Product Manual

ManualsBrandsThermal Dynamics ManualsPlasma CuttersCutmaster 82 Plasma Cutter — Inverter, 230V, 55-80 Amp Output

Manual 0-5185

Scope

This kit is for use only with Victor Thermal Dynamics

CutMaster

Plasma Cutting Power Supplies listed above.

Do not use this kit with any other equipment.

Supplied Parts

The kits include:

• Contactor

• Contactor,2pieceenclosure

• Contactor,coilharness

• Contactorwires

• Installationinstructions

Tools Required

T-20Torxdriverwithminimum4”(100mm)

Needle nosed pliers

Diagonal cutters.

Instructions

WARNINGS

Disconnect primary power at the source before

performing any inspection or repairs.

Only a qualiﬁed technician should perform

this procedure.

Follow the electrostatic discharge instructions

included with the component to prevent dam-

age to the component.

Main PCB Removal

NOTE:

Keep all hardware for remounting and attach-

ing components and wires.

Throughout the rest of this instruction guide

theterms“Smaller”and“Larger”willbeused

referring to the power supply as follows:

Smaller-CM52,CM82,A40,A60,12mm,

20mmand25mm

Larger- CM102, CM152,A80,A120, 35mm

and40mm

1. Removethepowersupplycover.10Torxscrews.Do

not lose any and note the difference in them and where

they came from. See following two illustrations.

Upper

Screws

Lower

Screws

Lower

Screws

Art # A-08317

Slots

Figure1

OriginalPublicationDate:2011 Manualno.:0-5185

RevisionDate:3/18/2014   Revision:AD

CutMaster

52, 82, 102, 152,

A40, A60, A80, A120, 12mm,

20mm, 25mm, 35mm and 40mm

Replacement Kit: 9-8587

Installation Instructions

Summary of content (12 pages)

PAGE 1
CutMasterTM 52, 82, 102, 152, A40, A60, A80, A120, 12mm, 20mm, 25mm, 35mm and 40mm Replacement Kit: 9-8587 Original Publication Date: 2011 Revision Date: 3/18/2014 Manual no.: 0-5185 Revision: AD Scope Installation Instructions Main PCB Removal This kit is for use only with Victor Thermal Dynamics CutMasterTM Plasma Cutting Power Supplies listed above. Do not use this kit with any other equipment. Supplied Parts NOTE: Keep all hardware for remounting and attaching components and wires.
PAGE 2
Upper Screws Lower Screws Slots Lower Screws Art # A-08429 Figure 2 2. Remove the green air line that connects between the front and rear of the unit. To release the line from the connector, press the ring back against the fitting and hold while pulling the tube out. Figure 3: Contactor Location, Cutmaster True Std (left) and European Model w/CE Filter (right) 3. Remove the screws holding transformer wires ‘A’ and ‘B’ to the Main PCB and the ‘WORK1’ connection with the T-20 Torx Screwdriver.
PAGE 3
Figure 4: Air Hose, Transformer and Worklead Connections 4. Remove the T-20 Torx screws from the contactor base both front and rear. Figure 5: Front Contactor Mounting Screw Figure 6: Rear Contactor Mounting Screw 5. (SKIP this step if unit contains an CE Filter)To assist with the contactor removal, it is recommended to loosen/ remove the AC power cord grip from the rear of the Cutmaster. This will allow the cord to be pushed/pulled through the Cutmaster rear panel.
PAGE 4
Contactor Replacement 6. Remove the contactor from the metal base of the Cutmaster. CAUTION NOTE ALL WIRE LOCATIONS. DO NOT MISWIRE UNIT AS NON-REPAIRABLE DAMAGE WILL OCCUR TO THE CONTACTOR AND PCB. NOTE Notations in following illustration designate permanent wire connections to the 9X160 contactor. Additional connections are noted for single and three phase on the labels internal to the True Series CutMaster and next to the contactor (if applicable). 7. Reconnect AC power cord as previous.
PAGE 5
8. CM 12, 20, 25 & 40 UNITS WITH CE FILTERS: Remove wires #5 & #6 from the contactor and replace with the harness included with the kit. This will involve clipping wires ties as in Figure 16. Remove J6 from the Main PCB and replace with the harness connection. In addition the CM25 and CM40 units require wires #7 and #8 to be replaced with contents of the modification kit, location ‘T1’ & ‘T2’. Use care to ensure that the wires are installed in the same locations.
PAGE 6
9. Pull the contactor away from the PCB and expose the harness wires attached to the LINE side of the contactor in the previous step. Move the previously detached ‘A’ and ‘B’ black sleeved wires from in front of, to behind the contactor wires #1, #2, #5 & #6. Re-attach the ‘A’ and ‘B’ wires to the Main PCB. Keep wires twisted as original and run over the top of the enclosure. Figure 15. Cut the wire tie on the contactor harness, Figure 16.
PAGE 7
Enclosure Installation 10. Installation: Lift up the contactor and place the bottom enclosure underneath. The end with the Oblong slot in the bottom and the four detents goes toward the front of the Cutmaster. Slide the Contactor completely forward and attach the parts to the original contactor mounting points. Tighten all electrical connections to 17 +/-1 In/ lbs. Lifting the Cutmaster and shining a light below the base panel will illuminate the mounting holes to assist with alignment.
PAGE 8
11. Verify all electrical connections are tightened properly to the contactor and “A and “B” transformer wires. Snap the enclosure top onto the bottom placing the rear edge of the box down first then pressing the front and latching to the base in the front. Attempt to pull the top up from the bottom, this should not occur without releasing the latches. There should be no gap around the box lip. Figure 21: Latches engaged on the Enclosure.
PAGE 9
Re-Assembly 13. Re-attach the worklead ‘Work1’ connection and torque to 17 +/-1 in/lbs. Connect the internal gas filter hose previously removed. Orient transformer and Contactor wires so that they are not pinched or pressed up against the PCB and the installed enclosure top. Also see Figure 15. Figure 23: Worklead Connection re-installed Figure 24: Hose re-installed Figure 25: Installation for Cutmaster 40mm 14. Re-install the Metal Cover and secure with the previously removed screws.
PAGE 10
Figure 26: Cord Grip Screws End of Procedure 15. It is advisable to test the CE power circuit to the Cutmaster True Power Supply after this procedure is completed. Refer to the owners manual for the specific version for instruction. Removal for Voltage Changeover WARNING Disconnect the Mains Power to the power supply before attempting to remove the contactor enclosure cover! 16.
PAGE 11
APPENDIX: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes. 1. Disconnect the power from the power supply. 2. Remove the screws that attach the power supply cover to the chassis. Remove the cover. 3. Route the cable through the customer supplied strain relief at the rear of the power supply.
PAGE 12
Art # A-10288 -V out (-) Polarity Work1 (+) Polarity 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control. INNOVATION TO SHAPE THE WORLD™ U.S. Customer Care: 800-426-1888 Canada Customer Care: 905-827-4515 © 2001 Victor Technologies International, Inc. www.victortechnologies.