Thermal Dynamics 42 CUTMASTER User manual

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

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
provider visit us on the web at www.cigweld.com.au (Asia
Pacific) www.thermal-dynamics.com (Americas and Europe).
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 market-
leading, 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, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster™ 42
SL40 Torch™
Operating Manual Number 0-5141
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2010, 2011 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 negli-
gence, accident, or any other cause.
Printed in the United States of America
Publication Date: October 15, 2010
Revision AD Date: November 22, 2011
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________________
Purchase Date:____________________________________________________
Power Supply Serial #:______________________________________________
Torch Serial #:___________________________________ _________________
i

TABLE OF CONTENTS

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ................................................................................. 1-1
1.02 Important Safety Precautions................................................................................... 1-1
1.03 Publications.............................................................................................................. 1-3
1.04 Note, Attention et Avertissement.............................................................................. 1-4
1.05 Precautions De Securite Importantes....................................................................... 1-4
1.06 Documents De Reference......................................................................................... 1-6
1.07 Declaration of Conformity......................................................................................... 1-7
1.08 Statement of Warranty ............................................................................................. 1-8
SECTION 2 SYSTEM:
INTRODUCTION .............................................................................................................................. 2-1
2.01 Working Principle..................................................................................................... 2-1
2.02 Power Supply Specifications.................................................................................... 2-1
2.03 Input Wiring Specifications ...................................................................................... 2-2
2.04 Power Supply Features............................................................................................. 2-3
2.05 Torch Specifications ................................................................................................. 2-4
SECTION 2TORCH:
INTRODUCTION ............................................................................................................................ 2T-1
2T.01 Scope of Manual..................................................................................................... 2T-1
2T.02 Specifications ........................................................................................................ 2T-1
2T.03 Introduction to Plasma........................................................................................... 2T-2
SECTION 3:
INSTALLATION ................................................................................................................................ 3-1
3.01 Unpacking ................................................................................................................ 3-1
3.02 Lifting Options.......................................................................................................... 3-1
3.03 Primary Input Power Connections............................................................................ 3-2
SECTION 4 SYSTEM:
OPERATION ..................................................................................................................................... 4-1
4.01 Control Panel............................................................................................................ 4-1
4.02 Preparations For Operating....................................................................................... 4-2
4.03 Sequence of Operation ............................................................................................. 4-4
4.04 Cut Quality................................................................................................................ 4-6
4.05 General Cutting Information ..................................................................................... 4-7
SECTION 5 SYSTEM: SERVICE ................................................................................................................. 5-1
5.01 General Maintenance................................................................................................ 5-1
5.02 Basic Troubleshooting Guide.................................................................................... 5-2
SECTION 5 TORCH:
SERVICE........................................................................................................................................ 5T-1
5T.01 General Maintenance.............................................................................................. 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts....................................... 5T-1

TABLE OF CONTENTS
SECTION 6:
PARTS LISTS................................................................................................................................... 6-1
6.01 Introduction.............................................................................................................. 6-1
6.02 Power Supply Replacement Parts ............................................................................ 6-2
APPENDIX 1:
CIRCUIT DIAGRAM..........................................................................................................................A-1

CUTMASTER 42
Manual 0-5141 1-1 GENERAL INFORMATION
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:
NOTE
An operation, procedure, or background information
which requires additional emphasis or is helpful in ef-
ficient operation of the system.
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.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnet-
ic 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 equip-
ment to determine whether a hazard exists.
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.
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.
• Useanair-suppliedrespiratorifventilationisnotadequateto
remove all fumes and gases.
• Thekindsoffumesandgasesfromtheplasmaarcdependon
the kind of 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:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• AlwaysreadtheMaterialSafetyDataSheets(MSDS)thatshould
be supplied with the material 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.
• 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.
• Usespecialequipment,suchaswaterordowndraftcutting
tables, to capture fumes and gases.
• 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chlo-
rinated solvents and cleansers. Remove all sources of these
vapors.
• 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.)
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.
• Nevertouchanypartsthatareelectrically“live”or“hot.”
• Weardryglovesandclothing.Insulateyourselffromthework
piece or other parts of the welding circuit.
• Repairorreplaceallwornordamagedparts.
• 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.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma
arc.
• Besurethereisnocombustibleorammablematerialinthe
workplace. Any material that cannot be removed must be
protected.
• Ventilate all ammable or explosive vapors from the work-
place.
• Donotcutorweldoncontainersthatmayhaveheldcombus-
tibles.

CUTMASTER 42
GENERAL INFORMATION 1-2 Manual 0-5141
• Providearewatchwhenworkinginanareawherere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.
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.
• Toprotectyourhearingfromloudnoise,wearprotectiveear
plugs and/or ear muffs. Protect others in the workplace.
• Noiselevelsshouldbemeasuredtobesurethedecibels(sound)
do not exceed safe levels.
• Forinformationonhowtotestfornoise,seeitem1inSubsec-
tion 1.03, Publications, in this manual.
LEAD WARNING
This product contains chemicals, including lead, or otherwise
produces chemicals known to the State of California to cause
cancer, birth defects and other reproductive harm. Wash hands
after handling. (California Health & Safety Code § 25249.5 et seq.)
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infrared 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.
• Wearweldingglovesandsuitableclothingtoprotectyourskin
from the arc rays and sparks.
• Keephelmetandsafety glassesingood condition.Replace
lenses when cracked, chipped or dirty.
• Protectothersintheworkareafromthearcrays.Useprotective
booths, screens or shields.
• Usetheshadeoflensassuggestedinthefollowingchart.
NOTE
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.
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
(from AWS F2.2, Lens Shade Selector)
Shade numbers are given as a guide only and may be varied to suit individual needs.
Process Electrode Size in. (mm) Arc Current (Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Shielded Metal Arc Welding (SMAW)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Less than 60
60-160
160-250
250-550
7
8
10
11
-
10
12
14
Gas Metal Arc Weding (GMAW) and
Flux Cored Arc Welding (FCAW)
Less than 60
60-160
160-250
250-550
7
10
10
10
-
11
12
14
Gas Tungsten arc Welding (GTAW) Less than 50
50-150
150-500
8
8
10
10
12
14
Air Carbon Arc Cutting (CAC-A) (Light)
(Heavy) Less than 500 500-1000 10 11 12 14
Plasma Arc Welding (PAW)
Less than 20
20-100
100-400
400-800
6
8
10
11
6 to 8
10
12
14
Plasma Arc Cutting (PAC)
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade
which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding,
cutting,orbrazingwherethetorchand/ortheuxproducesahighyellowlight,itisdesirabletousea
filter lens that absorbs the yellow or soduim line of the visible light spectrum.
Table 1-1

CUTMASTER 42
Manual 0-5141 1-3 GENERAL INFORMATION
1.03 Publications
Refer to the following standards or their latest revisions for more
information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtain-
able from the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, ob-
tainable 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
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
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 WELD-
ING, CUTTING AND ALLIED PROCESSES, obtainable from the
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269
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, Bat-
terymarch 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
14. American Welding Society Standard AWSF4.1, RECOMMENDED
SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZ-
ARDOUS SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTEC-
TION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018

CUTMASTER 42
GENERAL INFORMATION 1-4 Manual 0-5141
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.
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.
!
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.
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 pro-
fessionel 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 avertisse-
ments, 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.
• Eloigneztoutefuméeetgazdevotrezonederespiration.Gardez
votre tête hors de la plume de fumée provenant du chalumeau.
• Utilisezunappareilrespiratoireàalimentationenairsil’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
•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 cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Liseztoujourslesches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 rensei-
gnements 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.
• Netouchezjamaisunepièce“soustension”ou“vive”;portezdes
gants et des vêtements secs. Isolez-vous de la pièce de travail ou
des autres parties du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendommagée.
• 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.