Thermal Dynamics CutMaster 38 Operating Manual

38
CUTMASTER
PLASMA CUTTING SYSTEM
A-03286
Operating Manual
30
120
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 0-2888
Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711
www.thermal-dynamics.com
Copyright 2002, 2003, 2004, 2005, 2006 by Thermal Dynamics Corporation
All rights reserved.
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: October 20, 2006
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 Declaration of Conformity ............................................................................. 1-4
1.05 Statement of Warranty .................................................................................. 1-5
SECTION 2: SPECIFICATIONS ............................................................................................... 2-1
Options and Accessories ...................................................................................... 2-2
Torch Specifications ............................................................................................. 2-3
SECTION 3:
INSTALLATION .................................................................................................................. 3-1
3.01 Unpacking .................................................................................................... 3-1
3.02 Lifting Options .............................................................................................. 3-1
3.03 Primary Input Power Connections ................................................................. 3-2
3.04 Gas Connections .......................................................................................... 3-3
3.05 Torch Connections ........................................................................................ 3-6
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-3
4.03 Sequence of Operation ................................................................................. 4-8
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-6
5.03 Basic Troubleshooting Guide ......................................................................... 5-7
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Replacement Assemblies ............................................................................ 6-1
6.04 Power Supply Replacement Parts ................................................................. 6-1
6.05 Options and Accessories .............................................................................. 6-2
6.06 Torch Consumables ...................................................................................... 6-2
PATENT INFORMATION ............................................................................................................ 6-3
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM) .......................................................................................................... A-1
APPENDIX 2: DATA TAG INFORMATION .................................................................................. A-2
APPENDIX 3: SYSTEM SCHEMATIC ...................................................................................... A-4
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 1-603-298­5711 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 0-2888 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 alu- minum 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 0-2888
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
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
Manual 0-2888 1-3 GENERAL INFORMATION
1.04 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
GENERAL INFORMATION 1-4 Manual 0-2888
1.05 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor) CUTMASTER™ 38 3 Years 1 Year CUTMASTER™ 51 3 Years 1 Year CUTMASTER™ 81 3 Years 1 Year CUTMASTER™ 101 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation 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 customer of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 the goods covered by or furnished by Thermal Dynamics 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 liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective January 15, 2004
Manual 0-2888 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 Manual 0-2888
SECTION 2: SPECIFICATIONS
)
CutMaster 38 Power Supply Specifications
Input Power (See Note 1)
Power Sensing Input Power Cable Output Current
Power Supply Gas Filtering Ability
CutMaster 38 Power Supply Duty Cycle (Note 2
Ambient Temperature Duty Cycle 35% 60% DC Voltage 78 vdc 89 vdc Current 30 Amps 22 Amps
Gas Type Gas specifications Maximum Input Gas Pressure Operating Gas Pressure Gas Flow Requirements
. Power supply accepts 120-230 VAC input power. No manual switching is required.
1
. Duty Cycle is the percentage of time the system can be operated without overheating. Duty c yc le
2
is reduced if primary input voltage (AC) is low or the DC voltage is higher than shown in this c hart.
. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may
3
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear. Optional filters provide increased filtering capabilities.
120 VAC (± 10%), Single-Phase, 50/60 Hz 208 - 230 VAC (± 10%), Single-Phase, 50/60 Hz Automatic Voltage Selection. See Note 1. Cable with plug, for 120VAC, 20-Amp Single-Phase input power. 20-30 Amps, continuously variable
Particulates to 20 Microns
104° F (40° C)
n/a %
n/a vdc
n/a Amps
SL 60 Torch Gas Requirements
Compressed Air Clean, dry, oil-free (Note 3 ) 125 psi / 8.6 bar 65 psi / 4.5 bar 300 scfh / 141.5 lpm
Notes
15.75"
400 mm
21"
0.53 m
43 lb / 19.5 kg
Weight includes torch & leads, input power cord, and work cable with clamp.
Manual 0-2888 2-1 SPECIFICATIONS
A-03378
10"
254 mm
Art # A-03379
6"
150 mm
24"
0.6 m
6"
150 mm
6"
150 mm
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit proper cooling and reduce duty cycle.
Electrical Requirements
CutMaster 38 Input Power Requirements
Input
Voltage Freq. (kVA)
(Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph
120 50 / 60 208 50 / 60 230 50 / 60
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.
Cable conductor temperature used is 167° F (75° C).
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.
Power Input Current Input
(Amps) Fuse (Amps) Wire (AWG) Wire (Canada)
3.629351212
3.516201212
3.414201212
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTES
Suggested Sizes (See Notes)
Extension Cords
Extension cords must meet National Electric Code Guidelines (and OSHA Guidelines, where applicable). Extension cords must have the same rating as the service and must have a three-pronged plug.
Options and Accessories
The following options and accessories are available for this Power Supply. Section 6 provides catalog numbers and ordering information.
A. Single-Stage Air Filter Kit
A single-stage air filter for use on compressed air shop systems. Highly effective at removing moisture and particulate matter from the air stream to at least 0.85 microns.
B. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf is 12 " (305 mm) x 20 (508 mm). Steel handle is 30" (762 mm) high.
C. Cutting Guide Kit
Easy add-on attachments for straight line, circle, or bevel cutting.
SPECIFICATIONS 2-2 Manual 0-2888
Torch Specifications
p
g
The Torch provides cutting capacity of up to 3/8 inch / 9.5 mm at 30 amperes.
A. Torch Configuration and Dimensions
The torch head is at 75° to the torch handle. The torch includes a torch handle and torch trigger assembly.
9.5" (241 mm)
3.75"
(95 mm)
1.17" (29 mm)
Torch Configuration and Dimensions
B. Torch Leads Lengths
Leads are available in 20 ft (6.1 m) lengths.
C. Parts-In-Place (PIP)
Torch has built-in switch.
12 vdc circuit rating
D. Type of Cooling
Combination of ambient air and gas stream through torch
E. SL60 Torch Ratings
(Refer to Note)
Ambient
Tem
erature
Duty Cycle
Maximum Current
Vol tage (V
Arc Striking Voltage
SL60 Torch Ratin
)
pea k
Art # A-03322
s
104° F
(40° C)
100% @ 60 Amps @ 400 scfh
60 Amps
500V
7kV
Ratings shown apply to the SL60 Torch only. Refer to the Specifications chart on page 2-1 for CutMaster 38 data.
F. Plasma Power Supply Used With
Thermal Dynamics CutMaster 38
Manual 0-2888 2-3 SPECIFICATIONS
NOTE
SPECIFICATIONS 2-4 Manual 0-2888
SECTION 3:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.
WARNINGS
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-2888 3-1 INSTALLATION
3.03 Primary Input Power Connections
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.
Power Cord and Plug
This power supply includes an input power cord and plug suitable for 120 VAC, 20 Amp, Single - Phase input power.
A-03382
120 V, 20A, 1Ø
For 208 / 230 VAC input power, replace the supplied power plug. Use only an approved replacement input power plug with ground.
Replace the plug as follows:
1. Cut the original cord close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according to the plug manufacturer's instructions. All three conductors must be connected to the plug.
Connect the input power cord as follows:
1. Check the power source for correct voltage before plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
INSTALLATION 3-2 Manual 0-2888
3.04 Gas Connections
A. Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure gas cylinders. Refer to subsection 3.4-C if an optional air line filter is to be installed.
1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. 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.
Min. 1/4 inch
6.4 mm
A-03272
Gas Connection to Inlet Port
B. 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
26
24
22
A-03385
28
3020
Manual 0-2888 3-3 INSTALLATION
C. Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the gas line to the Filter. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. 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. Connect as follows:
Filter Hose
Single-Stage
Filter Kit
No. 7-7507
Hose Clamp
1/4 NPT Hose Fitting
Gas Supply Hose
A-03281
Optional Single - Stage Filter Installation
INSTALLATION 3-4 Manual 0-2888
D. Using High Pressure Gas Cylinders
When using high pressure gas cylinders as the gas supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows of at least 300 scfh (141.5 lpm).
4. Connect gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. 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.
Manual 0-2888 3-5 INSTALLATION
3.05 Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 Torch to this power supply.
WARNING
Disconnect primary power at the source before connecting the torch.
1. Align the male connector (on the torch lead) with the female receptacle on the power supply. Press the connector into the receptacle fully.
2. Turn the locking ring on the male connector fully clockwise until it clicks.
A-03380
Connecting the Torch to the Power Supply
3. The system is ready for operation.
1
2
INSTALLATION 3-6 Manual 0-2888
4.01 Product Features
A. General Features
SECTION 4:
OPERATION
Handle and Leads WrapGas Pressure Knob
Torch Leads Connector
Control Panel
Work Cable and Clamp
A-03287
Manual 0-2888 4-1 OPERATION
B. Control Panel
2
1
24
22
A
26
28
3020
A-03283
4 5
6 7
3
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.
3. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit opens frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate input power. Refer to Section 2 for input power requirements.
4. AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective interlock
mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details.
5. TEMP Indicator
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Shut unit OFF; let the unit cool before continuing operation.
6. GAS Indicator
Indicator is ON when adequate input gas pressure is present.
7. DC Indicator
Indicator is ON when DC output circuit is active.
OPERATION 4-2 Manual 0-2888
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). Use only genuine Ther­mal Dynamics parts with this torch.
Art # A-03409
Large O-Ring, Cat. No. 8-3487
Small O-Ring, Cat. No. 8-3486
Electrode, Cat. No. 9-8215
Start Cartridge, Cat. No. 9-8213
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Worn Electrode
Worn Tip
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. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
Manual 0-2888 4-3 OPERATION
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 re­quirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure gas source meets requirements (refer to Section 2). Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.
Art # A-03387
OPERATION 4-4 Manual 0-2888
F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on.
A
26
24
22
28
A-03384
3020
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. Gas indicator turns on.
NOTE
If gas regulator leaks, reset gas pressure to 0 psi, then reset to 65 psi / 4.5 bar.
1
2
65 psi / 4.5 bar
A
26
24
22
3020
A-03385
Manual 0-2888 4-5 OPERATION
28
A-03389
H. Select Current Output Level
Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level.
A
26
24
22
A-03386
28
3020
I. Cutting Operation
Refer to Section 1, Important Safety Precautions. Wear heavy welding gloves and protective clothing. Protect eyes with appropriate shielding. Aim the torch head away from yourself. Slide the trigger release to the rear. Squeeze and hold the trigger. Gas flows for approximately 1 second, then shuts off briefly. The pilot arc then starts. DC indicator turns on. Bring the torch within transfer distance to the workpiece. The pilot arc stops and the main arc transfers to the workpiece.
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. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
Trigger
1
2
Trigger Release
3
4
OPERATION 4-6 Manual 0-2888
Art # A-03383
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. Good cutting speeds create a slight trailing arc.
K. Typical Cutting Speeds
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds shown are typical for this cutting system using air plasma to cut mild steel, with output current at 30 amps and torch held at 0 - 1/16" (0 - 1.6 mm) standoff.
MM
8
7
6
5
4
3
2
1
Inches
Meters
Inch
0.5
0.4
0.375
0.35
0.3
0.25
0.2
0.15
0.1
0.05
10
0.25
20
0.5401.00
60
1.5
Typical Cutting Speeds
Air Plasma on Mild Steel
100
120
80
2.5
2.0
Inches/ Meters per Minute
3.05
CUTTING SPEED
140
3.5
160
4.06
180
4.57
200
5.08
220
5.56
240
6.1
Gage
12.7
9.5
6
12
MATERIAL THICKNESS
18
20
24
A-03381
400
10.1
Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, using a template or cutting guide while still producing cuts of excellent quality.
L. Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 10 seconds. During post ­flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.
M. Shutdown
Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.
Manual 0-2888 4-7 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. Place the ON / OFF switch on the Power Supply to ON (up) position.
a. AC indicator turns on; fan turns on.
NOTES
If there is adequate gas supply pressure to the power supply, gas comes on if Torch Trigger is pressed.
If torch trigger is held while user turns on main AC power, system goes into 'protective interlock' mode. AC indicator flashes; torch will not pilot. Release torch trigger, turn AC switch OFF then ON.
3. Put RUN / SET switch to SET (down position).
a. Gas flows to set pressure. Turn gas pressure adjustment knob to set pressure to 65 psi / 4.5 bar; Gas
indicator turns ON when there is sufficient gas pressure for power supply operation.
NOTE
Minimum pressure for power supply operation is lower than minimum pressure for torch operation.
4. Put RUN / SET switch to RUN (up position). Gas flow stops.
5. Wear protective clothing and welding gloves. Protect eyes. Slide the trigger release to the rear; squeeze and hold the trigger. Gas flows briefly, then shuts off momentarily. Then gas flow will resume. Pilot arc is estab­lished. DC indicator turns ON. Move Torch within transfer distance of workpiece.
a. Main arc transfers to workpiece.
6. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc will automatically restart.
7. Release the torch trigger.
a. Main arc stops; gas flows for approximately 10 seconds.
8. Set the power supply ON / OFF switch to OFF (down position).
a. AC indicator turns OFF; fan turns OFF.
9. Set the main power disconnect to OFF, or unplug input power cord.
a. Input power is removed from the system.
OPERATION 4-8 Manual 0-2888
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. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
Art # A-03409
Electrode, Cat. No. 9-8215
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Large O-Ring, Cat. No. 8-3487
Small O-Ring, Cat. No. 8-3486
Start Cartridge, Cat. No. 9-8213
Worn Electrode
Manual 0-2888 5-1 SERVICE
Worn Tip
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.
Upper screws
Ground wire
Upper screws
Lower screws
A-03285
Cover Removal
SERVICE 5-2 Manual 0-2888
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.
7. Note the correct assembly of the filter / spool then remove the filter from the spool and either clean it or replace it.
8. Screw the filter element and spool, with the baffle ring in place (teeth facing downward) back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand.
Ring
Replacement Element No. 9-4414
Spool
Bowl
A-03377
Regulator / Filter Element Replacement
9. Clean the inside of the bowl if necessary. Check that the knurled valve on the bottom of the bowl is fully open.
10. Reinstall the bowl. Reconnect the drain tube.
11. Reinstall the cover as follows:
a. Reconnect the ground wire, if necessary.
b. Set the cover onto the base so that it rests on the lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the upper screws.
12. Turn on the air supply.
Manual 0-2888 5-3 SERVICE
C. O-Ring Lubrication
An o-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential performance problems.
It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.
NOTE
DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain
“unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.
ATC Male Connector
Art #A-03791
Gas Fitting
O-Ring
SERVICE 5-4 Manual 0-2888
D. Check Optional Single - Stage Filter Element, replace if necessary.
1. Shut off input power.
2. Shut off air supply, bleed down system.
3. Disconnect gas supply hose from filter.
4. Turn the Cover counter - clockwise.
5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply hose. If unit leaks between housing and cover, inspect the "O" Ring for cuts or other damage.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Manual 0-2888 5-5 SERVICE
5.02 Common Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
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
4. Short Torch Parts Life
a. Oil or 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. Non - Genuine Thermal Dynamics parts used
5. Difficult Starting
a. Worn torch parts
b. Non - Genuine Thermal Dynamics parts used
SERVICE 5-6 Manual 0-2888
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. It is helpful for solving many of the common problems that can arise with this system. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for this prod­uct.
B. How to Use This Guide
The following information will help the Customer / Operator determine the most likely causes for various symptoms. Follow all instructions as listed and complete each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions
1. Cause
a. Check / Remedy
Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that unit operates properly after any repairs.
C. Common Symptoms
A. Gas regulator leaks
1. Regulator is open
a. Reset regulator to 0 psi, then adjust to 65 psi ( 4.5 bar ).
B. AC indicator OFF
1. Switch at customer's main power panel in OFF (open) position.
a. Close main power switch.
2. Power Supply ON / OFF switch in OFF position.
a. Turn switch to ON.
3. Customer's main power line fuse(s) or circuit breaker(s) blown
a. Check main power panel fuse(s) and replace as required.
4. Actual input voltage does not correspond to voltage of unit
a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
Manual 0-2888 5-7 SERVICE
C. AC indicator flashing; Torch cannot be activated
1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.)
a. Release torch trigger, set ON / OFF switch to OFF (down). Return ON / OFF switch to ON (up) position.
2. System is in protective interlock mode. (Torch parts are missing or loose.)
a. Release torch trigger, and set ON / OFF switch to OFF (down). Open main disconnect switch. Check torch
parts, including O - rings on torch head. Refer to illustration on page 5 - 1. Replace parts as needed. Reinstall shield cup; hand - tighten it securely against the torch head. Close main disconnect switch. Set ON / OFF switch to ON (up) position.
3. System is in protective interlock mode. (User removed shield cup from torch while power supply ON / OFF switch was ON.)
a. Release torch trigger, and set ON / OFF switch to OFF (down). Set ON / OFF switch to ON (up).
D. Torch will not pilot; DC indicator and GAS indicator flash alternately when torch trigger is activated
1. Gas pressure is too low. Adjust gas pressure to 65 psi / 4.5 bar.
E. AC indicator flashing; Temp indicator ON
1. Fan disconnected or blocked.
a. Clear fan if blocked; let power supply cool.
F. AC indicator ON; TEMP indicator ON
1. Air flow blocked
a. Check for blocked air flow around the unit and correct condition.
2. Fan blocked
a. Check and correct condition.
3. Unit is overheated
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to duty cycle data in Section 2.
4. Input line voltage is below 100 Volts
a. Check and connect to proper input power line.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
SERVICE 5-8 Manual 0-2888
G. Torch will not pilot when torch switch is activated
1. System is in SET mode
a. Change to RUN mode.
2. Upper O-ring on torch head is in wrong position.
a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.
Art # A-03640
Upper Groove with Vent Holes Must Remain Open
Upper O-Ring in Correct Groove
Threads Lower O-Ring
3. Faulty torch parts
a. Inspect torch parts and replace if necessary.
4. Gas pressure too high or too low
a. Adjust to proper pressure.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
H. No cutting output; Torch activated; AC indicator ON; Gas flows; Fan operates
1. Torch not properly connected to power supply
a. Check that torch leads are properly connected to power supply.
2. Work cable not connected to work piece, or connection is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Shield cup not properly installed on torch
a. Open main disconnect switch. Check that shield cup is fully seated against torch head. Set ON / OFF switch
to OFF, check shield cup, close main disconnect switch, turn power supply ON, and try cutting.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
5. Faulty Torch
a. Return for repair or have qualified technician repair.
Manual 0-2888 5-9 SERVICE
I. Low cutting output
1. Incorrect setting of CURRENT (A) control
a. Check and adjust to proper setting.
2. Faulty components in unit
a. Return for repair or have qualified technician repair.
J. 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. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
K. Erratic or improper cutting output
1. Poor input or output connections
a. Check all input and output connections.
2. Poor work cable connection
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Fluctuations in input power
a. Have electrician check input line voltage.
L. Difficult Starting
1. Worn torch parts (consumables)
a. Shut off input power. Remove and inspect torch shield cup, tip, starter cartridge, and electrode. Replace
electrode or tip if worn; replace starter cartridge if end piece does not move freely; replace shield cup if excessive spatter adheres to it.
SERVICE 5-10 Manual 0-2888
M. Arc shuts off during operation; arc will not restart when torch switch is activated.
1. Power Supply is overheated (TEMP indicator
ON)
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to Section 2 for duty cycle specifications.
2. Fan blades blocked (AC indicator
flashing; TEMP indicator ON)
a. Check and clear blades.
3. Air flow obstructed (AC indicator flashing; TEMP indicator ON)
a. Check for obstructed air flow around the unit and correct condition.
4. Gas pressure too low (GAS indicator OFF when torch switch is activated)
a. Check source for at least 65 psi / 4.5 bar; adjust as needed.
5. Torch consumables worn
a. Check torch shield cup, tip, starter element, and electrode; replace as needed.
6. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
N. 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. Faulty components in unit
a. Return for repair or have qualified technician repair.
O. Torch cuts but not adequately
1. Current (A) control set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not
activate torch). If there are contaminants in the gas, additional filtering may be needed.
Manual 0-2888 5-11 SERVICE
SERVICE 5-12 Manual 0-2888
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. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor.
6.03 Replacement Assemblies
The following items are included with the replacement power supply: input power cord and plug, work cable & clamp, gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 38 Power Supply with input power cord and 120 VAC, 20A plug 3-3820 1 Surelok Model SL60 Torch 7-5204
6.04 Power Supply Replacement Parts
Qty Description Catalog #
1 Regulator / Filter Assembly Filter Element 9-4414 1 Input Power Cord with 120 VAC, 20A plug (for units through Unit Rev AE) 9-8628 1 Input Power Cord with 120 VAC, 20A plug (for units at Unit Rev AF and later) 9-8660
Manual 0-2888 6-1 PARTS LISTS
6.05 Options and Accessories
Qty Description Catalog #
1 120V, 15 - Amp Plug 9-8644 1 120V, 20 - Amp Receptacle 9-8645 1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741 1 Multi - Purpose Cart 7-8888
Housing
Filter
Single - Stage Air Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Assembled Filter
6.06 Torch Consumables
Art # A-03409
Electrode, Cat. No. 9-8215
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Barbed
Fitting
Large O-Ring, Cat. No. 8-3487
Small O-Ring, Cat. No. 8-3486
Start Cartridge, Cat. No. 9-8213
Art # A-02476
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. Do not attempt to over tighten the shield cup as irrepa­rable damage to internal components may result.
Worn Electrode
PARTS LISTS 6-2 Manual 0-2888
Worn Tip
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 0-2888 6-3 PARTS LISTS
PARTS LISTS 6-4 Manual 0-2888
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
ON / OFF switch
to ON.
RESULT
AC indicator ON.
Fan on.
Power circuit ready.
ACTION
Protect eyes and
activate torch.
RESULT
Gas flows briefly,
then stops.
Gas restarts.
DC indicator on.
Pilot arc established.
ACTION
Release torch trigger.
RESULT
Main arc stops.
Gas flow stops after post - flow.
ACTION
RUN / SET switch to SET.
RESULT
Gas flows to set pressure.
GAS indicator on when input
pressure is adequate.
PILOT ARC
ON / OFF switch
All indicators off.
Power supply fan shuts off.
ACTION
to OFF
RESULT
ACTION
RUN / SET switch
to RUN.
RESULT
Gas flow stops.
Torch moved away
from work (while
still activated).
Main arc stops.
Pilot arc automatically
Torch moved within
transfer distance of workpiece.
Main arc transfers.
Pilot arc off.
Connect work cable
Set output amperage
ACTION
RESULT
restarts.
ACTION
RESULT
ACTION
Unplug input
power cord or
open external
disconnect.
RESULT
No power to system.
ACTION
to workpiece.
RESULT
System is ready
for operation.
A-03299
Manual 0-2888 A-1 APPENDIX
APPENDIX 2: DATA TAG INFORMATION
Type of Power Supply (Note 1)
Plasma Cutting Symbol
Input Power Symbol
Input Power Specifications (Phase, AC or DC Hertz Rating)
Model:
Date of Mfr:
f
1/3
1
f
2
Output Current Type
U
Rated No­Load Voltage
Degree of Protection
=
0
U
Conventional Load Voltage
X
I
2
U
1
Rated Supply Voltage (Note 2)
West Lebanon, NH USA 03784
S/N
Duty Cycle Factor
Rated Maximum Supply Current
1max 1eff
I
1
Made in USA
I
1
Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code
Regulatory Standard Covering This Type of Power Supply
Output Range (Amperage/ Voltage)
Duty Cycle Data (Note 3)
Maximum Effective Supply Current
Manufacturer's Electrical Schematic File Number and Revision Level
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. TDC duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.
NOTE
Sections of the data tag may be applied in separate locations on the Power Supply.
Standard Symbols
AC
DC
Phase
Ø
Art # A-03288
APPENDIX A-2 Manual 0-2888
This page left blank.
Manual 0-2888 A-3 APPENDIX
APPENDIX 3: SYSTEM SCHEMATIC
A
12 0/208/230V
INPUT 50/60HZ
B
C
D
1
INP UT 230V ONLY
EMC FILTER CE ONLY
CH ASSIS GND
M1
FAN1
CURRENT
CONTROL
CURRENT ADJUST
20 - 30
SET
SW2
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
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
E14B
E15B
PANEL INDICATOR
AC
TEMP
GAS
DC
2
(E14A)
BR1
1
4
E14A
-+
(E16A)
E16A
E12B
(E14B)
123
BR2
4
-+
(E16B)
E16B
D7
D13
D16
D19
(E12A)
3
(E12B)
E11
(E15A)
(E15B)
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-4 Manual 0-2888
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
D22
D99
MAIN
T3
SEC
7
8
9
10
OUTPUT INDUCTOR
o
E10
E9
E20
L1
E4
(E4)
TORCH
P8J8
A
(-)
D53
D54
Q11
E8
(E8)
J3
P3
(12)
1
1
4
(13)
22
3
(14)
3
2
3
(15)
44
1
PILOT
4
3 2
1
PIP
TORCH SWITCH
T O R C H
WORK
B
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:
Size
C
DWG No:
42X1089
10
Sheet
11
of
A-03405
E
F
Manual 0-2888 A-5 APPENDIX
Global Customer Service Contact Information
Thermadyne USA
2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermadyne.com
Thermadyne Victor Brasil
Avenida Brasil 13629-Cordovil Rio de Janeiro, Brazil 21012-351 Telephone: 55-21-2485-8998 Fax: 55-21-2-485-8735
Thermadyne Canada
2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648
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: 61-3-9474-7400 Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773
Thermadyne Chile
Piloto Lazo #90 Cerrillos Santiago, Chile 7278-654 Telephone: 56-2-557-2465 Fax: 56-2-557-5349
Thermadyne Europe
Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800
Thermadyne, China
RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139
Thermadyne South Africa
209 Risi Ave. Linmeyer Johannesberg, 2197 South Africa Tel: (27) 11-917 3600 Fax: (27) 11-917 8580
Thermadyne International
2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com
www.thermadyne.com
Loading...