Thermal Dynamics 38 Cutmaster Service Manual
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Thermal Dynamics 38 Cutmaster Service Manual

Plasma cutting system
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38

Service Manual

CUTMASTER
PLASMA CUTTING SYSTEM
Rev. AB
Date: March 3, 2008
Operating Features:
™
A-03286
Manual # 0-2898
30
208-
230

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Summary of Contents for Thermal Dynamics 38 Cutmaster

  • Page 1: Service Manual

    ™ CUTMASTER PLASMA CUTTING SYSTEM A-03286 Service Manual Rev. AB Date: March 3, 2008 Manual # 0-2898 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 CutMaster 38 Power Supply Model SL60 Air Plasma Cutting Torch Operating Manual Number 0-2898 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, 2007, 2008 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 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................6-1 6.01 Introduction ....................6-1 6.02 Ordering Information ..................6-1 6.03 Major External Replacement Parts ............... 6-2 6.04 Front Panel Replacement Parts ..............6-3 6.05 Left Side Replacement Parts ............... 6-4 6.06 Right Side Replacement Parts ..............

  • Page 7: 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 8: 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 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.

  • Page 13: 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 14: Statement Of Warranty

    None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.

  • Page 15: Introduction

    C. Customer/Operator Responsibilities It is the customer/operator's responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the operating manual, and to protect the equipment from accidental or mali- cious damage.
  • Page 16 INTRODUCTION Manual 0-2898...

  • Page 17: Description

    SECTION 3: DESCRIPTION 3.01 Scope The purpose of this section is: • To familiarize the service technician with the capabilities and limitations of the equipment, • To provide an overall understanding which will allow the technician, in turn, to properly train customer oper- ating personnel.
  • Page 18 DESCRIPTION Manual 0-2898...

  • Page 19: Troubleshooting

    4.04 Common Operating Problems SECTION 4: TROUBLESHOOTING WARNINGS 4.01 Introduction Disconnect primary power at the source before dis- assembling the power supply, torch, or torch leads. This section provides service diagnostics for the CutMas- ter 38 Power Supply, allowing the Technician to isolate Frequently review the Important Safety Precau- any faulty subassemblies.

  • Page 20: Troubleshooting Guide - General Information

    'High speed dross' usually forms a narrow bead g. Non-Genuine Thermal Dynamics parts used along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is 4.05 Troubleshooting Guide -...

  • Page 21: Circuit Fault Isolation

    4.06 Circuit Fault Isolation B. How to Use the Troubleshooting Guide The following information is a guide to help the Service This section is to help isolate the defective circuit before Technician determine the most likely causes for various troubleshooting, identify symptoms, and test the unit for symptoms.

  • Page 22: Main Input And Internal Power Problems

    C. Pilot Arc Test C. Fan does not operate; AC indicator is OFF 1. Front Panel ON/OFF switch in OFF (down) position 1. Close the torch switch and check the following: a. Place switch to ON (up) position. • Gas flows briefly, then stops. •...
  • Page 23 D. AC indicator flashing, TEMP indicator OFF (on 3. Wire E8 not connected to PC Board terminal E8 system start-up); RUN / SET switch in RUN a. Check connection; reconnect if necessary. position 4. PC board fault circuit defective 1. Torch shield cup loose a.

  • Page 24: Pilot Arc Problems

    K. AC indicator steady ON: TEMP indicator ON; B. No arc or intermittent arc in torch; Gas flows; AC RUN/SET switch in SET position indicator ON; TEMP indicator OFF; GAS and DC indicators ON 1. PC board temperature sensor disconnected or faulty. 1.

  • Page 25: Main Arc Problems

    B. Opening Power Supply Enclosure 4.09 Main Arc Problems The cover of the Power Supply must be removed to gain Locate your symptom below: access to the input power connections. A. Main cutting arc will not start 1. Work cable not connected. WARNING a.
  • Page 26 C. Diode Testing Basics 6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly Testing of diode modules requires a digital volt/ohm- functioning diode will block in the reverse bias direc- meter that has a diode test scale. Remember that even tion and depending on the meter function will indi- if the diode module checks good, it may still be bad.
  • Page 27 D. Diode Bridge Checks Check for shorted Diode Bridges. E16A Diode Bridge 1 E15A E14A + Mark E12A E16B E16B Diode Bridge 2 E15B E15B E14B + Mark E12B A-03508 Disconnect primary input power. With an ohmmeter set on the diode range, make the following checks on both diode bridges: CutMaster 38 Diode Bridge Check Meter (+) Meter (-)
  • Page 28 TROUBLESHOOTING 4-10 Manual 0-2898...

  • Page 29: Service

    B. Procedure SECTION 5: 1. Open the wrist strap and unwrap the first two folds SERVICE of the band. Wrap the adhesive side firmly around your wrist. 5.01 Introduction 2. Unroll the rest of the band and peel the liner from the copper foil at the opposite end.

  • Page 30: Major External Parts Replacement

    5.04 Major External Parts 5.05 Front Panel Parts Replacement Replacement Refer to Section 6 for Front Panel Replacement Parts and overall detailed drawing. Refer to Section 6 for Major External Replacement Parts and overall detailed drawing. WARNING WARNING Disconnect primary power from the source before opening or disassembling the power supply.

  • Page 31: Left Side Internal Parts Replacement

    A. Diode Bridge Replacement C. Run/Set ( ) Switch 1. Remove the Power Supply cover per Subsection 5.04-A. Replacement 2. Label and remove the wires from the diode bridge 1. Remove the Power Supply cover per Subsection to the PC Board. Refer to the illustration. 5.04-A.

  • Page 32: Rear Panel Parts Replacement

    7. Secure the diode bridge to the Fan Panel with the 7. Thread the replacement Pressure Gauge into the hardware removed previously. Torque the hard- Power Supply the Regulator/Filter Assembly. ware to 15 in-lbs (1.7 Nm). Tighten securely. 8. Apply RTV silicone over the securing hardware. 8.

  • Page 33: Right Side Internal Parts Replacement

    3. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is lo- cated inside the Housing. 4. Remove the Filter Element from the Housing and set Element aside to dry. Ring 5. Wipe inside of housing clean, then insert the re- placement Filter Element open side first, as shown.
  • Page 34 B. Pressure Switch Replacement 1. Remove the cover per Subsection 5.04-A. 2. Label and disconnect the wires to the Pressure Switch. 3. Turn the Pressure Switch to remove it from the Regulator/Filter Assembly. 4. Apply thread sealant to the threads of the replace- ment Pressure Switch.

  • Page 35: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts lists provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Major External Replacement Parts Section 6.04 Front Panel Replacement Parts Section 6.05 Left Side Replacement Parts Section 6.06 Right Side Replacement Parts Section 6.07 Options and Accessories NOTE...

  • Page 36: Major External Replacement Parts

    6.03 Major External Replacement Parts Item # Description Catalog # Cover with labels 9-8631 Base Enclosure Assembly 9-8640 Tube, roll handle 9-8632 A-03433 NOTE Illustration may vary slightly from unit. PARTS LISTS Manual 0-2898...

  • Page 37: Front Panel Replacement Parts

    6.04 Front Panel Replacement Parts Item# Description Ref. Catalog # On/Off Switch 8-4248 Output Current Control Potentiometer with wire harness 9-8629 Run/Set Switch 9-1042 Output Current Control Knob 9-8527 Work Cable with Clamp, 20 Ft / 6.1 m 9-8642 A-03496 NOTE Illustration may vary slightly from unit.

  • Page 38: Left Side Replacement Parts

    6.05 Left Side Replacement Parts Item # Description Catalog # PCB Assembly 9-8630 Diode Bridge BR1, BR2 7-3345 Thermal Pad 9-4466 Input Power Cable with plug, for non-CE units through Unit Rev AE 9-8628 Input Power Cable with plug, for non-CE units at Unit Rev AF or later 9-8660 Input Power Cable for CE units Rev AA / AB 9-8661...
  • Page 39 A-03498 Input Filter & Bracket (CE Units only) NOTE Illustration may vary slightly from unit. Manual 0-2898 PARTS LISTS...

  • Page 40: Right Side Replacement Parts

    6.06 Right Side Replacement Parts Item # Description Catalog # Console ATC Assembly 9-8641 Regulator/Filter Assembly (includes Pressure Switch, 9-8643 Pressure Gauge, Solenoid) Pressure Gauge 9-1045 Pressure Switch 9-1044 Regulator/Filter Replacement Element 9-0182 Regulator Mounting Nut 9-5804 Assembly, Output Inductor 9-8626 8A / 8B PFC Choke (Type 8B assembly replaces Type 8A)
  • Page 41 A-03499 Fan Panel Fan Shroud Transformer Bracket NOTE Illustration may vary slightly from unit. Manual 0-2898 PARTS LISTS...

  • Page 42: Options And Accessories

    6.07 Options and Accessories Description Catalog # Single-Stage Filter Kit (Includes Filter And Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Element 9-7741 Replacement Filter Hose (Not Shown) 9-7742 Not shown: Multi-Purpose Cart 7-8888 Housing Filter Element (Cat. No. 9-7741) Spring O-ring (Cat.

  • 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 6-10 Manual 0-2898...

  • Page 45: Appendix 1: Input Wiring Requirements

    APPENDIX 1: INPUT WIRING REQUIREMENTS CutMaster 38 Input Power Requirements Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. (kVA) (Amps) Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph 50 / 60 50 / 60 50 / 60 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code...

  • Page 46: Appendix 2: Main Power Pc Board Layout

    APPENDIX 2: MAIN POWER PC BOARD LAYOUT TP16 MAIN PCB ASSEMBLY 19X1773 REV OVER-TEMP PRESSURE RUN/SET TEST TEMP E14B TP20 E14A TORCH SWITCH E15B E15A TP101 E12A TP23 TP23 TP24 E12A E12B TP26 E12B TP26 E16B E16A E16B PILOT E16A TP24 TP21 TP21...

  • Page 47: Appendix 3: Main Pc Board Wiring

    APPENDIX 3: MAIN PC BOARD WIRING To Temperature To Pressure Sensor To Fan Switch To Solenoid MAIN PCB ASSEMBLY 19X1773 REV OVER-TEMP PRESSURE TEST RUN/SET To Current Control To Torch TEMP Receptacle To Run / Set Switch TP20 TORCH SWITCH To PFC Inductor To On / Off...

  • Page 48: Appendix 4: Maintenance Schedule

    APPENDIX 4: MAINTENANCE SCHEDULE This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Cutting Hours: Check torch consumable parts, replace if damaged or worn.

  • Page 49: Appendix 5: Torch Connector Diagram

    APPENDIX 5: TORCH CONNECTOR DIAGRAM ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Open 4 - Green / Switch 4 - Switch 3 - Switch 7 - Open 7 - Open 3 - White / Switch...

  • Page 50: Appendix 6: System Schematic

    APPENDIX 6: SYSTEM SCHEMATIC PFC INDUCTOR INP UT 230V ONLY TEST E MC FILTER E12A CE ONLY CHASSIS GND (E12A) (E15A) (E14A) (E1) 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 51 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 52: Appendix 7: Publication History

    APPENDIX 7: PUBLICATION HISTORY Cover Date Details 1/31/2003 Manual Released. 4/8/2003 Revised; updated trouble-shooting per Tech Service, updated system schematic to Rev. AC, added CE input filter. 7/3/2003 Updated power cord per ECO 100487, added pin-out diagram for torch connector. 4/12/2006 Added input power cords &...

  • Page 53: 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 54 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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