60 208230V 460V 600V CUTMASTER™ 52 PLASMA CUTTING SYSTEM Operating Manual Art # A-08617_AD Revision: AQ Issue Date: October 3, 2013 Manual No.: 0-4961 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.VictorThermalDynamics.com.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ 52 SL60 1Torch™ Operating Manual Number 0-4961 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 1.04 1.05 Notes, Cautions and Warnings......................................................................... 1-1 Important Safety Precautions.......................................................................... 1-1 Publications.....................................................................................................
TABLE OF CONTENTS SECTION 4 TORCH: OPERATION......................................................................... 4T-1 4T.01 4T.02 4T.03 4T.04 4T.05 4T.06 4T.07 4T.08 4T.09 Torch Parts Selection......................................................................................4T-1 Cut Quality......................................................................................................4T-1 General Cutting Information............................................................................
CUTMASTER 52 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 52 • 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 Section "1.03 Publications" on page 1-2. • Disconnect power source before performing any service or repairs. • Read and follow all the instructions in the Operating Manual.
CUTMASTER 52 NOTE Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système. 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 52 Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions. • Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.
CUTMASTER 52 • Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie. • Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.
CUTMASTER 52 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 52 1.04 Declaration of Conformity Manufacturer: Victor Technologies Address: 16052 Swingley Ridge Road, Suite 300 Chesterfield, MO 63033 USA Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements.
CUTMASTER 52 1.05 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies, Inc. warrants to the original retail purchaser that new Victor Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Victor Technologies, Inc.
CUTMASTER 52 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 52 2.04 Power Supply Specifications CutMaster 52 Power Supply Specifications 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 Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 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 52 2.05 Input Wiring Specifications CutMaster 52 Power Supply Input Cable Wiring Requirements 1 Phase 3 Phase Input voltage Freq Power Input Suggested Sizes Volts Hz kVA I max I1eff Fuse (amps) Flexible Cord (Min. AWG) 208 60 10.4 47 30 50 10 230 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 14 400 50/60 6.4 16 11 20 14 460 60 7.4 16 10 20 12 600 60 7.
CUTMASTER 52 2.
CUTMASTER 52 SECTION 2 TORCH: INTRODUCTION 10.125" (257 mm) 2T.01 Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60/Manual and SL100/Mechanized Plasma Cutting Torches. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. 3.75" (95 mm) Art # A-03322_AB 1.
CUTMASTER 52 F. Torch Ratings 2T.05 Introduction to Plasma Manual Torch Ratings A. Plasma Gas Flow Ambient Temperature 104° F 40° C Duty Cycle 100% @ 60 Amps @ 400 scfh Maximum Current 60 Amps Voltage (Vpeak) 500V Arc Striking Voltage 7kV Mechanized Torch Ratings Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive.
CUTMASTER 52 The plasma gas flows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orifice. Remote Pendant 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. To ATC PIP Switch Shield Cup C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip.
CUTMASTER 52 This Page Intentionally Blank 2T-4 INTRODUCTION Manual 0-4961
CUTMASTER 52 SECTION 3 SYSTEM: INSTALLATION 1 2 1 Unpacking 2 3.01 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. Contactor cover 3.
CUTMASTER 52 NOTE There is only one jumper setting that changes between the single and three phase settings. To change from single phase to three phase, the jumper connected to L2 needs to be removed and placed on the other L3 connection so both ends of the jumper are attached to the same electrical point. See previous illustrations. 7. With a little slack in the wires, tighten the through - hole protector to secure the power cable. 8. Reinstall the Power Supply cover per instructions found in Section 5.
CUTMASTER 52 7. With a little slack in the wires, tighten the through - hole protector to secure the power cable. 8. Reinstall the Power Supply cover per instructions found in Section 5. 9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect. NOTE For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions.
CUTMASTER 52 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 52 SECTION 3 TORCH: INSTALLATION 3. Place a welding filter lens in front of the torch and turn ON the air. Do not start an arc! Any oil or moisture in the air will be visible on the lens. 3T.02 Setting Up Mechanical Torch 3T.01 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 / Manual or SL100 / Mechanical Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
CUTMASTER 52 This Page Intentionally Blank 3T-2 INSTALLATION Manual 0-4961
CUTMASTER 52 SECTION 4 SYSTEM: OPERATION 4.01 1 2 3 4 Front Panel Controls / Features MIN A MAX See Illustration for numbering Identification PSI BAR MAX MAX MIN MIN + 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 for standoff cutting. ! 2. Function Control Function Control Knob; Used to select between the different operating modes.
CUTMASTER 52 4.02 Preparations for Operation Power ON Place the Power Supply ON / OFF switch to the ON turns ON. Gas (up) position. AC indicator At the start of each operating session: 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 52 Typical Cutting Speeds STANDOFF CutMaster 52 Gas Pressure Settings Leads Length SL60 (Hand Torch) SL100 (Mechanized Torch) Up to 25' (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 Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Section "4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip" and following for greater details.
CUTMASTER 52 This Page Intentionally Blank 4-4 OPERATION Manual 0-4961
CUTMASTER 52 SECTION 4 TORCH: OPERATION Torch Head Electrode 4T.01 Torch Parts Selection Depending on the type of operation to be done determines the torch parts to be used. Start Cartridge Type of operation: Drag cutting, standoff cutting or gouging Tip Torch parts: Shield Cup Shield Cup, Cutting Tip, Electrode and Starter Cartridge A-03510_AB Torch Parts (Drag Shield Cap & Shield Cup Body Shown) NOTE Refer to Section 4T.07 and following for additional information on torch parts. 3.
CUTMASTER 52 Kerf Width 4T.03 General Cutting Information Cut Surface Bevel Angle ! Top Spatter Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Top Edge Rounding Dross Build-Up Cut Surface Drag Lines WARNING Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection.
CUTMASTER 52 Left Side Cut Angle NOTE The tip should never come in contact with the workpiece except during drag cutting operations. Right Side Cut Angle 2. Depending on the cutting operation, do one of the following: a. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start. A-00512 Side Characteristics Of Cut b.
CUTMASTER 52 Shield Cup With Straight Edge NOTE The gas preflow and postflow are a characteristic of the power supply and not a function of the torch. The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand. Trigger WARNING The straight edge must be non - conductive.
CUTMASTER 52 Piercing With Hand Torch 1. 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. Choose the technique that feels most comfortable and allows good control and movement. Trigger Trigger Release A-02986 7. Bring the torch within transfer distance to the work.
CUTMASTER 52 7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it. Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance: CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear.
CUTMASTER 52 Slag Buildup Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or standoff height. 4T.
CUTMASTER 52 For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer. Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also.
CUTMASTER 52 4T.07 Parts Selection for Manual and Mechanized Torch Cutting Tips: Shield Cup Body, 9-8237 DRAG TIP CUTTING 20A 30A 40A 60A 40A 9-8205 9-8206 9-8207 9-8252 DRAG SHIELD CUTTING Tip: CUTTING 40A 9-8208 STANDOFF CUTTING 50-60A DRAG SHIELD CUTTING Tips: CUTTING Start Cartridge 9-8213 50-55A 9-8209 60A 9-8210 STANDOFF CUTTING Electrode 9-8215 70-120A DRAG SHIELD CUTTING CUTTING 70A 80A 90/100A 120A Shield Cap, Deflector 9-8243 Shield Cup 9-8218 O-Ring No.
CUTMASTER 52 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches Tip mm Output Amperage (Cat. No.) Volts (VDC) 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 104 40 340 8.64 0.19 4.8 70 4.8 55 170 0.
CUTMASTER 52 Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches Tip mm Output Amperage (Cat. No.) Volts (VDC) 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 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8 0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 75 5.
CUTMASTER 52 Type Torch: SL60 With Exposed Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches mm Tip (Cat. No.) Output Amperage Speed (Per Minute) Standoff Volts (Amps) Inches Meters Inches mm (VDC) Plasma Gas Press psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.00 0.25 6.4 0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 75 5.
CUTMASTER 52 4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip Type Torch: SL60 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches Tip Output Amperage (Cat. No.) mm Volts (VDC) 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 70 4.8 55 170 0.
CUTMASTER 52 Type Torch: SL60 With Shielded Tip Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches Tip Output Amperage (Cat. No.) mm Volts (VDC) 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 75 5.2 90 245 0.00 0.2 5.1 0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 75 5.
CUTMASTER 52 Type Torch: SL60 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Inches mm Tip (Cat. No.) Output Amperage Volts (VDC) Speed (Per Minute) Standoff (Amps) Inches Meters Inches mm Plasma Gas Press psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1 0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 75 5.
CUTMASTER 52 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER 52 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 52 This Page Intentionally Blank 4T-18 OPERATION Manual 0-4961
CUTMASTER 52 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 52 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 52 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 75 psi indicators are ON indicating the version would be 2.3.
CUTMASTER 52 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 52 Problem - Symptom FAULT & 80 PSI indicators flashing. Gas flow is cycling ON and OFF. Possible Cause 1. Torch shield cup is loose. 2. Torch tip, electrode or starter cartridge missing. 3. Torch start cartridge is stuck. 4. Open conductor in torch leads. Recommended Action 1. Tighten shield cup by hand. Do not overtighten. 2. Turn OFF power supply. Remove shield cup. Install missing parts. 3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and start cartridge.
CUTMASTER 52 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 (Section 5.02), and either cleaned or replaced. WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system.
CUTMASTER 52 6. Disconnect the input line from the filter element assembly. Housing 7. Remove the filter element assembly through the rear opening. NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly. Filter Element (Cat. No. 9-7741) Spring O-ring (Cat. No. 9-7743) Assembled Filter Cover Barbed Fitting Filter Element Art # A-02476 Optional Single-Stage Filter Element Replacement 5.
CUTMASTER 52 First & Second Stage Cartridges (as marked) Art # A-02942 Optional Two-Stage Filter Replacement 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.
CUTMASTER 52 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 Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.
CUTMASTER 52 5T.02 Inspection and Replacement of Consumable Torch Parts 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. 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 52 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: 6.03 Power Supply Replacement 6.04 Replacement Power Supply Parts 6.05 Options and Accessories 6.06 Replacement Parts for Hand Torch 6.07 Replacement Parts - for Machine Torches with Unshielded Leads 6.08 Replacement Shielded Machine Torch Leads Assemblies 6.09 Torch Consumable Parts (SL60) 6.
CUTMASTER 52 NOTE *9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting. If there is a transducer and wire harness instead of the tube, the kit is not needed. 6.
CUTMASTER 52 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 52 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 52 9 7 10 8 10 1 2 11 3 4 12 13 5&6 A-07994_AB Manual 0-4961 PARTS LIST 6-5
CUTMASTER 52 6.08 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description 1 Mechanized Shielded 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 / 7.6 m Leads Assembly with ATC Connector 1 50 - foot / 15.2 m Leads Assembly with ATC Connector Catalog No.
CUTMASTER 52 6.09 Torch Consumable Parts (SL60) Tips: Shield Cup Body, 9-8237 DRAG TIP CUTTING 20A 30A 40A 60A 40A 9-8205 9-8206 9-8207 9-8252 DRAG SHIELD CUTTING Tip: CUTTING 40A 9-8208 STANDOFF CUTTING 50-60A DRAG SHIELD CUTTING Tips: CUTTING Start Cartridge 9-8213 50-55A 9-8209 60A 9-8210 STANDOFF CUTTING Electrode 9-8215 70-120A DRAG SHIELD CUTTING CUTTING 70A 80A 90/100A 120A Shield Cap, Deflector 9-8243 Shield Cup 9-8218 O-Ring No.
CUTMASTER 52 6.
CUTMASTER 52 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 52 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 Specific
CUTMASTER 52 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 52 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 52 This Page Intentionally Blank Manual 0-4961 APPENDIX A-5
CUTMASTER 52 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS 5 4 3 2 J3 1 2 3 T1 K1-K4 J12 D 1 /460 /230 1 2 3 4 5 4 PRI 4 A D PRI 3 C MTH2 MTH1 Q1 K1 INRUSH RESISTORS 2 B J1 3 PRI 1 PRI 2 +12VDC BIAS SUPPLY SW1 1 2 3 K5, K6 C1-C4* /INRUSH + D1 MTH3 W1 L1 * PRIMARY AC INPUT L2 L3 JUMPER GND L1 T1 L2 T2 L3 T3 L4 T4 MTH4 AC1 7 AC2 8 K1 K2 K5 K3 K6 K4 AC3 9 7A MTH6 MTH8 Q2 C *PRIMARY POWER CONNECTIONS: 3PH USE L1,L2,L3 & GND REMOVE JUMPER BETWEEN L
CUTMASTER 52 1 CM82 / A60 ONLY TS1 1TORCH L1 PIP SWITCH 1 2 J11 SEC1 CHOKE1 SEC2 D +12VDC TORCH SWITCH TEMP CIRCUIT /OVERTEMP ATC CONNECTOR J1 1 2 3 4 5 6 7 8 NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + ELECTRODE1 D3 TIP1 Q5 AUTOMATION TORCH SOLENOID PILOT IGBT WORK1 WORK J9 /PIP 78 79 80 81 82 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY C 83 CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE +12VDC 1
CUTMASTER 52 APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS 5 4 PRI 1 PRI 2 D SW1 1 EMI *CHOKE UNITS * CEONLY EMI *FILTER 1 1 L2 2 2 L3 PRI 3 C Q1 K1 + C1-C4* /INRUSH D1 L1 GND D +12VDC 1 2 3 4 5 4 PRI 4 A MTH2 MTH1 J1 3 INRUSH RESISTORS 2 C B BIAS SUPPLY 3 3 4 4 MTH4 W1 L1 T1 L2 T2 L3 T3 L4 T4 MTH3 AC1 7 AC2 8 AC3 9 7A MTH8 MTH6 Q2 380/400/415V OR 600V 3 PH AC INPUT + C5-C8* PRIMARY POWER CONNECTIONS: USE L1, L2, L3 & GND MTH7 MTH5 PCB2 INPUT CAPACITO
CUTMASTER 52 3 2 1 TS1 T1 1TORCH L1 PIP SWITCH 1 2 J11 SEC1 CHOKE1 SEC2 D +12VDC TORCH SWITCH TEMP CIRCUIT /OVERTEMP ATC CONNECTOR J1 1 2 3 4 5 6 7 8 NTC -V OUT 1 E64 - E35 + ELECTRODE1 D3 TIP1 Q5 1 2 3 4 5 6 7 8 AUTOMATION TORCH SOLENOID PILOT IGBT WORK1 WORK J9 /PIP 78 79 80 81 82 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY C 83 CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE +12VDC 1 2 3 4
CUTMASTER 52 APPENDIX 7: Publication History Cover Date Rev. Change(s) Sept 17, 2007 AA Manual released. Oct. 2, 2007 AB Upgraded information in Section 4Torch to make easier to understand Apr. 15, 2008 AC Per ECOB752 updated firmware changes to pgs. 4-1 and 5-5. Per ECOB845 corrected drag cutting statement to ¼” pg. 4T-5. Per ECOB803 releasing 400 – 460V systems. May 7, 2008 AD Per ECOB890 Updated system schematic to Rev. AB.
This Page Intentionally Blank
THE AMERICAS Denton, TX USA U.S.
