82 PlazMaster ™ PLASMA CUTTING SYSTEM Art # A-08740 Operating Manual Rev.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new 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 1-800426-1888, 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 PlazMaster™ 82 SL60 1Torch™ Operating Manual Number 0-5096 Published by: Thermal Dynamics Corporation 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 5 SYSTEM: SERVICE..............................................................................................5-1 5.01 5.02 5.03 5.04 5.05 5.06 General Maintenance..................................................................................5-1 Maintenance Schedule................................................................................5-2 Common Faults...........................................................................................5-2 Fault Indicator........
PLAZMASTER 82 SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
PLAZMASTER 82 FIRE AND EXPLOSION LEAD WARNING Fire and explosion can be caused by hot slag, sparks, or the plasma arc. • Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combustibles. • Provide a fire watch when working in an area where fire hazards may exist.
PLAZMASTER 82 1.04 Note, Attention et Avertissement Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit : NOTE Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
PLAZMASTER 82 • Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation. • Lisez et respectez toutes les consignes du Manuel de consignes. BRUIT Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dúez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.
PLAZMASTER 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.
PLAZMASTER 82 1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
PLAZMASTER 82 1.08 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 PlazMaster™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
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PLAZMASTER 82 SECTION 2 SYSTEM: INTRODUCTION 2.01 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.
PLAZMASTER 82 2.04 Power Supply Specifications PlazMaster 82 Power Supply Specifications 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz Input Power 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable.
PLAZMASTER 82 2.05 Input Wiring Specifications PlazMaster 82 Power Supply Input Cable Wiring Requirements Input voltage 1 Phase 3 Phase Freq Power Input Suggested Sizes Flexible Cord Fuse (amps) (Min. AWG) 50 10 Volts 460 Hz 60 kVA 20 I max 44 I1eff 28 380 50/60 11.8 18 12 20 14 400 50/60 11.
PLAZMASTER 82 2.
PLAZMASTER 82 SECTION 2 TORCH: INTRODUCTION 2T.03Specifications A. Torch Configurations 1. Hand/Manual Torch, Models 2T.01Scope of Manual The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly. This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60/Manual and SL100/Mechanized Plasma Cutting Torches.
PLAZMASTER 82 2T.05Introduction to Plasma F. Torch Ratings Manual Torch Ratings Ambient Temperature 104° F 40° C Duty Cycle 100% @ 60 Amps @ 400 scfh Maximum Current 80 Amps Voltage (Vpeak) 500V Arc Striking Voltage 7kV 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. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece.
PLAZMASTER 82 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma and secondary gases. The torch includes a 'Parts - In - Place' (PIP) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open. The plasma gas flows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orifice.
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PLAZMASTER 82 SECTION 3 SYSTEM: INSTALLATION 3.03 Primary Input Power Connections 3.01 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.
PLAZMASTER 82 A. Connections to Single Phase Input Power B. Connections to Three Phase Input Power WARNING WARNING Disconnect input power from the power supply and input cable before attempting this procedure. Disconnect input power from the power supply and input cable before attempting this procedure. These instructions are for changing the input power and or cable on the 400, 460 VAC Power Supply to Single - Phase input power. 1. Remove the Power Supply cover per instructions found in section 5. 2.
PLAZMASTER 82 3.04 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. 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. Inlet Port Art # A-07944 NOTE Hose Clamp For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
PLAZMASTER 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.
PLAZMASTER 82 SECTION 3 TORCH: INSTALLATION Check Air Quality To test the quality of air: 1. Put the ON / OFF switch in the ON (up) position. 2. Put the Function Control switch in the SET 3T.01Torch 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.
PLAZMASTER 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 Parts Selection for Manual and Mechanized Torch Cutting" on page 4T-9 for details.
PLAZMASTER 82 SECTION 4 SYSTEM: OPERATION 1 4.01 Front Panel Controls / Features MIN 2 A MAX See Illustration for numbering Identification 1. Output Current Control 3 PSI BAR MAX MAX MIN MIN 4 + ! 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. 5 6 7 8 9 10 6.
PLAZMASTER 82 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.
PLAZMASTER 82 Typical Cutting Speeds STANDOFF PlazMaster 82 Gas Pressure Settings Leads Length 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 W/Exposed Tip" or "4T.09 Recommended Cutting Speeds for Mechanized Torch W/Shielded Tip" and following for greater details. SL60 SL100 (Hand Torch) (Mechanized Torch) Up to 25' (7.6 m) 75 psi 5.2 bar 75 psi 4.
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PLAZMASTER 82 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. SECTION 4 TORCH: OPERATION 4T.01Torch Parts Selection Torch Head Depending on the type of operation to be done determines the torch parts to be used. Type of operation: Electrode Drag cutting, standoff cutting or gouging Torch parts: Start Cartridge Shield Cup, Cutting Tip, Electrode and Starter Cartridge Tip NOTE Refer to Section "4T.
PLAZMASTER 82 4T.02Cut 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. Cut quality requirements differ depending on application.
PLAZMASTER 82 4T.04Hand 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.
PLAZMASTER 82 3. Hold the torch away from your body. 4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. NOTE When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components. 8.
PLAZMASTER 82 Drag Cutting With a Hand Torch Trigger Drag cutting works best on metal 1/4" (6 mm) thick or less. 1 2 NOTE Trigger Release For best parts performance and life, always use the correct parts for the type of operation. 1. Install the drag cutting tip and set the output current. 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.
PLAZMASTER 82 3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete. 4. Hold the torch away from your body. 5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start. 4T.
PLAZMASTER 82 4T.06Mechanized Torch Operation Current Setting Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed. Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC. Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°.
PLAZMASTER 82 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.
PLAZMASTER 82 4T.07Parts 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 Shield Cup 9-8218 DRAG SHIELD CUTTING Tip: CUTTING 40A 9-8208 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 O-Ring No. 8-3488 Shield Cup Body, 9-8237 Standoff Guide 9-8251 O-Ring No.
PLAZMASTER 82 4T.08Recommended Cutting Speeds for Mechanized Torch W/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) 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 0.00 0.
PLAZMASTER 82 Type Torch: SL60 With Exposed Tip Type Plasma Gas: Air Thickness Tip Output Inches mm (Cat. No.) Volts(VDC) 0.060 1.5 9-8210 0.075 1.9 9-8210 0.120 3.0 0.135 0.188 Type Material: Mild 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 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8 120 60 285 7.24 0.19 4.8 75 5.2 90 245 0.
PLAZMASTER 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.
PLAZMASTER 82 Type Torch: SL60 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 70 4.8 115 340 0.00 0.25 6.4 0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 70 4.
PLAZMASTER 82 4T.09Recommended Cutting Speeds for Mechanized Torch W/Shielded Tip Type Torch: SL60 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 Flow (CFH) Pierce Pierce Height (Amps) Inches Meters Inches mm psi* bar 0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1 0.06 1.
PLAZMASTER 82 Type Torch: SL60 With Shielded Tip Type Plasma Gas: Air Thickness Tip Inches mm 0.060 1.5 9-8210 0.075 1.9 9-8210 0.120 3.0 0.135 0.188 Output (Cat. No.) Volts (VDC) Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff (Amps) Inches Meters 124 60 250 6.35 0.19 126 60 237 6.02 0.19 9-8210 126 60 230 5.84 3.4 9-8210 128 60 142 4.8 9-8210 128 60 125 0.250 6.4 9-8210 123 60 0.375 9.
PLAZMASTER 82 Type Torch: SL60 With Shielded Tip Type Plasma Gas: Air Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Thickness Tip Output Inches mm (Cat. No.) Volts(VDC) Amperage Speed (Per Minute) (Amps) Inches Meters Inches Standoff mm psi* bar 0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 70 4.8 115 340 0.00 0.2 5.1 0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1 0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 70 4.
PLAZMASTER 82 Type Torch: SL60 With Shielded Tip Type Material: Aluminum Type Secondary Gas: Single Gas Torch Type Plasma Gas: Air Thickness Inches Tip Output mm (Cat. No.) Volts(VDC) Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height (Amps) Inches Meters Inches mm psi* bar 0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 70 4.8 Plasma Total** Delay (Sec) Inches 115 340 0.00 0.25 mm 6.4 0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 70 4.
PLAZMASTER 82 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
PLAZMASTER 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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PLAZMASTER 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.
PLAZMASTER 82 5.02 Maintenance Schedule 5.03 Common Faults NOTE Problem - Symptom 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.
PLAZMASTER 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.
PLAZMASTER 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. Turn primary power disconnect switch to ON position. 1. Primary power disconnect is in OFF position. 2.
PLAZMASTER 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.
PLAZMASTER 82 5.06 Power Supply Basic Parts Replacement ! WARNING 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. 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system. 2. Remove the system cover. See "A. Cover Removal" in this section.
PLAZMASTER 82 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. Optional Single-Stage Filter Element Replacement 6. Disconnect the input line from the filter element assembly. 7. Remove the filter element assembly through the rear opening. The Power Supply shuts down automatically when the Filter Element becomes completely saturated.
PLAZMASTER 82 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 "6.04 Options and Accessories" on page 6-2, for replacement filter element catalog number. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
PLAZMASTER 82 SECTION 5 TORCH: SERVICE Upper Groove with Vent Holes Must Remain Open 5T.01General Maintenance NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System: Service" for common and fault indicator descriptions. Threads Lower O-Ring Cleaning Torch 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.
PLAZMASTER 82 5T.02Inspection 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.
PLAZMASTER 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 Replacement Power Supply Parts" Section "6.04 Options and Accessories" Section "6.05 Replacement Parts for Hand Torch" Section "6.06 Replacement Parts - for Machine Torches with Unshielded Leads" Section "6.07 Replacement Shielded Machine Torch Leads Assemblies" Section "6.
PLAZMASTER 82 6.03 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.
PLAZMASTER 82 6.05 Replacement Parts for Hand Torch Item # Qty Description Catalog # 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.
PLAZMASTER 82 6.06 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty 1 1 2 1 3 1 4 1 5 1 1 1 1 6 1 1 1 1 7 1 8 1 9 1 10 2 11 1 12 1 13 1 1 1 Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) Large O-Ring Small O-Ring PIP Switch Kit Unshielded Automated 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.
PLAZMASTER 82 9 7 10 8 10 1 2 11 3 4 12 13 5&6 A-07994_AB Manual 0-5096 6-5 PARTS LIST
PLAZMASTER 82 6.07 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. 4-7846 4-7847 4-7848 4-7849 1 Remote Pendant Adapter is present on Mechanized leads only.
PLAZMASTER 82 6.08 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 Shield Cup 9-8218 DRAG SHIELD CUTTING Tip: CUTTING 40A 9-8208 DRAG SHIELD CUTTING Tips: CUTTING Start Cartridge 9-8213 50-55A 9-8209 60A 9-8210 70-120A DRAG SHIELD CUTTING CUTTING 70A 80A 90/100A 120A Shield Cup Body, 9-8237 Standoff Guide 9-8251 O-Ring No.
PLAZMASTER 82 6.
PLAZMASTER 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. RUN / Rapid Auto Restart / SET / LATCH switch to SET GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. RESULT: Gas flows to set pressure.
PLAZMASTER 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 1Ø I 1max 3Ø 1Ø I 1eff Maximum Effective Supply C
PLAZMASTER 82 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.
PLAZMASTER 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 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.
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PLAZMASTER 82 APPENDIX 5: SYSTEM SCHEMATIC, 460V UNITS 5 3 4 1 2 3 J3 1 2 3 K1-K4 J12 1 2 3 1 2 3 K5-K6 D 1 SW1 2 4 A PRI 4 PRI 3 D C MTH2 MTH1 J1 1 2 3 4 5 1 2 3 4 5 3 PRI 1 PRI 2 B /460 /230 BIAS SUPPLY +12VDC Q1 INRUSH LIMITING RESISTORS K1 C1-C4* + K1 /INRUSH D1 MTH3 W1 L1 PRIMARY AC INPUT L2 *JUMPER L3 GND C L1 T1 L2 T2 L3 T3 L4 T4 MTH4 AC1 7 AC2 8 K1 K2 K3 K6 K5 K4 AC3 9 7A MTH6 MTH8 Q2 *PRIMARY POWER CONNECTIONS: + C5-C8* 3PH USE L1
PLAZMASTER 82 1 2 T1 CM82 ONLY TS1 1TORCH 1 2 L1 PIP SWITCH 1 2 J11 SEC1 SEC2 D CHOKE1 +12VDC TORCH SWITCH TEMP CIRCUIT /OVERTEMP ATC CONNECTOR J1 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 NTC AUTOMATION TORCH SOLENOID -V OUT 1 E64 - E35 + ELECTRODE1 D3 TIP1 Q5 PILOT IGBT WORK1 WORK J9 1 2 3 4 5 6 7 /PIP /START 24VAC RETURN 24VAC SUPPLY C 78 79 80 81 82 1 2 3 4 5 6 7 83 BASIC CNC INTERFACE OPTION J10 1 2 3 4 5 6 7 8 OK-TO-MOVE +12VDC J2 14 13 12 11 10 9 8 7 6 5 4 3 2 1 P10 1 2
PLAZMASTER 82 APPENDIX 6: Publication History Cover Date Rev. Change(s) Nov. 13, 2008 AA Manual released. Mar. 20, 2012 AB Updated ART A-08066 and changed COO text. Per ECOB2149 April 25, 2012 AC Updated ART A-07994 per ECOB2136.
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