Thermal Dynamics CUTMASTER User manual

Art # A-08797_AB
380V
400V
415V
PLASMA CUTTING SYSTEM
40mm
CUTMASTER™
Rev. AK Date: April 25, 2012 Manual # 0-5085
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™ 40mm
SL100 1Torch™
Service Manual Number 0-5085
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2008, 2009, 2010, 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 negligence, accident, or any other cause.
Publication Date: December 9, 2008
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-2
4T.03 General Cutting Information......................................................................4T-2
4T.04 Hand Torch Operation ..............................................................................4T-3
4T.05 Gouging ....................................................................................................4T-7
4T.06 Mechanized Torch Operation ...................................................................4T-8
4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip......4T-10
4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip......4T-15

TABLE OF CONTENTS
PATENT INFORMATION .....................................................................................................4T-20
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......................................................................5-6
5.06 Circuit Fault Isolation ..................................................................................5-8
5.07 Main Input and Internal Power Problems..................................................5-12
5.08 Pilot Arc Problems ....................................................................................5-16
5.09 Main Arc and Controls Problems ..............................................................5-19
5.10 CNC Interface Problems...........................................................................5-20
5.11 Test Procedures .......................................................................................5-20
5.12 Main PCB Layout & Signals......................................................................5-26
5.13 Capacitor PCB Layout & Signals..............................................................5-30
5.14 Logic PCB Layout & Signals.....................................................................5-32
5.15 40AMP Logic PCB Layout & Signals........................................................5-34
5.16 Right Side Wiring Diagram .......................................................................5-36
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 Machine Torches with Unshielded Leads ............6-8
6.11 Replacement Shielded Machine Torch Leads Assemblies ......................6-10
6.12 Torch Consumable Parts (SL100 SV) ......................................................6-11
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 ..................................................................7-6
7.08 Right Side Internal Parts Replacement.......................................................7-8

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, 380-415V UNITS...................................................... A-6
APPENDIX 6: PUBLICATION HISTORY ............................................................................... A-8
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ...................................Rear Cover

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CUTMASTER 40mm
Manual 0-5085 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 informa-
tion which requires additional emphasis or is help-
ful 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 op-
erating 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 HAZARD-
OUS 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.

CUTMASTER 40mm
GENERAL INFORMATION 1-2 Manual 0-5085
• 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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