Thermal Dynamics CutMaster 38 Operating Manual

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CUTMASTER

PLASMA CUTTING SYSTEM

A-03286

Operating Manual

Rev. AA.01 Date: October 20, 2006 Manual # 0-2888 Operating Features:

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

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.

. Duty Cycle is the percentage of time the system can be operated without overheating. Duty c yc le

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

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

150 mm

24"

0.6 m

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

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

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-03385

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.

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.

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

3020

A-03283

4 5

6 7

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-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.

65 psi / 4.5 bar

3020

A-03385

Manual 0-2888 4-5 OPERATION

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-03386

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

Trigger

Trigger Release

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.

Inches

Meters

Inch

0.5

0.4

0.375

0.35

0.3

0.25

0.2

0.15

0.1

0.05

0.25

0.5401.00

1.5

Typical Cutting Speeds

Air Plasma on Mild Steel

100

120

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

MATERIAL THICKNESS

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

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

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:

1/3

Output Current Type

Rated NoLoad Voltage

Degree of Protection

Conventional Load Voltage

Rated Supply Voltage (Note 2)

West Lebanon, NH USA 03784

S/N

Duty Cycle Factor

Rated Maximum Supply Current

1max 1eff

1Ø

3Ø

Made in USA

3Ø1Ø

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

Phase

Art # A-03288

APPENDIX A-2 Manual 0-2888

This page left blank.

Manual 0-2888 A-3 APPENDIX

APPENDIX 3: SYSTEM SCHEMATIC

12 0/208/230V

INPUT 50/60HZ

INP UT 230V ONLY

EMC FILTER CE ONLY

CH ASSIS GND

FAN1

CURRENT

CONTROL

CURRENT ADJUST

20 - 30

SET

SW2

RUN

NORMALLY CLOSED

OVER-TEMP

PRESSURE SW

SW1

STUD

12VDC

TS1

PS1

(E1)

(E2)

RED

BLACK

(10) (11)

E13

(5) (6)

(7)

(8)

(9)

P9 J9

TEST

E12A

FILTERING

323

1 2

ZERO

E15A

E14B

E15B

PANEL INDICATOR

TEMP

GAS

(E14A)

BR1

E14A

(E16A)

E16A

E12B

(E14B)

123

BR2

(E16B)

E16B

D13

D16

D19

(E12A)

(E12B)

E11

(E15A)

(E15B)

PFC INDUCTOR

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

BIAS CONVERTER

CIRCUITRY

FACTOR CORRECTION

TORCH PROTECTION

A-03405

APPENDIX A-4 Manual 0-2888

C70, 72, 81

C71, 73, 75

D56

TORCH SWITCH ON

Q13

Q12

+14VA

+12VB

D55

BGND

PWM ON

AGND

PRI

D22

D99

MAIN

SEC

OUTPUT INDUCTOR

E10

E20

(E4)

TORCH

P8J8

(-)

D53

D54

Q11

(E8)

(12)

(13)

(14)

(15)

PILOT

3 2

PIP

TORCH SWITCH

T O R C H

WORK

QUICK DISCONNECT

E19

WORK

SOL1

GAS SOLENOID

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

Last Modified:

REL ECO 100213

REL ECO 100333

REL ECO 100535

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

DateByRevisionsRev

LOCATION

D2 C1 D1 D9

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

PCB No:

Assy No:

SupersedesScale

Date:

Tuesday, May 15, 2001

Drawn: References

GCW

Chk: App:

Size

DWG No:

42X1089

Sheet

A-03405

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

Thermal Dynamics CutMaster 38 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual