20 208230V 460V 600V CUTMASTER™ 152 PLASMA CUTTING SYSTEM Operating Manual Art # A-08619_AC Revision: AN Issue Date: Februrary 11, 2014 Manual No.: 0-4987 VictorThermalDynamics.
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 distributor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.
! WARNING 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™ 152 SL100 1Torch™ Operating Manual Number 0-4987 Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
This Page Intentionally Blank
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION..............................................................................................1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 Notes, Cautions and Warnings....................................................................1-1 Important Safety Precautions......................................................................1-1 Publications.................................................................................................
TABLE OF CONTENTS 4T.04 4T.05 4T.06 4T.07 4T.08 4T.09 Hand Torch Operation...............................................................................4T-3 Gouging.....................................................................................................4T-6 Mechanized Torch Operation....................................................................4T-7 Parts Selection for SL100 Torch Cutting...................................................
CUTMASTER 152 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.
CUTMASTER 152 • 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.
CUTMASTER 152 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.
CUTMASTER 152 CHOC ELECTRIQUE 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. • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.
CUTMASTER 152 • Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs. 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.
CUTMASTER 152 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 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 2. Norme ANSI Z49.
CUTMASTER 152 1.07 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation 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.
CUTMASTER 152 This Page Intentionally Blank 1-8 GENERAL INFORMATION Manual 0-4987
CUTMASTER 152 SECTION 2 SYSTEM: INTRODUCTION 2.01 2.02 How To Use This Manual This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
CUTMASTER 152 2.04 Power Supply Specifications CutMaster 152 Power Supply Specifications Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable.
CUTMASTER 152 2.05 Input Wiring Specifications CutMaster 152 Power Supply Input Cable Wiring Requirements Input Freq Power Suggested Sizes voltage Input Volts Hz kVA I max I eff Fuse Flexible Cord (amps) (Min. AWG) 1 Phase 208 60 26.2 126 98 150 4 Type W 230 60 27.6 118 95 125 4 Type W 460 60 35 76 68 100 4 3 Phase 208 60 21.6 60 55 60 4 230 60 22.3 56 50 60 4 380 50 23 35 32 40 8 400 50 23.6 34 31 40 8 460 60 29.5 37 33 40 8 600 60 29.
CUTMASTER 152 2.
CUTMASTER 152 SECTION 2 TORCH: INTRODUCTION 2T.03 Specifications A. Torch Configurations 1. Hand/Manual Torch, Models 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.
CUTMASTER 152 2T.04 Options And Accessories F. Torch Ratings Manual Torch Ratings For options and accessories, see section 6. Ambient Temperature 104° F 40° C Duty Cycle 100% @ 100 Amps @ 400 scfh Maximum Current 120 Amps Voltage (Vpeak) 500V Arc Striking Voltage 7kV 2T.05 Introduction to Plasma A. Plasma Gas Flow Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive.
CUTMASTER 152 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma and secondary gases. 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. The torch includes a 'Parts - In - Place' (PIP) circuit.
CUTMASTER 152 This Page Intentionally Blank 2T-4 INTRODUCTION Manual 0-4987
CUTMASTER 152 2 1 1 3.01 2 SECTION 3 SYSTEM: INSTALLATION Unpacking 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. 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.
CUTMASTER 152 These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Single - Phase input power. B. Connections to Three Phase Input Power WARNING 1. Remove the Power Supply cover per instructions found in section 5. 2. Disconnect the original input power cable from the main input contactor and the chassis ground connection. 3. Loosen the through - hole protector on the back panel of the power supply.
CUTMASTER 152 3.05 Gas Connections Regulator/Filter Assembly Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed. Inlet Port 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
CUTMASTER 152 Regulator/Filter Assembly Regulator Input 2-Stage Filter Inlet Port (IN) Outlet Port (OUT) Two Stage Filter Assembly Hose Clamp Gas Supply Hose 1/4 NPT to 1/4” (6mm) Fitting Art # A-07945_AC Optional Two - Stage Filter Installation Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators. 2.
CUTMASTER 152 SECTION 3 TORCH: INSTALLATION Check Air Quality To test the quality of air: 1. Put the ON / OFF position. 3T.01 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions. switch in the ON (up) 2. Put the Function Control switch in the SET position. 3.
CUTMASTER 152 Pinch Block Assembly Square Workpiece A-02585 Mechanical Torch Set - Up 3. The proper torch parts (shield cup, tip, start cartridge, and electrode) must be installed for the type of operation. Refer to Section 4T.07, Torch Parts Selection for details.
CUTMASTER 152 SECTION 4 SYSTEM: OPERATION 4.01 1 Front Panel Controls / Features MIN 2 A MAX See Illustration for numbering Identification 3 PSI BAR MAX MAX MIN MIN 4 + 1. Output Current Control Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting. ! 2. Function Control Function Control Knob, Used to select between the different operating modes.
CUTMASTER 152 4.02 Preparations for Operation Power ON Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns ON. At the start of each operating session: Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cooling fans turn ON. WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
CUTMASTER 152 Typical Cutting Speeds STANDOFF CutMaster 152 Gas Pressure Settings Leads Length SL100 SL100 (Hand Torch) (Mechanized Torch) Up to 50' (7.6 m) 75 psi 5.2 bar 75 psi 5.2 bar Each additional 25' (7.6 m) Add 5 psi 0.4 bar Add 5 psi 0.4 bar Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality. 3.
CUTMASTER 152 This Page Intentionally Blank 4-4 OPERATION Manual 0-4987
CUTMASTER 152 SECTION 4 TORCH: OPERATION 1. Unscrew and remove the shield cup assembly from the torch head. 2. Remove the Electrode by pulling it straight out of the Torch Head. 4T.01 Torch Parts Selection Torch Head Depending on the type of operation to be done determines the torch parts to be used. Electrode Type of operation: Drag cutting, standoff cutting or gouging Torch parts: Start Cartridge Shield Cup, Cutting Tip, Electrode and Starter Cartridge Tip NOTE Refer to Section 4T.
CUTMASTER 152 Bottom Dross Buildup 4T.02 Cut Quality 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. NOTE Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability. Kerf Width Cut quality requirements differ depending on application.
CUTMASTER 152 Edge Starting 4T.04 Hand Torch Operation 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.
CUTMASTER 152 8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece. Trigger Trigger Release A-02986 5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
CUTMASTER 152 1. Install the drag cutting tip and set the output current. 8. Cut as usual. Simply release the trigger assembly to stop cutting. 2. 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.
CUTMASTER 152 NOTE The gas preflow and postflow are a characteristic of the power supply and not a function of the torch. Gouging Parameters Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff). When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle.
CUTMASTER 152 Standoff Distance The tip to work distance affects gouge quality and 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.
CUTMASTER 152 4T.
CUTMASTER 152 4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip Type Torch: SL100 With Exposed Tip Type Plasma Gas: Air Thickness Inches Tip Output mm (Cat. No.) Volts(VDC) Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) (Amps) Inches Standoff Meters Inches mm Plasma Gas Press psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 65 4.5 55 170 0.00 0.
CUTMASTER 152 Type Torch: SL100 With Exposed Tip Type Plasma Gas: Air Thickness Inches Tip Output mm (Cat. No.) Volts(VDC) Type Material: Aluminum Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press (Amps) Inches Meters Inches mm psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 65 4.5 55 170 0.00 0.2 5.1 0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 65 4.
CUTMASTER 152 Type Torch: SL100 With Exposed Tip Type Plasma Gas: Air Thickness Tip Output Type Material: Aluminum Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar 0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4 0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4 0.120 3.
CUTMASTER 152 Type Torch: SL100 with Exposed Tip Type Plasma Gas: Air Thickness Inches Tip Output mm (Cat. No.) Volts(VDC) Type Material: Aluminum Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press (Amps) Inches Meters Inches mm psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 65 4.5 115 340 0.00 0.25 6.4 0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 65 4.
CUTMASTER 152 Type Torch: SL100 With Exposed Tip Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Type Plasma Gas: Air Thickness Inches mm Tip Output (Cat. No.) Volts(VDC) Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height (Amps) Inches Meters Inches mm psi* bar 0.250 6.4 9-8253 138 120 150 3.81 0.19 4.8 75 5.2 Plasma Total** Delay (Sec) Inches 180 360 0.10 0.25 mm 6.4 0.375 9.5 9-8253 140 120 85 2.16 0.19 4.
CUTMASTER 152 4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Thickness Inches Tip mm Output (Cat. No.) Volts (VDC) Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press (Amps) Inches Meters Inches mm psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 65 4.5 55 170 0.
CUTMASTER 152 Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Thickness Inches mm Tip Output (Cat. No.) Volts(VDC) Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press (Amps) Inches Meters Inches mm psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1 0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.
CUTMASTER 152 Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Thickness Tip Output Amperage Speed (Per Minute) Standoff Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar 0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 65 4.5 115 340 0.00 0.2 5.1 0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 65 4.5 115 340 0.10 0.2 5.1 0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 65 4.
CUTMASTER 152 Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Thickness Inches mm Tip Output Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar 0.250 6.4 9-8212 124 100 110 2.80 0.180 4.6 75 5.2 130 390 0.4 0.200 5.1 0.375 9.5 9-8212 127 100 75 1.90 0.180 4.6 75 5.2 130 390 0.5 0.200 5.1 0.
CUTMASTER 152 Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Thickness Inches mm Tip Output Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Inches Plasma Gas Press Flow (CFH) Pierce Pierce Height (Cat. No.) Volts(VDC) (Amps) Inches Meters mm psi* bar 0.250 6.4 9-8253 140 120 165 4.19 0.125 3.2 75 5.2 Plasma Total** Delay (Sec) Inches 180 360 0.20 0.20 mm 5.1 0.375 9.5 9-8253 142 120 85 2.16 0.125 3.
CUTMASTER 152 This Page Intentionally Blank Manual 0-4987 OPERATION 4T-19
CUTMASTER 152 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER 152 Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No.
CUTMASTER 152 This Page Intentionally Blank 4T-22 OPERATION Manual 0-4987
CUTMASTER 152 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip, electrode, start cartridge and shield cup Visually inspect the cables and leads.
CUTMASTER 152 5.02 Maintenance Schedule 5.03 Common Faults Problem - Symptom NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Insufficient Penetration 1. Cutting speed too fast. 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts 5. Cutting current too low. 6. Non - Genuine Thermal Dynamics parts used 7. Incorrect gas pressure Main Arc Extinguishes 1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3.
CUTMASTER 152 5.04 Fault Indicator At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 76 psi indicators are ON indicating the version would be 2.3.
CUTMASTER 152 5.05 Basic Troubleshooting Guide 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. Problem - Symptom Possible Cause Recommended Action ON / OFF Switch is ON but the A/C Indicator does not light 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position. OFF position. 2.
CUTMASTER 152 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI indicators flashing. Gas flow is cycling ON and OFF. 1. Torch shield cup is loose. 2. Torch tip, electrode or starter cartridge missing. 3. Torch starter cartridge is stuck. Nothing happens when torch switch or remote switch is closed (Or CNC START signal is active) No gas flow, DC LED OFF. 1. Problem in the torch and leads switch circuit (Remote pendant switch circuit). 2. CNC Contoller device not providing Start signal.
CUTMASTER 152 5.06 Power Supply Basic Parts Replacement C. Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced. WARNING 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system. Disconnect primary power to the system before disassembling the torch, leads, or power supply. 2.
CUTMASTER 152 5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous illustration. 6. Disconnect the input line from the filter element assembly. 7. Remove the filter element assembly through the rear opening. Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
CUTMASTER 152 Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
CUTMASTER 152 SECTION 5 TORCH: SERVICE Upper Groove with Vent Holes Must Remain Open 5T.01 General Maintenance NOTE Refer to Previous "Section 5 System" for common and fault indicator descriptions. Upper O-Ring in Correct Groove Threads Cleaning Torch Lower O-Ring Art # A-03725 Torch Head O-Ring Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue.
CUTMASTER 152 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. 5T.02 Inspection and Replacement of Consumable Torch Parts Worn Tip Good Tip 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. A-03406 Example of Tip Wear 5. Remove the starter cartridge.
CUTMASTER 152 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section "6.03 Power Supply Replacement" Section "6.04 Replacement Power Supply Parts" Section "6.05 Options and Accessories" Section "6.06 Replacement Parts for Hand Torch" Section "6.07 Replacement Parts - for Machine Torches with Unshielded Leads" Section "6.
CUTMASTER 152 6.04 Replacement Power Supply Parts Qty Description Catalog # 1 Regulator 1 Filter Assembly Replacement Element 1 Input Power Cord for 208 / 230 V Power Supply 1 460/600V Power Supply 6.
CUTMASTER 152 6.06 Replacement Parts for Hand Torch Item # Qty Description 1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 2 1 Trigger Assembly Replacement Kit 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 4 1 Torch Head Assembly Replacement Kit (includes items No.
CUTMASTER 152 6.07 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog No. 1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 2 1 Large O-ring 3 1 Small O-ring 4 1 PIP Switch Kit 5 Unshielded Automated Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 1 10 - foot / 3.05 m Leads Assembly with ATC connector 1 25 - foot / 7.
CUTMASTER 152 9 7 10 8 10 1 2 11 3 4 12 13 5&6 A-07994_AB Manual 0-4987 PARTS LIST 6-5
CUTMASTER 152 6.08 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description 1 1 1 1 1 Mechanized Shielded Leads Assemblies with ATC Connectors 5 - foot / 1.5 m Leads Assembly with ATC Connector 10 - foot / 3.05 m Leads Assembly with ATC Connector 25 - foot / 7.6 m Leads Assembly with ATC Connector 50 - foot / 15.2 m Leads Assembly with ATC Connector Catalog No.
CUTMASTER 152 6.
CUTMASTER 152 This Page Intentionally Blank 6-8 PARTS LIST Manual 0-4987
CUTMASTER 152 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: Close external disconnect switch. RESULT: Power to system. ACTION: ON / OFF switch to ON RESULT: AC indicator ON. GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. RUN / Rapid Auto Restart / SET / LATCH switch to SET RESULT: Gas flows to set pressure.
CUTMASTER 152 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Model : Dat e of Mf r : Type of Power Supply (Note 1) 1/ 3 f1 S/N Made in USA Regulatory Standard Covering This Type of Power Supply f2 Output Current Type Duty Cycle Factor Output Range (Amperage/ Voltage) Plasma Cutting Symbol X U0 = Rated NoLoad Voltage Duty Cycle Data (Note 3) I U2 Conventional Load Voltage Rated Maximum Supply Current Input Power Symbol U1 I 1max 3Ø 1 1Ø 1 1Ø I 1eff 3Ø Input Power Specif
CUTMASTER 152 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram 8 - Open 4 - Green / Switch 3 - White / Switch Negative / Plasma 8 - Ground 4 - Switch 4 3 2- Orange / PIP 1 - Black / PIP ATC Female Receptacle Front View ATC Male Connector Front View Negative / Plasma 6 5 2 1 8 7 7 - Open 7 - Open 6 - Open 6 - Open 8 7 6 5 2 1 2 - PIP 5 - Open 5 - Open 3 - Switch 4 3 1 - PIP Pilot Pilot A-03701 B.
CUTMASTER 152 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Torch Head Male ATC Leads Connector ATC Female Receptacle Power Supply Torch Leads Black PIP Switch 1 1 2 2 5 5 6 6 Green 4 4 White 3 3 8 8 7 7 Orange Torch Switch Negative / Plasma To Power Supply Circuitry To Power Supply Circuitry Negative / Plasma Pilot Pilot Art # A-03797 B.
CUTMASTER 152 This Page Intentionally Blank Manual 0-4987 APPENDIX A-5
CUTMASTER 152 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS T1 3 C 1 2 3 4 5 4 2 PRI 4 PRI 3 J1 SW1 1 BIAS SUPPLY PRI 2 INRUSH RESISTORS +12VDC PRI 1 + TP2 MTH1 B A D PRI 2 PRI 1 + MTH2 TP1 K1 Q1 /INRUSH +12VDC BIAS SUPPLY D1 + TP8 L1 PRIMARY AC INPUT _ W1 L2 L3 GND L1 T1 L2 T2 L3 T3 L4 T4 MTH7 AC1 80A_AC1 AC2 80A_AC2 AC3 80A_AC3 MTH4 TP5 7 8 9 K1 K2 K3 K4 K5 K6 7A SW2 J3 * 460_IN 1 2 BUSS BARS/JUMPERS * C3,C4,C7,C8* * CM102 & A80 C7 & C10 not in
CUTMASTER 152 A120 ONLY 1TORCH TS1 PIP SWITCH L1 TORCH SWITCH 1 2 J11 SEC1 SEC2 +12VDC CHOKE1 ATC CONNECTOR J1 TEMP CIRCUIT 1 2 3 4 5 6 7 8 /OVERTEMP NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + AUTOMATION TORCH SOLENOID ELECTRODE1 D3 TIP1 Q5 PILOT IGBT WORK1 WORK J9 /PIP 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY 78 79 80 81 82 CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS 83 J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE (5A @ 250VAC / 30VDC) +
CUTMASTER 152 APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS 5 4 T1 3 2 C 1 2 3 4 5 4 PRI 4 PRI 3 J1 SW1 1 BIAS SUPPLY PRI 2 D INRUSH RESISTORS +12VDC PRI 1 + TP2 MTH1 B A D PRI 2 PRI 1 + MTH2 TP1 K1 Q1 EMI *CHOKE /INRUSH +12VDC BIAS SUPPLY D1 + C3,C4,C7,C8* UNITS * CEONLY TP8 EMI *FILTER L1 1 1 L2 2 2 L3 3 3 GND 4 4 _ W1 MTH7 AC1 80A_AC1 AC2 80A_AC2 AC3 80A_AC3 MTH4 TP5 7 L1 T1 L2 T2 L3 T3 L4 T4 8 9 7A 380/400/415V OR 600V 3 PH AC INPUT PRIMARY POWE
CUTMASTER 152 3 2 1 1TORCH TS1 PIP SWITCH L1 TORCH SWITCH 1 2 J11 SEC1 SEC2 +12VDC CHOKE1 ATC CONNECTOR J1 TEMP CIRCUIT 1 2 3 4 5 6 7 8 /OVERTEMP NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + AUTOMATION TORCH SOLENOID D ELECTRODE1 D3 TIP1 Q5 PILOT IGBT WORK1 WORK J9 /PIP 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY 78 79 80 81 82 CNC INTERFACE STANDARD ON A80 & A120 UNITS CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS 83 J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE (5A @ 250VAC / 30VDC) +
CUTMASTER 152 APPENDIX 7: Publication History Cover Date May 30, 2008 Rev. Change(s) AA Manual released. June 23, 2008 AB Updated with new Cut Charts, updated system schematic per ECOB935 and added 460V version per ECOB939. Nov. 19, 2008 Updated system schematic. AC Jan 27, 2009 AD Corrected art sizing in section 3 to show missing information per ECOB1248. Up dated power supply specs and input wiring charts in section 2 per ECOB1197. Apr.
This Page Intentionally Blank
THE AMERICAS Denton, TX USA U.S.
