Thermal Dynamics 38 Cutmaster Service Manual

38

™

CUTMASTER

PLASMA CUTTING SYSTEM

A-03286

Service Manual

Rev. AB Date: March 3, 2008 Manual # 0-2898
Operating Features:

30

208­230

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800­426-1888, or visit us on the web at www.thermal-dynamics.com.

This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product.
Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire
manual, especially the Safety Precautions. They will help you to
avoid potential hazards that may exist when working with this
product.

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 market­leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical
support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically
advanced products to achieve a safer working environment within
the welding industry.

W ARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat­ing, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.

Plasma Cutting System

CutMasterTM 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
[phone]

www.thermal-dynamics.com

Copyright 2002, 2003, 2004, 2005, 2006, 2007, 2008 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: March 3, 2008

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

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 ............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 Scope Of Manual ......................................................................................... 2-1

2.02 General Service Philosophy ......................................................................... 2-1

2.03 Service Responsibilities ............................................................................... 2-1

SECTION 3:

DESCRIPTION .................................................................................................................. 3-1

3.01 Scope .......................................................................................................... 3-1

3.02 Specifications/Design Features ................................................................... 3-1

SECTION 4:

TROUBLESHOOTING ...................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-1

4.02 Periodic Inspection & Cleaning Procedures................................................... 4-1

4.03 System Design ............................................................................................. 4-1

4.05 Troubleshooting Guide - General Information ................................................. 4-2

4.06 Circuit Fault Isolation .................................................................................... 4-3

4.07 Main Input and Internal Power Problems ....................................................... 4-4

4.08 Pilot Arc Problems........................................................................................ 4-6

4.09 Main Arc Problems ....................................................................................... 4-7

4.10 Test Procedures ............................................................................................ 4-7

SECTION 5:

SERVICE .......................................................................................................................... 5-1

5.01 Introduction ................................................................................................... 5-1

5.02 Anti-Static Handling Procedures ................................................................... 5-1

5.03 Parts Replacement - General Information ..................................................... 5-1

5.04 Major External Parts Replacement ............................................................... 5-2

5.05 Front Panel Parts Replacement..................................................................... 5-2

5.06 Left Side Internal Parts Replacement ........................................................... 5-3

5.07 Rear Panel Parts Replacement ..................................................................... 5-4

5.08 Right Side Internal Parts Replacement ......................................................... 5-5

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 ..................................................................... 6-6

6.07 Options and Accessories ............................................................................. 6-8

PATENT INFORMATION ............................................................................................................ 6-9

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: MAIN POWER PC BOARD LAYOUT.................................................................. A-2

APPENDIX 3: MAIN PC BOARD WIRING.................................................................................. A-3

APPENDIX 4: MAINTENANCE SCHEDULE ............................................................................ A-4

APPENDIX 5: TORCH CONNECTOR DIAGRAM....................................................................... A-5

APPENDIX 6: SYSTEM SCHEMATIC ...................................................................................... A-6

APPENDIX 7: PUBLICATION HISTORY .................................................................................... A-8

Global Customer Service Contact Information ..................................................... Inside Rear Cover

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high­lights are categorized as follows:

NOTE

An operation, procedure, or background informa­tion which requires additional emphasis or is help­ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may
cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may
cause injury to the operator or others in the oper­ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN­GEROUS AND HAZARDOUS TO YOUR
HEALTH.

Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per­sons who work near plasma arc cutting applica­tions should consult their medical health profes­sional and the manufacturer of the health
equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and
follow all warnings, safety precautions and in­structions before using the equipment. Call 1-603­298-5711 or your local distributor if you have any
questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met­als which may contain one or more of the follow­ing:

Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in­formation regarding the kind and amount of fumes
and gases that may be dangerous to your health.

• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.

• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com­bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.

• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de­fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op­erator or others in the workplace.

• Never touch any parts that are electrically “live”
or “hot.”

Manual 0-2898 1-1 GENERAL INFORMATION

• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is
moist or damp.

• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publica­tions.

• Disconnect power source before performing any
service or repairs.

• Read and follow all the instructions in the Operat­ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.

• Be sure there is no combustible or flammable ma­terial in the workplace. Any material that cannot
be removed must be protected.

• Ventilate all flammable or explosive vapors from
the workplace.

• Do not cut or weld on containers that may have
held combustibles.

• Provide a fire watch when working in an area where
fire hazards may exist.

• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under­water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis­sipated. Trapped hydrogen gas that is ignited will
cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro­cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per­manent loss of hearing.

• To protect your hearing from loud noise, wear pro­tective ear plugs and/or ear muffs. Protect others
in the workplace.

• Noise levels should be measured to be sure the deci­bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel­met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro­tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work­piece.

1.03 Publications

Refer to the following standards or their latest revisions
for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu­ments, U.S. Government Printing Office, Washington,
D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So­ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern­ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU­PATION AND EDUCATIONAL EYE AND FACE PRO­TECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the Ameri­can National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-2898

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430
Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON­TAINERS WHICH HAVE HELD COMBUSTIBLES, ob­tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONTAIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter
l’endommagement du matériel en cas de non­respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.

1.05 Precautions De Securite
Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

Manual 0-2898 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au person­nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.

• Eloignez toute fumée et gaz de votre zone de respira­tion. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.

• Réparez ou remplacez toute pièce usée ou
endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combus­tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de tra­vail est humide ou moite.

• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)

• Débranchez l’alimentation électrique avant tout tra­vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de
consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com­bustibles ou provoquer l’explosion de fumées
inflammables.

• Soyez certain qu’aucune matière combustible ou in­flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.

• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Manual 0-2898

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons

ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin­tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRA­VAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na­tional Standards Institute), 1430 Broadway, New York,
NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American Na­tional Standards Institute, 1430 Broadway, New York,
NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

8. Norme 51 de l’Association Américaine pour la Pro­tection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na­tional Fire Protection Association, Batterymarch Park,
Quincy, MA 02269

Manual 0-2898 1-5 GENERAL INFORMATION

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA­TIONAL, disponible auprès de la National Fire Pro­tection 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. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan­dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Manual 0-2898

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. 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.

Manufacturers responsible representative: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

Manual 0-2898 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days 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. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective November 15, 2001

GENERAL INFORMATION 1-8 Manual 0-2898

SECTION 2:

2.03 Service Responsibilities

INTRODUCTION

2.01 Scope Of Manual

This manual provides service instructions for the Ther­mal Dynamics CutMaster 38 Plasma Cutting Power Sup­ply. Information in this manual is intended for use by
properly-trained service technicians familiar with this
equipment.

For setup of this equipment, individual operating proce­dures, and basic troubleshooting, refer to Operating
Manual (0-2888).

Read both the operating manual and the service manual
thoroughly. A complete understanding of the capabili­ties and functions of this equipment will assure obtain­ing the performance for which it was designed.

2.02 General Service Philosophy

Several key points are essential to properly support the
application and operation of this equipment.

A. Application

The service technician should be familiar with the equip­ment and its capabilities and should be prepared to rec­ommend arrangements of components which will pro­vide the most efficient layout, utilizing the equipment to
its best possible advantage.

Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equip­ment does not function as specified, contact the Tech­nical Services Department at West Lebanon, NH for
assistance (1-603-298-5711).

The equipment should satisfy the customer’s require­ments as supplied and as described in Section 3 of this
manual. Be sure to confirm that the equipment is capable
of the application desired.

B. Modifications

No physical or electrical modifications other than selec­tion of standard options and Accessories are to be made
to this equipment.

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 mali­cious damage.

D. Repair Restrictions

The electronics consists of a Printed Circuit Board (PCB)
Assembly which must be carefully handled and must be
replaced as a unit. No replacement of individual printed
circuit components is allowed except as noted in this
manual.

Printed Circuit Board Assemblies to be returned must be
properly packaged in protective material and returned
intact per normal procedures.

Manual 0-2898 2-1 INTRODUCTION

INTRODUCTION 2-2 Manual 0-2898

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 oper­ating personnel.

3.02 Specifications/Design Features

CutMaster 38 Power Supply Specifications

Input Power (See Note 1)

Power Sens ing
Input Powe r Ca bl e
Output Current
Power Supply Gas Filtering Ability

CutMaster 38 Power Supply Duty Cycle (Not e 2

Ambi ent Temperature
Duty Cy cle 35% 60%
DC Volt age 78 vdc 89 vdc
Current 30 Amps 22 Amps

120 VAC (± 10% ), Single-P hase, 50/ 60 Hz
208 - 230 VAC (± 10%), Singl e-Phase, 50/ 60 Hz
Aut om at i c Volt age Select ion. See Note 1.
Cord with plug, for 120VAC, 20-Am p S i ngle-P has e i nput power.
20-30 Amps , c ont i nuous l y variable
Part iculat es t o 20 M i c rons

104° F (40° C)

n/a %

n/a vdc

n/a A m ps

SL 60 Torch Gas Requirements

Gas Type
Gas specific ations
Maximum Input Gas Pressure
Operating Gas Pres sure
Gas F l ow Requirement s

Compressed A ir
Clean, dry , oi l -free (Note 3)
125 psi / 8. 6 bar
65 psi / 4. 5 bar
300 sc fh / 141. 5 l pm

Notes

. P ower suppl y ac cept s 120-230 V A C input power. No manual s wi t ching i s required.

1

. Dut y Cy cl e is t he perc ent age of ti m e t he sy st em can be operated without overheating. Duty cy c l e

2

is reduc ed i f primary i nput voltage (AC) is l ow or the DC voltage i s higher t han s hown in this chart.

. A i r s upply m us t be free of oil, moi st ure, and ot her c ontami nant s. E xc ess i ve oil and mois t ure m ay

3

cause double-arci ng, rapid tip wear, or even complet e t orc h fail ure. Cont am i nant s may c ause poor
cut ting performance and rapid el ec trode wear. Opt ional filters provide increas ed filt eri ng c apabi l ities.

Manual 0-2899 3-1 DESCRIPTION

DESCRIPTION 3-2 Manual 0-2898

SECTION 4:

4.04 Common Operating Problems

TROUBLESHOOTING

4.01 Introduction

This section provides service diagnostics for the CutMas­ter 38 Power Supply, allowing the Technician to isolate
any faulty subassemblies.

Under no circumstances are field repairs to be attempted
on Printed Circuit Boards or other subassemblies of this
unit. Evidence of unauthorized repairs will void the fac­tory warranty.

NOTE

This manual covers the Power Supply only.
Troubleshooting other parts of the system is cov­ered in separate manuals for those products.

4.02 Periodic Inspection & Cleaning
Procedures

This subsection describes inspection procedures which
should be performed at periodic intervals as required.

A. Physical Inspection

Check that all wiring connections are secure.

B. Cleaning

Open the enclosure and use a vacuum cleaner to re­move any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents for clean­ing electrical apparatus may be used.

WARNINGS

Disconnect primary power at the source before dis­assembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precau­tions in Section 1 of this manual. Be sure the op­erator is equipped with proper gloves, clothing, and
eye and ear protection. Make sure no part of the
operator's body comes into contact with the work­piece while the torch is activated.

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

Handle torch leads with care and protect them from
damage.

A. Piloting

Piloting is harder on parts life than actual cutting be­cause the pilot arc is directed from the electrode to
the tip rather than to a workpiece. Whenever pos­sible, avoid excessive pilot arc time to improve parts
life.

B. Torch Standoff

Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect
the bevel angle. Reducing standoff generally results
in a more square cut.

Refer to Appendix for maintenance schedule and pro­cedures. Clean or replace filters per Section 5.07.

4.03 System Design

The CutMaster 38 System is designed for hand cutting
only.

Manual 0-2898 4-1 TROUBLESHOOTING

C. Edge Starting

For edge starts, hold the torch perpendicular to the
workpiece with the front of the torch tip at the edge
of the workpiece, not touching, at the point where the
cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to “reach”
for the edge of the metal. Establish the cutting arc as
quickly as possible.

D. Direction of Cut

The plasma gas stream swirls as it leaves the torch.
The purpose of the swirl is to maintain a smooth col­umn of gas. The swirl effect results in one side of a
cut being more square than the other. Viewed along
the direction of travel, the right side of the cut is more
square than the left.

E. Dross

4. Short Torch Parts Life

When dross is present on carbon steel, it is commonly
referred to as either 'high speed, slow speed, or top
dross'. Dross present on top of the plate is normally
caused by too great a torch to plate distance. 'Top
dross' is normally very easy to remove and can often
be wiped off with a welding glove. 'Slow speed dross'
is normally present on the bottom edge of the plate.
It can vary from a light to heavy bead, but does not
adhere tightly to the cut edge, and can be scraped off
easily. 'High speed dross' usually forms a narrow bead
along the bottom of the cut edge and is very difficult
to remove. When cutting a troublesome steel, it is
sometimes useful to reduce the cutting speed to pro­duce 'slow speed dross'. Any resultant cleanup can
be accomplished by scraping, not grinding.

F. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

a. Moisture in air source

b. Exceeding system capability (material too thick)

c. Excessive pilot arc time

d. Gas pressure too low

e. Improperly assembled torch

f. Incorrect torch parts for the operation

g. Non-Genuine Thermal Dynamics parts used

4.05 Troubleshooting Guide ­General Information

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.

e. Cutting current too low

f. Non-Genuine Thermal Dynamics parts used

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts

f. Non-Genuine Thermal Dynamics parts used

3. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

d. Improper cutting current

e. Non-Genuine Thermal Dynamics parts used

A. General Information

The CutMaster 38 Operating Manual describes basic
troubleshooting and parts replacement procedures.

This Service Manual covers advanced troubleshooting,
which requires power supply disassembly and live mea­surements. Advanced troubleshooting and repair of this
unit should be undertaken only by those familiar with
high voltage high power electronic equipment.

If major complex subassemblies are faulty, the faulty sub­assembly must be returned for repair.

NOTE

Follow all instructions as listed and complete each
in the order presented.

The troubleshooting guide has subsections as follows:

Section 4.06 - Circuit Fault Isolation

Section 4.07 - Main Input and Internal Power Prob-

lems

Section 4.08 - Pilot Arc Problems

Section 4.09 - Main Arc Problems

TROUBLESHOOTING 4-2 Manual 0-2898

Section 4.10 - Test Procedures

Subsection 4.10 includes specific test procedures, indica­tions, and measurements. The subsection is referenced
by the troubleshooting guide for the specific test to be
performed.

B. How to Use the Troubleshooting Guide

4.06 Circuit Fault Isolation

The following information is a guide to help the Service
Technician determine the most likely causes for various
symptoms. This guide is set up as follows:

1. Perform operational check(s) on the equipment to iso­late problem to possible circuit(s) per Subsection 4.06,
Circuit Fault Isolation.

2. Determine symptom and isolate to defective assem­bly using the following format:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

3. Locate your symptom in the appropriate Subsection.

4. Check the causes (easiest listed first) for the symptom.

5. Check the remedies listed for each cause. Remedies
may have different specific information depending on
the input voltage of the power supply.

6. Repair as needed being sure to verify that unit is fully
operational after any repairs.

NOTES

This section is to help isolate the defective circuit before
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to iden­tify the possible symptom(s) and the defective circuit.
After repairs are complete, run the following tests again
to verify that the unit is fully operational.

A. Initial Setup Conditions

1. Connect gas supply to rear of Power Supply.

2. Turn on gas supply and adjust Power Supply Gas
Regulator to 65 psi / 4.5 bar.

3. Set the Power Supply controls as follows:

• ON/OFF / switch to OFF .

• CURRENT (A) control knob to maximum

• RUN / SET switch to SET

B. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

2. Set the Power Supply ON/OFF switch to ON (up
position) and check the following:

• AC indicator steady ON

Many signals are transferred between Power Sup­ply components on cables. If these cables become
faulty they can cause various problems. Do not
forget about these cables when troubleshooting.

While troubleshooting visually inspect the inter­nal components for signs of overheating, fractures
and damage.

• TEMP Indicator OFF

• GAS Indicator ON

• Gas flows from torch

• Fan operates

• DC lndicator is OFF

3. Turn RUN / SET switch to RUN

• Gas should stop flowing

4. Turn ON / OFF switch to OFF, then back to ON. Check
the following:

• AC indicator ON

• Temp indicator OFF

• Gas indicator ON (gas does not flow)

• Fan Operates

• DC indicator OFF

This completes the Main Input and Internal Power Tests.
If the unit functions as described then proceed to para­graph 'C'. If the unit does not function as described then
note the symptom and proceed to Subsection 4.07, Main
Input and Internal Power Problems.

Manual 0-2898 4-3 TROUBLESHOOTING

C. Pilot Arc Test

C. Fan does not operate; AC indicator is OFF

1. Close the torch switch and check the following:

• Gas flows briefly, then stops.

• Gas flow re-starts; pilot arc starts. DC indicator is
ON.

This completes the Pilot Arc Test. If the equipment oper­ates as described then proceed to paragraph 'D'. If the
equipment does not function as noted then note the symp­tom and proceed to Subsection 4.08, Pilot Arc Problems.

D. Main Arc Test

Activate the Torch to establish a pilot arc.

Bring the torch to approximately 3/16" (4.7 mm) from
the workpiece to establish the main cutting arc, and note
the following:

• Main cutting arc starts

• Cutting arc transfers to workpiece

This completes the Main Arc Test. If the equipment op­erates as described, proceed to Subsection 4.07. If prob­lems still persist then contact Technical Services.

If the equipment does not function as described, note the
symptom and proceed to Subsection 4.09, Main Arc Prob­lems.

4.07 Main Input and Internal Power
Problems

1. Front Panel ON/OFF switch in OFF (down) position

a. Place switch to ON (up) position.

2. Main power disconnect open (OFF)

a. Close main power disconnect.

3. Main power line fuses blown

a. Replace main power line fuses.

4. Input power cable disconnected or faulty

a. Check power cable for proper connections to

On/Off Switch.

b. Check power cable for continuity through all

conductors.

5. Wires from On/Off Switch to PC Board disconnected
or faulty

a. Check for proper connections.

b. Disconnect wires; check for continuity.

6. Faulty ON/OFF switch

a. Disconnect primary input power. Set the On/

Off switch to ON (UP) position. Test for conti­nuity between terminals 1 and 2, and between
terminals 3 and 4. If there is no continuity, re­place the ON/OFF Switch.

Locate your symptom below:

A. Main power line fuses blow as soon as main

disconnect is closed

1. Input power cable installed incorrectly or defective

a. Refer to the Appendix pages for PC Board Wir-

ing Layout. Check the input power cable for
proper connections. Reconnect if necessary.

b. Test input power cable for continuity through

all conductors. Replace cable if any conductor
does not show continuity.

B. Main power line fuses blow immediately after the

ON/OFF Switch is turned on.

1. Faulty input diode bridge(s)

a. Test input diode bridges per section 4.10-D; re-

place as needed.

A-03500

Terminal 2

Terminal 3

To PC Board
Terminal E2

Terminal 1

Input Power Cord
Line 2

Input Power Cord
Line 1

To PC Board
Terminal E1

Terminal 4

7. Faulty Bias Transformer

a. Refer to PC Board Wiring Layout in the Appen-

dix. Test for 380-410 vdc between TP-21 and
TP-101 on PC Board. If voltage is not correct,
replace the PC Board.

TROUBLESHOOTING 4-4 Manual 0-2898

D. AC indicator flashing, TEMP indicator OFF (on

system start-up); RUN / SET switch in RUN
position

1. Torch shield cup loose

a. Shut power supply off. Tighten shield cup se-

curely. Turn unit back on.

3. Wire E8 not connected to PC Board terminal E8

a. Check connection; reconnect if necessary.

4. PC board fault circuit defective

a. Replace PC board

H. AC indicator flashes; Temp indicator steady ON

2. Torch connection at power supply loose.

a. Shut power supply off. Tighten torch leads

male connector into female receptacle on power
supply securely. Turn power supply back on.

3. Faulty PIP switch or open PIP wires in torch leads

a. Check torch PIP switch for continuity.

b. Check torch PIP leads for continuity.

4. J3 wire connector disconnected from PC board.

a. Check J3 connector; reconnect if necessary.

E. Gas flows continuously; AC indicator ON; TEMP

indicator OFF; DC indicator OFF; GAS indicator
ON

1. RUN /SET Switch in SET (down) position

a. Change to RUN (up) position.

2. Faulty RUN / SET switch

a. Disconnect primary input power. Disconnect

wires from RUN / SET switch. Put switch in
RUN (up) position. Check switch for open con­dition. If switch is shorted, replace switch.

F. AC indicator flashing (on start-up); TEMP

indicator OFF; RUN / SET switch in RUN posi­tion; gas flows from torch

1. Torch switch stuck ON or torch switch wires shorted

a. Check indicator D22 on PC board. Indicator

should be OFF unless torch switch is closed.

b. Check torch switch for proper operation.

1. Fan wire harness disconnected from terminal J4 on PC
board.

a. Check fan wire harness; reconnect if necessary

2. Faulty fan or fan wire harness

a. Check fan and harness; replace as needed.

I. AC indicator flashes; TEMP indicator blinks

slowly; RUN/SET switch in SET position

1. Fan is blocked

a. Check fan blades; clear as needed.

2. Faulty PC Board

a. Replace PC Board

J. No gas flow; AC indicator ON; TEMP indicator

OFF; DC indicator OFF; Gas indicator ON; RUN/
SET switch in SET position

1. Inlet gas pressure too high (over 120 psi / 8.3 bar)

a. Set inlet gas pressure below 120 psi / 8.3 bar

2. Faulty RUN/SET switch

a. Disconnect wires from RUN/SET switch. Test

switch for continuity in SET position. If no con­tinuity in SET position, replace switch.

3. Faulty gas solenoid or solenoid wire harness.

a. Disconnect solenoid wire harness from termi-

nal J1 on PC board. Test resistance in wire har­ness. Resistance should be 20 ohm ± 5 ohm. If
resistance is not correct, replace solenoid assem­bly.

c. Check torch switch for coninuity.

G. AC indicator flashing (on start-up); TEMP indica-

tor OFF, RUN / SET switch in RUN position,

1. Torch tip, starter cartridge, or electrode missing or badly
worn.

a. Check torch parts; replace as needed.

2. Dirty or defective starter cartridge

a. Check starter cartridge; clean or replace as

needed.

Manual 0-2898 4-5 TROUBLESHOOTING

4. Faulty PC board

a. Leave RUN/SET switch in SET position. Dis-

connect wire harness from terminal J1 on PC
board. Test voltage across pins of terminal J1.
Voltage should be 10-13vdc. If voltage is not
correct, replace PC board.

K. AC indicator steady ON: TEMP indicator ON;

RUN/SET switch in SET position

1. PC board temperature sensor disconnected or faulty.

a. Check wire harness connection at terminal J5

on PC board. Reconnect if necessary.

b. Disconnect PC board temperature sensor wire

harness from J5 on PC board. Install a tempo­rary jumper across the pins on PC board termi­nal J5. Check temperature indicator on Power
Supply front panel. If TEMP indicator is OFF,
replace PC board.

B. No arc or intermittent arc in torch; Gas flows; AC

indicator ON; TEMP indicator OFF; GAS and DC
indicators ON

1. Gas pressure set incorrectly (too high)

a. Set gas pressure on the Power Supply gas regu-

lator to 65 psi / 4.5 bar.

2. Oil/moisture in air lines

a. Purge system. If problem is corrected, add fil-

ters in line with air source.

3. Torch consumable parts incorrect or worn

L. No gas flow; AC indicator ON; GAS indicator

OFF; TEMP indicator OFF; DC indicator OFF;
RUN/SET switch in SET position

1. Gas supply not connected to unit

a. Connect gas supply.

2. Gas supply not turned on

a. Turn gas supply on.

3. Gas pressure too low

a. Shut power supply off. Set gas pressure on the

power supply gas regulator to 65 psi / 4.5 bar.
turn power supply back on.

4. Faulty PC board

a. Disconnect pressure switch wire harness from

terminal J9 on PC board. Test for continuity
between sockets 2 and 3 on the wire harness
connector. If gas pressure is above 65 psi / 4.5
bar and there is continuity between sockets 2
and 3, replace PC board.

4.08 Pilot Arc Problems

Locate your symptom below:

a. Refer to Operator's Manual.

4. Starter cartridge missing from torch

a. Shut off power. Remove shield cup from torch.

Install starter cartridge if missing.

5. Faulty leads

a. Check continuity.

6. Faulty torch

a. Check continuity.

7. Faulty PC Board

a. Replace PC Board.

C. No pilot arc; GAS and DC indicators blink

1. Gas pressure is too low.

a. Set gas pressure to 65 psi / 4.5 bar.

D. No gas flow; AC and GAS indicators ON, TEMP

and DC indicators OFF

1. 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.

A. No pilot arc; Gas flows continuously; AC indica-

tor ON; TEMP indicator OFF; GAS indicator ON;
DC indicator OFF

1. Shorted Torch

a. Test torch and leads for continuity.

2. Faulty PC Board

a. Replace PC Board.

TROUBLESHOOTING 4-6 Manual 0-2898

Art # A-03640

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads
Lower O-Ring

4.09 Main Arc Problems

B. Opening Power Supply Enclosure

Locate your symptom below:

A. Main cutting arc will not start

1. Work cable not connected.

a. Connect work cable.

2. Holding too high of a standoff

a. Refer to Operating Manual for recommended

standoff heights.

3. Workpiece is painted or rusty.

a. Clean workpiece.

4. Starter cartridge missing from torch

a. Shut off power. Remove shield cup from torch.

Install starter cartridge if missing.

5. Faulty Main Power PC Board

a. Replace PC Board.

4.10 Test Procedures

The test procedures in this subsection are referenced in
the troubleshooting section.

The cover of the Power Supply must be removed to gain
access to the input power connections.

WARNING

Disconnect primary power at the source before as­sembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.

1. Remove the upper screws securing the cover to the
main assembly.

2. Loosen, but do not remove, the lower screws.

NOTE

There is a ground wire attached from the cover to
the main body of the unit.

3. Carefully lift the cover off the unit, and remove the
nut securing the ground wire to the side panel.

4. Reinstall the cover by reversing the above steps.

A. Safety Precautions

1. Significant DC Voltage exists after removal of input
power. Allow two minutes for discharge time. Volt­age measured on input capacitors must be zero be­fore performing service on the power supply.

2. Do Not touch electrical components with any part of
the human body when power is applied.

3. Keep away from any moving parts.

4. Hot surfaces can cause severe burns. Allow equip­ment to cool before servicing.

5. Electrostatic discharge can damage printed circuit
board assemblies. Transport printed circuit boards in
proper antistatic shielded packages. Use proper
grounding techniques with wrist strap before handling
printed circuit boards.

6. Misaligned plugs can cause printed circuit board dam­age. Be sure plugs are properly aligned and com­pletely seated.

7. Excessive pressure can damage printed circuit board.
Use only minimal pressure and gentle movement
when disconnecting or connecting printed circuit
board plugs.

Upper screws

Upper screws

Ground
wire

Lower screws

A-03285

Manual 0-2898 4-7 TROUBLESHOOTING

C. Diode Testing Basics

Testing of diode modules requires a digital volt/ohm­meter that has a diode test scale. Remember that even
if the diode module checks good, it may still be bad.
If in doubt, replace the diode module.

6. Reverse the meter leads across the diode for reverse
bias testing (refer to following figure). A properly
functioning diode will block in the reverse bias direc­tion and depending on the meter function will indi­cate an open or “OL”.

1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to iso­late the module.

3. Set digital volt/ohmmeter to diode test scale.

4. Using the Figures for each test, check each diode in
the module. Each diode must be checked in forward
bias (plus to negative) and reverse bias (negative to
plus) direction.

5. Connect the volt/ohmmeter positive lead to the an­ode (+) of the diode and the negative lead to the cath­ode (-) of the diode for forward bias testing (refer to
following figure). A properly functioning diode will
conduct in the forward bias direction and indicate be­tween 0.3 to 0.9 volts.

Art # A-00307

0.75

Reverse Bias

Diode Not Conducting

Cathode

Anode

Testing Diode Reverse Bias

Art # A-00306

OL

VR

+

COM

_

A

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

Cathode

Testing Diode Forward Bias

VR

+

COM

_

A

TROUBLESHOOTING 4-8 Manual 0-2898

D. Diode Bridge Checks

Check for shorted Diode Bridges.

E16A

Diode Bridge 1

E14A

E12A

E16B

E16B

Diode Bridge 2

E15A

+ Mark

E15B

E15B

E14B

+ Mark

A-03508

E12B

Disconnect primary input power. With an ohmmeter set
on the diode range, make the following checks on both
diode bridges:

CutMast er 38 Diode Bri dge Chec k

Met e r (+) Meter (-) Indicati on

E16 E15 Diode Drop
E15 E16 Open
E16 E14 Diode Drop
E14 E16 Open
E14 E12 Diode Drop
E12 E14 Open
E15 E12 Diode Drop
E12 E15 Open

The meter should indicate a diode drop in one direction
and an open in the other direction for each check.

Manual 0-2898 4-9 TROUBLESHOOTING

TROUBLESHOOTING 4-10 Manual 0-2898

SECTION 5:

SERVICE

B. Procedure

1. Open the wrist strap and unwrap the first two folds
of the band. Wrap the adhesive side firmly around
your wrist.

5.01 Introduction

This section describes parts replacement procedures and
all repairs which may be performed on the CutMaster 38
Power Supply. Replacement instructions not included in
this manual are supplied with the replacement kit.

Under no circumstances are field repairs to be attempted
on Printed Circuits or other subassemblies of this unit.
Evidence of unauthorized repairs may void the factory
warranty.

5.02 Anti-Static Handling
Procedures

A. General

Caution: PC Boards can be irreparably damaged by im­proper handling due to electrostatic discharge (ESD).

Replacement PC Boards are shipped in a protective en­closure to prevent damage from electrostatic discharge
(ESD) during shipping. Included with each replacement
board is a ground strap to prevent static damage during
installation.

WARNINGS

Read and understand these instructions and the
instructions on the grounding wrist strap package
before opening the equipment enclosure or remov­ing the replacement PC board from its protective
enclosure.

Disconnect primary power to the system before dis­assembling the torch, torch leads, or power supply
enclosure.

Do not operate the equipment or test equipment
under power while wearing the grounding wrist
strap.

2. Unroll the rest of the band and peel the liner from
the copper foil at the opposite end.

3. Attach the copper foil to a convenient and exposed
electrical ground.

4. Connect the equipment primary cable ground to
the same electrical ground as the wrist strap.

5. Open the equipment enclosure and remove the
failed PC board.

6. Carefully open the ESD protective bag and remove
the replacement PC Board.

7. Install the replacement PC Board in the equipment
and make all necessary connections.

8. Place the failed PC Board in the ESD protective
bag and seal for return shipping.

9. Replace the power supply cover.

10. Remove the grounding wrist strap from your wrist
and from the electrical ground connection before
reconnecting primary power to the equipment.

5.03 Parts Replacement - General
Information

The parts replacement procedures described in this
manual require that the Power Supply be opened and
partially disassembled. The part to be replaced will de­termine the extent of disassembly.

Before removing any connection mark each wire with the
connection designation. When reassembling make sure
the wires go to the proper terminals.

Note the routing of wires and make sure the wires are
put back in the same place when re-assembling the unit.

Refer to Section 6 for parts lists and overall detailed draw­ings.

Observe torquing requirements where given. Fail­ure to torque properly will cause component dam­age.

Manual 0-2898 5-1 SERVICE

WARNING

Disconnect the power supply from input power be­fore opening or disassembling the power supply.

Before disassembling any part of the Power Supply first
read the procedure for the part to be replaced, then pro­ceed with the disassembly.

5.04 Major External Parts
Replacement

Refer to Section 6 for Major External Replacement Parts
and overall detailed drawing.

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

A. Cover Removal and Replacement

1. Remove the upper screws securing the cover to
the unit then loosen the lower screws securing the
cover to the base.

Upper screws

5.05 Front Panel Parts Replacement

Refer to Section 6 for Front Panel Replacement Parts and
overall detailed drawing.

WARNING

Disconnect primary power from the source before
opening or disassembling the power supply.

A. Output Control (A) Knob Replacement

1. Turn the adjustment knob fully clockwise and note
the location of the pointer on the knob.

2. Loosen the screw securing the Knob to the poten­tiometer shaft and remove the Knob.

3. Place the replacement Knob on the potentiometer
shaft with the location of the pointer the same as
noted in step 1.

4. Tighten the screw to secure the knob to the poten­tiometer shaft.

Upper screws

Ground
wire

Lower screws

A-03285

2. Carefully lift the cover up and away from the unit
to gain access to the ground wire connection on
the inside of the cover (left side near front).

3. Remove the nut and washer from the ground stud
on the inside of the cover.

4. Install the replacement cover by reversing the above
steps.

B. ON/OFF ( / ) Switch Replacement

1. Remove the cover per Subsection 5.04-A.

2. Disconnect wires E1 and E2 leading from the
switch to terminals E1 and E2 on the PC Board.

3. Remove the hardware securing the switch to the
Power Supply front panel.

4. Note the positions of the wires from the input
power cable to the switch.

5. Disconnect the input power cable from the switch.

6. Connect the input power cable to the replacement
switch, with the wires positioned as noted previ­ously.

7. Transfer wires E1 and E2 to the replacement
switch.

8. Attach the replacement Switch to the Power Sup­ply front panel. Tighten the hardware securely.

9. Connect wires E1 and E2 to terminals E1 and E2
on the PC Board.

10. Reinstall the Power Supply cover.

11. Connect the Power Supply to primary input power.
Test the Power Supply for proper operation.

SERVICE 5-2 Manual 0-2898

C. Run/Set ( / ) Switch

Replacement

1. Remove the Power Supply cover per Subsection

5.04-A.

2. Disconnect the Run/Set Switch wire harness from
terminal J2 on the PC Board.

3. Squeeze together the clips on the rear of the
Switch, then remove the switch and wire harness
through the Front Panel.

A. Diode Bridge Replacement

1. Remove the Power Supply cover per Subsection

5.04-A.

2. Label and remove the wires from the diode bridge
to the PC Board. Refer to the illustration.

3. Remove RTV silicone over the screw head secur­ing the diode bridge to the Fan Panel.

4. Remove hardware securing the diode bridge to the
Fan Panel.

5. Remove the diode bridge.

4. Transfer the wiring harness to the replacement
switch. Refer to the illustration for wire connec­tions.

Top clip

Wire # 8

Wire # 9

A-03493

5. Pass the wiring harness through the front opening
in the Power Supply. Press the switch into posi­tion in the Power Supply front panel firmly.

6. Connect the wiring harness to terminal J2 on the
PC Board.

7. Reinstall the Power Supply cover.

6. Refer to the illustration. Position the diode bridge
as shown. Note the location of the notched area
marked (+) on the diode bridge. Position the re­placement diode bridge on the thermal pad on the
Fan Panel. Replace the thermal pad if it is dam­aged.

Thermal Pad

E16A

Diode Bridge 1

E14A

E12A

E15A

+ Mark

8. Connect the Power Supply to primary input power.
Test the Power Supply for proper operation.

5.06 Left Side Internal Parts
Replacement

Refer to Section 6 Left Side Internal Replacement Parts.

WARNING

Disconnect input power at the source and bleed
down the system before attempting these proce­dures.

Manual 0-2898 5-3 SERVICE

Thermal Pad

E16B

E16B

Diode Bridge 2

E14B

E14B

E12B

E12B

E15B

E15B

+ Mark

+ Mark

A-03494

7. Secure the diode bridge to the Fan Panel with the
hardware removed previously. Torque the hard­ware to 15 in-lbs (1.7 Nm).

7. Thread the replacement Pressure Gauge into the
Power Supply the Regulator/Filter Assembly.
Tighten securely.

8. Apply RTV silicone over the securing hardware.
Use care to avoid getting RTV on the electrical con­nectors.

9. Refer to the illustration. Connect wires from the
PC Board to the diode bridge(s) being replaced.

10. Reinstall the Power Supply cover. Test the Power
Supply for proper operation.

5.07 Rear Panel Parts Replacement

Refer to Section 6 for parts list and overall detailed draw­ing.

WARNING

Disconnect input power at the source and bleed
down the system before attempting these proce­dures.

A. Pressure Gauge Replacement

1. Disconnect the gas input line from the Power Supply.

2. Remove the Power Supply cover per Subsection

5.04-A.

3. Disconnect the gas tube from the Pressure Switch
Assembly Adapter Fitting. Hold a wrench or simi­lar tool against the locking ring on the Fitting and
pull the tube to release it.

8. Position the Regulator/Filter Assembly in the
bracket at the top of the Power Supply. Secure
with the locking ring.

9. Connect the gas tube to the Pressure Switch As­sembly Adapter Fitting. Push in the Fitting, and
insert the gas tube. Release the Fitting. The fitting
will automatically lock. Check for a secure con­nection.

10. Position the bottom end of the drain tube in the
hole in the Power Supply base.

11. Reinstall the Power Supply cover. Connect the gas
input line to the inlet port. Connect the Power Sup­ply to primary input power.

12. Test the Power Supply for proper operation.

C. Optional Single-Stage Filter Element

Replacement

NOTES

The Power Supply shuts down automatically when
the Filter Element becomes completely saturated.
The Filter Element can be removed from its hous­ing, dried, and reused. Allow 24 hours for Ele­ment to dry.

1. Remove power from power supply.

2. Disconnect gas supply hose.

4. Disconnect the Filter/Regulator Assembly as fol­lows:

a. Pull the Regulator/Filter drain tube out of the

hole in the base of the Power Supply.

b. Release the securing ring on the top of the

Regulator/Filter Assembly.

c. Move the Regulator/Filter Assembly forward

to disengage the inlet port and pressure gauge
from the Power Supply rear panel.

5. Turn the Pressure Gauge to release it from the
Regulator/Filter Assembly.

6. Apply thread sealant to the threads of the replace­ment Pressure Gauge.

NOTE

Do Not use Teflon tape as a thread sealer, as small
particles of the tape may break off and block the
small gas passages in the torch.

SERVICE 5-4 Manual 0-2898

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

3. Turn the Cover counter-clockwise and remove it
from the Filter Housing. The Filter Element is lo­cated inside the Housing.

4. Remove the Filter Element from the Housing and
set Element aside to dry.

5. Wipe inside of housing clean, then insert the re­placement Filter Element open side first, as shown.

6. Replace Housing on Cover.

7. Attach gas supply hose.

NOTE

Ring

Replacement
Element,
No. 9-4414

Spool

If unit leaks between housing and cover, inspect
the O-Ring for cuts or other damage.

5.08 Right Side Internal Parts
Replacement

Refer to Section 6 for Right Side Internal Parts List and
overall detailed drawing.

WARNING

Disconnect input power at the source and bleed
down the system before attempting these proce­dures.

A. Standard Filter Element Replacement

1. Remove Power Supply Cover per Section 5.04A

2. Remove power from the power supply; turn off
the gas supply.

3. Remove the drain tube from the bottom of the bowl
on the Regulator/Filter Assembly.

Bowl

Drain Tube

A-03571

4. Unscrew the bowl on the bottom of the Regula­tor/Filter Assembly. The filter element will be
visible and still attached to the main body of the
Regulator/Filter Assembly.

5. Grasp the filter element and unscrew it from the
Regulator/Filter body. The filter element will
come off with a spool and some additional pieces.

6. Note the correct assembly of the filter/spool then
remove the filter from the spool. Either clean or
replace the filter element.

7. The filter element and spool, with the baffle ring
in place (teeth facing downward) can be screwed
back into the Regulator body by compressing the
spring on the spool. Tighten firmly by hand.

8. Reinstall the bowl. Connect the drain tube to the
bowl.

Manual 0-2898 5-5 SERVICE

9. Reinstall Power Supply cover per Section 5.04A.

10. Turn on the air supply. Test the Power Supply for
proper operation.

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 replace­ment Pressure Switch.

NOTE

Do Not use Teflon tape as a thread sealer as small
particles of the tape may break off and block the
small gas passages in the torch.

5. Thread the replacement Pressure Switch into place
on the Regulator/Filter Assembly. Tighten se­curely.

6. Connect the wires from the Pressure Switch wire
harness, with the wires positioned as marked pre­viously.

7. Reinstall the Power Supply cover.

8. Reconnect the gas supply and primary input
power. Test the Power Supply for proper opera­tion.

SERVICE 5-6 Manual 0-2898

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

Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.

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. Also include the model and serial
number of the torch. Address all inquiries to your autho­rized distributor.

Manual 0-2898 6-1 PARTS LISTS

6.03 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-8631
2 1 Base Enclosure Assembly 9-8640
3 1 Tube, roll handle 9-8632

1

NOTE

2

3

3

A-03433

Illustration may vary slightly from unit.

PARTS LISTS 6-2 Manual 0-2898

6.04 Front Panel Replacement Parts

Item# Qty Description Ref. Catalog #

1 1 On/Off Switch SW1 8-4248
2 1 Output Current Control Potentiometer with wire harness 9-8629
3 1 Run/Set Switch SW2 9-1042
4 1 Output Current Control Knob 9-8527
5 1 Work Cable with Clamp, 20 Ft / 6.1 m 9-8642

2

1

3

4

A-03496

NOTE

Illustration may vary slightly from unit.

Manual 0-2898 6-3 PARTS LISTS

5

6.05 Left Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 PCB Assembly 9-8630
2 1 Diode Bridge BR1, BR2 7-3345
3 1 Thermal Pad 9-4466
4 1 Input Power Cable with plug, for non-CE units through Unit Rev AE 9-8628
4 1 Input Power Cable with plug, for non-CE units at Unit Rev AF or later 9-8660
4 1 Input Power Cable for CE units Rev AA / AB 9-8661
4 1 Input Power Cable for CE units Rev AC or later 9-8671
4 1 Input Power Cable for (CE) Australian units 9-8663

Not Shown:

1 Power Cable Strain Relief, for non-CE units through Unit Rev AE 8-4263
1 Power Cable Strain Relief, for non-CE units at Unit Rev AF or later 8-7072
1 Power Cable Strain Relief, for CE units Rev AA / AB 8-7072
1 Power Cable Strain Relief, for CE units Rev AC or later 9-8672
1 Power Cable Strain Relief, for (CE) Australian units 8-4250

PARTS LISTS 6-4 Manual 0-2898

A-03498

1

4

Input Filter & Bracket
(CE Units only)

NOTE

Illustration may vary slightly from unit.

2

2

3

3

Manual 0-2898 6-5 PARTS LISTS

6.06 Right Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Console ATC Assembly 9-8641
2 1 Regulator/Filter Assembly (includes Pressure Switch, 9-8643

Pressure Gauge, Solenoid)
3 1 Pressure Gauge 9-1045
4 1 Pressure Switch PS1 9-1044
5 1 Regulator/Filter Replacement Element 9-0182
6 1 Regulator Mounting Nut 9-5804
7 1 Assembly, Output Inductor L1 9-8626

8A / 8B 1 PFC Choke (Type 8B assembly replaces Type 8A) T1 9-8627

9 1 Main Transformer Assembly T3 9-8625

10 1 Fan M1 9-8639

PARTS LISTS 6-6 Manual 0-2898

1

A-03499

10

Fan Panel

2

6

3

7

9

4

5

Fan Shroud

8A

8B

NOTE

Illustration may vary slightly from unit.

Manual 0-2898 6-7 PARTS LISTS

Transformer Bracket

6.07 Options and Accessories

Qty Description Catalog #

1 Single-Stage Filter Kit (Includes Filter And Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Element 9-7741
1 Replacement Filter Hose (Not Shown) 9-7742

Not shown:

1 Multi-Purpose Cart 7-8888

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Single-Stage Filter Kit

Assembled Filter

Art # A-02476

PARTS LISTS 6-8 Manual 0-2898

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 Shield Cap, Machine 40A

Manual 0-2898 6-9 PARTS LISTS

PARTS LISTS 6-10 Manual 0-2898

APPENDIX 1: INPUT WIRING REQUIREMENTS

CutMa ster 38 Input Power Requi re m ents

Input

Voltage Freq. (kVA)

(Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph

120 50 / 60 3.6 29 35 12 12
208 50 / 60 3.5 16 20 12 12
230 50 / 60 3.4 14 20 12 12

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer
to local or national codes.

Cable conductor temperature used is 167° F (75° C).

Pow e r I nput Current Input

(Amps) Fuse (Amps) Wire (AWG) Wire (Canada)

Line Voltages wit h S ugges ted Circ uit Protect ion and Wire S i z es

Bas ed on Nati onal Elect ric Code and Canadian El ec t ri c Code

NOTES

Sugge sted Si z es (See Notes)

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.

NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-2898 A-1 APPENDIX

APPENDIX 2: MAIN POWER PC BOARD LAYOUT

D22

J3

TP101

TP1

TP2

TP23

TP8

TP26

E18

E8

E4

PILOT

E8

E4

TP26

TP1

TP8

TORCH

SWITCH

ON

J3

TP16

J2

J2

RUN/SET

J1

E18

MAIN PCB ASSEMBLY
19X1773 REV

J1

SOL

D99

J9

J7

J9

PWM

ON

J7

PRESSURE

TEST

3

2

1

J5

OVER-TEMP

2

J5

1

J4

J6

J4

J6

FAN

POT

AC

TEMP

GAS

TP20

DC

D7
D13

D16
D19

E14B
E14A

E2

E14A

E14B

E2

TP2

TP23

TP3

TP6
TP24

E15B

E12A

E12B

E15A

E16B

E16A

E13

E1

E11

E15B
E15A

E1
E13

TP6

E12A
E12B
E11

E16B
E16A

TP24

TP3

TP7

TP21

TP21

E19

WORK

E19

E10

E10

E9

E6

E20

E9

E20

E6

E5

E5

A-03441

APPENDIX A-2 Manual 0-2898

APPENDIX 3: MAIN PC BOARD WIRING

To Torch
Receptacle

To PFC
Inductor
(See NOTE)

To Torch
Receptacle

To Output
Inductor
(See NOTE)

PILOT

To Pressure

To Solenoid

MAIN PCB ASSEMBLY
19X1773 REV

J1

J2

SOL

RUN/SET

TORCH

SWITCH

ON

J3

TP1

TP8

TP26

E18

E8

E4

Switch

PWM

ON

TP2

TP23

To Temperature

J9

J7

PRESSURE

TEST

3

2

1

TP3

TP7

Sensor

J5

OVER-TEMP

2

1

TP21

To Fa n

J4

J6

FAN

POT

AC

To Current

TEMP

Control

GAS

To Run / Set

DC

TP20

E14A

E14B

E2

TP6
TP24

E15B

E12A

E12B

E15A

E16B

E16A

E13

E1

E11

Switch

To On / Off
Switch

To
Bridge 1

To
Bridge 2

To Main Transformer

E19

WORK

A-03442

Work Cable

NOTE: Terminals E4, E11, and E18 are
on the back of the PC Board.

E10

E9

E6

E20

To Output
Inductor

E5

Torch Ground

To Ground

Manual 0-2898 A-3 APPENDIX

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:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

APPENDIX A-4 Manual 0-2898

APPENDIX 5: TORCH CONNECTOR DIAGRAM

Negative /
Plasma

4 - Green /
Switch

3 - White /
Switch

2- Orange /
PIP

1 - Black /
PIP

Pilot

ATC Male Connector

Front View

4

3

2

1

ATC Female Receptacle

Front View

8 - Open

8
7

6

5

7 - Open

6 - Open

5 - Open

8 - Open

7 - Open

6 - Open

5 - Ground

Pilot

8
7

6
5

2
1

Negative /
Plasma

4 - Switch

3 - Switch

4
3

2 - PIP

1 - PIP

A-03694

Manual 0-2898 A-5 APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC

A

12 0/208/230V

INPUT
50/60HZ

B

C

D

1

INP UT 230V ONLY

EMC
FILTER
CE ONLY

CURRENT ADJUST

SW2

CH ASSIS GND

M1

FAN1

CURRENT

CONTROL

20 - 30

SET

RUN

NORMALLY CLOSED

OVER-TEMP

PRESSURE SW

L1

SW1

SW1

STUD

+

12VDC

TS1

PS1

(E1)

(E2)

RED

BLACK

CW

(10)
(11)

2

E1

E2

E13

P4

P6

(5)
(6)

(7)

P2

(8)

(9)

P5

P9 J9

3

J7

TEST

1

4

E12A

K1

(E14A)

BR1

1

E14A

(E16A)

FILTERING

J4

1

1

2

2

J6
1

1

2

2

3

3

J2

1

1

2

323

J5

1

1

2

2

ZERO

1

1

2

2

3

3

E15A

E16A

E12B

(E14B)

E14B

(E16B)

E15B

E16B

PANEL INDICATOR

AC

TEMP

GAS

DC

D7

D13

D16

D19

123

BR2

E11

(E12A)

2

(E15A)

3

4

-+

(E12B)

(E15B)

4

-+

4

PFC INDUCTOR

T1

Q7

LOGIC AND CONTROL

TEST POINTS:

TP1 LOGIC COMMON
TP2 SHORT TO TP23 TO DISABLE BIAS SUPPLY
TP6 SHORT TO TP24 TO DISABLE POWER

TP8 SHORT TO TP26 TO DISABLE SHORTED

CAUTION: SOME PORTIONS OF THE CONTROL/
LOGIC CIRCUITRY ARE CONNECTED TO THE
INPUT LINE. CONNECTION TO A GROUNDED
INSTRUMENT COULD CAUSE A SHOCK
HAZARD OR DESTROY THE POWER SUPPLY.
ACCESS BY AN AUTHORIZED TECHNICIAN ONLY.

MAIN PCB ASSEMBLY

19X1773

E18

D47

Q8

BIAS
CONVERTER

CIRCUITRY

FACTOR CORRECTION

TORCH PROTECTION

E

F

A-03405

1

APPENDIX A-6 Manual 0-2898

2

3

4

5

C70, 72, 81

C71, 73, 75

D56

TORCH SWITCH ON

Q13

Q12

+14VA

+12VB

6

E5

D55

BGND

PWM ON

E6

AGND

o

PRI

D99

D22

MAIN

T3

SEC

o

E10

7

D53

E20

OUTPUT INDUCTOR

E9

D54

8

L1

E4

(E4)

9

P8J8

10

A

TORCH

(-)

T
O
R

TORCH
SWITCH

C
H

WORK

B

Q11

E8

(E8)

J3

P3

(12)

1

1

4

(13)

22

3

(14)

3

2

3

(15)

1

44

PILOT

4

3

2

1

PIP

5

QUICK DISCONNECT

E19

WORK

C

J1

P1

1

1

2

2

SOL1

B

A

GAS SOLENOID

D

COMP DESCRIPTION

TS1

OVER-TEMP. SENSOR
M1 FAN, 4.5" 12VDC
PS1 PRESSURE SWITCH
SOL1 GAS SOLENOID
T1
T3

PFC INDUCTOR
MAIN TRANSFORMER

L1 OUTPUT INDUCTOR
SW1
SW2

AA

AB

A

Last Modified:

5

6

7

REL ECO 100213

REL ECO 100333

REL ECO 100535

C

Thursday, March 20, 2003

SWITCH, ON/OFF

SWITCH, RUN/SET

7/29/02

GCW

10/04/02

GCW

2/27/03

DAT

15:05:29

8

DateByRevisionsRev

LOCATION

D2
C1
D1
D9

A4

A7
A8
B2
D1

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

TITLE:

CM38 120/208/230V SINGLE PHASE 50/60 Hz

SCHEMATIC,

603-298-5711

9

PCB No:

Assy No:

SupersedesScale

Date:

Tuesday, May 15, 2001

Drawn: References

GCW

Chk: App:

Sheet

11

DWG No:

Size

42X1089

C

A-03405

10

E

F

of

Manual 0-2898 A-7 APPENDIX

APPENDIX 7: PUBLICATION HISTORY

Cover Date Rev 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 AA Added input power cords & strain reliefs, per ECOs 101877 & B049.

9/29/06 AA.01 Added patent information at the end of section 6 per ECO-B193. Updated rear cover

adding contact information. Applied next rev level fomat.

Global Customer Service Contact Information

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Victor Brasil

Avenida Brasil
13629-Cordovil
Rio de Janeiro, Brazil 21012-351
Telephone: [phone]
Fax: [phone]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Asia Sdn Bhd

Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085

Cigweld, Australia

71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne Chile

Piloto Lazo #90
Cerrillos
Santiago, Chile 7278-654
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne South Africa

209 Risi Ave.
Linmeyer
Johannesberg, 2197
South Africa
Tel: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Corporate Headquarters

16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017

Telephone: [phone]
Email: [e-mail]

www.thermadyne.com