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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™ 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

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 negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: September 17, 2007

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

Содержание CUTMASTER 39

Страница 1: ...30 120 208 230 PLASMA CUTTING SYSTEM 39 CUTMASTER Rev AA Date September 17 2007 Manual 0 4976 Operating Features Service Manual...

Страница 2: ......

Страница 3: ...All rights reserved 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 par...

Страница 4: ...This Page Intentionally Blank...

Страница 5: ...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...

Страница 6: ...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 Pow...

Страница 7: ...ed during the plasma cut ting process can be dangerous and hazardous to your health Keep all fumes and gases from the breath ing area Keep your head out of the welding fume plume Use an air supplied r...

Страница 8: ...gas can be eliminated or dissipated Trapped hydro gen gas that is ignited will cause an explo sion NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed sa...

Страница 9: ...Park Quincy MA 02269 10 NFPAStandard 51B CUTTINGAND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF C...

Страница 10: ...vanadium Lisez toujours les fiches de donn es sur la s cu rit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignem...

Страница 11: ...sale ou com portant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nua...

Страница 12: ...disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protect...

Страница 13: ...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 instal...

Страница 14: ...CutMaster 39 GENERAL INFORMATION 1 8 Manual 0 4976 This Page Intentionally Blank...

Страница 15: ...to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link http www thermal dynamics com 2 02 Equipment Identification The unit s identification nu...

Страница 16: ...o 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 highe...

Страница 17: ...cuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements...

Страница 18: ...f 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 Dime...

Страница 19: ...be cut A single torch lead provides gas from a single source to be used as both the plasma and second ary gas The air flow is divided inside the torch head Single gas operation provides a smaller siz...

Страница 20: ...sma Gas Flow Plasma is a gas which has been heated to an ex tremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting and gouging processes use this plasma...

Страница 21: ...ablished 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 out...

Страница 22: ...CutMaster 39 INTRODUCTION 2T 4 Manual 0 4976 This Page Intentionally Blank...

Страница 23: ...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 powe...

Страница 24: ...input 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...

Страница 25: ...as small particles of the tape may break off and block the small gas passages in the torch A 07926 Min 1 4 inch 6 4 mm Gas Connection to Inlet Port B Check Air Quality To test the quality of air put t...

Страница 26: ...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 Brief...

Страница 27: ...ly 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 r...

Страница 28: ...CutMaster 39 INSTALLATION 3 6 Manual 0 4976 This Page Intentionally Blank...

Страница 29: ...39 Manual 0 4976 4 1 OPERATION SECTION 4 SYSTEM OPERATION 4 01 Product Features A General Features 1 Art A 07930 Handle and Leads Wrap Gas Pressure Knob Work Cable and Clamp Control Panel Torch Leads...

Страница 30: ...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 indicate...

Страница 31: ...487 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 NOTE When operating the torch in a...

Страница 32: ...ly 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 par...

Страница 33: ...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 A 07927 A 30 20 26 28 24 22 A 07933 1 2 65 psi 4 5 bar H Sel...

Страница 34: ...ents may result 3 4 Art A 03383 Trigger 2 1 Trigger Release 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 work piece witho...

Страница 35: ...turns ON when there is sufficient gas pressure for power supply opera tion NOTE Minimum pressure for power supply operation is lower than minimum pressure for torch operation 4 Put RUN SET switch to R...

Страница 36: ...CutMaster 39 OPERATION 4 8 Manual 0 4976 This Page Intentionally Blank...

Страница 37: ...r to Appendix Pages for additional informa tion 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 Contro...

Страница 38: ...Cut Quality NOTES Cut quality depends heavily on setup and pa rameters such as torch standoff alignment with the workpiece cutting speed gas pressures and operator ability Refer to Appendix Pages for...

Страница 39: ...s 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...

Страница 40: ...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...

Страница 41: ...ility of the cutting arc During operation posi tion the legs of the standoff guide against the workpiece Shield Cup Workpiece Standoff Guide Art A 04034 Torch Tip Drag Cutting With a Hand Torch Drag c...

Страница 42: ...h slightly to direct blowback particles away from the torch tip and op erator rather than directly back into it until the pierce is complete 3 In a portion of the unwanted metal start the pierce off t...

Страница 43: ...oducing cuts of excellent quality 4T 09Gouging WARNINGS 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...

Страница 44: ...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 tha...

Страница 45: ...isual check of torch tip and electrode Weekly Visually inspect the torch body tip electrode and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supp...

Страница 46: ...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 resu...

Страница 47: ...ry 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 groun...

Страница 48: ...ace 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 Art A 07936 R...

Страница 49: ...in unknown elements that may react with the atmosphere This reaction can leave contaminants inside the torch Either of these conditions can lead to inconsistent per formance or poor parts life ATC Mal...

Страница 50: ...ve cir cuit 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 re pairs...

Страница 51: ...ons 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...

Страница 52: ...n 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 torc...

Страница 53: ...pply 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 abov...

Страница 54: ...s The test procedures in this subsection are refer enced in the troubleshooting section A Safety Precautions 1 Significant DC Voltage exists after removal of input power Allow two minutes for discharg...

Страница 55: ...sting 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...

Страница 56: ...12 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 A General Caution PC Boards can be irreparabl...

Страница 57: ...nit Refer to Section 6 for parts lists and overall de tailed drawings WARNING Disconnect the power supply from input power before opening or disassembling the power supply Before disassembling any par...

Страница 58: ...ctions A 03493 Wire 8 Wire 9 Top clip 5 Pass the wiring harness through the front opening in the Power Supply Press the switch into position in the Power Supply front panel firmly 6 Connect the wiring...

Страница 59: ...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...

Страница 60: ...Ring for cuts or other damage 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 sourc...

Страница 61: ...ent 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 i...

Страница 62: ...CutMaster 39 SERVICE 5 18 Manual 0 4976 This Page Intentionally Blank...

Страница 63: ...aned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring o...

Страница 64: ...Tip Shield Cup Torch Head Consumable Parts 3 Remove the tip Check for excessive wear indi cated by an elongated or oversized orifice Clean or replace the tip if necessary Good Tip Worn Tip A 03406 Tip...

Страница 65: ...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 Assembli...

Страница 66: ...rnal 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 Art A 08110...

Страница 67: ...tion Ref Catalog 1 1 On Off Switch SW1 8 4248 2 1 Output Current Control Potentiometer with wire harness 9 8629 3 1 Run Set Switch SW2 9 1042 4 1 Output Current Control Knob 9 8527 5 1 Work Cable with...

Страница 68: ...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...

Страница 69: ...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...

Страница 70: ...Cat No 9 7741 Housing Cover Barbed Fitting Spring Assembled Filter O ring Cat No 9 7743 6 10 Torch Consumables Single Stage Air Filter Art A 03409 Large O Ring Cat No 8 3487 Small O Ring Cat No 8 348...

Страница 71: ...AS 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 indi...

Страница 72: ...d 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 I Art A 03288 Date of Mfr Output Range Amperage Volt...

Страница 73: ...PRESSURE J5 OVER TEMP AC TEMP GAS DC TP20 E15B E15A E14B E14A E16B E16A E12B E12A E1 E13 J4 FAN J6 POT E2 TP24 E11 J3 TORCH SWITCH ON TP1 TP26 E8 E4 E19 E10 E9 E20 E6 E5 E18 TP2 TP23 TP6 TP3 J2 J4 J1...

Страница 74: ...TP24 E11 J3 TORCH SWITCH ON TP1 TP26 E8 E4 E19 WORK E10 E9 E20 E6 E5 E18 TP2 TP23 TP6 TP3 TP8 To Run Set Switch To Solenoid To Pressure Switch To Temperature Sensor To Fan To Current Control To Outpu...

Страница 75: ...5 6 7 8 5 6 7 8 1 2 3 4 ATC Female Receptacle Front View Pilot 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 Whi...

Страница 76: ...12VDC NORMALLY CLOSED TEST POINTS TP1 LOGIC COMMON TP2 SHORT TO TP23 TO DISABLE BIAS SUPPLY TP6 SHORT TOTP24 TO DISABLE POWER FACTOR CORRECTION TP8 SHORT TO TP26 TO DISABLE SHORTED TORCH PROTECTION E...

Страница 77: ...CO 100213 GCW 7 29 02 AA 42X1089 Tuesday June 19 2007 1 1 INDUSTRIAL PARK No 2 WEST LEBANON NH 0 3784 603 298 57 11 CM38 120 208 230V SINGLE PH ASE 50 60 Hz Tuesday May 15 2001 15 05 29 THERMAL DYNAM...

Страница 78: ...CutMaster 39 APPENDIX A 8 Manual 0 4976 This Page Intentionally Blank...

Страница 79: ...hanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Wes...

Страница 80: ...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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