80 208230V 400V 460V 600V CUTMASTER™ 82 PLASMA CUTTING SYSTEM Operating Manual Art # A-08607_AD Revision: AR Issue Date: February 11, 2014 Manual No.: 0-4979 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.
! 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™ 82 SL60 1Torch™ Operating Manual Number 0-4979 Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
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TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION.........................................................................1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 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-2 General Cutting Information.......................................
CUTMASTER 82 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 82 • Never touch any parts that are electrically “live” or “hot.” • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. PLASMA ARC RAYS • Extra care must be taken when the workplace is moist or damp. Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
CUTMASTER 82 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 Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
CUTMASTER 82 • 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. • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés.
CUTMASTER 82 • Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1: INCENDIE ET EXPLOSION Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.
CUTMASTER 82 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 82 1.07 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 82 1.08 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 82 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 82 2.04 Power Supply Specifications CutMaster 82 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 82 2.05 Input Wiring Specifications CutMaster 82 Power Supply Input Cable Wiring Requirements 1 Phase 3 Phase Input voltage Freq Power Input Suggested Sizes Volts 208 Hz 60 kVA 16 I max 75 I1eff 48 230 60 17 72 46 100 6 460 60 20 44 28 50 10 208 60 16 40 26 50 8 230 50/60 16 39 25 50 10 380 50/60 11.8 18 12 20 12 400 50/60 11.8 18 12 20 12 460 60 17 21 14 25 12 600 60 9.6 16 10 20 12 Flexible Cord Fuse (amps) (Min.
CUTMASTER 82 2.
CUTMASTER 82 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 82 2T.05 Introduction to Plasma F. Torch Ratings 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 82 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. C. Pilot Arc The torch includes a 'Parts - In - Place' (PIP) circuit.
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CUTMASTER 82 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 82 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 82 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 82 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 82 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 SL60 / 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 82 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 82 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 82 4.02 Power ON Preparations for Operation 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 82 STANDOFF Typical Cutting Speeds CutMaster 82 Gas Pressure Settings Leads Length SL60 SL100 (Hand Torch) (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 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. For Drag cutting, adjust gas pressure from 75 95 psi / 5.
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CUTMASTER 82 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 82 4T.02 Cut Quality Bottom Dross Buildup 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 82 4T.04 Hand Torch Operation Edge Starting 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 82 Forcing the shield cup against the torch head or torch handle can damage components. 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.
CUTMASTER 82 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 82 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 82 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.
AE CUTMASTER 82 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 50-55A 9-8209 60A 9-8210 STANDOFF CUTTING 70-120A DRAG SHIELD CUTTING CUTTING 70A 80A 90/100A 120A Shield Cap, Deflector 9-8243 Shield Cup 9-8218 O-Ring No.
CUTMASTER 82 4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip Type Torch: SL60 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 70 4.8 55 170 0.00 0.
CUTMASTER 82 Type Torch: SL60 With Exposed Tip Type Plasma Gas: Air Thickness 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 Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar 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 5.2 90 245 0.10 0.19 4.8 0.120 3.
CUTMASTER 82 Type Torch: SL60 With Exposed Tip Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Type Plasma Gas: Air Thickness Tip Inches mm 0.060 1.5 9-8211 0.120 3.0 9-8211 0.135 3.4 0.188 0.250 0.375 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 113 80 320 8.13 0.19 4.8 70 4.8 115 340 0.00 0.19 4.8 113 80 230 5.84 0.19 4.8 70 4.
CUTMASTER 82 Type Torch: SL60 with Exposed Tip Type Plasma Gas: Air Thickness Inches Tip Output Type Material: Aluminum Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) mm (Cat. No.) Volts(VDC) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height (Amps) Inches Meters Inches mm psi* bar 0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 70 4.8 Plasma Total** Delay (Sec) Inches 115 340 0.00 0.25 mm 6.4 0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 70 4.
CUTMASTER 82 Type Torch: SL60 With Shielded Tip Type Plasma Gas: Air Thickness Inches Tip mm Output (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 116 40 220 5.59 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1 0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 70 4.
CUTMASTER 82 Type Torch: SL60 With Shielded Tip Type Material: Aluminum Type Plasma Gas: Air Thickness Inches mm Tip Output (Cat. No.) Volts(VDC) 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 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 82 Type Torch: SL60 With Shielded Tip Type Plasma Gas: Air Thickness Tip Output Inches mm (Cat. No.) Volts(VDC) Type Material: Stainless Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height (Amps) Inches Meters Inches mm psi* bar 0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 70 4.8 115 340 0.00 0.2 5.1 0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1 0.
CUTMASTER 82 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER 82 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.
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CUTMASTER 82 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 82 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 82 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 82 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 82 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 82 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 82 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. to Section 6, Parts List, for replacement filter element catalog number. 1. Remove power from power supply. 2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element. 6. Disconnect the input line from the filter element assembly. 3.
CUTMASTER 82 ! WARNING Always turn OFF the air supply and bleed the system before disassembling the Filter Assembly as injury could result. 3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely. 4. Note the location and orientation of the old Filter Elements. 5. Slide out the old Filter Elements. First & Second Stage Cartridges (as marked) Art # A-02942 Optional Two-Stage Filter Replacement 6.
CUTMASTER 82 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 82 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. Good Tip Worn 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 82 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 82 6.04 Replacement Power Supply Parts Qty Description Catalog # 1 Regulator 9-0115* 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 208 / 230 V Power Supply 8-4384 1 Input Power Cord for 460/600 V Power Supply 9-8593 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.
CUTMASTER 82 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 82 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 82 9 7 10 8 10 1 2 11 3 4 12 13 5&6 A-07994_AB Manual 0-4979 PARTS LIST 6-5
CUTMASTER 82 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 82 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 82 6.
CUTMASTER 82 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 82 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 Specifi
CUTMASTER 82 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram Negative / Plasma 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 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 82 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 PIP Switch Torch Switch Black 1 1 Orange 2 2 5 5 6 6 Green 4 4 White 3 3 8 8 7 7 Negative / Plasma To Power Supply Circuitry To Power Supply Circuitry Negative / Plasma Pilot Pilot Art # A-03797 B.
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CUTMASTER 82 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 82 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 82 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 /INRUSH + C1-C4* 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 CAPACIT
CUTMASTER 82 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 82 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.
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