Thermal Dynamics CUTMASTER 39 Manuel utilisateur

30 120 208-

230

PLASMA CUTTING SYSTEM

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

(603) 298-5711

www.thermal-dynamics.com

Thermadyne Corporation

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 #:___________________________________ ________________

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.

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