Thermal Dynamics CUTMASTER 39 User manual

30 120 208-
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

cutmaster 39
Manual 0-4976 1-5 GENERAL INFORMATION
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 provo-
querl’explosiondefuméesinammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de
la zone de travail.
• 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.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• 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.
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 ocu-
laire.
• Portez des gants de soudeur et un vêtement pro-
tecteur 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 com-
portant 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:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 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.
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
and’éviterunepertepermanentedel’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections au-
riculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• 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, dis-
ponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRA-
TIONS DE COUPE ET DE SOUDAGE, disponible
auprès de la Société Américaine de Soudage (Ameri-
can 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 Superin-
tendent 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

cutmaster 39
GENERAL INFORMATION 1-6 Manual 0-4976
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. NormeANSI 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
7. Norme A6.0 de l’Association Américaine du Soud-
age (AWS), LE SOUDAGE ET LA COUPE DE CON-
TENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de laAmerican
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protec-
tion contre les Incendies (NFPA), LES SYSTEMES À
GAZAVECALIMENTATION 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 NA-
TIONAL, 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 Compri-
més (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 LASÉCURITÉ
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
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUXAY-
ANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126
15. NormeANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

cutmaster 39
Manual 0-4976 1-7 GENERAL INFORMATION
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 17, 2007
This Page Intentionally Blank

cutmaster 39
GENERAL INFORMATION 1-8 Manual 0-4976
This Page Intentionally Blank

cutmaster 39
Manual 0-4976 2-1 INSTALLATION
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Operating Manual applies to just
specication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 dam-
age.
NOTE
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
identication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
2.02 Equipment Identification
Theunit’sidenticationnumber(specication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identied
onlybythespecication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 in-
spect the equipment for possible damage due to
shipping. If there is any damage, notify the car-
rierimmediatelytoleaclaim.Furnishcomplete
information concerning damage claims or ship-
ping errors to the location in your area listed in
the inside back cover of this manual.
Includeallequipmentidentication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.

cutmaster 39
INSTALLATION 2-2 Manual 0-4976
2.04 Power Supply Specifications
CutMaster 39 Power Supply Specications
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 specications 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 lters provide increased ltering 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.

cutmaster 39
Manual 0-4976 2-3 INSTALLATION
Power Supply Dimensions & Weight Ventilation Clearance Requirements
15"
381 mm
12"
305 mm
24"
0.61 m
45 lb / 20.4 kg
Art # A-07924
6"
150 mm
24"
0.6 m
6"
150 mm
6"
150 mm
Art # A-07925
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). Exten-
sion cords must have the same rating as the service and must have a three-pronged plug.

cutmaster 39
INSTALLATION 2-4 Manual 0-4976
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 mobil-
ity 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

cutmaster 39
Manual 0-4976 2T-1 INTRODUCTION
SECTION 2 TORCH:
INTRODUCTION
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 prop-
erlytrainedpersonnel;unqualied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 under-
standing of the characteristics and capabilities of
this equipment will assure the dependable opera-
tion for which it was designed.
2T.02General Description
Plasma torches are similar in design to the auto-
motive 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owsthroughthesmallorice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 second-
arygas.Theairowisdividedinsidethetorch
head. Single - gas operation provides a smaller
sized torch and inexpensive operation.
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 specifi-
cations as related to the Power Supply used.
2T.03Specifications
A. Torch Configurations
1. Hand Torch, Model SL60
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)
Art # A-03322
B. Torch Leads Lengths
Hand Torches are available as follows:
• 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
G. Current Ratings
SL60 Current Ratings
SL60 Torch & Leads Up to 60 Amps, DC,
Straight Polarity
NOTE
Power Supply characteristics will determine mate-
rial thickness range.

cutmaster 39
INTRODUCTION 2T-2 Manual 0-4976
H. Gas Requirements
SL60 Torch Gas Specications
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
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, op-
erating 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 perfor-
mance.
• Deluxe Cutting Guide Kit - Easy add - on
attachments for precise straight line, circle
cutting, and beveling. Includes carrying
case.
• Trigger Guard Kits - These offer additional
protection from accidental activation of the
torch switch.
• Leads Extensions for torches with ATC con-
nectors
• Leather Leads Covers
2T.05Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an ex-
tremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma 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.
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.
A-00002
Workpiece
Power
Supply
+
_
C
B
A
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.
Zone Achannels 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.