Tweco CutMaster 101 with SL100SV User Manual download pdf (Page 19)

Manual 0-4642 2-3 INTRODUCTION

2.04 Power Supply Features

Art # A-04214

Input Power Cord

Gas Inlet Port

Gas Pressure Regulator / Filter Assembly

Gas Pressure Gauge

CPC Connector for

Thermal Dynamics CNC Controller

Knockout for Alternate

CNC Controller

Wire Harness

Art # A-04507

Work Cable

and Clamp

Handle and Leads Wrap

Torch Leads Receptacle

Control Panel

1 2 ... 14 15 16 17 18 19 20 21 22 23 24 ... 171 172

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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Tweco CutMaster 101 with SL100SV User Manual Page 19

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