CutMaster True Service Manual - Victor Technologies - Europe

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CUTMASTER 35mm 2.06 Power Supply Features Art # A-08359 Filter Assembly Gas Inlet Port Input Power Cord Handle and Leads Wrap Control Panel Port for Optional Automation Interface Cable Torch Leads Receptacle Work Cable and Clamp Art # A-08547 INTRODUCTION 2-4 Manual 0-5083
SECTION 2 TORCH: INTRODUCTION 2T.01 Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL100/Manual and SL100/Mechanized Plasma Cutting Torches. 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. 2T.02 General Description Plasma torches are similar in design to the automotive spark plug. They consist of negative and positive sections separated by a center insulator. Inside the torch, the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas flows through the small orifice in the torch tip, which is focused on the metal to be cut. A single torch lead provides gas from a single source to be used as both the plasma and secondary gas. The air flow is divided inside the torch head. Single - gas operation provides a smaller sized torch and inexpensive operation. NOTE Refer to Section 2T.05, Introduction To Plasma, for a more detailed description of plasma torch operation. Refer to the Appendix Pages for additional specifications as related to the Power Supply used. 2T.03 Specifications A. Torch Configurations 1. Hand/Manual Torch, Models CUTMASTER 35mm The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly. 3.75" (95 mm) 10.125" (257 mm) 1.17" (29 mm) 2. Mechanized Torch, Model Art # A-03322_AB The standard machine torch has a positioning tube with rack & pinch block assembly. 1.75" / 44.5 mm 1.375" / 35 mm 0.625" / 16 mm B. Torch Leads Lengths 15.875" / 403 mm 9.285" / 236 mm 4.95" / 126 mm 1.175" / 30 mm Hand Torches are available as follows: • 20 ft / 6.1 m, with ATC connectors Art # A-02998 • 50 ft / 15.2 m, with ATC connectors Machine Torches are available as follows: • 5 foot / 1.5 m, with ATC connectors • 10 foot / 3.05 m, with ATC connectors • 25 foot / 7.6 m, with ATC connectors • 50 foot / 15.2 m, with ATC connectors C. Torch Parts Starter Cartridge, Electrode, Tip, Shield Cup D. Parts - In - Place (PIP) Torch Head has built - in switch 12 vdc circuit rating E. Type Cooling Combination of ambient air and gas stream through torch. Manual 0-5083 2T-1 INTRODUCTION
Page 1 and 2: 35mm CUTMASTER PLASMA CUTTING SYST
Page 3 and 4: ! WARNINGS Read and understand this
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: 2.05 Input Wiring Specifications 3
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 55 and 56: Catalog # Description Patent(s) 9-8
Page 57 and 58: 5.01 General Maintenance SECTION 5
Page 59 and 60: 5.04 Fault Indicator At initial pow
Page 61 and 62: This Page Intentionally Blank CUTMA
Page 63 and 64: Problem - Symptom Possible Cause Re
Page 65 and 66: If all of the Pre Power-Up Tests ar
Page 67 and 68: 11. Open the torch switch • DC LE
Page 69 and 70: 3. Open or improperly connected rib
Page 71 and 72:
L. AC LED on, TEMP, GAS, DC LED's a
Page 73 and 74:
5.08 Pilot Arc Problems A. AC LED o
Page 75 and 76:
should drop to less than 1vdc when
Page 77 and 78:
C. Main arc transfers but current c
Page 79 and 80:
D. PCB 2 Capacitor / Relay Test 1.
Page 81 and 82:
J. PCB 2 Capacitor / Relay Test (wi
Page 83 and 84:
This Page Intentionally Blank CUTMA
Page 85 and 86:
CUTMASTER 35mm Signal Source/Destin
Page 87 and 88:
This Page Intentionally Blank CUTMA
Page 89 and 90:
A. CAPACITOR PCB 2 SIGNALS J1-1 +12
Page 91 and 92:
B. LOGIC PCB 3 LED INDICATORS NORMA
Page 93 and 94:
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
Page 99 and 100:
6.01 Introduction A. Parts List Bre
Page 101 and 102:
6.05 Front Panel Replacement Parts
Page 103 and 104:
6.07 Right Side Replacement Parts C
Page 105 and 106:
6.09 Replacement Parts for Hand Tor
Page 107 and 108:
1 2 3 12 4 10 10 11 5 9 CUTMASTER 3
Page 109 and 110:
SECTION 7: REPLACEMENT PROCEDURES 7
Page 111 and 112:
7.05 Front Panel Parts Replacement
Page 113 and 114:
B. Main Transformer (T1) Replacemen
Page 115 and 116:
5. Remove the fitting from the filt
Page 117 and 118:
6. Install the replacement Contacto
Page 119 and 120:
ACTION: Close external disconnect s
Page 121 and 122:
APPENDIX 3: TORCH PIN - OUT DIAGRAM
Page 123 and 124:
C. Automation Torch Connection Diag
Page 125 and 126:
3 3 SEC1 SEC1 D2 TS1 +12VDC NTC D59
Page 127 and 128:
GLOBAL CUSTOMER SERVICE CONTACT The
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