Thermal Dynamics CutMaster 38 Operating Manual
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Thermal Dynamics CutMaster 38 Operating Manual

Thermal Dynamics CutMaster 38 Operating Manual

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Operating Manual
38
CUTMASTER
PLASMA CUTTING SYSTEM
Rev. AA.01
Operating Features:
A-03286
Date: October 20, 2006
30
™
Manual # 0-2888
208-
120
230

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John Munley
February 20, 2025

In my Cutmaster 38, compressed air flows from the plastic tube at the bottom of the internal filter under ALL conditions if air is connected.

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1 comments:
Mr. Anderson
February 20, 2025

Compressed air flows from the plastic tube at the bottom of the internal filter on a Thermal Dynamics CutMaster 38 due to excessive oil, moisture, or other contaminants in the air supply. The system requires clean, dry air for proper operation, and contaminants can cause double-arcing, rapid tip wear, or torch failure. The internal filter helps remove these impurities, and if excess moisture or contaminants accumulate, air may escape through the plastic tube as part of the filtration process.

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Summary of Contents for Thermal Dynamics CutMaster 38

  • Page 1 ™ CUTMASTER PLASMA CUTTING SYSTEM A-03286 Operating Manual Rev. AA.01 Date: October 20, 2006 Manual # 0-2888 Operating Features: 208-...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through market- leading, dependable products that have stood the test of time.
  • Page 3 Plasma Cutting System CutMaster 38 Power Supply Model SL60 Air Plasma Cutting Torch Operating Manual Number 0-2888 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2002, 2003, 2004, 2005, 2006 by Thermal Dynamics Corporation All rights reserved.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Declaration of Conformity ................1-4 1.05 Statement of Warranty .................. 1-5 SECTION 2: SPECIFICATIONS ....................2-1 Options and Accessories ..................

  • Page 5: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 6: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...
  • Page 7 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Society, 550 N.W.

  • Page 8: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 9: Statement Of Warranty

    Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
  • Page 10 GENERAL INFORMATION Manual 0-2888...

  • Page 11: Section 2: Specifications

    Cable with plug, for 120VAC, 20-Amp Single-Phase input power. Output Current 20-30 Amps, continuously variable Power Supply Gas Filtering Ability Particulates to 20 Microns CutMaster 38 Power Supply Duty Cycle (Note 2) Ambient Temperature 104° F (40° C) n/a % Duty Cycle...

  • Page 12: Options And Accessories

    Electrical Requirements CutMaster 38 Input Power Requirements Power Input Current Input Suggested Sizes (See Notes) Input (Amps) Fuse (Amps) Wire (AWG) Wire (Canada) Voltage Freq. (kVA) (Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph 50 / 60 50 / 60 50 / 60...

  • Page 13: Torch Specifications

    Voltage (V peak Arc Striking Voltage NOTE Ratings shown apply to the SL60 Torch only. Refer to the Specifications chart on page 2-1 for CutMaster 38 data. F. Plasma Power Supply Used With • Thermal Dynamics CutMaster 38 Manual 0-2888...
  • Page 14 SPECIFICATIONS Manual 0-2888...

  • Page 15: Installation

    SECTION 3: INSTALLATION 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.

  • Page 16: Primary Input Power Connections

    3.03 Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.

  • Page 17: Gas Connections

    3.04 Gas Connections A. Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure gas cylinders. Refer to subsection 3.4-C if an optional air line filter is to be installed. 1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
  • Page 18 C. Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port. 2.
  • Page 19 D. Using High Pressure Gas Cylinders When using high pressure gas cylinders as the gas supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present.

  • Page 20: Torch Connections

    3.05 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 Torch to this power supply. WARNING Disconnect primary power at the source before connecting the torch. Align the male connector (on the torch lead) with the female receptacle on the power supply. Press the connector into the receptacle fully.

  • Page 21: Operation

    SECTION 4: OPERATION 4.01 Product Features A. General Features Gas Pressure Knob Handle and Leads Wrap Torch Leads Connector Control Panel Work Cable A-03287 and Clamp Manual 0-2888 OPERATION...
  • Page 22 B. Control Panel A-03283 1. ON / OFF Switch Controls input power to the power supply. Up is ON, down is OFF. 2. RUN / SET Switch RUN (up) position is for general torch operation. SET (down) position is for setting gas pressure and purging lines.

  • Page 23: Preparations For Operating

    4.02 Preparations For Operating At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. A. Torch Parts Selection Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (30 amps maximum).
  • Page 24 B. Torch Connection Check that the torch is properly connected. C. Check Primary Input Power Source 1. Check the power source for proper input voltage. Make sure the input power source meets the power re- quirements for the unit per Section 2, Specifications. 2.
  • Page 25 F. Power On Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. A-03384 G. Set Operating Pressure Place the Power Supply RUN / SET switch to the SET (down) position. Gas will flow. Adjust gas pressure to 65 psi / 4.5 bar.
  • Page 26 H. Select Current Output Level Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level. A-03386 Cutting Operation Refer to Section 1, Important Safety Precautions. Wear heavy welding gloves and protective clothing. Protect eyes with appropriate shielding.
  • Page 27 J. Cutting Technique Hold the torch with one or two hands, with the torch tip close to the workpiece. Do not cut or handle the workpiece without welding gloves and protective clothing. Always wear protective eye shielding when cutting or gouging. Move the torch along the cut line so the arc penetrates the workpiece and sparks emerge from the bottom of the cut.

  • Page 28: Sequence Of Operation

    4.03 Sequence of Operation The following is a typical sequence of operation for this power supply. Refer to Appendix 1 for block diagram. 1. Plug the input power cord into an active circuit. a. AC power is available at the Power Supply. 2.

  • Page 29: Service

    SECTION 5: SERVICE 5.01 General Maintenance A. Each Use Check torch consumables for wear, replace if necessary. WARNING Shut off power before inspecting or removing torch parts. NOTE When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and torch handle.
  • Page 30 B. Every three months A. Check internal air filter, replace if necessary. 1. Shut off input power; turn off the gas supply. Bleed down the gas supply. 2. Remove the upper cover screws. 3. Loosen the lower screws. Pull the cover up and away from the unit. NOTE Leave internal ground wire in place.
  • Page 31 4. Pull the upper end of the drain tube off the fitting on the filter bowl. 5. Unscrew the bowl. The filter element will be visible and still attached to the main body of the Regulator / Filter. 6. Unscrew the filter element from the Regulator / Filter body. The filter element will come off with a spool and some additional pieces.
  • Page 32 C. O-Ring Lubrication An o-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis.
  • Page 33 D. Check Optional Single - Stage Filter Element, replace if necessary. 1. Shut off input power. 2. Shut off air supply, bleed down system. 3. Disconnect gas supply hose from filter. 4. Turn the Cover counter - clockwise. 5. Remove the Filter Element from the Housing and set Element aside to dry. 6.

  • Page 34: Common Faults

    Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Non - Genuine Thermal Dynamics parts used 4. Short Torch Parts Life a. Oil or moisture in air source b. Exceeding system capability (material too thick) c.

  • Page 35: Basic Troubleshooting Guide

    5.03 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. A. Basic Troubleshooting: Overview This guide covers basic troubleshooting.
  • Page 36 C. AC indicator flashing; Torch cannot be activated 1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.) a. Release torch trigger, set ON / OFF switch to OFF (down). Return ON / OFF switch to ON (up) position. 2.
  • Page 37 G. Torch will not pilot when torch switch is activated 1. System is in SET mode a. Change to RUN mode. 2. Upper O-ring on torch head is in wrong position. a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary. Art # A-03640 Upper Groove with Vent Holes...
  • Page 38 Low cutting output 1. Incorrect setting of CURRENT (A) control a. Check and adjust to proper setting. 2. Faulty components in unit a. Return for repair or have qualified technician repair. Limited output with no control 1. Poor input or output connections a.
  • Page 39 M. Arc shuts off during operation; arc will not restart when torch switch is activated. 1. Power Supply is overheated (TEMP indicator a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specifications.
  • Page 40 SERVICE 5-12 Manual 0-2888...

  • Page 41: Parts Lists

    The following items are included with the replacement power supply: input power cord and plug, work cable & clamp, gas pressure regulator / filter, and operating manual. Description Catalog # CutMaster 38 Power Supply with input power cord and 120 VAC, 20A plug 3-3820 Surelok Model SL60 Torch 7-5204 6.04 Power Supply Replacement Parts...

  • Page 42: Options And Accessories

    6.05 Options and Accessories Description Catalog # 120V, 15 - Amp Plug 9-8644 120V, 20 - Amp Receptacle 9-8645 Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Multi - Purpose Cart 7-8888...

  • Page 43: Patent Information

    PATENT INFORMATION The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512 Catalog Number Description 9-8235 Shield Cap, Drag 50-60A 9-8236 Sheild Cap, Drag 70-100A 9-8237 Shield Cup, Body 9-8238 Shield Cap, Machine 50-60A 9-8239 Shield Cap, Machine 70-100A 9-8244 Shield Cap, Drag 40A 9-8245...
  • Page 44 PARTS LISTS Manual 0-2888...

  • Page 45: Appendix 1: Sequence Of Operation

    APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION ACTION Close external ON / OFF switch RUN / SET switch Connect work cable RUN / SET switch to SET. to workpiece. disconnect switch. to ON. to RUN. Set output amperage RESULT RESULT RESULT...

  • Page 46: Appendix 2: Data Tag Information

    APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...
  • Page 47 This page left blank. Manual 0-2888 APPENDIX...

  • Page 48: Appendix 3: System Schematic

    APPENDIX 3: SYSTEM SCHEMATIC PFC INDUCTOR INP UT 230V ONLY TEST E MC FILTER E12A CE ONLY CHASSIS GND (E12A) (E15A) (E1) (E14A) E14A 120/208/230V INPUT (E16A) 50/60HZ (E2) E15A STUD E16A E12B BIAS (E12B) FAN1 CONVERTER 12VDC BLACK (E14B) (E15B) E14B LOGIC AND CONTROL CIRCUITRY...
  • Page 49 W EST LEBANON, NH 03784 10/04/02 603-298-5711 REL ECO 100535 2/27/03 Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, May 15, 2001 Not For Release, Reproduction, or Distribution without Written Consent. Drawn: References NOTE: Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

  • Page 50: Global Customer Service Contact Information

    Global Customer Service Contact Information Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 51 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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