CUTMASTER® 35mm PLASMA CUTTING SYSTEM Operating Manual Revision: AI Issue Date: February 17, 2014 Manual No.: 0-5082 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™ 35mm SL100 1Torch™ Operating Manual Number 0-5082 Published by: Victor Technologies, 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 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 35MM 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 35MM • 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. • 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.
CUTMASTER 35MM 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 35MM 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. FUMÉE et GAZ • Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés.
CUTMASTER 35MM • 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 35MM 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 35MM 1.07 Declaration of Conformity Declaration of Conformity Application of Council Directive(s): The equipment described in this document conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 2006/95/EC) and to the National legislation for the enforcement of this Directive.
CUTMASTER 35MM Classification: The equipment described in this manual is Class A and intended for industrial use. ! WARNING This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
CUTMASTER 35MM 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™ 1Series 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 35MM CIGWELD Terms of Warranty - 2014 Effective 1st January 2014, all warranties against defects (also known as a manufacturer’s warranty) supplied with goods or services must comply with the mandatory requirements in the new Australian Consumer Law and the Trade Practices (Australian Consumer Law) Amendment Regulations (2010) (No.1). This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the product.
CUTMASTER 35MM SECTION 2 SYSTEM: INTRODUCTION 2.02 Equipment Identification 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.
CUTMASTER 35MM 2.04 Power Supply Specifications CutMaster 35mm Power Supply Specifications 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz Input Power Cable Power Supply includes input cable.
CUTMASTER 35MM 2.05 Input Wiring Specifications 3 Phase CutMaster 35mm Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Fuse Flexible Cord Flexible Cord Volts Hz kVA I max I eff (amps) (Min. AWG) (Min. mm2) 380 50 18.4 28 25 32 10 6 400 50 18.
CUTMASTER 35MM 2.
CUTMASTER 35MM 2T.03 Specifications SECTION 2 TORCH: INTRODUCTION 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 35MM 2T.04 Options And Accessories E. Type Cooling Combination of ambient air and gas stream through torch. For options and accessories, see section 6. 2T.05 Introduction to Plasma F. Torch Ratings Manual Torch Ratings A.
CUTMASTER 35MM 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.
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CUTMASTER 35MM 3.03 Primary Input Power Connections SECTION 3 SYSTEM: INSTALLATION CAUTION 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.
CUTMASTER 35MM Regulator/Filter Assembly CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2). 6. Connect the wires as follows. • Wires to L1, L2 and L3 input. It does not matter what order these wires are attached. See previous illustration and on label in the power supply. • Green / Yellow wire to Ground.
CUTMASTER 35MM Regulator/Filter Assembly Regulator/Filter Assembly Regulator Input 2-Stage Filter Inlet Port (IN) Outlet Port (OUT) Inlet Port Two Stage Filter Assembly Hose Clamp Gas Supply Hose Art # A-07944 1/4 NPT to 1/4” (6mm) Fitting Art # A-07945_AC Hose Clamp 1/4 NPT to 1/4" (6mm) Fitting Gas Supply Hose Optional Single - Stage Filter Installation Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: Installing Optional Two - Stage Air Filter Kit This
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CUTMASTER 35MM 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 35MM 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 35MM SECTION 4 SYSTEM: OPERATION 1 4.01 Front Panel Controls / Features MIN 2 A MAX 3 PSI BAR MAX MAX MIN MIN See Illustration for numbering Identification 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. 4 + ! 2. Function Control Function Control Knob, Used to select between the different operating modes.
CUTMASTER 35MM 10. Pressure Indicators BAR MAX MAX 90 6.3 85 5.9 80 5.5 75 5.2 70 4.8 65 4.5 MIN MIN Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON. Connect Work Cable Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.
CUTMASTER 35MM Select Current Output Level 2 1 1. Place the Function Control Knob in one of the three operating positions available: RUN MIN A MAX PSI BAR MAX MAX MIN MIN , RAPID AUTO RESTART + or LATCH . Gas flow stops. 2. Set the output current to desired amperage with the Output Current Control Knob. ! Cutting Operation Art# A-07946 STANDOFF CutMaster 35mm Gas Pressure Settings Leads Length SL100 SL100 (Hand Torch) (Mechanized Torch) Up to 25' (7.6 m) 80 psi 5.5 bar 80 psi 5.
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CUTMASTER 35MM 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: Tip Drag cutting, standoff cutting or gouging Torch parts: Shield Cup Shield Cup, Cutting Tip, Electrode and Starter Cartridge NOTE Torch Parts (Drag Shield Cap & Shield Cup Body Shown) Refer to Section 4T.07 and following for additional information on torch parts.
CUTMASTER 35MM 4T.03 General Cutting Information Kerf Width 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 35MM 4T.04 Hand Torch Operation Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left. Left Side Cut Angle Right Side Cut Angle Standoff Cutting With Hand Torch NOTE For best performance and parts life, always use the correct parts for the type of operation.
CUTMASTER 35MM Trigger Shield Cup Standoff Guide Trigger Release Torch Tip 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. Workpiece Art # A-04034 Shield Cup With Straight Edge The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand. NOTE The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.
CUTMASTER 35MM 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. Choose the holding technique that feels most comfortable and allows good control and movement. 3. Keep the torch in contact with the workpiece during the cutting cycle. 4. Hold the torch away from your body. 5.
CUTMASTER 35MM Gouging Parameters NOTES The gas preflow and postflow are a characteristic of the power supply and not a function of the torch. 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 35MM 4T.06 Mechanized Torch Operation Torch Head Cutting With Mechanized Torch The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC. 35° 1. To start a cut at the plate edge, position the center of the torch along the edge of the plate. Standoff Height Travel Speed Workpiece Proper travel speed is indicated by the trail of the arc which is seen below the plate.
CUTMASTER 35MM 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.
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CUTMASTER 35MM 4T.
CUTMASTER 35MM 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) 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 65 4.5 55 170 0.00 0.
CUTMASTER 35MM 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 Meters Standoff Plasma Gas Press 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 70 4.8 90 245 0.00 0.19 4.8 0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.
CUTMASTER 35MM Type Torch: SL100 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 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 65 4.5 115 340 0.00 0.19 4.8 9-8211 113 80 230 5.84 0.19 4.8 65 4.
CUTMASTER 35MM 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 (Amps) Inches Meters Inches mm psi* bar Flow (CFH) Pierce Pierce Height Plasma Total** Delay (Sec) Inches mm 0.250 6.4 9-8212 110 100 105 2.65 0.190 4.8 75 5.2 130 390 0.4 0.200 5.1 0.375 9.5 9-8212 117 100 70 1.75 0.190 4.
CUTMASTER 35MM 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 35MM 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 35MM 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 35MM Type Torch: SL100 With Shielded Tip Type Plasma Gas: Air Thickness Inches mm Tip Output (Cat. No.) Type Material: Mild Steel Type Secondary Gas: Single Gas Torch Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height 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 35MM PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER 35MM 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 35MM 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 35MM 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.
CUTMASTER 35MM 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 35MM 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 35MM 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. 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 starter cartridge.
CUTMASTER 35MM 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 35MM 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. Optional Single-Stage Filter Element Replacement 6. Disconnect the input line from the filter element assembly. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused.
CUTMASTER 35MM 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 35MM SECTION 5 TORCH: SERVICE Upper Groove with Vent Holes Must Remain Open 5T.01 General Maintenance NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System" for common and fault indicator descriptions. 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 35MM 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. A-03406 DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. Example of Tip Wear 5. Remove the starter cartridge.
CUTMASTER 35MM 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 35MM 6.05 Options and Accessories Qty Description 1 Single - Stage Filter Kit (includes Filter & Hose) 1 Replacement Filter Body 1 Replacement Filter Hose (not shown) 2 Replacement Filter Element 1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 1 Two - Stage Air Filter Assembly 1 First Stage Cartridge 1 Second Stage Cartridge 1 Extended Work Cable (50 ft / 15.
CUTMASTER 35MM 1 8 2 4 5 6 3 7 Art # A-07993_AB Manual 0-5082 PARTS LIST 6-3
CUTMASTER 35MM 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 35MM 9 7 10 8 10 1 2 11 3 4 12 13 5&6 A-07994_AB Manual 0-5082 PARTS LIST 6-5
CUTMASTER 35MM 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 35MM 6.
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CUTMASTER 35MM 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 35MM 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 Speci
CUTMASTER 35MM 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 5 - Open 8 7 6 5 2 1 3 - Switch 4 3 2 - PIP 5 - Open 1 - PIP Pilot Pilot A-03701 B.
CUTMASTER 35MM 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 Black 1 1 Orange 2 2 5 5 6 6 4 4 3 3 8 8 7 7 Green Torch Switch White Negative / Plasma To Power Supply Circuitry To Power Supply Circuitry Negative / Plasma Pilot Pilot Art # A-03797 B.
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CUTMASTER 35MM APPENDIX 5: SYSTEM SCHEMATIC, 400V 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 8 L2 T2 L3 T3 L4 T4 9 7A 380/400/415V OR 600V 3 PH AC INPUT PRIMARY POW
CUTMASTER 35MM 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 35MM APPENDIX 6: PUBLICATION HISTORY Cover Date Sept. 19, 2008 Rev. Change(s) AA May 28, 2009 AB Manual released. Updated 400V/600V schematic in appendix per ECOB1399. Corrected part num bers in section 6 per ECOB1201. Jan. 7, 2010 AC Updated “Power Supply Input Cable Wiring Requirements” with metric cable sizes in Section 2. Updated Torch Consumable Parts in Section 6. Updated system schematic in Appendix. Updated torch consumables art section 4T and 6.
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THE AMERICAS Denton, TX USA U.S.
