Thermal Dynamics SL60 User manual

Plasma Cutting

System

CutMaster TM 38 Power Supply

SL60 Air Plasma CuttingTorch

Operating Manual

June 6, 2003 Manual No. 0-2888

A-03286

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

Thermal Dynamics 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: June 6, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

World Leader in Plasma CuttingTechnology

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 NASAspace 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: [email protected]

· 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 ofWarranty.................................................................................. 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 GeneralMaintenance ................................................................................... 5-1

5.02 Common Faults............................................................................................ 5-5

5.03 BasicTroubleshooting 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

Date: Nov. 15, 2001 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 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

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

• 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.

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

PLASMAARC 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, SAFETYAND 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 theAmerican 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. NFPAStandard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTINGANDALLIED 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. NFPAStandard 51B, CUTTINGAND WELDING PROCESSES, obtainable from the National Fire ProtectionAssocia-

tion, Batterymarch Park, Quincy, MA 02269

11. CGAPamphlet 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

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

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association,

1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society StandardAWSF4.1, 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

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