Thermal Dynamics CUTMASTER 39 User manual

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230
PLASMA CUTTING SYSTEM
39
CUTMASTER™
Rev. AA Date: September 17, 2007 Manual # 0-4976
Operating Features:
Service Manual

!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster™ 39
SL60 1Torch™
Service Manual Number 0-4976
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
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 17, 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 Notes, Cautions and Warnings ...................................................................1-1
1.02 Important Safety Precautions .....................................................................1-1
1.03 Publications.................................................................................................1-3
1.04 Note, Attention et Avertissement ................................................................1-3
1.05 Precautions De Securite Importantes.........................................................1-4
1.06 Documents De Reference...........................................................................1-5
1.07 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 Options and Accessories .....................................................2-4
2.07 Torch Specifications....................................................................................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: INSTALLATION ..................................................................................................3-1
3.01 Unpacking...................................................................................................3-1
3.02 Lifting Options.............................................................................................3-1
3.03 Primary Input Power Connections ..............................................................3-2
3.04 Gas Connections ........................................................................................3-3
3.05 Torch Connections ......................................................................................3-5
SECTION 4 SYSTEM:OPERATION .........................................................................................4-1
4.01 Product Features ........................................................................................4-1
4.02 Preparations For Operating ........................................................................4-3
4.03 Sequence of Operation...............................................................................4-7
SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1
4T.01 Introduction ............................................................................................... 4T-1
4T.02 Functional Overview ................................................................................. 4T-1
4T.03 Getting Started ......................................................................................... 4T-1
4T.04 Torch Parts Selection................................................................................ 4T-1
4T.05 Cut Quality ................................................................................................ 4T-2
4T.06 General Cutting Information...................................................................... 4T-3
4T.07 Hand Torch Operation............................................................................... 4T-4
4T.08 Recommended Cutting Speeds................................................................ 4T-7
4T.09 Gouging .................................................................................................... 4T-7

TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE .............................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Common Faults...........................................................................................5-6
5.03 Circuit Fault Isolation ..................................................................................5-6
5.04 Main Input and Internal Power Problems....................................................5-7
5.05 Pilot Arc Problems ......................................................................................5-9
5.06 Main Arc Problems....................................................................................5-10
5.07 Test Procedures........................................................................................5-10
5.08 Anti-Static Handling Procedures...............................................................5-12
5.09 Parts Replacement - General Information ................................................5-13
5.10 Major External Parts Replacement ...........................................................5-13
5.11 Front Panel Parts Replacement ................................................................5-13
5.12 Rear Panel Parts Replacement ................................................................5-15
5.13 Right Side Internal Parts Replacement.....................................................5-16
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 Replacement Assemblies ...........................................................................6-1
6.04 Power Supply Replacement Parts ..............................................................6-1
6.05 Major External Replacement Parts ............................................................6-2
6.06 Front Panel Replacement Parts ..................................................................6-3
6.07 Left Side Replacement Parts .....................................................................6-4
6.08 Right Side Replacement Parts ...................................................................6-5
PATENT INFORMATION ...............................................................................................................
6.09 Options and Accessories ............................................................................6-6
6.10 Torch Consumables ....................................................................................6-6
APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) ........................................ A-1
APPENDIX 2: DATA TAG INFORMATION ............................................................................. A-2
APPENDIX 3: MAIN POWER PC BOARD LAYOUT............................................................... A-3
APPENDIX 4: MAIN PC BOARD WIRING.............................................................................. A-4
APPENDIX 5: TORCH CONNECTOR DIAGRAM .................................................................. A-5
APPENDIX 6: SYSTEM SCHEMATIC.................................................................................... A-6
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

cutmaster 39
Manual 0-4976 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 informa-
tion. These highlights are categorized as follows:
NOTE
An operation, procedure, or background infor-
mation which requires additional emphasis or is
helpful in efficient 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 DAN-
GEROUS 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 cut-
ting process can be dangerous and hazardous to
your health.
• Keep all fumes and gases from the breath-
ing area. Keep your head out of the welding
fume plume.
• Use an air-supplied respirator if ventilation is
not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plas-
ma 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 chlorinated solvents and cleansers.
Remove all sources of these vapors.
• This product, when used for welding or cut-
ting, produces fumes or gases which contain
chemicals known to the State of California to
cause birth defects and, in some cases, can-
cer. (California Health & Safety Code Sec.
25249.5 et seq.)

cutmaster 39
GENERAL INFORMATION 1-2 Manual 0-4976
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 work-
place.
• Never touch any parts that are electrically
“live” or “hot.”
• Wear dry gloves and clothing. Insulate your-
self 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 workplace.
• Do not cut or weld on containers that may
have held combustibles.
• 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 hydro-
gen gas that is ignited will cause an explo-
sion.
NOISE
Noise can cause permanent hearing loss. Plasma
arc processes can cause noise levels to exceed
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 lev-
els.
• For information on how to test for noise, see
item 1 in Subsection 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 fol-
lowing 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.

cutmaster 39
Manual 0-4976 1-3 GENERAL INFORMATION
1.03 Publications
Refer to the following standards or their latest
revisions for more information:
1. OSHA, SAFETYAND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
ments, 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. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION 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 SAFE-
TY-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, obtain-
able fromAmerican National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS StandardA6.0, WELDINGAND CUTTING CON-
TAINERS 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 PRO-
CESSES, 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 Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPAStandard 51B, CUTTINGAND WELDING PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSAStandard W117.2, CODE FOR SAFETYIN WELD-
ING 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 Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDING AND CUTTING OF CONTAIN-
ERSAND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from theAmerican 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classiées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 bles-
sures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.

cutmaster 39
GENERAL INFORMATION 1-4 Manual 0-4976
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. Compo-
sez 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 respira-
tion. 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 fiches de données sur la sécu-
rité 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 au-
tres 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 endom-
magée.
• Prenez des soins particuliers lorsque la zone de tra-
vail 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