Thermal Dynamics 38 CUTMASTER Operating Manual
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Thermal Dynamics 38 CUTMASTER Operating Manual

Plasma cutting system
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Operating Manual
38
CUTMASTER
PLASMA CUTTING SYSTEM
Rev. AA.01
Operating Features:
A-03286
Date: September 29, 2006
30
™
Manual # 0-2964
208-
120
230

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Summary of Contents for Thermal Dynamics 38 CUTMASTER

  • Page 1 ™ CUTMASTER PLASMA CUTTING SYSTEM A-03286 Operating Manual Rev. AA.01 Date: September 29, 2006 Manual # 0-2964 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 CE CutMaster 38 Power Supply Model SL60 Air Plasma Cutting Torch Operating Manual Number 0-2964 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2003, 2004, 2005, 2006 by Thermal Dynamics Corporation All rights reserved.
  • Page 4 TABLE OF CONTENTS...

  • Page 5: 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 6 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ......................A-1 APPENDIX 2: DATA TAG INFORMATION .................. A-2 APPENDIX 3: SYSTEM SCHEMATIC ..................A-4 APPENDIX 4: Publication History ..................... A-6 Global Customer Service Contact Information ............. Inside Rear Cover...

  • 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

    • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet • Extra care must be taken when the workplace is and infra red light. These arc rays will damage your moist or damp.

  • Page 9: Note, Attention Et Avertissement

    7. AWS Standard A6.0, WELDING AND CUTTING ATTENTION CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS 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 yeux 1.06 Documents De Reference 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: Section 2: Specifications

    SECTION 2: SPECIFICATIONS CE CutMaster 38 Power Supply Specifications Input Power 208-230 VAC (± 10%), Single-Phase, 50/60 Hz Input Power Cable Suitable for 208-230VAC, 20-Amp Single-Phase input power. Output Current 20-30 Amps, continuously variable Power Supply Gas Filtering Ability Particulates to 20 Microns CE CutMaster 38 Power Supply Duty Cycle (Note 1) Ambient Temperature 104°...

  • Page 16: Options And Accessories

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

  • Page 17: Torch Specifications

    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 series G. Direct Contact Hazard For exposed tip the recommended standoff is 0 - 1/16 inch (0 - 2 mm).
  • Page 18 SPECIFICATIONS Manual 0-2964...

  • Page 19: Section 3: Installation

    SECTION 3: INSTALLATION 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 20: Primary Input Power Connections

    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 21: Gas Connections

    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-B 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. Other fittings may be used.
  • Page 22 B. 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 23: Torch Connections

    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. 1. Align the male connector (on the torch lead) with the female receptacle on the power supply. Press the connector into the receptacle fully.

  • Page 24: Check Air Quality

    Check Air Quality To test the quality of air, put the RUN / SET switch in the SET (down) position, place a welding filter lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens. Do not start an arc! A-03385 INSTALLATION Manual 0-2964...

  • Page 25: 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 0-2964 OPERATION...
  • Page 26 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 27: 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 28 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 29 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 30 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 31 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 32: 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 33: 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 34 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 35 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 36 B. 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 37: 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 38: 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 39 B. 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 40 3. Gas pressure too high or too low a. Adjust to proper pressure. 4. 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 41 I. Limited output with no control 1. Poor input or output connections a. Check all input and output connections. 2. Work cable connection to work piece is poor a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece. 3.
  • Page 42 M. No gas flow; AC indicator ON; Fan operates 1. Gas not connected or pressure too low a. Check gas connections. Adjust gas pressure to proper setting. 2. Shield Cup not properly installed. a. Check to see that Shield Cup is properly installed. 3.

  • Page 43: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. B. Returns If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted. 6.02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item.

  • Page 44: Power Supply Replacement Parts

    6.04 Power Supply Replacement Parts Description Catalog # Regulator/Filter Replacement Filter Element 9-4414 6.05 Options and Accessories Description Catalog # 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...

  • Page 45: 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 46 PARTS LISTS Manual 0-2964...

  • Page 47: Appendix 1: Sequence Of Operation (Block Diagram

    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 48: 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 49 This page left blank. Manual 0-2964 APPENDIX...

  • Page 50: 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) (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 4: Publication History

    Added Australian power supply version. Added dust cover to options list. Added publi cation history. 9/29/06 AA.01 Added patent information, new revision control and manual cover standards *NOTE: Thermal Dynamics uses the manual cover date to indicate release level. APPENDIX Manual 0-2964...

  • 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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