Thermal Dynamics A-08950 User manual

Art # A-08950
380V
400V
415V
40
PLASMA CUTTING SYSTEM
12mm
CUTMASTER™
Rev. AH Date: April 25, 2012 Manual # 0-5077
Operating Features:
Service 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 agency call 1-800-426-
1888, 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 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 ad-
vanced products to achieve a safer working environment within
the welding industry.

!
WARNING
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™ 12mm
SL60 1Torch™
Service Manual Number 0-5077
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2009, 2010, 2011, 2012 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.
Original Publication Date: January 9, 2009
Revision Date: April 25, 2012
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________________
Purchase Date:____________________________________________________
Power Supply Serial #:______________________________________________
Torch Serial #:___________________________________ _________________
i

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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 ................................................................................................1-2
1.04 Note, Attention et Avertissement ................................................................1-3
1.05 Precautions De Securite Importantes .........................................................1-3
1.06 Documents De Reference ..........................................................................1-5
1.07 Declaration of Conformity ...........................................................................1-6
1.08 Statement of Warranty................................................................................1-7
SECTION 2 SYSTEM: INTRODUCTION ................................................................................2-1
2.01 How To Use This Manual ...........................................................................2-1
2.02 Equipment Identification .............................................................................2-1
2.03 Receipt Of Equipment.................................................................................2-1
2.04 Power Supply Specifications ......................................................................2-2
2.05 Input Wiring Specifications .........................................................................2-3
2.06 Power Supply Features ..............................................................................2-4
SECTION 2 TORCH: INTRODUCTION ................................................................................2T-1
2T.01 Scope of Manual......................................................................................2T-1
2T.02 General Description.................................................................................2T-1
2T.03 Specifications ..........................................................................................2T-1
2T.04 Options And Accessories.........................................................................2T-2
2T.05 Introduction to Plasma.............................................................................2T-2
SECTION 3 SYSTEM: INSTALLATION ..................................................................................3-1
3.01 Unpacking...................................................................................................3-1
3.02 Lifting Options.............................................................................................3-1
3.03 Primary Input Power Connections ..............................................................3-1
3.04 Gas Connections ........................................................................................3-2
SECTION 3 TORCH: INSTALLATION ...................................................................................3T-1
3T.01 Torch Connections...................................................................................3T-1
3T.02 Setting Up Mechanical Torch...................................................................3T-1
SECTION 4 SYSTEM: OPERATION.......................................................................................4-1
4.01 Front Panel Controls / Features..................................................................4-1
4.02 Preparations for Operation .........................................................................4-2
SECTION 4 TORCH: OPERATION........................................................................................4T-1
4T.01 Torch Parts Selection ..............................................................................4T-1
4T.02 Cut Quality...............................................................................................4T-1
4T.03 General Cutting Information.....................................................................4T-2
4T.04 Hand Torch Operation .............................................................................4T-3
4T.05 Gouging ...................................................................................................4T-6
4T.06 Mechanized Torch Operation ..................................................................4T-7
4T.07 Parts Selection for Manual and Mechanized Torch Cutting.....................4T-9
4T.08 Recommended Cutting Speeds for SL60 Torch With Exposed Tip.......4T-10
4T.09 Recommended Cutting Speeds for SL60 Torch With Shielded Tip.......4T-11
PATENT INFORMATION .....................................................................................................4T-12

TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE.............................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Maintenance Schedule ...............................................................................5-2
5.03 Common Faults ..........................................................................................5-2
5.04 Fault Indicator.............................................................................................5-3
5.05 Basic Troubleshooting Guide......................................................................5-4
5.06 Power Supply Basic Parts Replacement ....................................................5-6
5.07 Circuit Fault Isolation ..................................................................................5-8
5.08 Main Input and Internal Power Problems..................................................5-11
5.09 Pilot Arc Problems ....................................................................................5-15
5.10 Main Arc and Controls Problems ..............................................................5-17
5.11 CNC Interface Problems...........................................................................5-17
5.12 Test Procedures .......................................................................................5-18
5.13 Capacitor PCB Layout & Signals..............................................................5-20
5.14 Logic PCB Layout & Signals.....................................................................5-22
5.15 Main PCB Layout & Signals......................................................................5-26
5.16 Main PCB Wiring Diagram........................................................................5-28
SECTION 5 TORCH: SERVICE.............................................................................................5T-1
5T.01 General Maintenance ..............................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts ......................5T-2
SECTION 6: PARTS LISTS......................................................................................................6-1
6.01 Introduction.................................................................................................6-1
6.02 Ordering Information...................................................................................6-1
6.03 Power Supply Replacement .......................................................................6-1
6.04 Major External Replacement Parts .............................................................6-2
6.05 Front Panel Replacement Parts..................................................................6-3
6.06 Left Side Replacement Parts .....................................................................6-4
6.07 Right Side Replacement Parts ...................................................................6-5
6.08 Options and Accessories............................................................................6-6
6.09 Replacement Parts for Hand Torch ...........................................................6-7
6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads ......6-8
6.11 Torch Consumable Parts Manual and Mechanized Torches....................6-10
SECTION 7: REPLACEMENT PROCEDURES ......................................................................7-1
7.01 Scope..........................................................................................................7-1
7.02 Anti-Static Handling Procedures.................................................................7-1
7.03 Parts Replacement - General Information ..................................................7-1
7.04 Major External Parts ..................................................................................7-2
7.05 Front Panel Parts Replacement..................................................................7-3
7.06 Left Side Internal Parts Replacement.........................................................7-4
7.07 Rear Panel Parts Replacement ..................................................................7-5
7.08 Right Side Internal Parts Replacement.......................................................7-7

TABLE OF CONTENTS
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)....................................... A-1
APPENDIX 2: DATA TAG INFORMATION ............................................................................ A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS...................................................................... A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS .............................................................. A-4
APPENDIX 5: SYSTEM SCHEMATIC, 380/400/415V UNITS ............................................... A-6
APPENDIX 6: Publication History........................................................................................... A-8
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ...................................Rear Cover

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CUTMASTER 12mm
Manual 0-5077 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.
WARNING
Gives information regarding possible electrical shock
injury. Warnings will be enclosed in a box such as this.
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
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.
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.

CUTMASTER 12mm
GENERAL INFORMATION 1-2 Manual 0-5077
• Ventilateallammableorexplosivevaporsfromtheworkplace.
• Donotcutorweldoncontainersthatmayhaveheldcombus-
tibles.
• 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.
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.
• 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perANSI/
ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 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.
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.)
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Ofce,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Ofce,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 CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS 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
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 As-
sociation, 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,RECOM-
MENDED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PRO-
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018