Tweco CutMaster 101 with SL100SV User Manual Page 108
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SERVICE 5-44 Manual 0-4642
5
D. Pressure Switch/Solenoid Assembly Replacement
The Pressure Switch and Solenoid Valve are one Assembly. Disconnect primary input power and bleed down the system.
1. Remove the power supply cover per Section 5.09-A.
2. Disconnect the following wires:
a. Wires #10 and #11 from the Pressure Switch Assembly.
b. Wires #8 and #9 from the Solenoid Assembly.
3. Push the clip on the front of the Heatsink Shroud to the left to release the Solenoid Assembly. Dislodge the Assembly
from underneath the clip on the top of the Heatsink Shroud.
Heatsink
Shroud
Dislodge Solenoid
Assembly
Push Clip
to the left to
release Solenoid
Assembly
Art # A-03705
2
3
1
4. Release the hose from the Adapter Fitting on the input side of the Solenoid Assembly. Hold a wrench or similar tool
against the locking ring on the Fitting, then pull on the hose to release it.
5. Release the hose from the Adapter Fitting on the output side of the Solenoid Assembly.
6. Install the replacement Pressure Switch/Solenoid Assembly by reversing steps 2-5. Once installed, the Solenoid Assem-
bly should fit securely on the Heatsink Shroud. It should not be moveable.
7. Re-install the power supply cover.
- CUTMASTER 1
- Operating Manual 1
- WE APPRECIATE YOUR BUSINESS! 2
- YOU ARE IN GOOD COMPANY! 2
- TABLE OF CONTENTS 5
- TABLE OF CONTENTS (continued) 6
- SECTION 1: 9
- GENERAL INFORMATION 9
- Minimum Protective Suggested 10
- Less Than 300* 8 9 10
- 300 - 400* 9 12 10
- 400 - 800* 10 14 10
- 1.03 Publications 11
- 1.04 Note, Attention et 11
- Avertissement 11
- 1.05 Precautions De Securite 12
- Importantes 12
- 1.06 Documents De Reference 13
- 1.08 Statement of Warranty 16
- SECTION 2: SPECIFICATIONS 17
- 2.04 Power Supply Features 19
- 2.06 Torch Specifications 21
- B. Torch Connector Dimensions 22
- C. Torch Parts 22
- D. Parts - In - Place (PIP) 22
- E. Direct Contact Hazard 22
- A. Plasma Gas Flow 23
- Typical Torch Head Detail 23
- B. Gas Distribution 23
- C. Pilot Arc 23
- D. Main Cutting Arc 24
- E. Parts - In - Place (PIP) 24
- SECTION 3: INSTALLATION 25
- L1 L2 L3 27
- 3.04 Gas Connections 28
- B. Optional Air Filters 29
- 3.05 Torch Connections 31
- B. Check Air Quality 32
- Art # A-03577 32
- 3.06 Torch Installation 33
- 3.07 Torch Parts Selection 34
- Connector for SC-11 35
- Standoff Control / CNC 35
- CPC Connector for 35
- Thermal Dynamics 36
- CNC Controller 36
- Knockout for Alternate 36
- Art # A-04149 37
- Pot / LED Board 39
- SECTION 4: OPERATION 41
- A. Torch Parts Selection 42
- B. Torch Connection 42
- D. Gas Selection 42
- E. Connect Work Cable 42
- F. Power On 43
- G. Set Operating Pressure 44
- I. Cutting Operation 45
- J. Typical Cutting Speeds 45
- K. Postflow 45
- Consumable Parts 46
- Good Tip 47
- Worn Tip 47
- A-03406 47
- 4.04 Cut Quality 48
- A. Piloting 49
- B. Torch Standoff 49
- C. Edge Starting 49
- D. Direction of Cut 49
- 4.06 Torch Operation 50
- B. Travel Speed 51
- 4.07 Cutting Parameters 52
- Thicknesses 53
- Material: Mild Steel 54
- Material: Stainless Steel 55
- Material: Aluminum 56
- Art # A-04204 57
- Manual 0-4642 4-19 OPERATION 59
- Material: 60
- A. Filter Element Replacement 65
- Art # A-02476 66
- First & Second 67
- Cartridges 67
- (as marked) 67
- D. Cleaning Torch 68
- E. O-Ring Lubrication 68
- 5.02 Common Faults 69
- B. How to Use This Guide 70
- C. Common Symptoms 70
- Art # A-03725 72
- Art # A-07168 73
- Spring-Loaded Cylinder 73
- A. General Information 75
- D. Pilot Arc Test 76
- E. Main Arc Test 76
- Cover Removal 77
- Art # A-03658 78
- Logic Board Layout 81
- 5.06 Pilot Arc Problems 83
- Art # A-03659 86
- 5.07 Main Arc Problems 88
- A. Safety Precautions 89
- B. Diode Testing Basics 90
- C. Diode Module Board Tests 91
- D. Main Input Power Test 93
- E. Gas Solenoid Circuit Test 94
- F. Output Power Tests 94
- A. Cover Removal 95
- B. Tube Handle Replacement 96
- C Cover Installation 96
- Wire #21 97
- Wire #24 97
- Top clip 97
- Wire #22 97
- Wire #23 97
- Art # A-03906 98
- Wire #25 98
- Wire #26 98
- Wire #46 98
- A. Fuse (F1) Replacement 99
- Internal Fuse Location 99
- T1 T2 T3 T4 100
- L1 L2 L3 100
- T1 T2 T3 100
- L1 L2 L3 L4 100
- Input Diode Replacement 102
- Art # A-03702 103
- E. Main PC Board Replacement 104
- 105
- A. Fan Replacement (M1, M2) 106
- B. Work Cable Replacement 107
- C. Pilot PC Board Replacement 107
- Art # A-03705 108
- This Page Left Blank 112
- A. Parts List Breakdown 113
- B. Returns 113
- Art # A-03709 115
- Art # A-06756 116
- Art # A-03005 117
- Manual 0-4642 6-7 PARTS LISTS 119
- Manual 0-4642 6-9 PARTS LISTS 121
- SL100 Torch 122
- Art # A-03872 123
- 6.12 Torch Replacement Parts 124
- Art # A-07113 125
- 6.13 Torch Consumables 126
- 6.14 Torch Spare Parts Kits 126
- Torch Consumables Selection 127
- (BLOCK DIAGRAM) 129
- Date of Mfr: 130
- APPENDIX A-4 Manual 0-4642 132
- Manual 0-4642 A-5 APPENDIX 133
- APPENDIX A-6 Manual 0-4642 134
- (MOST COMMON SETTINGS) 135
- (Division Factors 16-24) 136
- (Division Factors 24-30) 137
- (Division Factors 30-33) 138
- (Division Factors 33-36) 139
- (Division Factors 36-43) 140
- (Division Factors 43-50) 141
- WIRING LAYOUT 142
- LAYOUT and TEST POINTS 143
- APPENDIX A-16 Manual 0-4642 144
- Manual 0-4642 A-17 APPENDIX 145
- Main Power PC Board Signals 146
- APPENDIX A-20 Manual 0-4642 148
- Manual 0-4642 A-21 APPENDIX 149
- Logic Board Signals 150
- APPENDIX A-24 Manual 0-4642 152
- Manual 0-4642 A-25 APPENDIX 153
- Art # A-04218 154
- Manual 0-4642 A-27 APPENDIX 155
- APPENDIX A-28 Manual 0-4642 156
- Art # A-06753 158
- Art # A-07153 160
- APPENDIX A-34 Manual 0-4642 162
- Manual 0-4642 A-35 APPENDIX 163
- Art # A-07152 164
- APPENDIX A-38 Manual 0-4642 166
- Manual 0-4642 A-39 APPENDIX 167
- APPENDIX A-40 Manual 0-4642 168
- Manual 0-4642 A-41 APPENDIX 169
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