Plasma Cutting

System
CutMaster TM 38 Power Supply
SL60 Air Plasma Cutting Torch
A-03286

Operating Manual
June 6, 2003 Manual No. 0-2888
 WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-
ating, 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 System

CutMasterTM 38 Power Supply

Model SL60 Air Plasma Cutting Torch

Operating Manual Number 0-2888

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711

www.thermal-dynamics.com

Copyright 2002 by
Thermal Dynamics 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: June 6, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

World Leader in Plasma Cutting Technology
Professors James Browning and Merle Thorpe of the Thayer School of Engineering at Dartmouth
College, Hanover, NH., incorporated Thermal Dynamics in 1957. The two men had developed a
high - temperature electric - arc metallizing torch that led to the development of a plasma torch.
The fledgling company was housed in a garage in nearby Wilder, VT. In 1960, Thermal Dynamics
relocated to a plant in Lebanon, NH. By this time, company sales had grown to about $1 million,
largely in the areas of plasma - spraying and plasma - cutting equipment. The company designed
and built several very - high - power research systems for the NASA space program; these systems
were used to simulate re - entry conditions for Project Mercury and other space programs.

Covering the full range of plasma - cutting applications

In 1968, Professor Browning sold his interest in the company to a group of investors headed by Bradley
Dewey Jr., who became chairman and C.E.O. Under Dewey’s guidance, Thermal Dynamics concen-
trated its efforts on plasma - cutting and welding equipment. The company introduced progressively
smaller and easier to operate plasma - cutting systems to an eager market; the first system, introduced in
1970, was the PAK 40, a 400 - amp cutting system. Other key product introductions included the PAK
20, a “Low Amp” plasma cutting system produced in 1972 that brought affordability and portability to
the industry. The PAK 10, introduced in 1977, was the first plasma - cutting system that did not require
water cooling for the torch. In 1977, the Pacific Lumber Company (Palco) acquired Thermal Dynamics.
The company continued to pioneer the trend toward smaller, easier to run, reliable plasma - cutting
equipment. Thermadyne then acquired the company in 1987.

Today, Thermal’s innovative and performance proven products are the plasma cutting systems of choice
for hand held or automated cutting needs. Thermal plasma arc cutting systems can be used to cut
virtually any material, light gauge to 4" (9.6 cm) thick, and range from highly portable 110V units for
HVAC work to the most sophisticated high speed, high definition plasma cutting systems for precision
fabrication. Thermal Dynamics manufacturing operations remain headquartered in West Lebanon, NH.

Thermal Dynamics is an ISO 9001 registered company.

How to contact us:
· Call us: 603-298-5711
· E-mail info: TDCSales@Thermadyne.com
· Write: Thermal Dynamics Corp., 82 Benning Street, West Lebanon, NH 03784
· Fax: 603-298-5720
· Thermal Dynamics website: www.Thermal-Dynamics.com
 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
1.07 Declaration of Conformity ............................................................................. 1-5
1.08 Statement of Warranty .................................................................................. 1-6

SECTION 2: SPECIFICATIONS ............................................................................................... 2-1

Options and Accessories ..................................................................................... 2-2
Torch Specifications ............................................................................................. 2-3

SECTION 3: INSTALLATION .................................................................................................... 3-1

3.1 Unpacking .................................................................................................... 3-1
3.2 Lifting Options .............................................................................................. 3-1
3.3 Primary Input Power Connections ................................................................ 3-2
3.4 Gas Connections ......................................................................................... 3-3
3.5 Torch Connections ....................................................................................... 3-6

SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating .......................................................................... 4-3
4.03 Sequence of Operation ................................................................................ 4-8

SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance ................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-5
5.03 Basic Troubleshooting Guide ........................................................................ 5-6

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 Options and Accessories ............................................................................. 6-2
6.06 Torch Consumables ..................................................................................... 6-2

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ......................................... A-1

APPENDIX 2: DATA TAG INFORMATION ................................................................................. A-2

APPENDIX 3: SYSTEM SCHEMATIC ....................................................................................... A-4

 SECTION 1:
GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background information 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

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ-
ARDOUS 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 deter-
mine 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 Beryllium
Arsenic Cobalt Nickel Lead
Barium Copper Selenium Silver
Cadmium Manganese Vanadium

Date: Nov. 15, 2001 1-1 GENERAL INFORMATION

 • 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 cutting, produces fumes or gases which contain chemicals known to
the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec.
25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed
must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire 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 Subsection 1.03, Publications, in this manual.

GENERAL INFORMATION 1-2 Date: Nov. 15, 2001

 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.

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 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. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, 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 CUTTING AND WELDING PROCESSES, obtainable
from American National Standards Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtain-
able 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, obtain-
able 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 Associa-
tion, 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 Stan-
dards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

Date: Nov. 15, 2001 1-3 GENERAL INFORMATION

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, RECOMMENDED 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 PROTECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-4 Date: Nov. 15, 2001

1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

Date: Nov. 15, 2001 1-5 GENERAL INFORMATION

1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal 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 customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective November 15, 2001

GENERAL INFORMATION 1-6 Date: Nov. 15, 2001

 SECTION 2: SPECIFICATIONS
CutMaster 38 Power Supply Specifications
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 38 Power Supply Duty Cycle (Note 2)
Ambient Temperature 104° F (40° C)
Duty Cycle 35% 60% n/a %
DC Voltage 78 vdc 89 vdc n/a vdc
Current 30 Amps 22 Amps n/a Amps

SL 60 Torch Gas Requirements

Gas Type Compressed Air
Gas specifications 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 filters provide increased filtering capabilities.

A-03378

15.75"
6"
400 mm 150 mm

6"
150 mm
6" 6"
21" 150 mm 150 mm
0.53 m
10" A-03379

254 mm
CAUTION
43 lb / 19.5 kg
Provide clearance for proper air flow through
Weight includes torch & leads, input power cord, the power supply. Operation without proper
and work cable with clamp. air flow will inhibit proper cooling and reduce
duty cycle.

Manual 0-2888 2-1 SPECIFICATIONS

Electrical Requirements

CutMaster 38 Input P ower R equirements

Input P ower Input Current Input S uggested S izes (S ee Notes)
Voltage Freq. (kVA) (Amps) F use (Amps) W ire (AW G) W ire (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.
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). Extension
cords must have the same rating as the service and must have a three-pronged plug.

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 mobility 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.

SPECIFICATIONS 2-2 Manual 0-2888

Torch Specifications
The Torch provides cutting capacity of up to 3/8 inch / 9.5 mm at 30 amperes.
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) 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)

SL60 Torch Ratings

Ambient 104° F
Temperature (40° C)
Duty Cycle 100% @ 60 Amps @ 400 scfh
Maximum Current 60 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 7kV

NOTE
Ratings shown apply to the SL60 Torch only. Refer to the Specifications chart on page 2-1 for CutMaster 38 data.
F. Plasma Power Supply Used With
• Thermal Dynamics CutMaster 38

Manual 0-2888 2-3 SPECIFICATIONS

SPECIFICATIONS 2-4 Manual 0-2888
 SECTION 3: INSTALLATION

3.1 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping
company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information
block at the front of this manual.

3.2 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNINGS

Do not touch live electrical parts.

Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Manual 0-2888 3-1 INSTALLATION

3.3 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. The primary power source,
fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and
wiring requirements as specified in Section 2.
Power Cord and Plug
This power supply includes an input power cord and plug suitable for 120 VAC, 20 Amp, Single - Phase input
power.

A-03382 120 V, 20A, 1Ø

For 208 / 230 VAC input power, replace the supplied power plug. Use only an approved replacement input power
plug with ground.

Replace the plug as follows:

1. Cut the original cord close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according to the plug manufacturer's instructions. All three conductors
must be connected to the plug.
Connect the input power cord as follows:
1. Check the power source for correct voltage before plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

INSTALLATION 3-2 Manual 0-2888

3.4 Gas Connections
A. Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure gas cylinders. Refer to subsection 3.4-C if an optional
air line filter is to be installed.
1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the torch.

Min. 1/4 inch

6.4 mm

A-03272

Gas Connection to Inlet Port

B. Check Air Quality

To test the quality of air, put the RUN / SET switch in the SET (down) position, place a welding filter lens in front of
the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens. Do not start an arc!

A
26
28

24

22

20 30
A-03385

Manual 0-2888 3-3 INSTALLATION

C. Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of
the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the gas line to the Filter. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the torch.
Connect as follows:

Filter Hose

Single-Stage
Filter Kit
No. 7-7507

Hose
Clamp
1/4 NPT
Hose Fitting
Gas Supply Hose A-03281

Optional Single - Stage Filter Installation

INSTALLATION 3-4 Manual 0-2888

D. Using High Pressure Gas Cylinders
When using high pressure gas cylinders as the gas supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas
regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open
each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100
psi (6.9 bar) maximum and flows of at least 300 scfh (141.5 lpm).
4. Connect gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the torch.

Manual 0-2888 3-5 INSTALLATION

3.5 Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 Torch to this
power supply.

WARNING

Disconnect primary power at the source before connecting the torch.

1. Align the male connector (on the torch lead) with the female receptacle on the power supply. Press the
connector into the receptacle fully.
2. Turn the locking ring on the male connector fully clockwise until it clicks.

A-03380

Connecting the Torch to the Power Supply

3. The system is ready for operation.

INSTALLATION 3-6 Manual 0-2888

 SECTION 4:
OPERATION

4.01 Product Features

A. General Features

Gas Pressure Knob Handle and Leads Wrap

Torch Leads
Connector

Control Panel

Work Cable
A-03287
and Clamp

Manual 0-2888 4-1 OPERATION

B. Control Panel

4
2
5

1 A 6
26
28 7
24
3
22

20 30
A-03283

1. ON / OFF Switch
Controls input power to the power supply. Up is ON, down is OFF.
2. RUN / SET Switch
RUN (up) position is for general torch operation. SET (down) position is for setting gas pressure and purging
lines.
3. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit
opens frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate
input power. Refer to Section 2 for input power requirements.
4. AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective interlock
mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to Section 5
for details.

5. TEMP Indicator

Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Shut unit OFF; let
the unit cool before continuing operation.

6. GAS Indicator

Indicator is ON when adequate input gas pressure is present.

7. DC Indicator
Indicator is ON when DC output circuit is active.

OPERATION 4-2 Manual 0-2888

4.02 Preparations For Operating
At the start of each operating session:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and
leads assemblies.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type
of operation, and with the amperage output of this Power Supply (30 amps maximum). Use only genuine Ther-
mal Dynamics parts with this torch.

A-03409

Large O-Ring,
Cat. No. 8-3487

Small O-Ring,
Cat. No. 8-3486

Electrode, Cat. No. 9-8215

Starter Cartridge,
Cat. No. 9-8213

30Amp Cutting Tip, Cat. No. 9-8206

Shield Cup, Cat. No. 9-8218

Worn Electrode
Worn Tip

NOTE
When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield
cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components
may result.

Manual 0-2888 4-3 OPERATION

B. Torch Connection
Check that the torch is properly connected.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power re-
quirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure gas source meets requirements (refer to Section 2). Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect
only to the main part of the workpiece; do not connect to the part to be cut off.

A-03387

OPERATION 4-4 Manual 0-2888

F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on.

A
26
28

24

22

20 30
A-03384

G. Set Operating Pressure

Place the Power Supply RUN / SET switch to the SET (down) position. Gas will flow. Adjust gas pressure to 65

psi / 4.5 bar. Gas indicator turns on.

65 psi / 4.5 bar

A
26
28

24

22

20 30
A-03385

A-03389

Manual 0-2888 4-5 OPERATION

H. Select Current Output Level
Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level.

A
26
28

24

22

20 30
A-03386

I. Cutting Operation
Refer to Section 1, Important Safety Precautions. Wear heavy welding gloves and protective clothing. Protect
eyes with appropriate shielding. Aim the torch head away from yourself. Slide the trigger release to the rear.
Squeeze and hold the trigger. Gas flows for approximately 1 second, then shuts off briefly. The pilot arc then
starts. DC indicator turns on. Bring the torch within transfer distance to the workpiece. The pilot arc stops
and the main arc transfers to the workpiece.
NOTE
When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield
cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components
may result.

Trigger

1
2

Trigger Release

A-03383

OPERATION 4-6 Manual 0-2888

J. Cutting Technique
Hold the torch with one or two hands, with the torch tip close to the workpiece. Do not cut or handle the
workpiece without welding gloves and protective clothing. Always wear protective eye shielding when cutting
or gouging. Move the torch along the cut line so the arc penetrates the workpiece and sparks emerge from the
bottom of the cut. Good cutting speeds create a slight trailing arc.
K. Typical Cutting Speeds
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds shown
are typical for this cutting system using air plasma to cut mild steel, with output current at 30 amps and torch
held at 0 - 1/16" (0 - 1.6 mm) standoff.
e

ch
ag

In
G

A-03381
12.7 0.5

0.4
9.5 0.375
MATERIAL THICKNESS

0.35
8 Typical Cutting Speeds
0.3 Air Plasma on Mild Steel
7
6 0.25
6 5 0.2
4 0.15
3 0.1
12
2
18 1 0.05
20 24
Inches 10 20 40 60 80 100 120 140 160 180 200 220 240 400
Meters 0.25 0.5 1.00 1.5 2.0 2.5 3.05 3.5 4.06 4.57 5.08 5.56 6.1 10.1
Inches/ Meters per Minute
CUTTING SPEED

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, using a
template or cutting guide while still producing cuts of excellent quality.
L. Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 10 seconds. During post -
flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc
transfers to the workpiece if the torch tip is within transfer distance to the workpiece.
M. Shutdown
Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord
or disconnect input power. Power is removed from the system.

Manual 0-2888 4-7 OPERATION

4.03 Sequence of Operation
The following is a typical sequence of operation for this power supply. Refer to Appendix 1 for block diagram.
1. Plug the input power cord into an active circuit.
a. AC power is available at the Power Supply.
2. Place the ON / OFF switch on the Power Supply to ON (up) position.
a. AC indicator turns on; fan turns on.
NOTES
If there is adequate gas supply pressure to the power supply, gas comes on if Torch Trigger is pressed.
If torch trigger is held while user turns on main AC power, system goes into 'protective interlock' mode. AC
indicator flashes; torch will not pilot. Release torch trigger, turn AC switch OFF then ON.
3. Put RUN / SET switch to SET (down position).
a. Gas flows to set pressure. Turn gas pressure adjustment knob to set pressure to 65 psi / 4.5 bar; Gas

indicator turns ON when there is sufficient gas pressure.

4. Put RUN / SET switch to RUN (up position). Gas flow stops.
5. Wear protective clothing and welding gloves. Protect eyes. Slide the trigger release to the rear; squeeze and
hold the trigger. Gas flows briefly, then shuts off momentarily. Then gas flow will resume. Pilot arc is estab-
lished. DC indicator turns ON. Move Torch within transfer distance of workpiece.
a. Main arc transfers to workpiece.
6. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc will
automatically restart.
7. Release the torch trigger.
a. Main arc stops; gas flows for approximately 10 seconds.
8. Set the power supply ON / OFF switch to OFF (down position).
a. AC indicator turns OFF; fan turns OFF.
9. Set the main power disconnect to OFF, or unplug input power cord.
a. Input power is removed from the system.

OPERATION 4-8 Manual 0-2888

 SECTION 5:
SERVICE

5.01 General Maintenance

A. Each Use
Check torch consumables for wear, replace if necessary.

WARNING

Shut off power before inspecting or removing torch parts.

NOTE
When operating the torch in a normal condition, a
small amount of gas vents through the gap between the
shield cup and torch handle. Do not attempt to over
tighten the shield cup as irreparable damage to internal
components may result.

A-03409

Large O-Ring,
Cat. No. 8-3487

Small O-Ring,
Cat. No. 8-3486

Electrode, Cat. No. 9-8215

Starter Cartridge,
Cat. No. 9-8213

30Amp Cutting Tip, Cat. No. 9-8206

Shield Cup, Cat. No. 9-8218

Worn Electrode
Worn Tip

Manual 0-2888 5-1 SERVICE

B. Every three months
A. Check internal air filter, replace if necessary.
1. Shut off input power; turn off the gas supply. Bleed down the gas supply.
2. Remove the upper cover screws.
3. Loosen the lower screws. Pull the cover up and away from the unit.
NOTE
Leave internal ground wire in place.

Upper screws

Upper screws

Ground
wire

Lower screws

A-03285

Cover Removal

SERVICE 5-2 Manual 0-2888

4. Pull the upper end of the drain tube off the fitting on the filter bowl.
5. Unscrew the bowl. The filter element will be visible and still attached to the main body of the Regulator / Filter.
6. Unscrew the filter element from the Regulator / Filter body. The filter element will come off with a spool and some
additional pieces.
7. Note the correct assembly of the filter / spool then remove the filter from the spool and either clean it or replace it.
8. Screw the filter element and spool, with the baffle ring in place (teeth facing downward) back into the Regulator
body by compressing the spring on the spool. Tighten firmly by hand.

Ring
Replacement
Element
No. 9-4414

Spool

Bowl

A-03377

Regulator / Filter Element Replacement

9. Clean the inside of the bowl if necessary. Check that the knurled valve on the bottom of the bowl is fully open.
10. Reinstall the bowl. Reconnect the drain tube.
11. Reinstall the cover as follows:
a. Reconnect the ground wire, if necessary.
b. Set the cover onto the base so that it rests on the lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the upper screws.
12. Turn on the air supply.

Manual 0-2888 5-3 SERVICE

B. Check Optional Single - Stage Filter Element, replace if necessary.
1. Shut off input power.
2. Shut off air supply, bleed down system.
3. Disconnect gas supply hose from filter.
4. Turn the Cover counter - clockwise.
5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply hose. If unit leaks between housing and cover, inspect the "O" Ring for cuts or other damage.

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
Assembled Filter

Cover

Barbed
Fitting A-02476

SERVICE 5-4 Manual 0-2888

5.02 Common Faults
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non - Genuine Thermal Dynamics parts used
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f. Non - Genuine Thermal Dynamics parts used
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non - Genuine Thermal Dynamics parts used
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Gas pressure too low
e. Improperly assembled torch
f. Non - Genuine Thermal Dynamics parts used
5. Difficult Starting
a. Worn torch parts
b. Non - Genuine Thermal Dynamics parts used

Manual 0-2888 5-5 SERVICE

5.03 Basic Troubleshooting Guide

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair
unless you have had training in power electronics measurement and troubleshooting techniques.

A. Basic Troubleshooting: Overview

This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this
system. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for this prod-
uct.
B. How to Use This Guide
The following information will help the Customer / Operator determine the most likely causes for various symptoms.
Follow all instructions as listed and complete each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions
1. Cause
a. Check / Remedy
Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that
unit operates properly after any repairs.
C. Common Symptoms
A. AC indicator OFF
1. Switch at customer's main power panel in OFF (open) position.
a. Close main power switch.
2. Power Supply ON / OFF switch in OFF position.
a. Turn switch to ON.
3. Customer's main power line fuse(s) or circuit breaker(s) blown
a. Check main power panel fuse(s) and replace as required.
4. Actual input voltage does not correspond to voltage of unit
a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.

SERVICE 5-6 Manual 0-2888

B. AC indicator flashing; Torch cannot be activated
1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.)
a. Release torch trigger, set ON / OFF switch to OFF (down). Return ON / OFF switch to ON (up) position.

2. System is in protective interlock mode. (Torch parts are missing or loose.)

a. Release torch trigger, and set ON / OFF switch to OFF (down). Open main disconnect switch. Check torch
parts, including O - rings on torch head. Refer to illustration on page 5 - 1. Replace parts as needed. Reinstall
shield cup; hand - tighten it securely against the torch head. Close main disconnect switch. Set ON / OFF
switch to ON (up) position.
3. System is in protective interlock mode. (User removed shield cup from torch while power supply ON / OFF switch was
ON.)
a. Release torch trigger, and set ON / OFF switch to OFF (down). Set ON / OFF switch to ON (up).

C. Torch will not pilot; DC indicator and GAS indicator flash alternately when torch trigger is activated

1. Gas pressure is too low. Adjust gas pressure to 65 psi / 4.5 bar.

D. AC indicator flashing; Temp indicator ON

1. Fan disconnected or blocked.

a. Clear fan if blocked; let power supply cool.

E. AC indicator ON; TEMP indicator ON

1. Air flow blocked

a. Check for blocked air flow around the unit and correct condition.
2. Fan blocked
a. Check and correct condition.
3. Unit is overheated
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to duty cycle data in Section 2.
4. Input line voltage is below 100 Volts
a. Check and connect to proper input power line.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.

Manual 0-2888 5-7 SERVICE

F. Torch will not pilot when torch switch is activated
1. System is in SET mode
a. Change to RUN mode.
2. Upper O-ring on torch head is in wrong position.
a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.

A-03640

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring Threads

in Correct Groove Lower O-Ring

3. Faulty torch parts

a. Inspect torch parts and replace if necessary.
4. Gas pressure too high or too low
a. Adjust to proper pressure.
5. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
G. No cutting output; Torch activated; AC indicator ON; Gas flows; Fan operates
1. Torch not properly connected to power supply
a. Check that torch leads are properly connected to power supply.
2. Work cable not connected to work piece, or connection is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Shield cup not properly installed on torch
a. Open main disconnect switch. Check that shield cup is fully seated against torch head. Set ON / OFF switch
to OFF, check shield cup, close main disconnect switch, turn power supply ON, and try cutting.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
5. Faulty Torch
a. Return for repair or have qualified technician repair.

SERVICE 5-8 Manual 0-2888

H. Low cutting output
1. Incorrect setting of CURRENT (A) control
a. Check and adjust to proper setting.
2. Faulty components in unit
a. Return for repair or have qualified technician repair.
I. Limited output with no control
1. Poor input or output connections
a. Check all input and output connections.
2. Work cable connection to work piece is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
J. Erratic or improper cutting output
1. Poor input or output connections
a. Check all input and output connections.
2. Poor work cable connection
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
3. Fluctuations in input power
a. Have electrician check input line voltage.
K. Difficult Starting
1. Worn torch parts (consumables)
a. Shut off input power. Remove and inspect torch shield cup, tip, starter cartridge, and electrode. Replace
electrode or tip if worn; replace starter cartridge if end piece does not move freely; replace shield cup if
excessive spatter adheres to it.
L. Arc shuts off during operation; arc will not restart when torch switch is activated.

1. Power Supply is overheated (TEMP indicator ON)

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to Section 2 for duty cycle specifications.
2. Fan blades blocked (AC indicator flashing; TEMP indicator ON)
a. Check and clear blades.
3. Air flow obstructed (AC indicator flashing; TEMP indicator ON)
a. Check for obstructed air flow around the unit and correct condition.

4. Gas pressure too low (GAS indicator OFF when torch switch is activated)

a. Check source for at least 65 psi / 4.5 bar; adjust as needed.

Manual 0-2888 5-9 SERVICE

 5. Torch consumables worn
a. Check torch shield cup, tip, starter element, and electrode; replace as needed.
6. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
M. No gas flow; AC indicator ON; Fan operates
1. Gas not connected or pressure too low
a. Check gas connections. Adjust gas pressure to proper setting.
2. Shield Cup not properly installed.
a. Check to see that Shield Cup is properly installed.
3. Faulty components in unit
a. Return for repair or have qualified technician repair.
N. Torch cuts but not adequately
1. Current (A) control set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not
activate torch). If there are contaminants in the gas, additional filtering may be needed.

SERVICE 5-10 Manual 0-2888

 SECTION 6:
PARTS LISTS

6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable components.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial number of the torch. Address all inquiries to your autho-
rized distributor.

6.03 Replacement Assemblies

The following items are included with the replacement power supply: input power cord and plug, work cable &
clamp, gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 38 Power Supply with input power cord and 120 VAC, 20A plug 3-3820
1 Surelok Model SL60 Torch 7-5204

6.04 Power Supply Replacement Parts

Qty Description Catalog #
1 Regulator / Filter Assembly Filter Element 9-4414
1 Input Power Cord with 120 VAC, 20A plug (for units through Unit Rev AE) 9-8628

Manual 0-2888 6-1 PARTS LISTS

6.05 Options and Accessories
Qty Description Catalog #
1 120V, 15 - Amp Plug 9-8644
1 120V, 20 - Amp Receptacle 9-8645
1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Multi - Purpose Cart 7-8888

Housing

Filter
Element
Single - Stage Air Filter (Cat. No. 9-7741)

Spring

O-ring
Assembled Filter

Cover

Barbed
Fitting A-02476

6.06 Torch Consumables

A-03409
NOTE
Large O-Ring,
Cat. No. 8-3487 When operating the torch in a normal
condition, a small amount of gas vents
Small O-Ring,
Cat. No. 8-3486 through the gap between the shield cup
and torch handle. Do not attempt to
Electrode, Cat. No. 9-8215 over tighten the shield cup as irrepa-
rable damage to internal components
Starter Cartridge, may result.
Cat. No. 9-8213

30Amp Cutting Tip, Cat. No. 9-8206

Shield Cup, Cat. No. 9-8218

Worn Electrode
Worn Tip

PARTS LISTS 6-2 Manual 0-2888

 APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)

ACTION ACTION ACTION ACTION ACTION

Close external ON / OFF switch RUN / SET switch to SET. RUN / SET switch Connect work cable
disconnect switch. to ON. to RUN. to workpiece.
RESULT Set output amperage
RESULT RESULT RESULT
Gas flows to set pressure. RESULT
Power to system. AC indicator ON. GAS indicator on when input Gas flow stops.
Fan on. pressure is adequate. System is ready
Power circuit ready. for operation.

ACTION ACTION

Protect eyes and Torch moved away

activate torch. from work (while
still activated).
RESULT
RESULT
Gas flows briefly,
then stops. PILOT ARC Main arc stops.
Gas restarts. Pilot arc automatically
restarts.
DC indicator on.
Pilot arc established.

ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfers.
Pilot arc off.
ACTION
Release torch trigger.
RESULT
Main arc stops.
Gas flow stops after post - flow.
ACTION ACTION

ON / OFF switch Unplug input

to OFF power cord or
open external
RESULT disconnect.

All indicators off. RESULT

Power supply fan shuts off.
No power to system.
A-03299

Manual 0-2888 A-1 APPENDIX

 APPENDIX 2: DATA TAG INFORMATION

West Lebanon, NH USA 03784 Manufacturer's Name and/or

Logo, Location, Model and
Model: Revision Level, Serial Number
S/N
and Production Code
Made in USA
Type of Power Regulatory Standard Covering
Supply (Note 1) 1/3 f1
f2 This Type of Power Supply

Output Current Type Duty Cycle Factor

Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol X
I Duty Cycle Data (Note 3)
U0 =
U2
Rated No- Conventional
Load Voltage Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1 I 1max 3Ø I 1eff Maximum Effective
1
1Ø 1Ø
1 3Ø
Supply Current

Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)

NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
Second row: Rated cutting current values.
Third row: Conventional load voltage values. A-03288

NOTE
Sections of the data tag may be applied in
separate locations on the Power Supply.

APPENDIX A-2 Manual 0-2888

This page left blank.

Manual 0-2888 A-3 APPENDIX

 APPENDIX 3: SYSTEM SCHEMATIC
1 2 3 4

PFC INDUCTOR
A INP UT 230V ONLY
T1
J7
TEST E11 E18
E MC 1 4
FILTER
E12A D47
CE ONLY
CHASSIS GND

+
(E12A)
K1
L1 SW1 E1 2
(E15A)
(E1) (E14A)
1 BR1 3 Q7 Q8

RING
E14A 4
120/208/230V

-
INPUT FILTE (E16A)
50/60HZ
B E2
(E2) E15A
SW1
STUD E13
E16A

P4 J4 E12B
M1 +
+
RED 1 1 BIAS
FAN1 (E12B) CONVERTER
12VDC
BLACK 2 2 (E14B) 2
(E15B)
1 BR2 3
E14B 4
P6 J6 LOGIC AND CONTROL CIRCUITRY
-

(5) 1 (E16B)
1
C CURRENT (6) E15B
2 2 TEST POINTS:
CONTROL
(7) 3 3
CURRENT ADJUST CW E16B TP1 LOGIC COMMON
20 - 30 TP2 SHORT TO TP23 TO DISABLE BIAS SUPPLY
P2 J2 TP6 SHORT TO TP24 TO DISABLE POWER
(8) 1 1 PANEL INDICATOR FACTOR CORRECTION
SET
SW2 2 2 TP8 SHORT TO TP26 TO DISABLE SHORTED
(9) 3 3 AC D7 TORCH PROTECTION
RUN
TEMP D13 CAUTION: SOME PORTIONS OF THE CONTROL/
LOGIC CIRCUITRY ARE CONNECTED TO THE
NORMALLY CLOSED GAS D16 INPUT LINE. CONNECTION TO A GROUNDED
OVER-TEMP P5 J5 INSTRUMENT COULD CAUSE A SHOCK
1 1 DC D19 HAZARD OR DESTROY THE POWER SUPPLY.
D 2 2
TS1 ACCESS BY AN AUTHORIZED TECHNICIAN ONLY.
P9 J9 ZERO
1 1
(10) 2 2
(11) 3 3 MAIN PCB ASSEMBLY
19X1773
PS1
PRESSURE SW

A-03405 1 2 3 4

APPENDIX A-4 Manual 0-2888

 5 6 7 8 9 10

MAIN
T3
o OUTPUT INDUCTOR
PRI SEC J8 P8 A
o E9 L1 E4 (E4)
E5 E6 E10 E20 TORCH

(-)

Q13

D56
D54
T
O
R
C70, 72, 81 C
Q11 H
C71, 73, 75 D53 E8 (E8)
Q12 B
PILOT
D55 J3 P3
WORK
1 1 (12) 4 4
TORCH
SWITCH
2 2 (13) 3 3
3 3 (14) 2 2
+14VA AGND
+12VB BGND 4 4 (15) 1 1 PIP
5

QUICK DISCONNECT
E19
TORCH SWITCH ON D22
C
WORK
PWM ON D99

J1 P1 SOL1
A B
1 1
2 2 GAS SOLENOID

COMP DESCRIPTION LOCATION

TS1 OVER-TEMP. SENSOR D2
M1 FAN, 4.5" 12VDC C1
PS1 PRESSURE SWITCH D1 E
SOL1 GAS SOLENOID D9
T1 PFC INDUCTOR A4
T3 MAIN TRANSFORMER A7
L1 OUTPUT INDUCTOR A8
SW1 SWITCH, ON/OFF B2
SW2 SWITCH, RUN/SET D1

Rev Revisions By Date PCB No:

THERMAL DYNAMICS
AA REL ECO 100213 GCW 7/29/02 Assy No:
INDUSTRIAL PARK No. 2
AB REL ECO 100333 GCW 10/04/02 W EST LEBANON, NH 03784 Scale Supersedes
AC REL ECO 100535 603-298-5711
DAT 2/27/03
Date: F
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Tuesday, May 15, 2001
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
NOTE: GCW
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Thursday, March 20, 2003 15:05:29 CM38 120/208/230V SINGLE PHASE 50/60 Hz C 42X1089
5 6 7 8 9 10 A-03405

Manual 0-2888 A-5 APPENDIX