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WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat-

ing, 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™ 42

SL40 Torch™

Operating Manual Number 0-5141

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermadyne Corporation

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 negli-

gence, accident, or any other cause.

Printed in the United States of America

Publication Date: October 15, 2010

Revision AD Date: November 22, 2011

Record the following information for Warranty purposes:

Where Purchased:_______________________________ __________________

Purchase Date:__________________________________ __________________

Power Supply Serial #:___________________________ ___________________

Torch Serial #:___________________________________ _________________

Содержание 42 CUTMASTER

Страница 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...

Страница 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...

Страница 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...

Страница 4: ...TABLE OF CONTENTS...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 44: ...Notes...

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

Страница 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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