Thermal Dynamics 42 CUTMASTER Operating Manual Download

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CUTMASTER 42

PART LIST 6-2 Manual 0-5141

6.02 Power Supply Replacement Parts

Item

Qty

Description

Catalog

1 1 Logic

PCB

assembly

9-0076

2 1 Control

PCB

assembly

9-0077

3 1 Main

PCB

assembly

9-0079

4 1 Regulator 9-0081

5 1 Solenoid

assembly

9-0082

6 1 Pressure

Switch

9-0075

7 1 Front

Panel

with

Label

9-0071

8 1 Rear

Panel

with

Label

9-0072

9 1 Cover

with

Labels 9-0080

1 Hall

Current

Sensor

9-0088

CM42 Cutting Control Knob

9-0073

1 CM42

On/Off

Switch

9-0074

1 ATC

Connection

9-0083

1 Fan

9-0042

1 AC/DC

Rectifier

9-0049

1 Power

Cord

9-0025

CM42 Carry Case (not shown)

9-0084

1 Gloves

(not

shown)

9-0086

1 Glasses

(not

shown)

9-0087

1 Replacement

Torch

(not

shown)

7-0040

15A Power Cord Adapter(not shown)

9-0026

20A Power Cord Adapter(not shown)

9-0048

Art# A-09387-AE

Summary of Contents for 42 CUTMASTER

Page 1: ...40 AMP 1 DC PHASE Art A 09347_AE PLASMA CUTTING SYSTEM 42 CUTMASTER Rev AD Date November 22 2011 Manual 0 5141 Operating Features Operating Manual...

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

Page 3: ...rved 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...

Page 4: ...TABLE OF CONTENTS...

Page 5: ...Supply Features 2 3 2 05 Torch Specifications 2 4 SECTION 2TORCH INTRODUCTION 2T 1 2T 01 Scope of Manual 2T 1 2T 02 Specifications 2T 1 2T 03 Introduction to Plasma 2T 2 SECTION 3 INSTALLATION 3 1 3 0...

Page 6: ...TABLE OF CONTENTS SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Power Supply Replacement Parts 6 2 APPENDIX 1 CIRCUIT DIAGRAM A 1...

Page 7: ...romium 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...

Page 8: ...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 pr...

Page 9: ...Welding Society 550 N W LeJeune Rd Miami FL 33126 8 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELD ING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterym...

Page 10: ...de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant cont...

Page 11: ...des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez...

Page 12: ...de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR...

Page 13: ...ber 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC...

Page 14: ...es 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 indu...

Page 15: ...is re duced if primary input voltage AC is low or the DC voltage is higher than shown in this chart 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may caus...

Page 16: ...urrent Input Current Input Suggested Sizes See Note Voltage Freq kVA Max Amps Ieff Amps Fuse Amps Volts AC Hz 1 Ph 1 Ph 1 Ph 1 Ph 120 50 60 3 3 27 5 15 25 208 50 60 5 0 24 15 4 23 230 50 60 5 0 21 4 1...

Page 17: ...UCTION 2 04 Power Supply Features Air Inlet Control Panel Torch Lead 120 230 VAC Power Source Work Cable and Clamp Art A 09334_AC CUTMASTER 42 120V 15A 120V 20A 230V 20A A 24 40 20 20 30 27 Art A 0933...

Page 18: ...n and Dimensions B Torch Leads Lengths Leads are available in 10 ft 3 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 ga...

Page 19: ...8 3 210 82mm 2 6 66 04mm 96 24 38mm Art A 09336 B Torch Leads Lengths Hand Torches are available as follows 15 ft 4 6 m C Torch Parts Starter Cartridge Electrode Tip Shield Cup D Parts In Place PIP T...

Page 20: ...h 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 A 00002 Workpiece Power Supply _ C B A Typical Torch Head Detail B Gas...

Page 21: ...h 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 inc...

Page 22: ...gure 3 1 120VAC Adapter Pigtail 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...

Page 23: ...ressure 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...

Page 24: ...This page left blank intentionally...

Page 25: ...e input power circuit opens frequently either reduce cutting output reduce the cutting time or connect the unit to more adequate input power Note For 120V input power the unit will automatically limit...

Page 26: ...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 40 amps maximum Use only genuine Thermal Dynam...

Page 27: ...ection Ensure gas source meets requirements listed in section 2T 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 f...

Page 28: ...d a AC indicator turns on fan turns on NOTE During initial power up there will be a delay of about 2 seconds before the AC Indicator light will illuminate and the pre flow gas and fan starts The gas w...

Page 29: ...y one edge of the tip is in contact with the plate This prevents damage to the tip during the piercing process b For standoff cutting hold the torch tip on the work piece pull the trigger After the ar...

Page 30: ...plete cutting operation NOTE If the torch is lifted too far from the workpiece while cutting the main arc will stop and the pilot arc will automatically restart 4 Release the torch trigger a Main arc...

Page 31: ...ure 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...

Page 32: ...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 eas...

Page 33: ...blies are faulty then the Cutting Power Source must be returned to an Accredited Thermal Dynamics Service Provider for repair Each Use Visual check of torch tip and electrode Weekly Visually inspect t...

Page 34: ...u are an accredited service provider and you have had training in power electronics measurement and troubleshooting techniques Common Faults symptom LED Indicators A AC indicator OFF 1 Main input powe...

Page 35: ...manual E Torch will not pilot when torch trigger is activated 1 Faulty parts in torch a Check torch parts per section 4 02 replace as needed 2 Gas pressure too low a Adjust supply pressure to proper...

Page 36: ...heck input line voltage under load 2 Input or output connection is poor a Check all input and output connection leads 2 Working cable connection is poor a Make sure that work cable has a proper connec...

Page 37: ...in torch a Hold torch 1 8 inch 3 mm from clean surface while purging and observe oil or moisture buildup do not activate torch If there are contaminants in the gas additional filtering may be needed 4...

Page 38: ...This page left blank intentionally...

Page 39: ...d blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling 5T 02 Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system...

Page 40: ...ear 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...

Page 41: ...must be returned for service contact your distributor Materials returned without proper authorization will not be accepted C Ordering Information Order replacement parts by catalog number and complet...

Page 42: ...with Label 9 0072 9 1 Cover with Labels 9 0080 10 1 Hall Current Sensor 9 0088 11 1 CM42 Cutting Control Knob 9 0073 12 1 CM42 On Off Switch 9 0074 13 1 ATC Connection 9 0083 14 1 Fan 9 0042 15 1 AC D...

Page 43: ...K NO 2 WEST LEBANON NH03784 603 298 5711 G D S G D S G D S 1 3 4 5 6 2 7 1 2 3 4 5 6 7 DRIVE SIGNAL DRIVE SIGNAL 1 2 3 4 5 1 2 3 4 5 HF QF 1 2 3 1 2 1 2 3 4 TEST WV OUTPUT 1 2 3 1 2 3 WV OUTPUT 1 2 1...

Page 44: ...Notes...

Page 45: ...This Page Intentionally Blank...

Page 46: ...54 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Ca...

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