Thermal Dynamics CUTMASTER 39 Service Manual

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CUTMASTER

PLASMA CUTTING SYSTEM

Service Manual

Rev. AC Date: February 24, 2010 Manual # 0-4976 Operating Features:

WARNINGS

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 Power Supply CutMaster™ 39 SL60 1Torch™ Service Manual Number 0-4976

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: June 18, 2007 Revision Date: February 24, 2010

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ...................................................................................1-1

1.01 Notes, Cautions and Warnings ...................................................................1-1

1.02 Important Safety Precautions .....................................................................1-1

1.03 Publications.................................................................................................1-2

1.04 Note, Attention et Avertissement ................................................................1-3

1.05 Precautions De Securite Importantes .........................................................1-3

1.06 Documents De Reference ...........................................................................1-5

1.07 Declaration of Conformity ...........................................................................1-6

1.08 Statement of Warranty ................................................................................1-7

SECTION 2 SYSTEM:INTRODUCTION .................................................................................2-1

2.01 How To Use This Manual ............................................................................2-1

2.02 Equipment Identiﬁcation .............................................................................2-1

2.03 Receipt Of Equipment .................................................................................2-1

2.04 Power Supply Speciﬁcations .......................................................................2-2

2.05 Input Wiring Speciﬁcations ..........................................................................2-3

2.06 Power Supply Options and Accessories .....................................................2-4

2.07 Torch Speciﬁcations ....................................................................................2-4

SECTION 2 TORCH:INTRODUCTION .................................................................................. 2T-1

2T.01 Scope of Manual ....................................................................................... 2T-1

2T.02 General Description ..................................................................................2T-1

2T.03 Speciﬁcations ........................................................................................... 2T-1

2T.04 Options And Accessories .......................................................................... 2T-2

2T.05 Introduction to Plasma .............................................................................. 2T-2

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 ...................................................................................... 3-5

SECTION 4 SYSTEM:OPERATION .........................................................................................4-1

4.01 Product Features ........................................................................................ 4-1

4.02 Preparations For Operating ........................................................................4-3

4.03 Sequence of Operation ............................................................................... 4-7

SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1

4T.01 Introduction ............................................................................................... 4T-1

4T.02 Functional Overview ................................................................................. 4T-1

4T.03 Getting Started ......................................................................................... 4T-1

4T.04 Torch Parts Selection ................................................................................ 4T-1

4T.05 Cut Quality ................................................................................................ 4T-2

4T.06 General Cutting Information ...................................................................... 4T-3

4T.07 Hand Torch Operation ............................................................................... 4T-4

4T.08 Recommended Cutting Speeds ................................................................ 4T-7

4T.09 Gouging .................................................................................................... 4T-7

TABLE OF CONTENTS

SECTION 5 SYSTEM: SERVICE .............................................................................................5-1

5.01 General Maintenance .................................................................................5-1

5.02 Common Faults ...........................................................................................5-6

5.03 Circuit Fault Isolation ..................................................................................5-6

5.04 Main Input and Internal Power Problems ....................................................5-7

5.05 Pilot Arc Problems ......................................................................................5-9

5.06 Main Arc Problems....................................................................................5-10

5.07 Test Procedures ........................................................................................5-10

5.08 Anti-Static Handling Procedures ............................................................... 5-12

5.09 Parts Replacement - General Information ................................................5-13

5.10 Major External Parts Replacement ...........................................................5-13

5.11 Front Panel Parts Replacement ................................................................ 5-13

5.12 Rear Panel Parts Replacement ................................................................5-15

5.13 Right Side Internal Parts Replacement .....................................................5-16

SECTION 5 TORCH:SERVICE .............................................................................................. 5T-1

5T.01 General Maintenance ............................................................................... 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts ........................ 5T-2

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 Major External Replacement Parts ............................................................6-2

6.06 Front Panel Replacement Parts .................................................................. 6-3

6.07 Left Side Replacement Parts .....................................................................6-4

6.08 Right Side Replacement Parts ...................................................................6-5

6.09 Options and Accessories ............................................................................6-6

6.10 Torch Consumables .................................................................................... 6-7

PATENT INFORMATION .......................................................................................................... 6-8

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) ........................................ A-1

APPENDIX 2: DATA TAG INFORMATION ............................................................................. A-2

APPENDIX 3: MAIN POWER PC BOARD LAYOUT ............................................................... A-3

APPENDIX 4: MAIN PC BOARD WIRING ............................................................................... A-4

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

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

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

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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

• 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.)

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 1-603-298-5711 or your local distributor if you have any questions.

GASES AND FUMES

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

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

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

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.”

• 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.

Manual 0-4976 1-1 GENERAL INFORMATION

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

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

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

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

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.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California

Health & Safety Code § 25249.5 et seq.)

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

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

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN- ERS 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

GENERAL INFORMATION 1-2 Manual 0-4976

1.04 Note, Attention et Avertissement

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

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

NOTE

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

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

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

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

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

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

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

FUMÉE et GAZ

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

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

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

• Réparez ou remplacez toute pièce usée ou endommagée.

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

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

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

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

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

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

Manual 0-4976 1-3 GENERAL INFORMATION

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma

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produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inﬂammables.

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

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

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

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

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

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

BRUIT

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

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

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

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

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.

Il faut s e l a v e r les mains a p r è s t o u t e manipulatio n .

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

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

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

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

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

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

Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

GENERAL INFORMATION 1-4 Manual 0-4976

1.06 Documents De Reference

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

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

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

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

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

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

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

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

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

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

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

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

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

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

Manual 0-4976 1-5 GENERAL INFORMATION

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1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA

age 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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/ 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:

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

* For environments with increased hazard of electrical shock, Power Supplies bearing the mark conform to EN50192 when used in

conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufacturing 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: Steve Ward

Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Operations Director

GENERAL INFORMATION 1-6 Manual 0-4976

cutmaster 39

1.08 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™ 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™ 39 4 Years 1 Year

CUTMASTER™ 52 4 Years 1 Year

CUTMASTER™ 82 4 Years 1 Year

CUTMASTER™ 102 4 Years 1 Year

CUTMASTER™ 152 4 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 September 4, 2007

Manual 0-4976 1-7 GENERAL INFORMATION

cutmaster 39

GENERAL INFORMATION 1-8 Manual 0-4976

cutmaster 39

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Operating Manual applies to just

specication or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as

follows:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

2.02 Equipment Identiﬁcation

The unit’s identication number (specication or part number), model, and serial number usually appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identied only by the specication or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page 1 for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to le a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual. Include all equipment identication numbers as described above along with a full description of the parts in error. Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Dynamics at the address and phone number in your area listed in the inside back cover of this manual. Include the Operating Manual number and equipment identication numbers. Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: http://www.thermal-dynamics.com

Manual 0-4976 2-1 INSTALLATION

cutmaster 39

2.04 Power Supply Speciﬁcations

CutMaster 39 Power Supply Specications

Input Power (See Note 1) 120 VAC (± 10%), Single-Phase, 50/60 Hz

208 - 230 VAC (± 10%), Single-Phase, 50/60 Hz

Power Sensing Automatic Voltage Selection. See Note 1.

Cable with NEMA L6-20P plug, for use with one of two adapters provided,

Input Power Cable

Output Current 20-30 Amps, continuously variable

Power Supply Gas Filtering Ability Particulates to 20 Microns

CutMaster 39 Power Supply Duty Cycle (Note 2)

Ambient Temperature 104° F (40° C)

Duty Cycle 35% 60%

DC Voltage 78 vdc 89 vdc

Current 30 Amps 22 Amps

Gas Type Compressed Air

Gas specications Clean, dry, oil-free (Note 3)

Maximum Input Gas Pressure 125 psi / 8.6 bar

Operating Gas Pressure 65 psi / 4.5 bar

Gas Flow Requirements 300 scfh / 141.5 lpm

120V/15A with NEMA 5-15P plug or 240V/20A with NEMA 6-50P plug

SL 60 Torch Gas Requirements

Notes

1. Power supply accepts 120-230 VAC input power. No manual switching is required.

2. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is

reduced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.

3. 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 lters provide increased ltering capabilities.

NOTE

IEC Rating is determined as speciﬁed by the International Electro-Technical Commission. These speciﬁcations include calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.

TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, and actual cutting operation.

INSTALLATION 2-2 Manual 0-4976

cutmaster 39

Power Supply Dimensions & Weight Ventilation Clearance Requirements

NOTE

Weight includes torch & leads, input power cord, and work cable with clamp.

CAUTION

Provide clearance for proper air ﬂow through the power supply. Operation without proper air ﬂow will inhibit proper cooling and reduce duty cycle.

2.05 Input Wiring Speciﬁcations

CutMaster 39 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. 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.

Power Input Current Input Suggested Sizes (See Notes)

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

3.6 29 35 12 12

3.5 16 20 12 12

3.4 14 20 12 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTES

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.

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.

Manual 0-4976 2-3 INSTALLATION

cutmaster 39

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

2.06 Power Supply 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.

2.07 Torch Speciﬁcations

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.

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)

NOTE

Ratings shown apply to the SL60 Torch only. Refer to the Speciﬁcations chart on page 2T-1 for CutMaster 39 data.

F. Plasma Power Supply Used With

• Thermal Dynamics CutMaster 39

INSTALLATION 2-4 Manual 0-4976

cutmaster 39

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Model SL60 Plasma Cutting Torch. Service of this equipment is restricted to properly trained personnel; unqualied personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

Plasma torches are similar in design to the automotive spark plug. They consist of negative and positive sections separated by a center insulator. Inside the torch, the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas ows through the small orice in the torch tip, which is focused on the metal to be cut. A single torch lead provides gas from a single source to be used as both the plasma and secondary gas. The air ow is divided inside the torch head. Single - gas operation provides a smaller sized torch and inexpensive operation.

NOTE

Refer to Section 2T.05, Introduction To Plasma, for a more detailed description of plasma torch operation.

Refer to the Appendix Pages for additional speciﬁcations as related to the Power Supply used.

2T.03 Speciﬁcations

A. Torch Conﬁgurations

1. Hand Torch, Model SL60

The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly.

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m.

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

F. Torch Ratings

SL60 Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

G. Current Ratings

peak

)

100% @ 60 Amps @ 400 scfh

104° F

40° C

60 Amps

500V

7kV

Manual 0-4976 2T-1 INTRODUCTION

SL60 Current Ratings

SL60 Torch & Leads

Power Supply characteristics will determine material thickness range.

Up to 60 Amps, DC,

Straight Polarity

NOTE

cutmaster 39

A-00002

Workpiece

Power

Supply

H. Gas Requirements

SL60 Torch Gas Specications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 75 psi

4.1 - 5.2 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with oxygen (O2).

NOTE

Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to gas pressure settings charts for each model.

I. Direct Contact Hazard

For exposed tip the recommended standoff is 3/16 inches / 4.7 mm.

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.

While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

2T.04 Options And Accessories

These items can adapt a standard system to a particular application or further enhance performance.

• Deluxe Cutting Guide Kit - Easy add - on attachments for precise straight line, circle cutting, and beveling. Includes carrying case.

• Trigger Guard Kits - These offer additional protection from accidental activation of the torch switch.

• Leads Extensions for torches with ATC con-

nectors

• Leather Leads Covers

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a small oriﬁce, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.

Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.

INTRODUCTION 2T-2 Manual 0-4976

B. Gas Distribution

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

The single gas used is internally split into plasma and secondary gases.

The plasma gas ﬂows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip oriﬁce.

The secondary gas ﬂows down around the outside of the torch starter cartridge, and out between the tip and shield cup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.

cutmaster 39

E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4976 2T-3 INTRODUCTION

cutmaster 39

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4976

cutmaster 39

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.

WARNING

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 0-4976 3-1 INSTALLATION

cutmaster 39

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 Cords Included With Power Supply

Attached to the power supply is an input power cord with a twist-lock plug NEMA L6-20P for use on a 240V/20A system.

Also included are two addapter cords. One has a 120V/15A NEMA 5-15P plug for use with current settings up to 20 Amps. (Higher settings may result in tripping of 15 Amp curcuit breaker).

The other adapter cord is equiped with a 240V/20A NEMA 6-50P plug. Each of these adapter cords attaches to the power supply input cord via the twist-lock connection.

CAUTION

When using the 120V/15A adapter cord, do not exceed a current output setting of 20Amps on the power supply or the input power circuit breaker may trip.

Input Voltage Rated Output Amps (RMS) input at rated

kVA

output, 60 Hz, single-phase

120V, 15A Circuit 20A, 88V 18 2.2

120V, 20A Circuit 28A, 90V 26 3.1

120V, 30A Circuit 30A, 92V 29 3.5

208-230V, 20A Circuit 30A, 92V 16-14 3.3

INSTALLATION 3-2 Manual 0-4976

cutmaster 39

A-07926

Min. 1/4 inch

6.4 mm

A-07927

3020

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 lter 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.

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 lter 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!

Manual 0-4976 3-3 INSTALLATION

cutmaster 39

A-07928

1/4 NPT Hose Fitting

Hose Clamp

Gas Supply Hose

Filter Hose

Single-Stage

Filter Kit

No. 7-7507

C. Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for improved ltering 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:

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

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Brieﬂy open

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to

4. Connect gas supply hose to the cylinder.

Optional Single - Stage Filter Installation

regulators.

each cylinder valve to blow out any dust which may be present.

100 psi (6.9 bar) maximum and ﬂows of at least 300 scfh (141.5 lpm).

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.

INSTALLATION 3-4 Manual 0-4976

cutmaster 39

Art # A-07929

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.

Connecting the Torch to the Power Supply

3. The system is ready for operation.

Manual 0-4976 3-5 INSTALLATION

cutmaster 39

This Page Intentionally Blank

INSTALLATION 3-6 Manual 0-4976

4.01 Product Features

Art # A-07930

Handle and Leads Wrap

Gas Pressure Knob

Work Cable and Clamp

Control Panel

Torch Leads Connector

A. General Features

cutmaster 39

SECTION 4 SYSTEM:

OPERATION

Manual 0-4976 4-1 OPERATION

cutmaster 39

A-07931

4 5

3020

B. Control Panel

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 in-

terlock 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. Allow the unit to run with the fan on until the Temp indicator turns off.

6. GAS Indicator

Indicator is ON when adequate input gas pressure is present to operate the power supply.

7. DC Indicator

Indicator is ON when DC output circuit is active.

OPERATION 4-2 Manual 0-4976

cutmaster 39

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

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.

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.

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, Specications.

2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

Manual 0-4976 4-3 OPERATION

cutmaster 39

Art # A-03387

A-07932

3020

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.

F. Power On

Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on.

OPERATION 4-4 Manual 0-4976

cutmaster 39

A-07927

3020

A-07933

65 psi / 4.5 bar

A-07934

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.

H. Select Current Output Level

Place RUN / SET switch to RUN (up) position. Gas ﬂow will stop. Set the desired current output level.

Manual 0-4976 4-5 OPERATION

cutmaster 39

Art # A-03383

Trigger

Trigger Release

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

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. 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.

l. 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.

OPERATION 4-6 Manual 0-4976

cutmaster 39

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 ows to set pressure. Turn gas pressure adjustment knob to set pressure to 65 psi / 4.5

bar; Gas indicator turns ON when there is sufcient 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 ow stops.

5. Wear protective clothing and welding gloves. Protect eyes. Slide the trigger release to the rear; squeeze and hold the trigger. Gas ows briey, then shuts off momentarily. Then gas ow 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 ows 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.

Manual 0-4976 4-7 OPERATION

cutmaster 39

This Page Intentionally Blank

OPERATION 4-8 Manual 0-4976

cutmaster 39

SECTION 4 TORCH:

OPERATION

4T.01 Introduction

This section provides a description of the SL60 and SL100 Torch Assemblies followed by operating procedures.

4T.02 Functional Overview

The Torch is designed to operate with various Power Supplies to provide a plasma cutting system which can cut most metals. With gouging torch parts the torch can be used for plasma arc gouging.

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

4T.03 Getting Started

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

Power On

Place the ON - OFF Switch on the Power Supply to the ON position.

Function Control Knob

If the Function Control Knob is in SET position, gas will ﬂow. If the control knob is in the RUN position there will be no gas ﬂow.

Current Output Level

At the Power Supply, set the desired current output level. For drag cutting set the control at 40 amps or less only.

Pressure Settings

Place the Function Control Knob to the SET position. Adjust the gas pressure control on the Power Supply for the proper gas pressure. Refer to Appendix Pages for gas pressure and other speciﬁcs.

Follow this procedure at the beginning of each

shift:

WARNING

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

Torch Parts

Check the torch for proper assembly. Install proper torch parts for the desired application (refer to next SubSection called "Torch Parts Selection").

Input Power

Check the power source for proper input voltage. Close main disconnect switch or plug unit in to supply primary power to the system.

Work Cable

Check for a solid cable connection to the workpiece.

Gas Supply

Select desired single gas supply. Make sure gas sources meet requirements (see Note). Check connections and turn gas supply on.

Ready for Operation

Return the Function Control Knob to RUN position.

NOTES

For general cutting, use the RUN position which provides normal torch operation where the torch switch must be held throughout the main arc transfer.

For speciﬁc applications, use the LATCH position where the torch switch can be released after the main arc transfer. The torch remains activated until the main arc breaks from the workpiece.

Refer to Appendix 1 for a typical detailed block diagram of Sequence of Operation.

The system is now ready for operation.

4T.04 Torch Parts Selection

Depending on the type of operation to be done determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

Manual 0-4976 4T-1 OPERATION

cutmaster 39

A-03645

Electrode

Start Cartridge

Tip

Shield Cup

Torch Head

NOTE

Refer to Section 6 and the Appendix Pages for additional information on torch parts.

Change the torch parts for a different operation as

follows:

WARNING

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

NOTE

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup assembly from the torch head.

2. Remove the Electrode by pulling it straight out of the Torch Head.

4T.05 Cut Quality

NOTES

Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Refer to Appendix Pages for additional information as related to the Power Supply used.

Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when nish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following gure:

Cut Quality Characteristics

Cut Surface

The desired or speciﬁed condition (smooth or rough) of the face of the cut.

Nitride Build - Up

3. Install the replacement Electrode by push-

4. Install the starter cartridge and desired tip

5. Hand tighten the shield cup until it is seat-

Torch Parts

ing it straight into the torch head until it clicks.

for the operation into the torch head.

ed on the torch head. If resistance is felt when installing the cup, check the threads

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups may create difﬁculties if the material is to be welded after the cutting process.

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

before proceeding.

OPERATION 4T-2 Manual 0-4976

cutmaster 39

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Bottom Dross Buildup

Molten material which is not blown out of the cut area and resolidiﬁes on the plate. Excessive dross may require secondary cleanup operations after cutting.

Kerf Width

The width of the cut (or the width of material removed during the cut).

Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose oriﬁce has become elongated.

4T.06 General Cutting Information

Torch Standoff

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

Edge Starting

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

Direction of Cut

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

WARNINGS

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

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

CAUTION

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

NOTE

Handle torch leads with care and protect them from damage.

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Piloting

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

Manual 0-4976 4T-3 OPERATION

cutmaster 39

Art # A-03962

Trigger

Trigger Release

Dross

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

4T.07 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE

For best performance and parts life, always use the correct parts for the type of operation.

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

NOTE

b. For standoff cutting, hold the torch 1/8

- 3/8 in (3-9 mm) from the workpiece as shown below.

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Depending on the cutting operation, do one

of the following:

a. For edge starts, hold the torch perpen-

dicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.

OPERATION 4T-4 Manual 0-4976

5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

cutmaster 39

Art # A-03383

Trigger

Trigger Release

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

Art # A-03962

Trigger

Trigger Release

NOTE

The gas preﬂow and postﬂow are a characteristic of the power supply and not a function of the torch.

6. Cut as usual. Simply release the trigger assembly to stop cutting.

7. Follow normal recommended cutting practices as provided in the power supply operating manual.

NOTE

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm) thick or less.

NOTE

For best parts performance and life, always use the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current to 30 amps or less.

2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

4. Keep the torch in contact with the workpiece during the cutting cycle.

5. Hold the torch away from your body.

6. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

Manual 0-4976 4T-5 OPERATION

cutmaster 39

Art # A-03383

Trigger

Trigger Release

Art # A-03962

Trigger

Trigger Release

7. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

The gas preﬂow and postﬂow are a characteristic of the power supply and not a function of the torch.

NOTE

The tip should never come in contact with the workpiece except during drag cutting operations.

2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

4. Hold the torch away from your body.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

8. Cut as usual. Simply release the trigger assembly to stop cutting.

9. Follow normal recommended cutting practices as provided in the power supply operating manual.

NOTE

Piercing With Hand Torch

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

OPERATION 4T-6 Manual 0-4976

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut off.

NOTE

The gas preﬂow and postﬂow are a characteristic of the power supply and not a function of the torch.

7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

cutmaster 39

9.5

0.375

0.2

0.1

Inches/ Meters per Minute

CUTTING SPEED

Gage

MATERIAL THICKNESS

0.25

0.3

0.15

0.35

0.05

Inch

Inches

Meters

0.5401.00

1.5

2.0

100

2.5

120

3.05

140

3.5

160

4.06

180

4.57

200

5.08

220

5.56

240

6.1

400

10.1

Typical Cutting Speeds

Air Plasma on Mild Steel

0.25

0.5

12.7

0.4

A-03381

4T.08 Recommended 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.

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.

4T.09 Gouging

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

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

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 6 and the Appendix Pages for additional information on torch parts.

Gouging Parameters

Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).

Torch Travel Speed

Refer to Appendix Pages for additional information as related to the Power Supply used.

Manual 0-4976 4T-7 OPERATION

WARNINGS

CAUTIONS

NOTE

cutmaster 39

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

Current Setting

Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 80 amps, the recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

OPERATION 4T-8 Manual 0-4976

SECTION 5 SYSTEM: SERVICE

Warning! Disconnect input power before maintaining.

Each Use

Visual check of torch tip and electrode

Weekly

Visually inspect the torch body tip, electrode, start cartridge and shield cup

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Visually check and Carefully clean the interior

Maintain more often if used under severe conditions

Art # A-07938_AB

5.01 General Maintenance

cutmaster 39

Manual 0-4976 5-1 SERVICE

cutmaster 39

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

A. Each Use

Check torch consumables for wear, replace if necessary.

WARNING

Shut off power before inspecting or removing torch parts.

NOTE

SERVICE 5-2 Manual 0-4976

B. Every three months

Upper screws

Ground wire

Lower screws

Upper screws

Art #A-07935

Lower screws

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.

cutmaster 39

Manual 0-4976 5-3 SERVICE

Cover Removal

cutmaster 39

Art # A-07936

Replacement Element No. 9-0182

Ring

Spool

Bowl

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.

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.

SERVICE 5-4 Manual 0-4976

cutmaster 39

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

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 oring 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.

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.

Manual 0-4976 5-5 SERVICE

cutmaster 39

5.02 Common Faults

Problem - Symptom Common Cause

Insufﬁcient

Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

Difﬁcult Starting 1. Worn torch parts.

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics parts used

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

Exceeding system capability (material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine Thermal Dynamics parts used

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

5.03 Circuit Fault Isolation

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

A. Initial Setup Conditions

1. Connect gas supply to rear of Power Supply.

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

3. Set the Power Supply controls as follows:

• ON/OFF / switch to OFF .

• CURRENT (A) control knob to maxi-

mum

• RUN / SET switch to SET

B. Main Input and Internal Power Tests

1. Connect main AC power to the unit.

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

• AC indicator steady ON

• TEMP Indicator OFF

• GAS Indicator ON

• Gas ows from torch

• Fan operates

• DC lndicator is OFF

3. Turn RUN / SET switch to RUN

• Gas should stop owing

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

• AC indicator ON

• Temp indicator OFF

• Gas indicator ON (gas does not ow)

• Fan Operates

• DC indicator OFF

This completes the Main Input and Internal Power Tests. If the unit functions as described then proceed to paragraph ‘C’. If the unit does not function as described then note the symptom and proceed to Subsection 5.04, Main Input and Internal Power Problems.

SERVICE 5-6 Manual 0-4976

cutmaster 39

A-03500

Input Power Cord Line 2

To PC Board Terminal E1

To PC Board Terminal E2

Input Power Cord Line 1

Terminal 1

Terminal 2

Terminal 3

Terminal 4

C. Pilot Arc Test

1. Close the torch switch and check the fol-

lowing:

• Gas ows briey, then stops.

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

This completes the Pilot Arc Test. If the equipment operates as described then proceed to paragraph ‘D’. If the equipment does not function as noted then note the symptom and proceed to Subsection 5.05, Pilot Arc Problems.

D. Main Arc Test

Activate the Torch to establish a pilot arc. Bring the torch to approximately 3/16” (4.7 mm) from the workpiece to establish the main cutting arc, and note the following:

• Main cutting arc starts

• Cutting arc transfers to workpiece This completes the Main Arc Test. If the equipment operates as described, proceed to Subsection

5.04. If problems still persist then contact Technical Services. If the equipment does not function as described, note the symptom and proceed to Subsection 5.06, Main Arc Problems.

C. Fan does not operate; AC indicator is OFF

1. Front Panel ON/OFF switch in OFF (down) position a. Place switch to ON (up) position.

2. Main power disconnect open (OFF) a. Close main power disconnect.

3. Main power line fuses blown a. Replace main power line fuses.

4. Input power cable disconnected or faulty a. Check power cable for proper connec-

tions to On/Off Switch.

b. Check power cable for continuity

through all conductors.

5. Wires from On/Off Switch to PC Board disconnected or faulty a. Check for proper connections. b. Disconnect wires; check for continuity.

6. Faulty ON/OFF switch a. Disconnect primary input power. Set

the On/Off switch to ON (UP) position. Test for continuity between terminals 1 and 2, and between terminals 3 and

4. If there is no continuity, replace the ON/OFF Switch.

5.04 Main Input and Internal Power Problems

Locate your symptom below:

A. Main power line fuses blow as soon as

main disconnect is closed

1. Input power cable installed incorrectly or defective a. Refer to the Appendix pages for PC

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

b. Test input power cable for continuity

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

B. Main power line fuses blow immediately

after the ON/OFF Switch is turned on.

1. Faulty input diode bridge(s) a. Test input diode bridges per section

4.10-D; replace as needed.

7. Faulty Bias Transformer a. Refer to PC Board Wiring Layout in the

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

Manual 0-4976 5-7 SERVICE

cutmaster 39

D. AC indicator ﬂashing, TEMP indicator OFF

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

1. Torch shield cup loose a. Shut power supply off. Tighten shield

cup securely. Turn unit back on.

2. Torch connection at power supply loose. a. Shut power supply off. Tighten torch

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

3. Faulty PIP switch or open PIP wires in torch leads a. Check torch PIP switch for continuity. b. Check torch PIP leads for continuity.

4. J3 wire connector disconnected from PC board. a. Check J3 connector; reconnect if neces-

sary.

E. Gas ﬂows continuously; AC indicator ON;

TEMP indicator OFF; DC indicator OFF; GAS indicator ON

1. RUN /SET Switch in SET (down) position a. Change to RUN (up) position.

2. Faulty RUN / SET switch a. Disconnect primary input power. Dis-

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

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

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

1. Torch switch stuck ON or torch switch wires shorted a. Check indicator D22 on PC board.

Indicator should be OFF unless torch switch is closed.

b. Check torch switch for proper opera-

tion.

c. Check torch switch for coninuity.

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

indicator OFF, RUN / SET switch in RUN position,

1. Torch tip, starter cartridge, or electrode missing or badly worn. a. Check torch parts; replace as needed.

2. Dirty or defective starter cartridge a. Check starter cartridge; clean or replace

as needed.

3. Wire E8 not connected to PC Board termi-

nal E8

a. Check connection; reconnect if neces-

sary.

4. PC board fault circuit defective a. Replace PC board

H. AC indicator ﬂashes; Temp indicator

steady ON

1. Fan wire harness disconnected from terminal J4 on PC board. a. Check fan wire harness; reconnect if

necessary

2. Faulty fan or fan wire harness a. Check fan and harness; replace as

needed.

I. AC indicator ﬂashes; TEMP indicator

blinks slowly; RUN/SET switch in SET position

1. Fan is blocked a. Check fan blades; clear as needed.

2. Faulty PC Board a. Replace PC Board

J. No gas ﬂow; AC indicator ON; TEMP

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

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

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

8.3 bar

2. Faulty RUN/SET switch a. Disconnect wires from RUN/SET

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

3. Faulty gas solenoid or solenoid wire harness. a. Disconnect solenoid wire harness

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

SERVICE 5-8 Manual 0-4976

cutmaster 39

4. Faulty PC board a. Leave RUN/SET switch in SET posi-

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

K. AC indicator steady ON: TEMP indicator

ON; RUN/SET switch in SET position

1. PC board temperature sensor disconnected or faulty. a. Check wire harness connection at

terminal J5 on PC board. Reconnect if necessary.

b. Disconnect PC board temperature sen-

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

L. No gas ﬂow; AC indicator ON; GAS

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

1. Gas supply not connected to unit a. Connect gas supply.

2. Gas supply not turned on a. Turn gas supply on.

3. Gas pressure too low a. Shut power supply off. Set gas pressure

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

4. Faulty PC board a. Disconnect pressure switch wire har-

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

5.05 Pilot Arc Problems

Locate your symptom below:

A. No pilot arc; Gas ﬂows continuously; AC

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

1. Shorted Torch a. Test torch and leads for continuity.

2. Faulty PC Board a. Replace PC Board.

B. No arc or intermittent arc in torch; Gas

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

1. Gas pressure set incorrectly (too high) a. Set gas pressure on the Power Supply

gas regulator to 65 psi / 4.5 bar.

2. Oil/moisture in air lines a. Purge system. If problem is corrected,

add lters in line with air source.

3. Torch consumable parts incorrect or worn a. Refer to Operator’s Manual.

4. Starter cartridge missing from torch a. Shut off power. Remove shield cup

from torch. Install starter cartridge if missing.

5. Faulty leads a. Check continuity.

6. Faulty torch a. Check continuity.

7. Faulty PC Board a. Replace PC Board.

C. No pilot arc; GAS and DC indicators blink

1. Gas pressure is too low. a. Set gas pressure to 65 psi / 4.5 bar.

Manual 0-4976 5-9 SERVICE

cutmaster 39

Lower O-Ring

Upper O-Ring in Correct Groove

Upper Groove with Vent Holes Must Remain Open

Threads

Art # A-03640

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

TEMP and DC indicators OFF

1. Upper O-ring on torch head is in wrong position. a. Remove shield cup from torch; check

position of upper O-ring. Correct if necessary.

5.06 Main Arc Problems

Locate your symptom below:

A. Main cutting arc will not start

1. Work cable not connected. a. Connect work cable.

2. Holding too high of a standoff a. Refer to Operating Manual for recom-

mended standoff heights.

3. Workpiece is painted or rusty. a. Clean workpiece.

4. Starter cartridge missing from torch a. Shut off power. Remove shield cup

from torch. Install starter cartridge if missing.

5. Faulty Main Power PC Board a. Replace PC Board.

5.07 Test Procedures

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

A. Safety Precautions

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

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

3. Keep away from any moving parts.

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

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

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

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

SERVICE 5-10 Manual 0-4976

cutmaster 39

Upper screws

Ground wire

Lower screws

Upper screws

Art #A-07935

Lower screws

0.75

COM

Art # A-00307

Anode

Cathode

Forward Bias

Diode Conducting

Diode Test Symbol

B. Opening Power Supply Enclosure

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

WARNING

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

1. Remove the screws securing the cover to the unit.

C. Diode Testing Basics

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

1. Locate the diode module to be tested.

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

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

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

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

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

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

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

Manual 0-4976 5-11 SERVICE

Testing Diode Forward Bias

cutmaster 39

COM

Art # A-00306

Anode

Cathode

Reverse Bias

Diode Not Conducting

A-03508

E15B

E16B

E16A

E15A

E14A

E12A

+ Mark

E15B

E12B

E16B

E14B

Diode Bridge 1

Diode Bridge 2

+ Mark

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

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

CutMaster 38 Diode Bridge Check

Meter (+) Meter (-) Indication

E16 E15 Diode Drop

E15 E16 Open

E16 E14 Diode Drop

E14 E16 Open

E14 E12 Diode Drop

E12 E14 Open

E15 E12 Diode Drop

E12 E15 Open

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

5.08 Anti-Static Handling Procedures

D. Diode Bridge Checks

Check for shorted Diode Bridges.

Testing Diode Reverse Bias

A. General

Caution: PC Boards can be irreparably damaged by improper handling due to electrostatic discharge (ESD). Replacement PC Boards are shipped in a protective enclosure to prevent damage from electrostatic discharge (ESD) during shipping. Included with each replacement board is a ground strap to prevent static damage during installation.

WARNINGS

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

Disconnect primary power to the system before disassembling the torch, torch leads, or power supply enclosure. Do not operate the equipment or test equipment under power while wearing the grounding wrist strap. Observe torquing requirements where given. Failure to torque properly will cause component damage.

SERVICE 5-12 Manual 0-4976

cutmaster 39

B. Procedure

1. Open the wrist strap and unwrap the rst two folds of the band. Wrap the adhesive side rmly around your wrist.

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

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

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

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

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

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

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

9. Replace the power supply cover.

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

5.09 Parts Replacement - General Information

The parts replacement procedures described in this manual require that the Power Supply be opened and partially disassembled. The part to be replaced will determine the extent of disassembly. Before removing any connection mark each wire with the connection designation. When reassembling make sure the wires go to the proper terminals. Note the routing of wires and make sure the wires are put back in the same place when re-assembling the unit. Refer to Section 6 for parts lists and overall detailed drawings.

WARNING

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

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

5.10 Major External Parts Replacement

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

5.11 Front Panel Parts Replacement

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

WARNING

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

A. Output Control (A) Knob Replacement

1. Remove the cover per Subsection 5.07-B.

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

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

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

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

B. ON/OFF ( / ) Switch Replacement

1. Remove the cover per Subsection 5.07-B.

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

3. Remove Run/Set Switch per Subsection

5.11-C.

4. Remove Output Control knob per Subsection 5.11-A.

5. Remove the overlay from the front panel.

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

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

8. Disconnect the input power cable from the switch.

Manual 0-4976 5-13 SERVICE

cutmaster 39

A-03493

Wire # 8

Wire # 9

Top clip

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

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

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

12. Apply new overlay to the front panel.

13. Replace the run/set switch and output control knob.

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

15. Reinstall the Power Supply cover.

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

C. Run/Set ( / ) Switch

Replacement

1. Remove the cover per Subsection 5.07-B.

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

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

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

power. Test the Power Supply for proper operation.

5.06 Left Side Internal Parts Replacement

Refer to Section 6 Left Side Internal Replace-

ment Parts.

WARNING

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

A. Diode Bridge Replacement

1. Remove the cover per Subsection 5.07-B.

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

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

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

5. Remove the diode bridge.

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

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

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

7. Reinstall the Power Supply cover.

8. Connect the Power Supply to primary input

SERVICE 5-14 Manual 0-4976

+ Mark

E15B

E12B

A-03494

E16B

E14B

+ Mark

E16A

E15A

E14A

E12A

+ Mark

Diode Bridge 2

E15B

E12B

E16B

E14B

Thermal Pad

Diode Bridge 1

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

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

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

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

5.12 Rear Panel Parts Replacement

Refer to Section 6 for parts list and overall

detailed drawing.

WARNING

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

cutmaster 39

A. Pressure Gauge Replacement

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

2. Remove the cover per Subsection 5.07-B.

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

4. Disconnect the Filter/Regulator Assembly

as follows:

a. Pull the Regulator/Filter drain tube out

of the hole in the base of the Power Supply.

b. Release the securing ring on the top of

the Regulator/Filter Assembly.

c. Move the Regulator/Filter Assembly

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

5. Disconnect the Pressure Gauge air tube.

6. Loosen two nuts holding the Pressure Gauge to the rear panel.

7. Slide the Pressure Gauge out of the rear panel.

NOTE

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

8. Insert the replacement gauge through the front of the rear panel.

9. Tighten the two nuts securing the Pressure Gauge to the rear panel.

10. Insert the Pressure Gauge air tube into the rear of the gauge.

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

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

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

Manual 0-4976 5-15 SERVICE

cutmaster 39

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

Art # A-07936

Replacement Element No. 9-0182

Ring

Spool

Bowl

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

15. Test the Power Supply for proper operation.

C. Optional Single-Stage Filter Element

Replacement

NOTE

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

1. Remove power from power supply.

2. Disconnect gas supply hose.

5.13 Right Side Internal Parts Replacement

Refer to Section 6 for Right Side Internal

Parts List and overall detailed drawing.

WARNING

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

A. Standard Filter Element Replacement

1. Remove the cover per Subsection 5.07-B.

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

3. Turn the Cover counter-clockwise and re-

4. Remove the Filter Element from the Hous-

5. Wipe inside of housing clean, then insert

6. Replace Housing on Cover.

7. Attach gas supply hose.

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

move it from the Filter Housing. The Filter Element is located inside the Housing.

ing and set Element aside to dry.

the replacement Filter Element open side rst, as shown.

NOTE

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

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

5. Note the correct assembly of the lter/ spool then remove the lter from the spool. Either clean or replace the lter element.

6. The lter element and spool, with the bafe ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. Tighten rmly by hand.

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

8. Reinstall Power Supply cover .

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

SERVICE 5-16 Manual 0-4976

B. Pressure Switch Replacement

1. Remove the cover per Subsection 5.04-A.

2. Label and disconnect the wires to the Pressure Switch.

3. Turn the Pressure Switch to remove it from the Regulator/Filter Assembly.

4. Apply thread sealant to the threads of the replacement Pressure Switch.

NOTE

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

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

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

7. Reinstall the Power Supply cover.

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

cutmaster 39

Manual 0-4976 5-17 SERVICE

cutmaster 39

This Page Intentionally Blank

SERVICE 5-18 Manual 0-4976

cutmaster 39

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

NOTE

Refer to Previous "Section 5 System" for common and fault indicator descriptions.

Cleaning Torch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNINGS

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

O-Ring Lubrication

An o-ring on the Torch ATC Male Connector requires lubrication on a scheduled basis. 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 oring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.

NOTE

DO NOT use other lubricants or grease, they may

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

Manual 0-4976 5T-1 SERVICE

cutmaster 39

A-03645

Electrode

Start Cartridge

Tip

Shield Cup

Torch Head

Good Tip

Worn Tip

A-03406

Art # A-08064_AC

Spring-Loaded Lower End Fitting Full Compression

Spring-Loaded Lower End Fitting at Reset / Full Extension

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNINGS

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

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE

The shield cup holds the tip and starter cartridge shield cup in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup from the torch.

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized oriﬁce). Clean or replace the tip if necessary.

Tip Wear

4. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end ﬁtting for free motion. Replace if necessary.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

Consumable Parts

5. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following ﬁgure.

Electrode Wear

6. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

7. Reinstall the desired starter cartridge and tip into

the torch head.

8. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

SERVICE 5T-2 Manual 0-4976

cutmaster 39

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 / lter, and operating manual.

Qty Description Catalog #

1 CutMaster 39 Power Supply 3-3830 1 Surelok Model SL60 Torch 7-5204

6.04 Power Supply Replacement Parts

Qty Description Catalog #

1 Regulator / Filter Assembly Filter Element 9-0182 1 Input Power Cord with NEMA L6-20P plug 9-0215 1 Input Power Cord Adapter 230V 9-0217 1 Input Power Cord Adapter 120V 9-0177

Manual 0-4976 6-1 PARTS LISTS

cutmaster 39

Art # A-08110

6.05 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-0173 2 1 Base Enclosure Assembly 9-0174 3 1 Tube, roll handle 9-0121 4 1 Front Panel 9-0175 5 1 Rear Panel 9-0176

Illustration may vary slightly from unit.

NOTE

PARTS LISTS 6-2 Manual 0-4976

cutmaster 39

Art # A-08113

6.06 Front Panel Replacement Parts

Item# Qty Description Ref. Catalog #

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

NOTE

Illustration may vary slightly from unit.

Manual 0-4976 6-3 PARTS LISTS

cutmaster 39

A-08112

Input Filter & Bracket (CE Units only)

6.07 Left Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 PCB Assembly 9-0178 2 1 Diode Bridge BR1, BR2 7-3345 3 1 Thermal Pad 9-4466 4 1 Input Power Cable with plug, for non-CE units 9-8660 4 1 Input Power Cable for CE units 9-8671 4 1 Input Power Cable for (CE) Australian units 9-8663 Not Shown: 1 Power Cable Strain Relief, for all units 9-0111

NOTE

Illustration may vary slightly from unit.

PARTS LISTS 6-4 Manual 0-4976

cutmaster 39

Fan Panel

Transformer Bracket

Fan Shroud

Art # A-08111

6.08 Right Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Console ATC Assembly 9-8641 2 1 Regulator/Filter Assembly (includes Pressure Switch, 9-0180 Pressure Gauge, Solenoid) 3 1 Pressure Gauge 9-0181 4 1 Pressure Switch PS1 9-1044 5 1 Regulator/Filter Replacement Element 9-0182 6 1 Regulator Mounting Nut 9-0183 7 1 Assembly, Output Inductor L1 9-8626 8 1 PFC Choke 9-8627 9 1 Main Transformer Assembly T3 9-8625 10 1 Fan M1 9-8639

Manual 0-4976 6-5 PARTS LISTS

cutmaster 39

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

6.09 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

Single - Stage Air Filter

PARTS LISTS 6-6 Manual 0-4976

6.10 Torch Consumables

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

cutmaster 39

Manual 0-4976 6-7 PARTS LISTS

cutmaster 39

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

NOTE

PARTS LISTS 6-8 Manual 0-4976

cutmaster 39

ACTION

ON / OFF switch

to OFF

RESULT

All indicators off.

Power supply fan shuts off.

ACTION

RUN / SET switch

to RUN.

RESULT

Gas flow stops.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfers.

Pilot arc off.

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

RUN / SET switch to SET.

RESULT

Gas flows to set pressure.

GAS indicator on when input

pressure is adequate.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

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.

A-03299

PILOT ARC

ACTION

Unplug input

power cord or

open external

disconnect.

RESULT

No power to system.

ACTION

Release torch trigger.

RESULT

Main arc stops.

Gas flow stops after post - flow.

ACTION

Connect work cable

to workpiece.

Set output amperage

RESULT

System is ready

for operation.

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

Manual 0-4976 A-1 APPENDIX

cutmaster 39

1/3

West Lebanon, NH USA 03784

Made in USA

Model:

1max 1eff

3Ø

3Ø1Ø

1Ø

S/N

Standard Symbols

Phase

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.

Art # A-03288

Date of Mfr:

Output Range (Amperage/ Voltage)

Type of Power Supply (Note 1)

Output Current Type

Rated NoLoad Voltage

Plasma Cutting Symbol

Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code

Conventional Load Voltage

Regulatory Standard Covering This Type of Power Supply

Duty Cycle Data (Note 3)

Duty Cycle Factor

Input Power Specifications (Phase, AC or DC Hertz Rating)

Input Power Symbol

Rated Supply Voltage (Note 2)

Rated Maximum Supply Current

Maximum Effective Supply Current

Degree of Protection

Manufacturer's Electrical Schematic File Number and Revision Level

APPENDIX 2: DATA TAG INFORMATION

NOTE

Sections of the data tag may be applied in

APPENDIX A-2 Manual 0-4976

separate locations on the Power Supply.

cutmaster 39

TP7

TP21

A-03441

PILOT

TP8

RUN/SET

MAIN PCB ASSEMBLY 19X1773 REV

SOL

PWM

TEST

PRESSURE

OVER-TEMP

TEMP

GAS

TP20

E15B

E15A

E14B

E14A

E16B

E16A

E12B

E12A

E13

FAN

POT

TP24

E11

TORCH

SWITCH

TP1

TP26

E19

E10

E20

E18

TP2

TP23

TP6

TP3

D99

E14B E14A

E15B E15A

E12A E12B E11

E16B

E1 E13

TP6

TP24

E16A

E19

E10

E20

WORK

TP26

TP1

D22

D7 D13

D19

D16

E18

TP2

TP23

TP8

TP3

TP21

TP16

TP101

APPENDIX 3: MAIN POWER PC BOARD LAYOUT

Manual 0-4976 A-3 APPENDIX

cutmaster 39

TP7

TP21

PILOT

RUN/SET

MAIN PCB ASSEMBLY 19X1773 REV

SOL

PWM

TEST

PRESSURE

OVER-TEMP

TEMP

GAS

TP20

E15B

E15A

E14B

E14A

E16B

E16A

E12B

E12A

E13

FAN

POT

TP24

E11

TORCH

SWITCH

TP1

TP26

E19

WORK

E10

E20

E18

TP2

TP23

TP6

TP3

TP8

To Run / Set

Switch

To Solenoid

To Pressure

Switch

To Temperature

Sensor

To Fan

To Current

Control

To Output Inductor (See NOTE)

To Torch Receptacle

To On / Off Switch

To Bridge 1

To Output Inductor

Work Cable

A-03442

To PFC Inductor (See NOTE)

To Main Transformer

To Ground

To Bridge 2

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

Torch Ground

To Torch Receptacle

APPENDIX 4: MAIN PC BOARD WIRING

APPENDIX A-4 Manual 0-4976

cutmaster 39

ATC Female Receptacle

Front View

Pilot

6 - Open

7 - Open

8 - Open

5 - Open

Negative / Plasma

6 - Open

7 - Open

5 - Ground

2 - PIP

3 - Switch

4 - Switch

1 - PIP

4 - Green / Switch

2- Orange / PIP

3 - White / Switch

1 - Black / PIP

Negative / Plasma

8 - Open

ATC Male Connector

Front View

A-03694

APPENDIX 5: TORCH CONNECTOR DIAGRAM

Manual 0-4976 A-5 APPENDIX

cutmaster 39

A A

B B

C C

D D

E E

F F

CURRENT

CONTROL

MAIN PCB ASSEMBLY

GAS

FAN1

1 2

TEMP

CURRENT ADJUST

20 - 30

RED

BLACK

TS1

OVER-TEMP

FILTERING

PFC INDUCTOR

BIAS CONVERTER

LOGIC AND CONTROL

CIRCUITRY

PS1

PRESSURE SW

P9J9

D13

D16

D19

SW2

RUN

SET

1 2

323

BR2

PANEL INDICATOR

(5) (6)

(7)

(8)

(9)

(10) (11)

ZERO

TEST

12VDC

NORMALLY CLOSED

TEST POINTS:

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

FACTOR CORRECTION

TP8 SHORT TO TP26 TO DISABLE SHORTED

TORCH PROTECTION

(E14A)

(E16A)

(E15A)

(E12A)

(E16B)

(E12B)

(E14B)

123

BR1

E16A

- +

E14A

E15A

E12B

E13

E16B

STUD

E11

- +

E15B

D47

E14B

E12A

E18

A-03405_AB

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.

SW1

(E1)

SW1

120/208/230V

INPUT 50/60HZ

(E2)

INPUT 230V ONLY

CHASSIS GND

EM C FILTER CE ONLY

(E15B)

APPENDIX 6: SYSTEM SCHEMATIC

APPENDIX A-6 Manual 0-4976

cutmaster 39

SOL1

TORCH SWITCH

(13)

(12)

WORK

GAS SOLENOID

C H

COMPDESCRIPTION

SW1 SW2

M1FAN, 4.5" 12VDC

PS1PRESSURE SWITCH SOL1GAS SOLENOID

SWITCH, ON/OFF

SWITCH, RUN/SET

TS1

GCW

OVER-TEMP. SENSOR

L1OUTPUT INDUCTOR

MAIN TRANSFORMER

OUTPUT INDUCTOR

D22

D99

TORCH SWITCH ON

PWM ON

+14VA

AGND

+12VB

BGND

SEC

PRI

MAIN

TORCH

PILOT

WORK

PIP

C1 D1 D9

B2 D1

PFC INDUCTOR

(E8)

(14)

(15)

P8J8

QUICK DISCONNECT

(E4)

(-)

REL ECO 100213

GCW

7/29/02

42X1089

Tuesday, June 19, 2007

1 1

INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784 603-298-5711

CM38 120/208/230V SINGLE PH ASE 50/60 Hz

Tuesday, May 15, 2001

15:05:29

THERMAL DYNAMICS

DWG No:

Sheet

SupersedesScale

Date:

Drawn:References

DateByRevisionsRev PCB No:

Assy No:

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) Chk:App:

TITLE:

Last Modiﬁed:

Size

SCHEMATIC,

D55

E10

E19

Q11

E20

D53

C70, 72, 81

C71, 73, 75

Q13

D54

D56

Q12

REL ECO 100333

GCW

10/04/02

REL ECO 100535

DAT

2/27/03

LOCATION

REL ECO B505

RWH

6/19/07

A-03405_AB

Manual 0-4976 A-7 APPENDIX

cutmaster 39

This Page Intentionally Blank.

APPENDIX A-8 Manual 0-4976

GLOBAL CUSTOMER SERVICE CONTACT

Thermadyne USA

2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557

Thermadyne Canada

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648

Thermadyne Europe

Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800

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, China

RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139

Thermadyne International

2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797

Thermal Dynamics CUTMASTER 39 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual