38 CUTMASTER ™ PLASMA CUTTING SYSTEM A-03286 Operating Manual Rev. AA.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800426-1888, or visit us on the web at www.thermal-dynamics.com.
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.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications ..................................................................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings 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. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. 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.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
1.04 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
1.05 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
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SECTION 2: SPECIFICATIONS CutMaster 38 Power Supply Specifications Input Power (See Note 1) Power Sensing Input Power Cable Output Current 120 VAC (± 10%), Single-Phase, 50/60 Hz 208 - 230 VAC (± 10%), Single-Phase, 50/60 Hz Automatic Voltage Selection. See Note 1. Cable with plug, for 120VAC, 20-Amp Single-Phase input power.
Electrical Requirements Input Voltage Freq. (Volts) (Hz) 120 208 230 CutMaster 38 Input Power Requirements Power Input Current Input Suggested Sizes (See Notes) (Amps) Fuse (Amps) Wire (AWG) Wire (Canada) (kVA) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph 3.6 3.5 3.
Torch Specifications The Torch provides cutting capacity of up to 3/8 inch / 9.5 mm at 30 amperes. A. Torch Configuration and Dimensions The torch head is at 75° to the torch handle. The torch includes a torch handle and torch trigger assembly. 9.5" (241 mm) 3.75" (95 mm) 1.17" (29 mm) Art # A-03322 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.
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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.
3.03 Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2. Power Cord and Plug This power supply includes an input power cord and plug suitable for 120 VAC, 20 Amp, Single - Phase input power.
3.04 Gas Connections A. Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure gas cylinders. Refer to subsection 3.4-C if an optional air line filter is to be installed. 1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
C. Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port. 2. Attach the Filter Assembly to the filter hose. 3. Connect the gas line to the Filter. The illustration shows typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions.
D. Using High Pressure Gas Cylinders When using high pressure gas cylinders as the gas supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present. 3.
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. 1 2 A-03380 Connecting the Torch to the Power Supply 3.
SECTION 4: OPERATION 4.01 Product Features A.
B. Control Panel 4 5 2 A 1 6 7 26 28 24 3 22 20 30 A-03283 1. ON / OFF Switch Controls input power to the power supply. Up is ON, down is OFF. 2. RUN / SET Switch RUN (up) position is for general torch operation. SET (down) position is for setting gas pressure and purging lines. 3. (A) Output Current Control Sets the desired output current.
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.
B. Torch Connection Check that the torch is properly connected. C. Check Primary Input Power Source 1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system. D. Gas Selection Ensure gas source meets requirements (refer to Section 2). Check connections and turn gas supply on. E.
F. Power On Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. A 26 28 24 22 20 30 A-03384 G. Set Operating Pressure Place the Power Supply RUN / SET switch to the SET (down) position. Gas will flow. Adjust gas pressure to 65 turns on. psi / 4.5 bar. Gas indicator NOTE If gas regulator leaks, reset gas pressure to 0 psi, then reset to 65 psi / 4.5 bar. 1 2 65 psi / 4.
H. Select Current Output Level Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level. A 26 28 24 22 20 30 A-03386 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.
J. Cutting Technique Hold the torch with one or two hands, with the torch tip close to the workpiece. Do not cut or handle the workpiece without welding gloves and protective clothing. Always wear protective eye shielding when cutting or gouging. Move the torch along the cut line so the arc penetrates the workpiece and sparks emerge from the bottom of the cut. Good cutting speeds create a slight trailing arc. K. Typical Cutting Speeds MATERIAL THICKNESS 12.
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.
SECTION 5: SERVICE 5.01 General Maintenance A. Each Use Check torch consumables for wear, replace if necessary. WARNING Shut off power before inspecting or removing torch parts. NOTE When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result. Art # A-03409 Large O-Ring, Cat. No. 8-3487 Small O-Ring, Cat. No. 8-3486 Electrode, Cat.
B. Every three months A. Check internal air filter, replace if necessary. 1. Shut off input power; turn off the gas supply. Bleed down the gas supply. 2. Remove the upper cover screws. 3. Loosen the lower screws. Pull the cover up and away from the unit. NOTE Leave internal ground wire in place.
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.
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.
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.
5.02 Common Faults 1. Insufficient Penetration a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting current too low f. Non - Genuine Thermal Dynamics parts used 2. Main Arc Extinguishes a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non - Genuine Thermal Dynamics parts used 3. Excessive Dross Formation a. Cutting speed too slow b.
5.03 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. A. Basic Troubleshooting: Overview This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this system.
C. AC indicator flashing; Torch cannot be activated 1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.) a. Release torch trigger, set ON / OFF switch to OFF (down). Return ON / OFF switch to ON (up) position. 2. System is in protective interlock mode. (Torch parts are missing or loose.) a. Release torch trigger, and set ON / OFF switch to OFF (down). Open main disconnect switch. Check torch parts, including O - rings on torch head.
G. Torch will not pilot when torch switch is activated 1. System is in SET mode a. Change to RUN mode. 2. Upper O-ring on torch head is in wrong position. a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary. Art # A-03640 Upper Groove with Vent Holes Must Remain Open Threads Lower O-Ring Upper O-Ring in Correct Groove 3. Faulty torch parts a. Inspect torch parts and replace if necessary. 4. Gas pressure too high or too low a. Adjust to proper pressure. 5.
I. Low cutting output 1. Incorrect setting of CURRENT (A) control a. Check and adjust to proper setting. 2. Faulty components in unit a. Return for repair or have qualified technician repair. J. Limited output with no control 1. Poor input or output connections a. Check all input and output connections. 2. Work cable connection to work piece is poor a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece. 3. Faulty components in unit a.
M. Arc shuts off during operation; arc will not restart when torch switch is activated. 1. Power Supply is overheated (TEMP indicator ON) a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specifications. 2. Fan blades blocked (AC indicator flashing; TEMP indicator ON) a. Check and clear blades. 3. Air flow obstructed (AC indicator flashing; TEMP indicator ON) a.
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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.
6.05 Options and Accessories Qty Description 1 1 1 1 1 2 1 Catalog # 120V, 15 - Amp Plug 120V, 20 - Amp Receptacle Single - Stage Filter Kit (includes Filter & Hose) Replacement Filter Body Replacement Filter Hose (not shown) Replacement Filter Element Multi - Purpose Cart 9-8644 9-8645 7-7507 9-7740 9-7742 9-7741 7-8888 Housing Filter Element (Cat. No. 9-7741) Single - Stage Air Filter Spring O-ring (Cat. No. 9-7743) Assembled Filter Cover Barbed Fitting Art # A-02476 6.
PATENT INFORMATION The following parts are licensed under U.S. Patent No(s).
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APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION Close external disconnect switch. ACTION ON / OFF switch to ON. ACTION ACTION RUN / SET switch to RUN. Connect work cable to workpiece. Set output amperage ACTION RUN / SET switch to SET. RESULT RESULT Power to system. RESULT AC indicator ON. Fan on. Power circuit ready. RESULT Gas flows to set pressure. GAS indicator on when input pressure is adequate. RESULT Gas flow stops. System is ready for operation.
APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Model: Date of Mfr: Type of Power Supply (Note 1) 1/3 S/N Made in USA Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code Regulatory Standard Covering This Type of Power Supply f1 f2 Output Current Type Duty Cycle Factor Output Range (Amperage/ Voltage) Plasma Cutting Symbol X U0 = Duty Cycle Data (Note 3) I U2 Rated NoLoad Voltage Conventional Load Voltage Rated Maximum Supply Curr
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APPENDIX 3: SYSTEM SCHEMATIC 1 2 3 4 PFC INDUCTOR A INP UT 230V ONLY T1 J7 TEST 1 4 E MC FILTER CE ONLY E11 D47 E12A + CHASSIS GND (E12A) K1 E1 (E14A) 120/208/230V INPUT 50/60HZ (E2) SW1 STUD E2 2 1 BR1 3 (E15A) Q7 4 E14A Q8 - (E1) FILTE RING L1 SW1 B E18 (E16A) E15A E13 E16A E12B C CURRENT CONTROL CURRENT ADJUST 20 - 30 CW 1 4 (E16B) E15B 2 3 (9) 3 3 RUN NORMALLY CLOSED OVER-TEMP TS1 P5 J5 1 1 2 2 P9 J9 BR2 E14B E16B PANEL INDICATOR 2 2 SW2 D 2 (E14B) J
5 6 7 8 9 10 MAIN T3 o OUTPUT INDUCTOR PRI SEC J8 P8 o E6 E5 L1 E9 E10 A (E4) E4 TORCH E20 (-) Q13 D56 D54 C70, 72, 81 C71, 73, 75 Q11 D53 E8 T O R C H (E8) Q12 WORK TORCH SWITCH 2 2 (13) 3 3 3 3 (14) 2 2 +14VA +12VB AGND BGND B PILOT J3 P3 1 1 (12) 4 4 D55 4 4 (15) 1 1 PIP 5 QUICK DISCONNECT TORCH SWITCH ON D22 PWM ON D99 E19 C WORK J1 P1 1 1 A SOL1 B GAS SOLENOID 2 2 D COMP TS1 M1 PS1 SOL1 T1 T3 L1 SW1 SW2 Rev DESCRIPTION OVER-TEMP. SENSOR FAN, 4.
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