Cutmaster Plasma
Cutmaster Plasma
Cutmaster Plasma
460V 600V
230V
CUTMASTER™ 52
PLASMA CUTTING SYSTEM
Operating
Manual
Art # A-08617_AD
VictorThermalDynamics.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Victor 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 distribu-
tor 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
Victor 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 Pre-
cautions. They will help you to avoid potential hazards that may exist when working with this product.
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, excel-
lent 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, operat-
ing, 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.
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.victortechnologies.com
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 negli-
gence, accident, or any other cause.
Where Purchased:__________________________________________________
Purchase Date:_____________________________________________________
i
This Page Intentionally Blank
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION............................................................................ 1-1
1.01 Notes, Cautions and Warnings......................................................................... 1-1
1.02 Important Safety Precautions.......................................................................... 1-1
1.03 Publications..................................................................................................... 1-2
1.04 Note, Attention et Avertissement...................................................................... 1-3
1.05 Precautions De Securite Importantes.............................................................. 1-3
1.06 Documents De Reference................................................................................ 1-6
1.07 Statement of Warranty..................................................................................... 1-7
SECTION 2 SYSTEM:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt Of Equipment...................................................................................... 2-1
2.04 Power Supply Specifications........................................................................... 2-2
2.05 Input Wiring Specifications.............................................................................. 2-3
2.06 Power Supply Features.................................................................................... 2-4
SECTION 2 TORCH:
INTRODUCTION ..................................................................................... 2T-1
2T.01 Scope of Manual.............................................................................................2T-1
2T.02 General Description........................................................................................2T-1
2T.03 Specifications ................................................................................................2T-1
2T.04 Options And Accessories................................................................................2T-2
2T.05 Introduction to Plasma...................................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION ........................................................................................ 3-1
3.01 Unpacking........................................................................................................ 3-1
3.02 Lifting Options................................................................................................. 3-1
3.03 Opening the Contactor Cover........................................................................... 3-1
3.04 Primary Input Power Connections................................................................... 3-1
3.05 Gas Connections.............................................................................................. 3-3
SECTION 3 TORCH:
INSTALLATION....................................................................................... 3T-1
3T.01 Torch Connections..........................................................................................3T-1
3T.02 Setting Up Mechanical Torch..........................................................................3T-1
SECTION 4 SYSTEM:
OPERATION........................................................................................... 4-1
4.01 Front Panel Controls / Features........................................................................ 4-1
4.02 Preparations for Operation............................................................................... 4-2
SECTION 4 TORCH:
OPERATION........................................................................................... 4T-1
4T.01 Torch Parts Selection......................................................................................4T-1
4T.02 Cut Quality......................................................................................................4T-1
4T.03 General Cutting Information............................................................................4T-2
TABLE OF CONTENTS
4T.04 Hand Torch Operation.....................................................................................4T-3
4T.05 Gouging..........................................................................................................4T-6
4T.06 Mechanized Torch Operation...........................................................................4T-7
4T.07 Parts Selection for Manual and Mechanized Torch Cutting.............................4T-9
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip.....4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip.....4T-13
PATENT INFORMATION.................................................................................. 4T-16
SECTION 5 SYSTEM:
SERVICE................................................................................................ 5-1
5.01 General Maintenance....................................................................................... 5-1
5.02 Maintenance Schedule..................................................................................... 5-2
5.03 Common Faults................................................................................................ 5-2
5.04 Fault Indicator.................................................................................................. 5-3
5.05 Basic Troubleshooting Guide........................................................................... 5-4
5.06 Power Supply Basic Parts Replacement.......................................................... 5-6
SECTION 5 TORCH:
SERVICE............................................................................................... 5T-1
5T.01 General Maintenance......................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts...............................5T-2
SECTION 6:
PARTS LISTS.......................................................................................... 6-1
6.01 Introduction..................................................................................................... 6-1
6.02 Ordering Information....................................................................................... 6-1
6.03 Power Supply Replacement............................................................................. 6-1
6.04 Replacement Power Supply Parts.................................................................... 6-1
6.05 Options and Accessories................................................................................. 6-2
6.06 Replacement Parts for Hand Torch ................................................................. 6-3
6.07 Replacement Parts - for Machine Torches with Unshielded Leads................... 6-4
6.08 Replacement Shielded Machine Torch Leads Assemblies ............................... 6-6
6.09 Torch Consumable Parts (SL60)...................................................................... 6-7
6.10 Torch Consumable Parts (SL100).................................................................... 6-8
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)................................................................................... A-1
APPENDIX 2: DATA TAG INFORMATION................................................................. A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS............................................................ A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS....................................................... A-4
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS................................................ A-6
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS...................................................... A-8
APPENDIX 7: PUBLICATION HISTORY..................................................................A-10
CUTMASTER 52
SECTION 1: To prevent possible injury, read, understand
and follow all warnings, safety precautions
GENERAL INFORMATION and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.
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: GASES AND FUMES
Gases and fumes produced during the plasma cutting
NOTE
process can be dangerous and hazardous to your health.
An operation, procedure, or background
information which requires additional em- • Keep all fumes and gases from the breathing area.
phasis or is helpful in efficient operation of Keep your head out of the welding fume plume.
the system. • Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
CAUTION depend on the kind of metal being used, coatings
A procedure which, if not properly followed, on the metal, and the different processes. You must
may cause damage to the equipment. be very careful when cutting or welding any metals
which may contain one or more of the following:
! WARNING
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
A procedure which, if not properly followed, Beryllium Lead Silver
may cause injury to the operator or others in Cadmium Manganese Vanadium
the operating area. • Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formation regarding the kind and amount of fumes
WARNING and gases that may be dangerous to your health.
Gives information regarding possible electri- • For information on how to test for fumes and
cal shock injury. Warnings will be enclosed gases in your workplace, refer to item 1 in "1.03
in a box such as this. Publications" on page 1-2 in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
1.02 Important Safety Precautions • Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
! WARNING
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN- • WARNING: This product contains chemicals,
GEROUS AND HAZARDOUS TO YOUR including lead, known to the State of California to
HEALTH. cause birth defects and other reproductive harm.
Wash hands after handling.
Plasma arc cutting produces intense electric
and magnetic emissions that may interfere
with the proper function of cardiac pacemak-
ELECTRIC SHOCK
ers, hearing aids, or other electronic health
equipment. Persons who work near plasma Electric Shock can injure or kill. The plasma arc process
arc cutting applications should consult their uses and produces high voltage electrical energy. This
medical health professional and the manufac- electric energy can cause severe or fatal shock to the
turer of the health equipment to determine operator or others in the workplace.
whether a hazard exists.
• Never touch any parts that are electrically “live”
or “hot.”
Manual 0-4961 GENERAL INFORMATION 1-1
CUTMASTER 52
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit. PLASMA ARC RAYS
• Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin.
• Extra care must be taken when the workplace is The plasma arc process produces very bright ultra violet
moist or damp. and infra red light. These arc rays will damage your eyes
• Install and maintain equipment according to NEC and burn your skin if you are not properly protected.
code, refer to item 9 in Section "1.03 Publi- • To protect your eyes, always wear a welding helmet
cations" on page 1-2. or shield. Also always wear safety glasses with side
• Disconnect power source before performing any shields, goggles or other protective eye wear.
service or repairs. • Wear welding gloves and suitable clothing to protect
• Read and follow all the instructions in the Operat- your skin from the arc rays and sparks.
ing Manual. • 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.
FIRE AND EXPLOSION Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or • Use the shade of lens as suggested in the following
the plasma arc. per ANSI/ASC Z49.1:
Minimum Protective Suggested
• Be sure there is no combustible or flammable mate-
Arc Current Shade No. Shade No.
rial in the workplace. Any material that cannot be
removed must be protected. Less Than 300* 8 9
• Ventilate all flammable or explosive vapors from 300 - 400* 9 12
the workplace.
400 - 800* 10 14
• Do not cut or weld on containers that may have
held combustibles. * These values apply where the actual arc
is clearly seen. Experience has shown that
• Provide a fire watch when working in an area where
lighter filters may be used when the arc is
fire hazards may exist.
hidden by the workpiece.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
! WARNING
unless the hydrogen gas can be eliminated or dis-
WARNING: This product contains chemicals, includ-
sipated. Trapped hydrogen gas that is ignited will
ing lead, known to the State of California to cause birth
cause an explosion.
defects and other reproductive harm. Wash hands after
handling.
NOISE
1.03 Publications
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits. Refer to the following standards or their latest revisions
for more information:
You must protect your ears from loud noise to prevent
permanent loss of hearing. 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
• To protect your hearing from loud noise, wear pro- ments, U.S. Government Printing Office, Washington,
tective ear plugs and/or ear muffs. Protect others D.C. 20402
in the workplace. 2. ANSI Standard Z49.1, SAFETY IN WELDING AND
• Noise levels should be measured to be sure the CUTTING, obtainable from the American Welding
decibels (sound) do not exceed safe levels. Society, 550 N.W. LeJeune Rd, Miami, FL 33126
• For information on how to test for noise, see item 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
1 in Section "1.03 Publications", in this manual. from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE
1-2 GENERAL INFORMATION Manual 0-4961
CUTMASTER 52
PROTECTION, obtainable from American National NOTE
Standards Institute, 1430 Broadway, New York, NY Toute opération, procédure ou renseigne-
10018
ment général sur lequel il importe d’insister
5. ANSI Standard Z41.1, STANDARD FOR MEN’S davantage ou qui contribue à l’efficacité de
SAFETY-TOE FOOTWEAR, obtainable from the fonctionnement du système.
American National Standards Institute, 1430 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES, ATTENTION
obtainable from American National Standards Insti- Toute procédure pouvant résulter l’endom-
tute, 1430 Broadway, New York, NY 10018 magement du matériel en cas de non-res-
7. AWS Standard A6.0, WELDING AND CUTTING pect de la procédure en question.
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
! AVERTISSEMENT
FOR WELDING, CUTTING AND ALLIED PRO- Toute procédure pouvant provoquer des bles-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269 sures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, non-respect de la procédure en question.
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro- AVERTISSEMENT
tection Association, Batterymarch Park, Quincy, MA
02269 Fournit l'information concernant des dom-
11. CGA Pamphlet P-1, SAFE HANDLING OF COM- mages possibles de choc électrique. Des
PRESSED GASES IN CYLINDERS, obtainable from avertissements seront enfermés dans une
the Compressed Gas Association, 1235 Jefferson Davis boîte de ce type.
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the 1.05 Precautions De Securite
Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W Importantes
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Asso- ! AVERTISSEMENTS
ciation, 1900 Arch Street, Philadelphia, PA 19103
L’OPÉRATION ET LA MAINTENANCE DU
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE MATÉRIEL DE SOUDAGE À L’ARC AU JET
PREPARATION FOR WELDING AND CUTTING DE PLASMA PEUVENT PRÉSENTER DES
OF CONTAINERS AND PIPING THAT HAVE HELD RISQUES ET DES DANGERS DE SANTÉ.
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Coupant à l’arc au jet de plasma produit
Miami, FL 33126 de l’énergie électrique haute tension et des
émissions magnétique qui peuvent interférer
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA- la fonction propre d’un “pacemaker” cardia-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New que, les appareils auditif, ou autre matériel
York, NY 10018 de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma
1.04 Note, Attention et Avertissement devrait consulter leur membre professionel de
médication et le manufacturier de matériel de
Dans ce manuel, les mots “note,” “attention,” et “aver- santé pour déterminer s’il existe des risques
tissement” sont utilisés pour mettre en relief des infor- de santé.
mations à caractère important. Ces mises en relief sont
classifiées comme suit :
CHOC ELECTRIQUE
FUMÉE et GAZ
Les chocs électriques peuvent blesser ou même tuer. Le
La fumée et les gaz produits par le procédé de jet de
procédé au jet de plasma requiert et produit de l’énergie
plasma peuvent présenter des risques et des dangers
électrique haute tension. Cette énergie électrique peut
de santé.
produire des chocs graves, voire mortels, pour l’opérateur
• Eloignez toute fumée et gaz de votre zone de respi- et les autres personnes sur le lieu de travail.
ration. Gardez votre tête hors de la plume de fumée
• Ne touchez jamais une pièce “sous tension” ou “vive”;
provenant du chalumeau.
portez des gants et des vêtements secs. Isolez-vous
• Utilisez un appareil respiratoire à alimentation en air de la pièce de travail ou des autres parties du circuit
si l’aération fournie ne permet pas d’éliminer la fumée de soudage.
et les gaz.
• Réparez ou remplacez toute pièce usée ou endomma-
• Les sortes de gaz et de fumée provenant de l’arc de gée.
plasma dépendent du genre de métal utilisé, des
• Prenez des soins particuliers lorsque la zone de travail
revêtements se trouvant sur le métal et des différents
est humide ou moite.
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un • Montez et maintenez le matériel conformément au
ou plusieurs des éléments suivants: Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
antimoine cadmium mercure
argent chrome nickel • Débranchez l’alimentation électrique avant tout tra-
arsenic cobalt plomb vail d’entretien ou de réparation.
baryum cuivre sélénium
béryllium manganèse vanadium • Lisez et respectez toutes les consignes du Manuel de
consignes.
• 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 INCENDIE ET EXPLOSION
quantité et la nature de la fumée et des gaz pouvant Les incendies et les explosions peuvent résulter des
poser des dangers de santé. scories chaudes, des étincelles ou de l’arc de plasma. Le
• Pour des informations sur la manière de tester la procédé à l’arc de plasma produit du métal, des étincelles,
fumée et les gaz de votre lieu de travail, consultez des scories chaudes pouvant mettre le feu aux matiè-
l’article 1 et les documents cités à la page 5. res combustibles ou provoquer l’explosion de fumées
inflammables.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour • Soyez certain qu’aucune matière combustible ou
capter la fumée et les gaz. inflammable ne se trouve sur le lieu de travail. Proté-
gez toute telle matière qu’il est impossible de retirer
• N’utilisez pas le chalumeau au jet de plasma dans de la zone de travail.
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs. • 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.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance
of any Victor Thermal Dynamics product.
This warranty is invalid if the Victor Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007
! WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
WARNING
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed in
a box such as this.
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the
output voltage (DC) is higher than shown in this chart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These speci-
fications 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.
10.75"
273 mm
Art # A-07941
Art # A-07925_AB
16.375"
416 mm
6"
150 mm
24"
610 mm
22.5"
0.57 m
6" 6"
43 lb / 19.5 kg 150 mm 150 mm
Flexible Cord
Volts Hz kVA I max I1eff Fuse (amps) (Min. AWG)
208 60 10.4 47 30 50 10
1 Phase 230 60 10.8 45 29 50 10
460 60 15.2 31 20 35 12
208 60 5.4 26 17 30 12
230 50/60 5.8 24 16 30 12
380 50/60 6.1 16 11 20 14
3 Phase
400 50/60 6.4 16 11 20 14
460 60 7.4 16 10 20 12
600 60 7.8 13 11 15 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
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.
Control Panel
Art # A-07942
Work Cable
and Clamp
Filter Assembly
Art # A-07981
Input Power Cord
INTRODUCTION
2T.01 Scope of Manual
3.75"
This manual contains descriptions, operating instruc- (95 mm)
Art # A-03322_AB
tions and maintenance procedures for the 1Torch Models
SL60/Manual and SL100/Mechanized Plasma Cut- 1.17" (29 mm)
ting Torches. Service of this equipment is restricted to 2. Mechanized Torch, Model
properly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or adjust- The standard machine torch has a positioning
ments not covered in this manual, at the risk of voiding tube with rack & pinch block assembly.
the Warranty. 15.875" / 403 mm
9.285" / 236 mm
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. 1.375" / 35 mm 1.175" / 30 mm
4.95" / 126 mm
1.75" /
2T.02 General Description 44.5 mm
0.625" /
16 mm Art # A-02998
Plasma torches are similar in design to the automotive B. Torch Leads Lengths
spark plug. They consist of negative and positive sec-
tions separated by a center insulator. Inside the torch, Hand Torches are available as follows:
the pilot arc starts in the gap between the negatively
• 20 ft / 6.1 m, with ATC connectors
charged electrode and the positively charged tip. Once
the pilot arc has ionized the plasma gas, the superheated • 50 ft / 15.2 m, with ATC connectors
column of gas flows through the small orifice in the torch Machine Torches are available as follows:
tip, which is focused on the metal to be cut.
• 5 foot / 1.5 m, with ATC connectors
A single torch lead provides gas from a single source
to be used as both the plasma and secondary gas. The • 10 foot / 3.05 m, with ATC connectors
air flow is divided inside the torch head. Single - gas • 25 foot / 7.6 m, with ATC connectors
operation provides a smaller sized torch and inexpensive
• 50 foot / 15.2 m, with ATC connectors
operation.
C. Torch Parts
NOTE Starter Cartridge, Electrode, Tip, Shield Cup
Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of D. Parts - In - Place (PIP)
plasma torch operation. Torch Head has built - in switch
Refer to the Appendix Pages for additional
specifications as related to the Power Sup- 12 VDC circuit rating
ply used. E. Type Cooling
G. Gas Requirements
Manual and Mechanized Torch Gas Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure 60 - 95 psi
Refer to NOTE 4.1 - 6.5 bar _
Maximum Input Pressure 125 psi / 8.6 bar Power
300 - 500 scfh Supply A
Gas Flow (Cutting and Gouging)
142 - 235 lpm +
! WARNING
B
Art # A-08168
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes Automation Torch
a switch. The torch will not operate if this switch
is open.
To ATC PIP Switch Shield Cup
Torch Switch Torch Trigger
To Control
Cable Wiring
PIP Switch Shield Cup Parts - In - Place Circuit Diagram for Machine Torch
A-02997
3.01 Unpacking
2
1
2
1. Use the packing lists to identify and account for
each item.
2. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor and
/ or shipping company before proceeding with
the installation. Art# A-11478
Contactor cover
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. 3.04 Primary Input Power Connections
! WARNING
unit for correct setting before plugging in
or connecting the unit. The primary power
source, fuse, and any extension cords used
Do not touch live electrical parts. must conform to local electrical code and the
recommended circuit protection and wiring
Disconnect input power cord before moving
requirements as specified in Section 2.
unit.
FALLING EQUIPMENT can cause serious Most units are shipped from the factory with a 230Volt
personal injury and can damage equipment. input power cable wired to the input contactor in the
single - phase configuration. The following illustrations
HANDLE is not for mechanical lifting. and directions are for changing that configuration to a
different voltage and or to three - phase operation or
back again if a change had already been made.
• Only persons of adequate physical strength should
Single-Phase (1ø) and Jumper Settings
lift the unit.
• Lift unit by the handles, using two hands. Do not
Jumper L1 -L4
use straps for lifting. L1 L1
3.03 Opening the Contactor Cover Single Phase Input Power Wiring
The input power cord is connected to the main contactor, Three-Phase (3ø) and Jumper Settings
the contactor is located inside a box with a snap on cover.
Store copper jumper in spare parts box
The cover is held in place with two or more snap lock
tabs. To remove the cover release the front latch and tilt L1 L1 Jumper L1 -L4
the cover up about ½ inch. Then squeeze both sides of L2 L2
the cover and lift it straight up. See the Primary Input
Art # A-07983_AB
L3
Power Connections section for the necessary changes to L3
L4
the Contactor. Remember to replace the Contactor Cover L4
GND
when the changes are complete.
WARNING
WARNING
Disconnect input power from the power
Disconnect input power from the power
supply and input cable before attempting
supply and input cable before attempting
this procedure.
this procedure.
These instructions are for changing the input power and These instructions are for changing the input power and
or cable on the 208/230, 400, 460 VAC Power Supply to or cable on the 208/230, 400, 460 VAC Power Supply to
Single - Phase input power. Three - Phase input power.
1. Remove the Power Supply cover per instructions 1. Remove the Power Supply cover per instructions
found in Section 5. found in Section 5.
2. Disconnect the original input power cable from 2. Disconnect the original input power cable from
the main input contactor and the chassis ground the main input contactor and the chassis ground
connection. connection.
3. Loosen the through - hole protector on the back 3. Loosen the through - hole protector on the back
panel of the power supply. Pull the original panel of the power supply. Pull the original
power cable out of power supply. power cable out of the power supply.
4. If the power cable being used is not the factory 4. Using a customer supplied four - conductor input
- supplied cable, use a three - conductor input power cable for the voltage desired, strip back
power cable for the voltage desired and strip the insulation on the individual wires.
back the insulation on the individual wires.
5. Pass the cable being used through the access
5. Pass the cable being used through the access opening in the back panel of the power supply.
opening in the back panel of the power supply. Refer to Section 2 for power cable specifications.
Refer to Section 2 for power cable specifications.
CAUTION
CAUTION
The primary power source and power cable
The primary power source and power cable must conform to local electrical code and the
must conform to local electrical code and the recommended circuit protection and wiring
recommended circuit protection and wiring requirements (refer to table in Section 2).
requirements (refer to table in Section 2).
6. Connect the wires as follows.
6. Connect the wires as follows.
• Set Jumper wires on the contactor. See previ-
• Set Jumper wires on the contactor. See previ- ous illustrations..
ous illustrations.
• Green / Yellow wire to Ground.
• Green / Yellow wire to Ground.
• Remaining wires to L1, L2 and L3 input. It
• Remaining wires to L1 and L2 input. It does does not matter what order these wires are
not matter what order these wires are at- attached.
tached.
NOTE
For a secure seal, apply thread sealant to the Hose Clamp
fitting threads, according to manufacturer's
Gas Supply 1/4 NPT to 1/4"
instructions. Do not use Teflon tape as a
Hose (6mm) Fitting
thread sealer, as small particles of the tape
may break off and block the small air pas- Optional Single - Stage Filter Installation
sages in the torch.
Installing Optional Two - Stage Air Filter Kit
Regulator/Filter
Assembly This optional two - stage air line filter is also for use on
compressed air shop systems. Filter removes moisture
and contaminants to at least 5 microns.
Inlet Port
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back
Hose Clamp of the power supply per instructions supplied
1/4 NPT or ISO-R with the filter assembly.
to 1/4” (6mm) Fitting
Gas Supply
Hose NOTE
For a secure seal, apply thread sealant to the
fitting threads according to manufacturer's
instructions. Do Not use Teflon tape as a
Art # A-07943
thread sealer as small particles of the tape
Air Connection to Inlet Port may break off and block the small air pas-
sages in the torch.
Installing Optional Single - Stage Air Filter 2. Connect the two stage filter outlet hose to the
An optional filter kit is recommended for improved fil- inlet port of the Regulator / Filter Assembly.
tering with compressed air, to keep moisture and debris 3. Use customer - supplied fittings to connect the air
out of the torch. line to the Filter. A 1/4 NPT to 1/4" hose barbed
1. Attach the Single - Stage Filter Hose to the Inlet fitting is shown as an example.
Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the air line to the Filter. The illustration
shows typical fittings as an example.
Manual 0-4961 INSTALLATION 3-3
CUTMASTER 52
Regulator/Filter
Assembly
2-Stage Filter
Regulator Inlet Port (IN)
Input
Outlet Port
(OUT)
Two Stage
Filter
Hose Clamp Assembly
Gas Supply
Hose
Art # A-07945_AC
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure 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
air passages in the torch.
WARNING
Disconnect primary power at the source be- WARNING
fore connecting the torch.
Disconnect primary power at the source be-
fore disassembling the torch or torch leads.
1. Align the ATC male connector (on the torch lead)
with the female receptacle. Push the male con-
The mechanical torch includes a positioning tube with
nector into the female receptacle. The connectors
rack and pinch block assembly.
should push together with a small amount of
pressure. 1. Mount the torch assembly on the cutting table.
2. Secure the connection by turning the locking nut 2. To obtain a clean vertical cut, use a square to
clockwise until it clicks. DO NOT use the locking align the torch perpendicular to the surface of
nut to pull the connection together. Do not use the workpiece.
tools to secure the connection.
Pinch Block
Assembly
2 Square
1
Art # A-07885
Workpiece
A-02585
OPERATION
4.01 Front Panel Controls / Features
A
MIN MAX
PSI BAR
cutting.
2. Function Control
Function Control Knob; Used to select between the
different operating modes. Art# A-07886
5 6 7 8 9 10
SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.
6. Temp Indicator
RUN Used for general cutting operations
Indicator is normally OFF. Indicator is ON when
RAPID AUTO RESTART Allows for faster internal temperature exceeds normal limits. Let the
restarting of the Pilot Arc for uninterrupted cutting. unit cool before continuing operation.
5. AC Indicator 85 5.9
80 5.5
Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in pro- 75 5.2
Art # A-08170
At the start of each operating session: Place the Power Supply ON / OFF switch to the ON
(up) position. AC indicator turns ON. Gas
+
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.
MIN MIN
Art# A-07946
Art # A-04509
SL60 Shutdown
Leads Length
(Hand Torch)
Up to 25' 80 psi Turn the ON / OFF switch to OFF
(7.6 m) 5.5 bar (down). All Power Supply indicators shut OFF.
Unplug the input power cord or disconnect input
Each additional 25' Add 5 psi power. Power is removed from the system.
(7.6 m) 0.4 bar
RUN ,
Electrode
4T.01 Torch Parts Selection
Depending on the type of operation to be done deter-
mines the torch parts to be used. Start Cartridge
Type of operation:
Drag cutting, standoff cutting or gouging Tip
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter Shield Cup
Cartridge
A-03510_AB
NOTE Torch Parts (Drag Shield Cap & Shield Cup Body Shown)
Refer to Section 4T.07 and following for ad-
ditional information on torch parts. 3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.
Change the torch parts for a different operation as fol-
4. Install the starter cartridge and desired tip for
lows:
the operation into the torch head.
5. Hand tighten the shield cup assembly until it
WARNING is seated on the torch head. If resistance is felt
when installing the cup, check the threads before
Disconnect primary power at the source be- proceeding.
fore assembling or disassembling torch parts,
or torch and leads assemblies.
4T.02 Cut Quality
NOTE
NOTE
Cut quality depends heavily on setup and
The shield cup holds the tip and starter car- parameters such as torch standoff, alignment
tridge in place. Position the torch with the with the workpiece, cutting speed, gas pres-
shield cup facing upward to keep these parts sures, and operator ability.
from falling out when the cup is removed.
Cut quality requirements differ depending on applica-
1. Unscrew and remove the shield cup assembly tion. For instance, nitride build - up and bevel angle
from the torch head. may be major factors when the surface will be welded
2. Remove the Electrode by pulling it straight out after cutting. Dross - free cutting is important when fin-
of the Torch Head. ish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are
illustrated in the following figure:
Trigger Release
Non-Conductive
Straight Edge
Cutting Guide
3
4 A-03539
4
Trigger
Art # A-03383
! WARNING
Lead Angle
The angle between the torch and workpiece depends
Be sure the operator is equipped with proper on the output current setting and torch travel speed.
gloves, clothing, eye and ear protection and The recommended lead angle is 35°. At a lead angle
that all safety precautions at the front of this greater than 45° the molten metal will not be blown
manual have been followed. Make sure no out of the gouge and may be blown back onto the
part of the operator’s body comes in contact torch. If the lead angle is too small (less than 35°),
with the workpiece when the torch is acti- less material may be removed, requiring more pass-
vated. es. In some applications, such as removing welds
Disconnect primary power to the system or working with light metal, this may be desirable.
before disassembling the torch, leads, or
power supply.
Torch Head
CAUTION
35°
Sparks from plasma gouging can cause dam-
age to coated, painted or other surfaces such
as glass, plastic, and metal.
Standoff Height
Check torch parts. The torch parts must cor-
respond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection. Workpiece
A-00941_AB
Gouging Parameters
Gouging Angle and Standoff Distance
Gouging performance depends on parameters
such as torch travel speed, current level, lead angle Standoff Distance
(the angle between the torch and workpiece), and
the distance between the torch tip and workpiece The tip to work distance affects gouge quality and
(standoff). depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
mm) allows for smooth, consistent metal removal.
Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater
than 1/4 inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.
Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el
Straight Arc
Trailing Arc
A-02586
Leading Arc
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
Shield Cap, Deflector
CUTTING Tip:
9-8237
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
CutMaster 152 uses 120A and less
Tip Gouging D 9-8228 (60 - 120 Amps)
Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Speed (Per Plasma Gas Pierce
Thickness Tip Output Amperage Standoff Flow (CFH) Pierce
Minute) Press Height
(Cat. Volts Delay
Inches (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm No.) (VDC) (Sec)
0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Speed (Per Plasma Gas Pierce
Thickness Tip Output Amperage Standoff Flow (CFH) Pierce
Minute) Press Height
(Cat. Volts Delay
Inches (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm No.) (VDC) (Sec)
0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 75 5.2 90 245 NR NR NR
NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
Section "Set Operating Pressure" on page 4-2.
** Total flow rate includes plasma and secondary gas flow.
Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Speed (Per Plasma Gas Pierce
Thickness Tip Output Amperage Standoff Flow (CFH) Pierce
Minute) Press Height
(Cat. Volts Delay
Inches (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm No.) (VDC) (Sec)
0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR
NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
Section "Set Operating Pressure" on page 4-2.
** Total flow rate includes plasma and secondary gas flow.
The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:
Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap
Each Use
Visual check of
torch tip and electrode
Weekly
3 Months
Replace all
Clean
broken parts
exterior
of power supply
6 Months
Art # A-07938_AB
2. Inspect torch for any cracks or exposed wires, Excessive Dross 1. Cutting speed too slow.
replace if necessary. Formation 2. Torch standoff too high from
workpiece.
3. Inspect input power cable for damage or exposed 3. Worn torch parts.
wires, replace if necessary. 4. Improper cutting current.
Six Months or Every 720 Cutting Hours: 5. Non - Genuine Thermal Dynamics
parts used
1. Check the in-line air filter(s), clean or replace as 6. Incorrect gas pressure
required.
Short Torch Parts Life 1. Oil or moisture in air source.
2. Check cables and hoses for leaks or cracks, re- 2. Exceeding system capability
place if necessary. (material too thick).
3. Excessive pilot arc time
3. Check all contactor points for severe arcing or
4. Gas pressure too low.
pits, replace if necessary.
5. Improperly assembled torch.
4. Vacuum dust and dirt out of the entire machine. 6. Non - Genuine Thermal Dynamics
parts used
Difficult Starting 1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
CAUTION parts used.
Do not blow air into the power supply during 3. Incorrect gas pressure.
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive
electrical components and cause damage to
the unit.
7
6
5 MIN
A
MAX
PSI
MAX
BAR
MAX
+
4
3
2
1 MIN MIN
0
!
Art# A-07988
1 2 3 4 5
When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights
depending on what the fault is. The following table explains each of those Faults.
Pressure Fault
Indicator
Max Over Pressure
90 Internal Error
85 Shorted Torch
80 Consumables Missing
75 Start Error
70 Parts in Place
65 Input Power
Min Under Pressure
NOTE
Fault explanations are covered in the following tables.
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and troubleshooting
techniques.
FAULT and 70 PSI 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
indicators flashing. 2. Torch not properly connected to 2. Insure torch ATC is securely fastened to unit.
power supply.
3. Problem in torch and leads PIP 3. Replace torch and leads or return to authorized service center
circuit. for repair or replacement.
4. Failed components in unit. 4. Return to authorized service center for repair or replacement.
FAULT and 75 PSI 1. Start signal is active when ON/ 1. Start can be active for one of the following:
indicators flashing. OFF SWITCH is turned to ON • Hand torch switch held closed
position. • Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service center
switch circuit. for repair or replacement.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.
5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6. Return to authorized service center for repair or
replacement.
Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC Controller device not 2. Contact Controller manufacturer.
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit. 3. Return to authorized service center for repair or
DC LED OFF. replacement.
FAULT and 85 PSI 1. Upper O-ring on torch head is in 1. Remove shield cup from torch; check upper O-ring position;
indicators flashing. wrong position. correct if necessary.
2. Torch starter cartridge is stuck. 2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Worn or faulty torch parts. 3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch. 4. Replace torch and leads or return to an authorized service
center for repair.
5. Temporary Short indicated by 5 5. Release torch switch and reactivate.
blinks per second.
6. Power Supply Failure (Standard 6. Return to authorized service center for repair or
rate of blinking) replacement.
No Fault lights ON, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 85 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service center
for repair.
Pilot arc is ON but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.
Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in Section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.
Upper
Screws
Lower 1
Screws
Slots
Lower
Screws
Art # A-07989
Art # A-07947
NOTE Filter
Element
If replacing or cleaning just the filter element (Cat. No. 9-7741)
refer to the following illustration for disas-
sembly. Spring
O-ring
(Cat. No. 9-7743) Assembled Filter
Cover
Barbed
Filter Element Fitting Art # A-02476
Art # A-02942
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4
above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque
may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom fitting is normal.
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.
CAUTION
Art #A-03791 O-Ring
Dry the torch thoroughly before reinstalling.
ATC O-Ring
O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male Con- NOTE
nector requires lubrication on a scheduled basis.
DO NOT use other lubricants or grease, they
This will allow the O-Rings to remain pliable and
may not be designed to operate within high
provide a proper seal. The O-Rings will dry out,
temperatures or may contain “unknown ele-
becoming hard and cracked if the lubricant is not
ments” that may react with the atmosphere.
used on a regular basis. This can lead to potential
This reaction can leave contaminants inside
performance problems.
the torch. Either of these conditions can lead
It is recommended to apply a very light film of O- to inconsistent performance or poor parts life.
Ring lubricant (Catalog # 8-4025) to the O-Rings on
a weekly basis.
NOTE
Slag built up on the shield cup that cannot Art # A-08064_AC
be removed may effect the performance of
the system. 6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
2. Inspect the cup for damage. Wipe it clean or Refer to the following figure.
replace if damaged.
New Electrode
Art # A-08067
Shield Cups
Worn Electrode
3. On torches with a shield cup body and a shield Art # A-03284
Art # A-03878
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit
5
6
3
Art # A-07993_AB
10
10
1
2 11
3
12
4
13
5&6
A-07994_AB
A-03684
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
Shield Cap, Deflector
CUTTING Tip:
9-8237
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
CutMaster 152 uses 120A and less
Tip Gouging D 9-8228 (60 - 120 Amps)
Ohmic Clip
Automation Torch
Ohmic Clip 9-8224
Manual Torch
9-8259
20-40A Tip:
Shield
Cup Body, Shield Cap, Machine
STANDOFF 40A 9-8245
9-8237
CUTTING
50-60A Tips:
Shield
Cup Body,
STANDOFF Shield Cap, Machine
CUTTING 9-8237
50-60A 9-8238
40-120A
GOUGING Shield
Cup Body,
9-8237
Tips:
Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288_AB
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.
5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot
Art # A-03799
Art # A-03797
Art # A-03798
J3
1
2
3
T1
K5, K6 K1-K4
J12
1
2
3
PRI 2 PRI 1 PRI 4 PRI 3
+12VDC
D
B A D C
/460
/230
BIAS
SUPPLY
J1 MTH1 MTH2
SW1
1 3 1
2
3 Q1
4
2 4 5
K1
RESISTORS
INRUSH
C1-C4* +
/INRUSH
D1
MTH3 MTH4
W1
AC1
* PRIMARY L1 7
AC INPUT L1 T1
AC2
L2 8
K1 K2 K5 K6 K3 K4
L2 T2
JUMPER AC3
L3 9
L3 T3
GND 7A
L4 T4 MTH6 MTH8
Q2
C
SW2
J3 MTH5 MTH7
1 460_IN
2
INPUT VOLTAGE SELECTOR * CM52 & A40
(Closed for 230VAC input) C3 & C5 not installed
24VAC
PCB2 INPUT CAPACITOR PCB
5
J6
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D
J5
1
2
3
J2
40 CIRCUIT
RIBBON CABLE
J1
38 COMMON L-M J3
1
2
3
5 4 3 2
1TORCH
L1
PIP SWITCH
J11
1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH
TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1
-
E64
ELECTRODE1
D3
+
TIP1 E35
Q5
PILOT IGBT
WORK1
WORK
J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7
J2
J10 P10 14
1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1
B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3
J7 To -V OUT 1
1
2
1
2
J8 J3
on PCB1
E1 J2
1
2
P10 J1 3
+12VDC
4 } /START / STOP
1 1 5 (-)
+ FAN - + FAN - 2 2 6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
}(+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14
AUTOMATION
PCB4 INTERFACE PCB
A-09131_AC A
*CHOKE RESISTORS
INRUSH
EMI + C1-C4*
/INRUSH
* CEONLY
UNITS D1
MTH3
*FILTER
EMI
W1
MTH4
AC1
7
L1 1 1
L1 T1
AC2
8
L2 2 2
L2 T2
AC3
9
L3 3 3
L3 T3
7A
GND 4 4 L4 T4 MTH6 MTH8
Q2
C
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS: + C5-C8*
USE L1, L2, L3 & GND
MTH7 MTH5
PCB2
INPUT CAPACITOR PCB
24VAC
5 *CM52/12mm/20mm/A40
J6
C3 & C5 may not be installed
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D
J5
1
2
3
J2
40 CIRCUIT
RIBBON CABLE
J1
38 COMMON L-M J3
1
2
3
5 4
3 2 1
TS1
T1
1TORCH
L1
PIP SWITCH
J11
1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH
TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1
-
E64
ELECTRODE1
+
D3
TIP1 E35
Q5
PILOT IGBT
WORK1
WORK
J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7
J2
J10 P10 14
1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1
B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3
J7 To -V OUT 1
1
2
1
2
J8 J3
on PCB1
E1 J2
1
2
P10 J1 3
+12VDC
4
} /START / STOP
(-)
+ FAN - + FAN -
1
2
1
2
5
6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
} (+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14
AUTOMATION
PCB4 INTERFACE PCB
A-09133_AD A
Miami, FL USA
Sales Office, Latin America
Ph 1-954-727-8371
Fax: 1-954-727-8376
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