WELDING INDUSTRIES MC100-0 Specifications

Patented TechnologyPLASMA CUTTING SYSTEM102CUTMASTER™Rev. AC Date: April 25, 2012 Manual # 0-5012Operat

CUTMASTER 102GENERAL INFORMATION 1-4 Manual 0-5012produit du métal, des étincelles, des scories chaudes pouvant mettre lefeuauxmatièrescombustib

CUTMASTER 102Manual 0-5012 1-5 GENERAL INFORMATION1.06 Documents De ReferenceConsultez les normes suivantes ou les révisions les plus récentes aya

CUTMASTER 102GENERAL INFORMATION 1-6 Manual 0-50121.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Str

CUTMASTER 102Manual 0-5012 1-7 GENERAL INFORMATION1.08 Statement of WarrantyLIMITED WARRANTY: Subject to the terms and conditions established bel

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CUTMASTER 102Manual 0-5012 2-1 INTRODUCTIONSECTION 2 SYSTEM: INTRODUCTION 2.01 How To Use This ManualThis Owner’s Manual applies to just specicati

CUTMASTER 102INTRODUCTION 2-2 Manual 0-50122.04 Power Supply SpecificationsCutMaster 102 Power Supply SpecicationsInput Power208 / 230 VAC (187 - 25

CUTMASTER 102Manual 0-5012 2-3 INTRODUCTION2.05 Input Wiring SpecificationsCutMaster 102 Power Supply Input Cable Wiring RequirementsInput voltage F

CUTMASTER 102INTRODUCTION 2-4 Manual 0-50122.06 Power Supply FeaturesHandle and Leads WrapTo rch Leads ReceptacleControl PanelArt # A-08359Work Cabl

CUTMASTER 102Manual 0-5012 2T-1 INTRODUCTIONSECTION 2 TORCH: INTRODUCTION 2T.01 Scope of ManualThis manual contains descriptions, operating instructi

Patented TechnologyWE APPRECIATE YOUR BUSINESS!Congratulations on your new Radnor/Thermal Dynamics product. We are proud to have you as our customer a

CUTMASTER 102INTRODUCTION 2T-2 Manual 0-5012F. Torch RatingsManual Torch RatingsAmbient Temperature104° F 40° C Duty Cycle100% @ 100 Amps @ 400 scfh

CUTMASTER 102Manual 0-5012 2T-3 INTRODUCTIONB. Gas DistributionThe single gas used is internally split into plasma and secondary gases.The plasma ga

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CUTMASTER 102Manual 0-5012 3-1 INSTALLATIONSECTION 3 SYSTEM: INSTALLATION 3.01 Unpacking1. Use the packing lists to identify and account for each i

CUTMASTER 102INSTALLATION 3-2 Manual 0-50123.03 Primary Input Power ConnectionsCAUTIONCheck your power source for correct voltage before plugging in

CUTMASTER 102Manual 0-5012 3-3 INSTALLATION6. Connect the wires as follows.• Connect Bus Bar Jumpers on the contactor as shown in prior illustratio

CUTMASTER 102INSTALLATION 3-4 Manual 0-50123.04 Gas ConnectionsConnecting Gas Supply to UnitThe connection is the same for compressed air or high pr

CUTMASTER 102Manual 0-5012 3-5 INSTALLATIONInstalling Optional Single - Stage Air FilterAn optional lter kit is recommended for improved ltering wi

CUTMASTER 102INSTALLATION 3-6 Manual 0-5012Installing Optional Two - Stage Air Filter KitThis optional two - stage air line lter is also for use on

CUTMASTER 102Manual 0-5012 3T-1 INSTALLATIONSECTION 3 TORCH: INSTALLATION 3T.01 Torch ConnectionsIf necessary, connect the torch to the Power Sup-p

!WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing, operat-ing, or servicing the equipment.While t

CUTMASTER 102INSTALLATION 3T-2 Manual 0-5012A-02585WorkpieceSquarePinch BlockAssemblyMechanical Torch Set - Up3. The proper torch parts (shield cup,

CUTMASTER 102Manual 0-5012 4-1 OPERATIONSECTION 4 SYSTEM: OPERATION4.01 Front Panel Controls / FeaturesSee Illustration for numbering Identification

CUTMASTER 102OPERATION 4-2 Manual 0-50124.02 Preparations for OperationAt the start of each operating session:WARNINGDisconnect primary power at the

CUTMASTER 102Manual 0-5012 4-3 OPERATIONSTANDOFFCutMaster 102 Gas Pressure SettingsLeads LengthMC100 (Hand Torch)MC100 (Mechanized Torch)Up to 25&a

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CUTMASTER 102 Manual 0-5012 4T-1 OPERATIONSECTION 4 TORCH: OPERATION4T.01 Torch Parts SelectionDepending on the type of operation to be done determin

CUTMASTER 102OPERATION 4T-2 Manual 0-50124T.02 Cut QualityNOTESCut quality depends heavily on setup and parameters such as torch stando, alignment

CUTMASTER 102 Manual 0-5012 4T-3 OPERATIONTorch StandoffImproper standoff (the distance between the torch tip and workpiece) can adversely affect tip

CUTMASTER 102OPERATION 4T-4 Manual 0-50122. Depending on the cutting operation, do one of the following:a. For edge starts, hold the torch perpen-di

CUTMASTER 102 Manual 0-5012 4T-5 OPERATIONShield Cup With Straight EdgeThe drag shield cup can be used with a non conduc-tive straight edge to make s

TABLE OF CONTENTSSECTION 1: GENERAL INFORMATION ...1-11.01 Notes, Cauti

CUTMASTER 102OPERATION 4T-6 Manual 0-5012Piercing With Hand Torch1. The torch can be comfortably held in one hand or steadied with two hands. Posit

CUTMASTER 102 Manual 0-5012 4T-7 OPERATION4T.05 Gouging!WARNINGSBe sure the operator is equipped with proper gloves, clothing, eye and ear protection

CUTMASTER 102OPERATION 4T-8 Manual 0-5012side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if la

CUTMASTER 102 Manual 0-5012 4T-9 OPERATION4T.07 Parts Selection for MC100 Torch CuttingStartCartridge64006513Electrode64006514Tips: 30A 6400650

CUTMASTER 102OPERATION 4T-10 Manual 0-50124T.08 Recommended Cutting Speeds for MC100 With Exposed TipType Torch: MC100 With Exposed Tip Type Materia

CUTMASTER 102 Manual 0-5012 4T-11 OPERATIONType Torch: MC100 With Exposed Tip Type Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: Si

CUTMASTER 102OPERATION 4T-12 Manual 0-5012Type Torch: MC100 With Exposed TipType Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: Sing

CUTMASTER 102 Manual 0-5012 4T-13 OPERATIONType Torch: MC100 With Exposed TipType Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: Sin

CUTMASTER 102OPERATION 4T-14 Manual 0-50124T.09 Recommended Cutting Speeds for MC100 With Shielded TipType Torch: MC100 With Shielded Tip Type Mater

CUTMASTER 102 Manual 0-5012 4T-15 OPERATIONType Torch: MC100 With Shielded Tip Type Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: S

TABLE OF CONTENTSSECTION 5 SYSTEM: SERVICE ...5-15.01 Gener

CUTMASTER 102OPERATION 4T-16 Manual 0-5012Type Torch: MC100 With Shielded Tip Type Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: Si

CUTMASTER 102 Manual 0-5012 4T-17 OPERATIONType Torch: MC100 With Shielded Tip Type Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: S

CUTMASTER 102OPERATION 4T-18 Manual 0-5012PATENT INFORMATIONPlasma Cuing Torch PatentsThe following parts are covered under U.S. and Foreign Patents

CUTMASTER 102 Manual 0-5012 4T-19 OPERATION Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) P

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CUTMASTER 102 Manual 0-5012 5-1 SERVICESECTION 5 SYSTEM: SERVICE5.01 General MaintenanceWarning!Disconnect input power before maintaining.Each Use

CUTMASTER 102 SERVICE 5-2 Manual 0-50125.02 Maintenance ScheduleNOTEThe actual frequency of maintenance may need to be adjusted according to the op

CUTMASTER 102 Manual 0-5012 5-3 SERVICE5.04 Fault IndicatorAt initial power up, two lights will temporarily illu-minate for 2-3 seconds to show th

CUTMASTER 102 SERVICE 5-4 Manual 0-50125.05 Basic Troubleshooting GuideWARNINGThere are extremely dangerous voltage and power levels present inside

CUTMASTER 102 Manual 0-5012 5-5 SERVICEProblem - Symptom Possible Cause Recommended ActionFAULT&80PSIindicatorsashing.Gasowiscyclin

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CUTMASTER 102 SERVICE 5-6 Manual 0-50125.06 Power Supply Basic Parts ReplacementWARNINGDisconnect primary power to the system before disassembling

CUTMASTER 102 Manual 0-5012 5-7 SERVICE5. Remove the fitting from the filter element as-sembly by inserting a 6 mm hex wrench into the internal hex

CUTMASTER 102 SERVICE 5-8 Manual 0-5012Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Fil

CUTMASTER 102Manual 0-5012 5T-1 SERVICESECTION 5 TORCH: SERVICE5T.01 General MaintenanceNOTERefer to Previous "Section 5 System" for com

CUTMASTER 102 SERVICE 5T-2 Manual 0-50125T.02 Inspection and Replacement of Consumable Torch PartsWARNINGSDisconnect primary power to the system bef

CUTMASTER 102Manual 0-5012 6-1 PARTS LISTSECTION 6: PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provide a breakdown of all r

CUTMASTER 102PARTS LIST 6-2 Manual 0-50126.04 Replacement Power Supply Parts Qty Description Catalog # 1 Regulator 9-0115 1 Filter A

CUTMASTER 102Manual 0-5012 6-3 PARTS LIST6.06 Replacement Parts for Hand Torch Item # Qty Description Catalog # 1 1 Torch Handle Replace

CUTMASTER 102PARTS LIST 6-4 Manual 0-50126.07 Replacement Parts - for Machine Torches with Unshielded Leads Item No. Qty Description Catalog

CUTMASTER 102Manual 0-5012 6-5 PARTS LISTA-07994_AB14235 & 67891012111013

CUTMASTER 102Manual 0-5012 1-1 GENERAL INFORMATIONSECTION 1: GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, ca

CUTMASTER 102PARTS LIST 6-6 Manual 0-50126.08 Torch Consumable Parts (MC100)Starter Cartridge64006513Electrode64006514Shield Cup, Gouging 64006524S

CUTMASTER 102Manual 0-5012 A-1 APPENDIXAPPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)ACTION:ON / OFF switch to ON RESULT:AC indicator

CUTMASTER 102 APPENDIX A-2 Manual 0-50121/ 3ff12West Lebanon, NH USA 03784Made in USAMo del:U11max 1effIIU23Ø3Ø1Ø1ØS/NU0=XStandard SymbolsØACDCPhase

CUTMASTER 102Manual 0-5012 A-3 APPENDIXAPPENDIX 3: TORCH PIN - OUT DIAGRAMSA. Hand Torch Pin - Out Diagram1234567856781234ATC Female ReceptacleFr

CUTMASTER 102 APPENDIX A-4 Manual 0-5012APPENDIX 4: TORCH CONNECTION DIAGRAMSA. Hand Torch Connection DiagramTo rch: MC60 / MC100 Hand To rchLeads

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CUTMASTER 102 APPENDIX A-6 Manual 0-5012APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS5544332211DDCCBBAA+12VDC+12VDC+12VDC+12VDC+12VDC+12VDC+12VDC24V

CUTMASTER 102Manual 0-5012 A-7 APPENDIX5544332211DDCCBBAA+12VDC+12VDC+12VDC+12VDC+12VDC+12VDC+12VDC24VAC+5VDC+12VDC+12VDC+12VDCDWG No:SheetofSupers

CUTMASTER 102 APPENDIX A-8 Manual 0-5012APPENDIX 6: Publication HistoryCover Date Rev. Change(s)July 21, 2008 AA Manual released.Mar. 20, 1

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CUTMASTER 102GENERAL INFORMATION 1-2 Manual 0-5012• Donotcutorweldoncontainersthatmayhaveheldcombus-tibles.• Providearewatchwhenw

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CUTMASTER 102Manual 0-5012 1-3 GENERAL INFORMATION1.04 Note, Attention et AvertissementDanscemanuel,lesmots“note,”“attention,”et“avertisse