDC NTC D59
Page 127 and 128:
GLOBAL CUSTOMER SERVICE CONTACT The
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