Thermal Dynamics 38 Cutmaster Operating Manual Download

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Manual 0-2888

6-3

PARTS LISTS

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

Summary of Contents for 38 Cutmaster

Page 1: ...30 120 208 230 PLASMA CUTTING SYSTEM 38 CUTMASTER Operating Manual Rev AA 01 Date October 20 2006 Manual 0 2888 Operating Features A 03286...

Page 2: ...please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY Th...

Page 3: ...2002 2003 2004 2005 2006 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher doe...

Page 4: ...ctions 3 6 SECTION 4 OPERATION 4 1 4 01 Product Features 4 1 4 02 Preparations For Operating 4 3 4 03 Sequence of Operation 4 8 SECTION 5 SERVICE 5 1 5 01 General Maintenance 5 1 5 02 Common Faults 5...

Page 5: ...head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of m...

Page 6: ...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 a...

Page 7: ...re Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis High...

Page 8: ...standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN500...

Page 9: ...MASTER 51 3 Years 1 Year CUTMASTER 81 3 Years 1 Year CUTMASTER 101 3 Years 1 Year Thiswarrantydoesnotapplyto 1 ConsumableParts suchastips electrodes shieldcups o rings startercartridges gasdistributor...

Page 10: ...GENERAL INFORMATION 1 6 Manual 0 2888...

Page 11: ...0 VAC 10 Single Phase 50 60 Hz Automatic Voltage Selection See Note 1 Cable with plug for 120VAC 20 Amp Single Phase input power 20 30 Amps continuously variable Particulates to 20 Microns CutMaster 3...

Page 12: ...ize 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 Na...

Page 13: ...ads 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...

Page 14: ...SPECIFICATIONS 2 4 Manual 0 2888...

Page 15: ...ing Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNINGS Do not touch live electrical parts Disconnect input power cord...

Page 16: ...power A 03382 120 V 20A 1 For 208 230 VAC input power replace the supplied power plug Use only an approved replacement input power plug with ground Replace the plug as follows 1 Cut the original cord...

Page 17: ...eal 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...

Page 18: ...er 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 instructi...

Page 19: ...h may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm 4 Connect...

Page 20: ...ARNING 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 recep...

Page 21: ...Manual 0 2888 4 1 OPERATION SECTION 4 OPERATION 4 01 Product Features A General Features A 03287 Handle and Leads Wrap Gas Pressure Knob Torch Leads Connector Work Cable and Clamp Control Panel...

Page 22: ...ce 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...

Page 23: ...operation and with the amperage output of this Power Supply 30 amps maximum Use only genuine Ther mal Dynamics parts with this torch Art A 03409 Large O Ring Cat No 8 3487 Small O Ring Cat No 8 3486...

Page 24: ...ection 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...

Page 25: ...84 A 30 20 26 28 24 22 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 re...

Page 26: ...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 tr...

Page 27: ...ING SPEED G a g e M M MATERIAL THICKNESS 0 25 0 3 0 15 0 35 0 05 20 12 8 6 7 2 4 1 3 I n c h Inches Meters 20 0 5 40 1 00 60 1 5 80 2 0 100 2 5 120 3 05 140 3 5 160 4 06 180 4 57 200 5 08 220 5 56 240...

Page 28: ...ON when there is sufficient gas pressure for power supply operation NOTE Minimum pressure for power supply operation is lower than minimum pressure for torch operation 4 Put RUN SET switch to RUN up p...

Page 29: ...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 componen...

Page 30: ...sary 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 gro...

Page 31: ...t 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 A 03377 Replacemen...

Page 32: ...not used on a regular basis This can lead to potential performance problems It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o ring on a weekly basis NOTE DO NOT...

Page 33: ...ckwise 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...

Page 34: ...onnected e Worn torch parts f Non Genuine Thermal Dynamics parts used 3 Excessive Dross Formation a Cutting speed too slow b Torch standoff too high from workpiece c Worn torch parts d Improper cuttin...

Page 35: ...ikely causes for various symptoms Follow all instructions as listed and complete each section in the order presented This guide is set up in the following manner X Symptom Bold Type Any Special Instru...

Page 36: ...orch while power supply ON OFF switch was ON a Release torch trigger and set ON OFF switch to OFF down Set ON OFF switch to ON up D Torch will not pilot DC indicator and GAS indicator flash alternatel...

Page 37: ...epair per Service Manual H No cutting output Torch activated AC indicator ON Gas flows Fan operates 1 Torch not properly connected to power supply a Check that torch leads are properly connected to po...

Page 38: ...nit a Return for repair or have qualified technician repair per Service Manual K Erratic or improper cutting output 1 Poor input or output connections a Check all input and output connections 2 Poor w...

Page 39: ...n a Check torch shield cup tip starter element and electrode replace as needed 6 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual N No gas flow AC i...

Page 40: ...SERVICE 5 12 Manual 0 2888...

Page 41: ...e 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 c...

Page 42: ...9 7741 Housing Cover Barbed Fitting Spring Assembled Filter O ring Cat No 9 7743 6 06 Torch Consumables Single Stage Air Filter Art A 03409 Large O Ring Cat No 8 3487 Small O Ring Cat No 8 3486 Elect...

Page 43: ...ed 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 Shie...

Page 44: ...PARTS LISTS 6 4 Manual 0 2888...

Page 45: ...cator 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 O...

Page 46: ...ng current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 03288 Date of Mfr Output Range Amperage Voltage Typ...

Page 47: ...Manual 0 2888 A 3 APPENDIX This page left blank...

Page 48: ...NTS 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 E...

Page 49: ...5 E4 REL ECO 100213 GCW 7 29 02 AA 42X1089 Thursday March 20 2003 1 1 INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 CM38 120 208 230V SINGLE PHASE 50 60 Hz Tuesday May 15 2001 15 05 29 THER...

Page 50: ...57 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrat...

Page 51: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com...

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