39 CUTMASTER™ Operating Manual

39 CUTMASTER™ Operating Manual
39
CUTMASTER
™
PLASMA CUTTING SYSTEM
Operating Manual
Rev. AA
Operating Features:
Date: September 4, 2007
30
Manual # 0-4975
120
208230
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 1-800-4261888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product. Your
satisfaction with this product and its safe operation is our ultimate
concern. 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 GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators
Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within
the welding industry.
!
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.
Plasma Cutting Power Supply
CutMaster™ 39
SL60 1Torch™
Operating Manual Number 0-4975
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2007 by
Thermadyne Corporation
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 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 4, 2007
Record the following information for Warranty purposes:
Where Purchased:________________________________ ________________
Purchase Date:___________________________________ ________________
Power Supply Serial #:____________________________ ________________
Torch Serial #:____________________________________________________
i
This Page Intentionally Blank
TABLE OF CONTENTS
SECTION 1:GENERAL INFORMATION....................................................................................1-1
1.01
1.02
1.03
1.04
1.05
1.06
1.07
Notes, Cautions and Warnings....................................................................1-1
Important Safety Precautions......................................................................1-1
Publications.................................................................................................1-3
Note, Attention et Avertissement.................................................................1-3
Precautions De Securite Importantes..........................................................1-4
Documents De Reference............................................................................1-5
Statement of Warranty.................................................................................1-7
SECTION 2 SYSTEM:INTRODUCTION ..................................................................................2-1
2.01
2.02
2.03
2.04
2.05
2.06
2.07
How To Use This Manual.............................................................................2-1
Equipment Identification..............................................................................2-1
Receipt Of Equipment..................................................................................2-1
Power Supply Specifications........................................................................2-2
Input Wiring Specifications...........................................................................2-3
Power Supply Options and Accessories......................................................2-4
Torch Specifications.....................................................................................2-4
SECTION 2 TORCH:INTRODUCTION .................................................................................. 2T-1
2T.01
2T.02
2T.03
2T.04
2T.05
Scope of Manual........................................................................................ 2T-1
General Description................................................................................... 2T-1
Specifications ........................................................................................... 2T-1
Options And Accessories........................................................................... 2T-2
Introduction to Plasma............................................................................... 2T-2
SECTION 3: INSTALLATION ...................................................................................................3-1
3.01
3.02
3.03
3.04
3.05
Unpacking....................................................................................................3-1
Lifting Options..............................................................................................3-1
Primary Input Power Connections...............................................................3-2
Gas Connections.........................................................................................3-3
Torch Connections.......................................................................................3-5
SECTION 4 SYSTEM:OPERATION..........................................................................................4-1
4.01
4.02
4.03
Product Features.........................................................................................4-1
Preparations For Operating.........................................................................4-3
Sequence of Operation................................................................................4-7
SECTION 4 TORCH:OPERATION.......................................................................................... 4T-1
4T.01
4T.02
4T.03
4T.04
4T.05
4T.06
4T.07
4T.08
4T.09
Introduction................................................................................................ 4T-1
Functional Overview.................................................................................. 4T-1
Getting Started.......................................................................................... 4T-1
Torch Parts Selection................................................................................. 4T-1
Cut Quality................................................................................................. 4T-2
General Cutting Information....................................................................... 4T-3
Hand Torch Operation................................................................................ 4T-4
Recommended Cutting Speeds................................................................. 4T-7
Gouging..................................................................................................... 4T-7
TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE..............................................................................................5-1
5.01
5.02
5.03
General Maintenance..................................................................................5-1
Common Faults............................................................................................5-6
Basic Troubleshooting Guide.......................................................................5-6
SECTION 5 TORCH:SERVICE............................................................................................... 5T-1
5T.01
5T.02
General Maintenance................................................................................ 5T-1
Inspection and Replacement of Consumable Torch Parts......................... 5T-2
SECTION 6:PARTS LISTS........................................................................................................6-1
6.01
6.02
6.03
6.04
6.05
6.06
Introduction..................................................................................................6-1
Ordering Information....................................................................................6-1
Replacement Assemblies............................................................................6-1
Power Supply Replacement Parts...............................................................6-1
Options and Accessories.............................................................................6-2
Torch Consumables.....................................................................................6-2
PATENT INFORMATION...........................................................................................................6-3
APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)......................................... A-1
APPENDIX 2: DATA TAG INFORMATION .............................................................................. A-2
APPENDIX 3: SYSTEM SCHEMATIC..................................................................................... A-4
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION.......................... Inside Rear Cover
cutmaster 39
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and
warnings are used to highlight important information. These highlights are categorized as follows:
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.
NOTE
• Use an air-supplied respirator if ventilation is
not adequate to remove all fumes and gases.
An operation, procedure, or background information which requires additional emphasis or is
helpful in efficient operation of the system.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being
used, coatings on the metal, and the different
processes. You must be very careful when
cutting or welding any metals which may
contain one or more of the following:
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
WARNING
Mercury
Nickel
Selenium
Silver
Vanadium
• For information on how to test for fumes and
gases in your workplace, refer to item 1 in
Subsection 1.03, Publications in this manual.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
• Use special equipment, such as water or
down draft cutting tables, to capture fumes
and gases.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons
who work near plasma arc cutting applications
should consult their medical health professional
and the manufacturer of the health equipment to
determine whether a hazard exists.
• Do not use the plasma torch in an area where
combustible or explosive gases or materials
are located.
• Phosgene, a toxic gas, is generated from the
vapors of chlorinated solvents and cleansers.
Remove all sources of these vapors.
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.
Manual 0-4975 Chromium
Cobalt
Copper
Lead
Manganese
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the
material you are using. These MSDSs will
give you the information regarding the kind
and amount of fumes and gases that may be
dangerous to your health.
1.02 Important Safety Precautions
!
Antimony
Arsenic
Barium
Beryllium
Cadmium
• This product, when used for welding or cutting, produces fumes or gases which contain
chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec.
25249.5 et seq.)
1-1
GENERAL INFORMATION
CutMaster 39
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc
process uses and produces high voltage electrical
energy. This electric energy can cause severe or
fatal shock to the operator or others in the workplace.
NOISE
Noise can cause permanent hearing loss. Plasma
arc processes can cause noise levels to exceed
safe limits. You must protect your ears from loud
noise to prevent permanent loss of hearing.
• Never touch any parts that are electrically
“live” or “hot.”
• To protect your hearing from loud noise,
wear protective ear plugs and/or ear muffs.
Protect others in the workplace.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the
welding circuit.
• Noise levels should be measured to be sure
the decibels (sound) do not exceed safe levels.
• Repair or replace all worn or damaged parts.
• For information on how to test for noise, see
item 1 in Subsection 1.03, Publications, in
this manual.
• 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.
• Disconnect power source before performing
any service or repairs.
• Read and follow all the instructions in the
Operating 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 and burn your skin if
you are not properly protected.
• To protect your eyes, always wear a welding
helmet or shield. Also always wear safety
glasses with side shields, goggles or other
protective eye wear.
Fire AND EXPLOSION
Fire and explosion can be caused by hot slag,
sparks, or the plasma arc.
• Wear welding gloves and suitable clothing
to protect your skin from the arc rays and
sparks.
• Be sure there is no combustible or flammable
material in the workplace. Any material that
cannot be removed must be protected.
• Keep helmet and safety glasses in good
condition. Replace lenses when cracked,
chipped or dirty.
• Ventilate all flammable or explosive vapors
from the workplace.
• Do not cut or weld on containers that may
have held combustibles.
• Protect others in the work area from the
arc rays. Use protective booths, screens or
shields.
• Provide a fire watch when working in an area
where fire hazards may exist.
• Hydrogen gas may be formed and trapped
under aluminum workpieces when they are
cut underwater or while using a water table.
DO NOT cut aluminum alloys underwater or
on a water table unless the hydrogen gas can
be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
GENERAL INFORMATION
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Arc Current
Less Than 300*
300 - 400*
400 - 800*
Minimum Protective
Shade No.
8
9
10
Suggested
Shade No.
9
12
14
* These values apply where the actual arc is
clearly seen. Experience has shown that lighter
filters may be used when the arc is hidden by the
workpiece.
1-2
Manual 0-4975
cutmaster 39
1.03 Publications
Refer to the following standards or their latest
revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
14.American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15.ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief
des informations à caractère important. Ces mises
en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American
National Standards Institute, 1430 Broadway, New
York, NY 10018
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
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
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. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13.NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
Manual 0-4975 1-3
GENERAL INFORMATION
CutMaster 39
1.05 Precautions De Securite
Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de
l’énergie électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc
au jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au
personnel TOUS les dangers possibles.
Afin d’éviter les blessures possibles, lisez,
comprenez et suivez tous les avertissements,
toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet
de plasma peuvent présenter des risques et des
dangers de santé.
• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même
tuer. Le procédé au jet de plasma requiert et
produit de l’énergie électrique haute tension.
Cette énergie électrique peut produire des chocs
graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs. Isolezvous de la pièce de travail ou des autres parties du
circuit de soudage.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine
argent
arsenic
baryum
béryllium
cadmium
chrome
cobalt
cuivre
manganèse
GENERAL INFORMATION
mercure
nickel
plomb
sélénium
vanadium
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout
travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
1-4
Manual 0-4975
cutmaster 39
Les incendies et les explosions peuvent résulter
des scories chaudes, des étincelles ou de l’arc de
plasma. Le procédé à l’arc de plasma produit du
métal, des étincelles, des scories chaudes pouvant
mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables. • Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de
la zone de travail.
Courant Arc
Moins de 300*
300 - 400*
400 - 800*
Nuance Minimum
Protective Numéro
8
9
10
Nuance Suggerée
Numéro
9
12
14
* Ces valeurs s’appliquent ou l’arc actuel est
observé clairement. L’experience a démontrer que
les filtres moins foncés peuvent être utilisés quand
l’arc est caché par moiceau de travail.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
BRUIT
Le bruit peut provoquer une perte permanente de
l’ouïe. Les procédés de soudage à l’arc de plasma
peuvent provoquer des niveaux sonores supérieurs
aux limites normalement acceptables. Vous dú4ez
vous protéger les oreilles contre les bruits forts
afin d’éviter une perte permanente de l’ouïe.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
PAS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent
blesser vos yeux et brûler votre peau. Le procédé
à l’arc de plasma produit une lumière infra-rouge
et des rayons ultra-violets très forts. Ces rayons
d’arc nuiront à vos yeux et brûleront votre peau si
vous ne vous protégez pas correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes
de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre
les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Manual 0-4975 • Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions
les plus récentes ayant été faites à celles-ci pour
de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible
auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami,
FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR
LA PROTECTION DES YEUX ET DU VISAGE AU
1-5
GENERAL INFORMATION
CutMaster 39
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. N o r m e A N S I Z 4 1 . 1 , N O R M E S P O U R L E S
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
15.Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À
GAZ AVEC ALIMENTATION EN OXYGENE POUR
LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
10.Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE
ET DE SOUDAGE, disponible auprès de la National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
11.Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12.Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès de
l’Association des Normes Canadiennes, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3
13.Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
14.Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
GENERAL INFORMATION
1-6
Manual 0-4975
cutmaster 39
1.07 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™ plasma cutting systems sold after the effective date of this warranty are
free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated
below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated
and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice,
correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at
which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty
periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics
Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER™ 39
4 Years
1 Year
CUTMASTER™ 52
4 Years
1 Year
CUTMASTER™ 82
4 Years
1 Year
CUTMASTER™ 102
4 Years
1 Year
CUTMASTER™ 152
4 Years
1 Year
This warranty does not 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 installed, improperly operated or misused based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1.
Repair of the defective product.
2.
Replacement of the defective product.
3.
Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4.
Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007
This Page Intentionally Blank
Manual 0-4975 1-7
GENERAL INFORMATION
CutMaster 39
GENERAL INFORMATION
1-8
Manual 0-4975
cutmaster 39
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Operating Manual applies to just
specification or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
2.02 Equipment Identification
The unit’s identification number (specification or
part number), model, and serial number usually
appear on a data tag attached to the rear panel.
Equipment which does not have a data tag such
as torch and cable assemblies are identified
only by the specification or part number
printed on loosely attached card or the shipping
container. Record these numbers on the bottom of
page 1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect the equipment for possible damage due to
shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors to the location in your area listed in
the inside back cover of this manual.
Include all equipment identification numbers as
described above along with a full description of
the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging
the equipment when using bars, hammers, etc., to
un-crate the unit.
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be
purchased by contacting Thermal Dynamics at
the address and phone number in your area listed
in the inside back cover of this manual. Include
the Operating Manual number and equipment
identification numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermal Dynamics web site listed below and
clicking on Thermal Dynamics and then on the
Literature link:
http://www.thermal-dynamics.com
Manual 0-4975 2-1
INSTALLATION
CutMaster 39
2.04 Power Supply Specifications
CutMaster 39 Power Supply Specifications
Input Power (See Note 1)
120 VAC (± 10%), Single-Phase, 50/60 Hz
208 - 230 VAC (± 10%), Single-Phase, 50/60 Hz
Power Sensing
Automatic Voltage Selection. See Note 1.
Input Power Cable
Cable with plug, for 120VAC, 20-Amp Single-Phase input power.
Output Current
20-30 Amps, continuously variable
Power Supply Gas Filtering Ability
Particulates to 20 Microns
CutMaster 39 Power Supply Duty Cycle (Note 2)
Ambient Temperature
104° F (40° C)
Duty Cycle
35%
60%
DC Voltage
78 vdc
89 vdc
Current
30 Amps
22 Amps
SL 60 Torch Gas Requirements
Gas Type
Compressed Air
Gas specifications
Clean, dry, oil-free (Note 3)
Maximum Input Gas Pressure
125 psi / 8.6 bar
Operating Gas Pressure
65 psi / 4.5 bar
Gas Flow Requirements
300 scfh / 141.5 lpm
Notes
1. Power supply accepts 120-230 VAC input power. No 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 higher than shown in this chart.
3. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear. Optional filters provide increased filtering capabilities.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting with
a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables,
and actual cutting operation.
INSTALLATION
2-2
Manual 0-4975
cutmaster 39
Power Supply Dimensions & Weight
Ventilation Clearance Requirements
Art # A-07924
Art # A-07925
15"
381 mm
6"
150 mm
24"
0.6 m
24"
0.61 m
12"
305 mm
6"
150 mm
45 lb / 20.4 kg
6"
150 mm
NOTE
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
2.05 Input Wiring Specifications
CutMaster 39 Input Power Requirements
Input
Power Input Current Input
Suggested Sizes (See Notes)
Voltage
Freq.
(kVA)
(Amps)
Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts)
(Hz)
1-Ph
1-Ph
1-Ph
1-Ph
1-Ph
120
50 / 60
3.6
29
35
12
12
208
50 / 60
3.5
16
20
12
12
230
50 / 60
3.4
14
20
12
12
Line Voltages with Suggested Circuit 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.
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should
be used to minimize 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 National Electric Code Guidelines (and OSHA Guidelines, where applicable). Extension cords must have the same rating as the service and must have a three-pronged plug.
Manual 0-4975 2-3
INSTALLATION
CutMaster 39
2.06 Power Supply Options and Accessories
The following options and accessories are available for this Power Supply. Section 6 provides catalog
numbers and ordering information.
A. Single-Stage Air Filter Kit
A single-stage air filter for use on compressed air shop systems. Highly effective at removing moisture and
particulate matter from the air stream to at least 0.85 microns.
B. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf 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 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. Type of Cooling
Combination of ambient air and gas stream through torch
E. SL60 Torch Ratings (Refer to Note)
NOTE
Ratings shown apply to the SL60 Torch only. Refer to the Specifications chart on page 2T-1 for CutMaster 39
data.
F. Plasma Power Supply Used With
• Thermal Dynamics CutMaster 39
INSTALLATION
2-4
Manual 0-4975
cutmaster 39
SECTION 2 TORCH:
INTRODUCTION
2T.03Specifications
A. Torch Configurations
1. Hand Torch, Model SL60
2T.01Scope of Manual
This manual contains descriptions, operating
instructions and maintenance procedures for
the 1Torch Model SL60 Plasma Cutting Torch.
Service of this equipment is restricted to properly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or
adjustments not covered in this manual, at the risk
of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of
this equipment will assure the dependable operation for which it was designed.
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
9.5" (241 mm)
3.75"
(95 mm)
1.17" (29 mm)
B. Torch Leads Lengths
Hand Torches are available as follows:
2T.02General Description
Plasma torches are similar in design to the automotive spark plug. They consist of negative and
positive sections separated by a center insulator.
Inside the torch, the pilot arc starts in the gap
between the negatively charged electrode and
the positively charged tip. Once the pilot arc has
ionized the plasma gas, the superheated column of
gas flows through the small orifice in the torch tip,
which is focused on the metal to be cut.
A single torch lead provides gas from a single
source to be used as both the plasma and secondary gas. The air flow is divided inside the torch
head. Single - gas operation provides a smaller
sized torch and inexpensive operation.
• 20 ft / 6.1 m.
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch Head has built - in switch
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through
torch.
F. Torch Ratings
SL60 Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle
100% @ 60 Amps @ 400 scfh
Maximum Current
60 Amps
Voltage (Vpeak)
500V
Arc Striking Voltage
7kV
NOTE
Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch
operation.
Refer to the Appendix Pages for additional specifications as related to the Power Supply used.
Art # A-03322
G. Current Ratings
SL60 Current Ratings
SL60 Torch & Leads
Up to 60 Amps, DC,
Straight Polarity
NOTE
Power Supply characteristics will determine material thickness range.
Manual 0-4975
2T-1
INTRODUCTION
CutMaster 39
2T.05Introduction to Plasma
H. Gas Requirements
SL60 Torch Gas Specifications
Gas (Plasma and Secondary)
Compressed Air
Operating Pressure
Refer to NOTE
60 - 75 psi
4.1 - 5.2 bar
Maximum Input Pressure
125 psi / 8.6 bar
Gas Flow (Cutting and Gouging)
300 - 500 scfh
142 - 235 lpm
!
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
and then blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
WARNING
This torch is not to be used with oxygen (O2).
In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
of plasma gas in Zone C.
NOTE
Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to
gas pressure settings charts for each model.
I. Direct Contact Hazard
For exposed tip the recommended standoff is 3/16
inches / 4.7 mm.
2T.04Options And Accessories
These items can adapt a standard system to a
particular application or further enhance performance.
• Deluxe Cutting Guide Kit - Easy add - on
attachments for precise straight line, circle
cutting, and beveling. Includes carrying
case.
_
Power
Supply
+
A
B
Workpiece
• Trigger Guard Kits - These offer additional
protection from accidental activation of the
torch switch.
C
• Leads Extensions for torches with ATC connectors
A-00002
Typical Torch Head Detail
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
• Leather Leads Covers
Zone A channels a secondary gas that cools the torch.
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.
INTRODUCTION
2T-2
Manual 0-4975
cutmaster 39
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.
The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
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 output is connected to the torch electrode
through the torch lead. The positive output is connected to the workpiece via the work cable and to
the torch through a pilot wire.
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
is open.
To Control
Cable Wiring
Torch Switch
PIP Switch
A-02997
Torch Trigger
Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
Manual 0-4975
2T-3
INTRODUCTION
CutMaster 39
This Page Intentionally Blank
INTRODUCTION
2T-4
Manual 0-4975
cutmaster 39
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. Be sure unit is lifted and transported safely
and securely.
!
WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-4975 3-1
INSTALLATION
CutMaster 39
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.
120 V, 20A, 1Ø
A-03382
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 close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according to the plug manufacturer's instructions. All three conductors
must be connected to the plug.
Connect the input power cord as follows:
1. Check the power source for correct voltage before plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
INSTALLATION
3-2
Manual 0-4975
cutmaster 39
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. 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.
Min. 1/4 inch
6.4 mm
A-07926
Gas Connection to Inlet Port
B. Check Air Quality
To test the quality of air, put the RUN / SET switch in the SET (down) position, place a welding filter
lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens.
Do not start an arc!
26
A
28
24
22
20
30
A-07927
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.
Manual 0-4975 3-3
INSTALLATION
CutMaster 39
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. 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. Connect as follows:
Filter Hose
Single-Stage
Filter Kit
No. 7-7507
Hose
Clamp
1/4 NPT
Hose Fitting
A-07928
Gas Supply Hose
Optional Single - Stage Filter Installation
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. 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 gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, 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 passages in
the torch.
INSTALLATION
3-4
Manual 0-4975
cutmaster 39
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
Art # A-07929
Connecting the Torch to the Power Supply
3. The system is ready for operation.
Manual 0-4975 3-5
INSTALLATION
CutMaster 39
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INSTALLATION
3-6
Manual 0-4975
cutmaster 39
SECTION 4 SYSTEM:
OPERATION
4.01 Product Features
A. General Features
Gas Pressure Knob
Handle and Leads Wrap
Torch Leads
Connector
1
Art # A-07930
Control Panel
Work Cable
and Clamp
Manual 0-4975 4-1
OPERATION
CutMaster 39
B. Control Panel
4
5
2
1
26
A
6
7
28
24
3
22
20
30
A-07931
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. If the overload protection (fuse or circuit breaker) on the input power circuit
opens frequently, either reduce cutting output, reduce 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 light indicates unit is in protective interlock mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to
Section 5 for details.
5.
TEMP Indicator
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Allow the unit
to run with the fan on until the Temp indicator turns off.
6.
GAS Indicator
Indicator is ON when adequate input gas pressure is present to operate the power supply.
7.
DC Indicator
Indicator is ON when DC output circuit is active.
OPERATION
4-2
Manual 0-4975
cutmaster 39
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.
Art # A-03409
Large O-Ring,
Cat. No. 8-3487
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 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.
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.
Manual 0-4975 4-3
OPERATION
CutMaster 39
D. Gas Selection
Ensure gas source meets requirements (refer to Section 2). 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 free from oil, paint and rust. Connect
only to the main part of the workpiece; do not connect to the part to be cut off.
Art # A-03387
F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator
26
turns on.
A
28
24
22
20
30
A-07932
OPERATION
4-4
Manual 0-4975
cutmaster 39
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 regulator leaks, reset gas pressure to 0 psi, then reset to 65 psi / 4.5 bar.
1
2
65 psi / 4.5 bar
26
A
28
24
22
20
A-07933
30
A-07927
H. Select Current Output Level
Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level.
26
A
28
24
22
20
30
A-07934
Manual 0-4975 4-5
OPERATION
CutMaster 39
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. The pilot arc then
starts. DC indicator
turns on. Bring the torch within transfer distance to the workpiece. The pilot arc
stops and the main arc transfers to the workpiece.
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.
Trigger
1
2
Trigger Release
3
4
Art # A-03383
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.Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 10 seconds. During post
- flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc
transfers to the workpiece if the torch tip is within transfer distance to the workpiece.
l. Shutdown
Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord
or disconnect input power. Power is removed from the system.
OPERATION
4-6
Manual 0-4975
cutmaster 39
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.
If torch trigger is held while user turns on main AC power, system goes into 'protective interlock' mode. AC
indicator flashes; torch will not pilot. Release torch trigger, turn AC switch OFF then ON.
3. Put RUN / SET switch to SET (down position).
a. Gas flows to set pressure. Turn gas pressure adjustment knob to set pressure to 65 psi / 4.5
bar; Gas indicator
tion.
turns ON when there is sufficient gas pressure for power supply operaNOTE
Minimum pressure for power supply operation is lower than minimum pressure for torch operation.
4. Put RUN / SET switch to RUN (up position). Gas flow stops.
5. Wear protective clothing and welding gloves. Protect eyes. Slide the trigger release to the rear;
squeeze and hold the trigger. Gas flows briefly, then shuts off momentarily. Then gas flow will
resume. Pilot arc is established. DC indicator
turns ON. Move Torch within transfer distance of workpiece.
a. Main arc transfers to workpiece.
6. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc
will automatically restart.
7. Release the torch trigger.
a. Main arc stops; gas flows for approximately 10 seconds.
8. Set the power supply ON / OFF switch to OFF (down position).
a. AC indicator
turns OFF; fan turns OFF.
9. Set the main power disconnect to OFF, or unplug input power cord.
a. Input power is removed from the system.
Manual 0-4975 4-7
OPERATION
CutMaster 39
This Page Intentionally Blank
OPERATION
4-8
Manual 0-4975
cutmaster 39
SECTION 4 TORCH:
OPERATION
4T.01Introduction
This section provides a description of the SL60
and SL100 Torch Assemblies followed by operating procedures.
NOTE
Refer to Appendix Pages for additional information 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 Control Knob is in SET position, gas
will flow. If the control knob is in the RUN position
there will be no gas flow.
4T.02Functional Overview
The Torch is designed to operate with various Power Supplies to provide a plasma cutting
system which can cut most metals. With gouging
torch parts the torch can be used for plasma arc
gouging.
NOTE
Current Output Level
At the Power Supply, set the desired current output
level. For drag cutting set the control at 40 amps or
less only.
Pressure Settings
Refer to Appendix Pages for additional information as related to the Power Supply used.
Place the Function Control Knob to the SET position.
Adjust the gas pressure control on the Power Supply for the proper gas pressure. Refer to Appendix
Pages for gas pressure and other specifics.
4T.03Getting Started
Follow this procedure at the beginning of each
shift:
Ready for Operation
Return the Function Control Knob to RUN position.
NOTES
WARNING
For general cutting, use the RUN position which
provides normal torch operation where the torch
switch must be held throughout the main arc
transfer.
Disconnect primary power at the source
before assembling or disassembling power
supply, torch parts, or torch and leads assemblies.
For specific applications, use the LATCH position
where the torch switch can be released after the
main arc transfer. The torch remains activated
until the main arc breaks from the workpiece.
Torch Parts
Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to next
SubSection called "Torch Parts Selection").
Input Power
Check the power source for proper input voltage.
Close main disconnect switch or plug unit in to
supply primary power to the system.
Work Cable
Check for a solid cable connection to the workpiece.
Refer to Appendix 1 for a typical detailed block
diagram of Sequence of Operation.
The system is now ready for operation.
4T.04Torch Parts Selection
Depending on the type of operation to be done
determines the torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
Gas Supply
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter
Cartridge
Select desired single gas supply. Make sure gas
sources meet requirements (see Note). Check connections and turn gas supply on.
Manual 0-4975
4T-1
OPERATION
CutMaster 39
NOTE
4T.05Cut Quality
Refer to Section 6 and the Appendix Pages for
additional information on torch parts.
NOTES
Cut quality depends heavily on setup and parameters such as torch standoff, alignment with
the workpiece, cutting speed, gas pressures, and
operator ability.
Change the torch parts for a different operation as
follows:
Refer to Appendix Pages for additional information as related to the Power Supply used.
WARNING
Disconnect primary power at the source before assembling or disassembling torch parts,
or torch and leads assemblies.
NOTE
The shield cup holds the tip and starter cartridge
in place. Position the torch with the shield cup
facing upward to keep these parts from falling out
when the cup is removed.
Cut quality requirements differ depending on
application. For instance, nitride build - up and
bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when finish cut quality is desired
to avoid a secondary cleaning operation. The
following cut quality characteristics are illustrated
in the following figure:
1. Unscrew and remove the shield cup assembly from the torch head.
2. Remove the Electrode by pulling it straight
out of the Torch Head.
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Torch Head
Top Edge
Rounding
Electrode
Dross
Build-Up
Start Cartridge
Cut Surface
Drag Lines
A-00007
Cut Quality Characteristics
Tip
Cut Surface
Shield Cup
The desired or specified condition (smooth or rough)
of the face of the cut.
Nitride Build - Up
A-03645
Torch Parts
3. Install the replacement Electrode by pushing it straight into the torch head until it
clicks.
4. Install the starter cartridge and desired tip
for the operation into the torch head.
5. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt
when installing the cup, check the threads
before proceeding.
OPERATION
Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.
Bevel Angle
The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0°
bevel angle.
4T-2
Manual 0-4975
cutmaster 39
Top - Edge Rounding
Torch Standoff
Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.
Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as
well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will
generally result in a more square cut.
Bottom Dross Buildup
Molten material which is not blown out of the cut
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after
cutting.
Edge Starting
For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where
the cut is to start. When starting at the edge of the
plate, do not pause at the edge and force the arc to
"reach" for the edge of the metal. Establish the cutting arc as quickly as possible.
Kerf Width
The width of the cut (or the width of material removed during the cut).
Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.
Direction of Cut
In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the
direction of travel, the right side of the cut is more
square than the left.
Left Side
Cut Angle
Right Side
Cut Angle
4T.06General Cutting Information
!
WARNINGS
Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.
Frequently review the Important Safety Precautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure
no part of the operator’s body comes into
contact with the workpiece while the torch
is activated.
A-00512
Side Characteristics Of Cut
To make a square - edged cut along an inside
diameter of a circle, the torch should move counterclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
NOTE
Handle torch leads with care and protect them
from damage.
Piloting
Piloting is 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 life.
Manual 0-4975
4T-3
OPERATION
CutMaster 39
b. For standoff cutting, hold the torch 1/8
- 3/8 in (3-9 mm) from the workpiece as
shown below.
Dross
When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed,
or top dross”. Dross present on top of the plate is
normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove
and can often 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 easily scraped off. "High speed
dross" usually forms a narrow bead along the bottom
of the cut edge and is very difficult to remove. When
cutting a troublesome steel, it is sometimes useful
to reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished
by scraping, not grinding.
Torch
Shield Cup
Standoff
Distance 1/8" - 3/8"
4T.07Hand Torch Operation
Standoff Cutting With Hand Torch
A-00024
NOTE
Standoff Distance
For best performance and parts life, always use the
correct parts for the type of operation.
3. Hold the torch away from your body.
4. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
1. The 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 for
maximum control or near the back end for
maximum heat protection. Choose the
holding technique that feels most comfortable and allows good control and movement.
Trigger
Trigger Release
NOTE
Art # A-03962
The tip should never come in contact with the
workpiece except during drag cutting operations.
5. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut off.
2. Depending on the cutting operation, do one
of the following:
a. For edge starts, hold the torch perpendicular to the workpiece with the front
of the tip on the edge of the workpiece
at the point where the cut is to start.
OPERATION
4T-4
Manual 0-4975
cutmaster 39
Drag Cutting With a Hand Torch
NOTE
The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
Drag cutting works best on metal 3/16" (4.7 mm)
thick or less.
NOTE
Trigger
For best parts performance and life, always use the
correct parts for the type of operation.
1
1. Install the drag cutting tip and set the output current to 30 amps or less.
2. The 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 for
maximum control or near the back end for
maximum heat protection. Choose the
holding technique that feels most comfortable and allows good control and movement.
4. Keep the torch in contact with the workpiece during the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
2
Trigger Release
3
4
Art # A-03383
6. Cut as usual. Simply release the trigger
assembly to stop cutting.
7. Follow normal recommended cutting
practices as provided in the power supply
operating manual.
NOTE
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
Trigger
8. For a consistent standoff height from the
workpiece, install the standoff guide by
sliding it onto the torch shield cup. Install
the guide with the legs at the sides of the
shield cup body to maintain good visibility
of the cutting arc. During operation, position the legs of the standoff guide against
the workpiece.
Trigger Release
Art # A-03962
Shield Cup
Standoff Guide
Torch Tip
Workpiece
Manual 0-4975
Art # A-04034
4T-5
OPERATION
CutMaster 39
7. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut off.
NOTE
The tip should never come in contact with the
workpiece except during drag cutting operations.
NOTE
2. Angle the torch slightly to direct blowback
particles away from the torch tip (and operator) rather than directly back into it until
the pierce is complete.
3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue
the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce
is complete.
4. Hold the torch away from your body.
5. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
Trigger
1
2
Trigger Release
3
4
Art # A-03383
Trigger
8. Cut as usual. Simply release the trigger
assembly to stop cutting.
9. Follow normal recommended cutting
practices as provided in the power supply
operating manual.
Trigger Release
Art # A-03962
6. Bring the torch within transfer distance to
the work. The main arc will transfer to the
work, and the pilot arc will shut off.
NOTE
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
NOTE
The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.
Piercing With Hand Torch
1. The 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 for
maximum control or near the back end for
maximum heat protection. Choose the
technique that feels most comfortable and
allows good control and movement.
OPERATION
7. Clean spatter and scale from the shield cup
and the tip as soon as possible. Spraying
the shield cup in anti - spatter compound
will minimize the amount of scale which
adheres to it.
mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and the
tip as soon as possible. Spraying or dipping the
shield cup in anti - spatter compound will minimize
the amount of scale which adheres to it.
4T-6
Manual 0-4975
cutmaster 39
4T.08Recommended Cutting Speeds
MATERIAL THICKNESS
12.7
In
ch
M
M
G
ag
e
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds shown
are typical for this cutting system using air plasma to cut mild steel, with output current at 30 amps and torch
held at 0 - 1/16" (0 - 1.6 mm) standoff.
A-03381
0.5
0.4
9.5 0.375
0.35
8
0.3
7
6 0.25
5
0.2
4
0.15
12
3
2
0.1
18
20 24
1
6
Typical Cutting Speeds
Air Plasma on Mild Steel
0.05
Inches
Meters
10 20
0.25 0.5
40
1.00
60
1.5
100
2.5
80
2.0
120
3.05
140
3.5
160
4.06
180
4.57
200
5.08
220
5.56
240
6.1
400
10.1
Inches/ Meters per Minute
CUTTING SPEED
Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, using
a template or cutting guide while still producing 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 have been followed. Make sure no part of the operator’s body comes in contact with the
workpiece when the torch is activated.
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTIONS
Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and
metal.
Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 6 and the Appendix
Pages for additional information on torch parts.
Gouging Parameters
Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle
between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).
Torch Travel Speed
NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.
Manual 0-4975
4T-7
OPERATION
CutMaster 39
Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).
Current Setting
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and the
amount of material 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 than 45° the molten metal will
not be blown out of the gouge and may be blown
back onto the torch. If the lead angle is too small
(less than 35°), less material may be removed, requiring more passes. In some applications, such as
removing welds or working with light metal, this
may be desirable.
OPERATION
4T-8
Manual 0-4975
cutmaster 39
SECTION 5 SYSTEM: SERVICE
5.01 General Maintenance
Warning!
Disconnect input power before maintaining.
Maintain more often
if used under severe
conditions
Each Use
Visual 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
Replace all
broken parts
Clean
exterior
of power supply
6 Months
Visually check and
Carefully clean the
interior
Art # A-07938
Manual 0-4975 5-1
SERVICE
CutMaster 39
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. No. 9-8215
Start Cartridge,
Cat. No. 9-8213
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Worn Electrode
SERVICE
Worn Tip
5-2
Manual 0-4975
cutmaster 39
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.
Upper screws
Upper screws
Ground
wire
Lower screws
Art #A-07935
Lower screws
Cover Removal
Manual 0-4975 5-3
SERVICE
CutMaster 39
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. 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.
Ring
Replacement
Element
No. 9-0182
Spool
Bowl
Art # A-07936
Regulator / Filter Element Replacement
9. Clean the inside of the bowl if necessary. Check that the knurled valve on the bottom of the bowl is fully
open.
10.Reinstall the bowl. Reconnect the drain tube.
11.Reinstall the cover as follows:
a. Reconnect the ground wire, if necessary.
b. Set the cover onto the base so that it rests on the lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the upper screws.
12.Turn on the air supply.
SERVICE
5-4
Manual 0-4975
cutmaster 39
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.
It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-ring on a
weekly basis.
NOTE
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.
DO NOT use other lubricants or grease, they may
not be designed to operate within high temperatures or may contain “unknown elements” that
may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent performance or poor parts life.
8. Reattach gas supply hose. If unit leaks between
housing and cover, inspect the "O" Ring for cuts or
other damage.
Housing
ATC Male Connector
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Assembled Filter
Cover
Barbed
Fitting
Art # A-02476
Gas Fitting
Art #A-03791
Manual 0-4975 O-Ring
5-5
SERVICE
CutMaster 39
5.02 Common Faults
Problem - Symptom
Insufficient
Penetration
Common Cause
1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts
5. Cutting current too low.
6. Non - Genuine Thermal Dynamics
parts used
7. Incorrect gas pressure
Main Arc
Extinguishes
1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Cutting current too high.
4. Work cable disconnected.
5. Worn torch parts.
6. Non - Genuine Thermal Dynamics
parts used
Excessive Dross
Formation
1. Cutting speed too slow.
2. Torch standoff too high from
workpiece.
3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine Thermal Dynamics
parts used
6. Incorrect gas pressure
Short Torch Parts Life1. Oil or moisture in air source.
Exceeding system capability (material
too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics
parts used
Difficult Starting
5.03 Basic Troubleshooting Guide
1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
parts used.
3. Incorrect gas pressure.
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. If major complex
subassemblies are faulty, the unit must be returned
to an authorized service center for repair.
Follow all instructions as listed and complete each
section in the order presented.
For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for
this product.
B. How to Use This Guide
The following information will help the Customer / Operator determine the most likely 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 Instructions
1. Cause
a. Check / Remedy
Locate your symptom, check the causes (easiest
listed first), then remedies. Repair as needed being sure to verify that unit operates properly after
any repairs.
C. Common Symptoms
A. Gas regulator leaks
1. Regulator is open
a. Reset regulator to 0 psi, then adjust to 65 psi
( 4.5 bar ).
SERVICE
5-6
Manual 0-4975
cutmaster 39
B. AC indicator
OFF
1. Switch at customer's main power panel in OFF (open)
position.
E. AC indicator
ON
1. Fan disconnected or blocked.
a. Close main power switch.
a. Clear fan if blocked; let power supply cool.
2. Power Supply ON / OFF switch in OFF position.
a. Turn switch to ON.
3. Customer's main power line fuse(s) or circuit
breaker(s) blown
F. AC indicator ON; TEMP indicator
a. Check for blocked air flow around the unit
and correct condition.
2. Fan blocked
4. Actual input voltage does not correspond to voltage of
unit
a. Check and correct condition.
a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.
3. Unit is overheated
a. Let unit cool down for at least 5 minutes.
Make sure the unit has not been operated
beyond Duty Cycle limit. Refer to duty cycle
data in Section 2.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
4. Input line voltage is below 100 Volts
flashing; Torch cannot be
a. Check and connect to proper input power
line.
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.)
ON
1. Air flow blocked
a. Check main power panel fuse(s) and replace
as required.
C. AC indicator
activated
flashing; Temp indicator
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
G. Torch will not pilot when torch switch is activated
1. System is in SET mode
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. Refer to illustration on page 5
- 1. Replace parts as needed. Reinstall shield
cup; hand - tighten it securely against the torch
head. Close main disconnect switch. Set ON
/ OFF switch to ON (up) position.
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
3. System is in protective interlock mode. (User removed
shield cup from torch 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
indicator
is activated
Upper Groove
with Vent Holes
Must Remain Open
and GAS
Upper O-Ring
in Correct Groove
flash alternately when torch trigger
Threads
Lower O-Ring
1. Gas pressure is too low. Adjust gas pressure to 65 psi
/ 4.5 bar.
Manual 0-4975 5-7
SERVICE
CutMaster 39
3. Faulty torch parts
3. Faulty components in unit
a. Inspect torch parts and replace if necessary.
a. Return for repair or have qualified technician
repair per Service Manual.
4. Gas pressure too high or too low
a. Adjust to proper pressure.
K. Erratic or improper cutting output
1. Poor input or output connections
5. Faulty components in unit
a. Check all input and output connections.
a. Return for repair or have qualified technician
repair per Service Manual.
2. Poor work cable connection
H. No cutting output; Torch activated; AC indicator
ON; Gas flows; Fan operates
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
1. Torch not properly connected to power supply
a. Check that torch leads are properly connected
to power supply.
2. Work cable not connected to work piece, or connection
is poor
3. Fluctuations in input power
a. Have electrician check input line voltage.
L. Difficult Starting
1. Worn torch parts (consumables)
a. Shut off input power. Remove and inspect
torch shield cup, tip, starter cartridge, and
electrode. Replace electrode or tip if worn;
replace starter cartridge if end piece does not
move freely; replace shield cup if excessive
spatter adheres to it.
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Shield cup not properly installed on torch
a. Open main disconnect switch. Check that
shield cup is fully seated against torch head.
Set ON / OFF switch to OFF, check shield
cup, close main disconnect switch, turn power
supply ON, and try cutting.
M.Arc shuts off during operation; arc will not restart when torch switch is activated.
4. Faulty components in unit
1. Power Supply is overheated (TEMP indicator
ON)
a. Return for repair or have qualified technician
repair per Service Manual.
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.
5. Faulty Torch
a. Return for repair or have qualified technician
repair.
2. Fan blades blocked (AC indicator
TEMP indicator ON)
I. Low cutting output
1. Incorrect setting of CURRENT (A) control
flashing;
a. Check and clear blades.
a. Check and adjust to proper setting.
3. Air flow obstructed (AC indicator
TEMP indicator ON)
2. Faulty components in unit
flashing;
a. Check for obstructed air flow around the unit
and correct condition.
a. Return for repair or have qualified technician
repair.
J. Limited output with no control
4. Gas pressure too low (GAS indicator
torch switch is activated)
1. Poor input or output connections
a. Check all input and output connections.
OFF when
a. Check source for at least 65 psi / 4.5 bar; adjust
as needed.
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.
SERVICE
5-8
Manual 0-4975
cutmaster 39
5. Torch consumables worn
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 indicator
ates
ON; Fan oper-
1. Gas not connected or pressure too low
a. Check gas connections. Adjust gas pressure
to proper setting.
2. Shield Cup not properly installed.
a. Check to see that Shield Cup is properly installed.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair.
O. Torch cuts but not adequately
1. Current (A) control set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
3. Excessive oil or moisture 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.
Manual 0-4975 5-9
SERVICE
CutMaster 39
This Page Intentionally Blank
SERVICE
5-10
Manual 0-4975
cutmaster 39
SECTION 5 TORCH:
SERVICE
O-Ring Lubrication
An o-ring on the Torch ATC Male Connector requires
lubrication on a scheduled basis. 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.
5T.01General Maintenance
NOTE
It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-ring on a
weekly basis.
Refer to Previous "Section 5 System" for common
and fault indicator descriptions.
Cleaning Torch
NOTE
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of
the torch.
DO NOT use other lubricants or grease, they may
not be designed to operate within high temperatures or may contain “unknown elements” that
may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent performance or poor parts life.
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
ATC Male Connector
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
CAUTION
Gas Fitting
Dry the torch thoroughly before reinstalling.
Art #A-03791
Manual 0-4975
5T-1
O-Ring
SERVICE
CutMaster 39
5T.02Inspection and Replacement
of Consumable Torch Parts
3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean
or replace the tip if necessary.
Worn Tip
Good Tip
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
A-03406
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
Tip Wear
Remove the consumable torch parts as follows:
4. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check
the lower end fitting for free motion. Replace if
necessary.
NOTE
The shield cup holds the tip and starter cartridge
shield cup in place. Position the torch with the
shield cup facing upward to prevent these parts
from falling out when the cup is removed.
Spring-Loaded
Lower End Fitting
Full Compression 1/8”
Spring-Loaded
Lower End Fitting at Rest /
Full Extension
1. Unscrew and remove the shield cup from the
torch.
NOTE
Slag built up on the shield cup that cannot be removed may effect the performance of the system.
Art # A-08064
2. Inspect the cup for damage. Wipe it clean or
replace if damaged.
5. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
Refer to the following figure.
Torch Head
New Electrode
Electrode
Start Cartridge
Art # A-03284
Worn Electrode
Electrode Wear
Tip
6. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
Shield Cup
7. Reinstall the desired starter cartridge and tip into
the torch head.
A-03645
8. Hand tighten the shield cup until it is seated on
the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
Consumable Parts
SERVICE
5T-2
Manual 0-4975
cutmaster 39
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. Address all
inquiries to your authorized distributor.
6.03 Replacement Assemblies
The following items are included with the replacement power supply: input power cord and plug, work
cable & clamp, gas pressure regulator / filter, and operating manual.
Qty
Description
Catalog #
1
1
CutMaster 39 Power Supply Surelok Model SL60 Torch
3-3830
7-5204
6.04 Power Supply Replacement Parts
Qty
Description
Catalog #
1
1
Regulator / Filter Assembly Filter Element
Input Power Cord with 120 VAC, 20A plug 9-0182
9-8660
Manual 0-4975 6-1
PARTS LISTS
CutMaster 39
6.05 Options and Accessories
Qty
Description
Catalog #
1
120V, 15 - Amp Plug
1
120V, 20 - Amp Receptacle
1
Single - Stage Filter Kit (includes Filter & Hose) 1
Replacement Filter Body 1
Replacement Filter Hose (not shown)
2
Replacement Filter Element 1
Multi - Purpose Cart
9-8644
9-8645
7-7507
9-7740
9-7742
9-7741
7-8888
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
Single - Stage Air Filter
O-ring
(Cat. No. 9-7743)
Assembled Filter
Cover
Barbed
Fitting
Art # A-02476
6.06 Torch Consumables
Art # A-03409
Large O-Ring,
Cat. No. 8-3487
Small O-Ring,
Cat. No. 8-3486
Electrode, Cat. No. 9-8215
Start Cartridge,
Cat. No. 9-8213
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.
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Worn Electrode
PARTS LISTS
Worn Tip
6-2
Manual 0-4975
cutmaster 39 & 15
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION
ACTION
Close external
disconnect switch.
ON / OFF switch
to ON.
RESULT
RESULT
Power to system.
AC indicator ON.
Fan on.
Power circuit ready.
ACTION
ACTION
RUN / SET switch
to RUN.
Connect work cable
to workpiece.
Set output amperage
ACTION
RUN / SET switch to SET.
RESULT
RESULT
Gas flows to set pressure.
GAS indicator on when input
pressure is adequate.
RESULT
Gas flow stops.
System is ready
for operation.
ACTION
ACTION
Protect eyes and
activate torch.
Torch moved away
from work (while
still activated).
RESULT
RESULT
Gas flows briefly,
then stops.
Gas restarts.
PILOT ARC
Main arc stops.
Pilot arc automatically
restarts.
DC indicator on.
Pilot arc established.
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfers.
Pilot arc off.
ACTION
Release torch trigger.
RESULT
Main arc stops.
Gas flow stops after post - flow.
ACTION
ACTION
ON / OFF switch
to OFF
Unplug input
power cord or
open external
disconnect.
RESULT
All indicators off.
Power supply fan shuts off.
RESULT
No power to system.
A-03299
Manual 0-4975 A-1
APPENDIX
CutMaster 39 & 15
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
=
Rated NoLoad Voltage
Duty Cycle Data (Note 3)
I
U2
Conventional
Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1
I 1max 3Ø
1
1Ø
1Ø
1
I 1eff
3Ø
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Maximum Effective
Supply Current
Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection
Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated 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.
Standard Symbols
AC
DC
Ø
Phase
Art # A-03288
NOTE
Sections of the data tag may be applied in
separate locations on the Power Supply.
APPENDIX
A-2
Manual 0-4975
cutmaster 39 & 15
This Page Intentionally Blank.
Manual 0-4975 A-3
APPENDIX
CutMaster 39 & 15
APPENDIX 3: SYSTEM SCHEMATIC
1
2
3
4
PFC INDUCTOR
A
INPUT 230V ONLY
E18
D47
E12A
+
CHASSIS GND
K1
E1
(E1)
(E14A)
120/208/230V
INPUT
50/60HZ
E2
(E2)
SW1
STUD
(E12A)
2
1
BR1
3
(E15A)
Q7
4
E14A
Q8
-
L1 SW1
B
E11
FILTE
RING
EMC
FILTER
CE ONLY
T1
J7
TEST
1
4
(E16A)
E15A
E13
E16A
RED
12VDC
BLACK
C
CURRENT ADJUST
20 - 30
CW
NORMALLY CLOSED
OVER-TEMP
D
TS1
P5 J5
1 1
2 2
P9J9
4
E15B
3
(9) 3 3
RUN
BR2
(E16B)
2
2 2
SW2
1
E16B
PANEL INDICATOR
AC
D7
TEMP
D13
GAS
D16
DC
D19
ZERO
1 1
(10) 2 2
(11) 3 3
BIAS
CONVERTER
(E12B)
2
E14B
J6
1
P2 J2
(8) 1 1
SET
(E14B)
2 2
P6
(5) 1
(6)
2
(7) 3
CURRENT
CONTROL
E12B
+
+
-
M1
FAN1
P4 J4
1 1
3
(E15B)
LOGIC AND CONTROL CIRCUITRY
TEST POINTS:
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
CAUTION: SOME PORTIONS OF THE CONTROL/
LOGIC CIRCUITRY ARE CONNECTED TO THE
INPUT LINE. CONNECTION TO A GROUNDED
INSTRUMENT COULD CAUSE A SHOCK
HAZARD OR DESTROY THE POWER SUPPLY.
ACCESS BY AN AUTHORIZED TECHNICIAN ONLY.
MAIN PCB ASSEMBLY
PS1
PRESSURE SW
E
F
A-03405
APPENDIX
1
2
3
A-4
4
Manual 0-4975
cutmaster 39 & 15
5
6
7
8
9
10
MAIN
T3
o
OUTPUT INDUCTOR
PRI
SEC
J8 P8
o
E6
E5
L1
E9
E10
E20
A
(E4)
E4
TORCH
(-)
Q13
D56
D54
C70, 72, 81
C71, 73, 75
Q11
D53
E8
Q12
T
O
R
C
H
(E8)
D55
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
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
COMPDESCRIPTION
TS1
OVER-TEMP. SENSOR
M1FAN, 4.5" 12VDC
PS1PRESSURE SWITCH
SOL1GAS SOLENOID
PFC INDUCTOR
T1
MAIN TRANSFORMER
T3
L1OUTPUT INDUCTOR
SW1
SWITCH, ON/OFF
SW2
SWITCH, RUN/SET
Rev
Revisions
AA REL ECO 100213
AB REL ECO 100333
AC REL ECO 100535
AD
REL ECO B505
By
Date
GCW
GCW
DAT
RWH
7/29/02
5
Manual 0-4975 6
7
8
A-5
D2
C1
D1
D9
A4
E
A7
A8
B2
D1
PCB No:
THERMAL DYNAMICS
Assy No:
INDUSTRIAL PARK
No. 2
WEST LEBANON, NH3784
0 Scale
603-298-57
11
10/04/02
2/27/03
6/19/07
15:05:29
Supersedes
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Tuesday, May 15, 2001
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn:References
NOTE:
GCW
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
Chk:App:
Sheet
1 of 1
TITLE:
Last Modified: Tuesday, June 19, 2007
LOCATION
SCHEMATIC,
CM38 120/208/230V SINGLE PH ASE 50/60 Hz
9
Size
F
DWG No:
C
42X1089
10
A-03405
APPENDIX
CutMaster 39 & 15
This Page Intentionally Blank.
APPENDIX
A-6
Manual 0-4975
GLOBAL CUSTOMER SERVICE CONTACT
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
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 Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
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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