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CUTMASTER 30+
Instruction manual
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ESAB CUTMASTER 30+ Instruction manual

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Page 1
INPUT POWER
VOLTAGE
120-
240V
OUTPUT MAX OUTPUT
CUTMASTER® 30+
PLASMA CUTTING SYSTEM
OPERATING MANUAL
Revision: AB Issue Date: Nov., 2022
Manual No.: 0700 400 908
esab.com
Page 2
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our exten­sive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.
Page 3
!
WARNING
Read and understand this entire Manual and your employer’s safety prac tices before installing, operating, or
!
servicing the equipment. While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply CutMaster® 30+ SL60™ 1Torch™ Operating Manual Number 0700 400 908
Published by: ESAB Group Incorporated 2800 Airport Rd. Denton, Texas 76207
www.esab.com
© Copyright 2022 by ESAB
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.
Original Publication Date: 30 March, 2022 Revision Date: 9 Nov., 2022
See website for Warranty Information.
Record the following information for Warranty purposes:
Where Purchased:_______________________________ _____________________
Purchase Date:__________________________ ____________________________
Power Supply Serial #:_______________________________ _________________
Torch Serial #:______________________________ _________________________
i
i
Page 4
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equip­ment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty mainte­nance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
PROTECT YOURSELF AND OTHERS!
OPERATING.
Page 5
ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOUR-
NISSEUR.
MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionne­ment et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux per-
sonnes non qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement.
Ne tentez PAS d’installer ou d’opérer cet équipement avant de lire et de bien com­prendre ces instructions. Si vous ne comprenez pas bien les instructions, commu­niquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagne­ment et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions
fournies. Vous devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne
fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant.
L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte,
un entretien fautif, des dommages, une réparation incorrecte ou une modication par une personne autre que le
fabricant ou un centre de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION
AVANT D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!
Page 6
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Page 9
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION.......................................................... 11
1.01 Notes, Cautions and Warnings ................................................................................. 11
SECTION 1 : INFORMATIONS GÉNÉRALES ................................................... 13
1.01 Remarques, avertissements et mises en garde ........................................................ 13
SECTION 2 SYSTEM: INTRODUCTION ......................................................... 15
2.01 How To Use This Manual .......................................................................................... 15
2.02 Equipment Identication ......................................................................................... 15
2.03 Receipt Of Equipment .............................................................................................. 15
2.04 Power Supply Specications ETL .............................................................................. 16
2.04.01 Additional Power Supply Specications ..........................................................16
2.05 Input Wiring Specications ETL................................................................................ 17
2.06 Power Supply Specications CE ...............................................................................18
2.06.01 Additional Power Supply Specications ..........................................................18
2.07 Input Wiring Specications CE .................................................................................18
2.08 Generator Recommendations .................................................................................. 19
2.09 Power Supply Features ............................................................................................ 19
SECTION 2 TORCH: INTRODUCTION ........................................................... 23
2T.01 Scope of Manual ...................................................................................................... 23
2T.02 General Description ................................................................................................. 23
2T.03 Specications ......................................................................................................... 23
SECTION 3 SYSTEM: INSTALLATION ........................................................... 25
3.01 Unpacking ............................................................................................................... 25
3.02 Lifting Options ......................................................................................................... 25
3.03 Gas Connections ...................................................................................................... 26
3.04 Primary Input Power Connections ........................................................................... 27
3.05 Work Lead Connections ........................................................................................... 28
SECTION 3 TORCH:
INSTALLATION ......................................................................................... 29
3T.01 Torch Connections.................................................................................................... 29
SECTION 4 SYSTEM: OPERATION ............................................................... 31
4.01 Front Panel Controls / Features ................................................................................31
4.02 Preparations for Operation ......................................................................................37
SECTION 4 TORCH: OPERATION .................................................................. 39
4T.01 Torch Parts Selection ............................................................................................... 39
4T.02 Hand Torch Operation .............................................................................................. 39
4T.03 Gouging................................................................................................................... 43
Page 10
TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE ..................................................................... 45
5.01 General Maintenance .............................................................................................. 45
5.02 Maintenance Schedule ............................................................................................ 45
5.03 Common Faults ........................................................................................................46
5.04 Basic Troubleshooting Guide .................................................................................... 47
5.05 Power Supply Basic Parts Replacement ................................................................... 48
SECTION 5 TORCH: SERVICE ...................................................................... 49
5T.01 General Maintenance .............................................................................................. 49
5T.02 Inspection and Replacement of Consumable Torch Parts ......................................... 50
SECTION 6: PARTS LISTS ........................................................................... 51
6.01 Introduction ............................................................................................................ 51
6.02 Ordering Information ..............................................................................................51
6.03 Power Supply Replacement ..................................................................................... 51
6.04 Replacement Parts .................................................................................................. 52
6.05 Options and Accessories ..........................................................................................53
6.06 Replacement Parts for SL60 Hand Torch .................................................................. 54
6.07 Torch Consumable Parts (SL60) ................................................................................55
APPENDIX 1: DATA TAG INFORMATION ...................................................... 57
APPENDIX 2: TORCH PIN  OUT DIAGRAMS ................................................ 58
APPENDIX 3: TORCH CONNECTION DIAGRAMS ........................................... 59
Page 11
CUTMASTER 30+
!!
!!

SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:
NOTE!
An operation, procedure, or background information which requires additional emphasis or is helpful in ecient 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.
WARNING
Gives information regarding possible electrical shock injury.
0700 400 908 GENERAL INFORMATION
11
Page 12
CUTMASTER 30+
WARNING
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn o power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn.
AVERTISSEMENT
1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce.
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation.
Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée.
Art # A-13294
GENERAL INFORMATION 0700 400 908
12
Page 13
CUTMASTER 30+
!!
!

SECTION 1 : INFORMATIONS GÉNÉRALES

1.01 Remarques, avertissements et mises en garde

Le présent manuel est ponctué de remarques, d’avertissements et de mises en garde qui attirent l’attention sur des informations importantes. Ces repères sont classés comme suit :
REMARQUE:
Fonction, procédé ou renseignement de base qui nécessite une plus grande attention ou contribue au bon fonctionnement du système.
ATTENTION
Procédé qui, s’il n’est pas suivi correctement, peut endommager l’équipement.
AVERTISSEMENT
Procédé qui, s’il n’est pas suivi correctement, peut causer des lésions à l’utilisateur ou aux personnes
!
dans la zone d’exploitation.
AVERTISSEMENT
Fournit des renseignements relatifs à d’éventuelles blessures se devant à une décharge électrique.
0700 400 908 GENERAL INFORMATION
13
Page 14
CUTMASTER 30+
WARNING
1. Cutting sparks can cause explosion or fire.
1.1 Do not cut near flammables.
1.2 Have a fire extinguisher nearby and ready to use.
1.3 Do not use a drum or other closed container as a cutting table.
2. Plasma arc can injure and burn; point the nozzle away from yourself. Arc starts instantly when triggered.
2.1 Turn o power before disassembling torch.
2.2 Do not grip the workpiece near the cutting path.
2.3 Wear complete body protection.
3. Hazardous voltage. Risk of electric shock or burn.
3.1 Wear insulating gloves. Replace gloves when wet or damaged.
3.2 Protect from shock by insulating yourself from work and ground.
3.3 Disconnect power before servicing. Do not touch live parts.
4. Plasma fumes can be hazardous.
4.1 Do not inhale fumes.
4.2 Use forced ventilation or local exhaust to remove the fumes.
4.3 Do not operate in closed spaces. Remove fumes with ventilation.
5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.
6. Become trained.
Only qualified personnel should operate this equipment. Use torches specified in the manual. Keep non-qualified personnel and children away.
7. Do not remove, destroy, or cover this label.
Replace if it is missing, damaged, or worn.
AVERTISSEMENT
1. Les étincelles de coupage peuvent provoquer une explosion ou un incendie.
1.1 Ne pas couper près des matières inflammables.
1.2 Un extincteur doit être à proximité et prêt à être utilisé.
1.3 Ne pas utiliser un fût ou un autre contenant fermé comme table de coupage.
2. L’arc plasma peut blesser et brûler; éloigner la buse de soi. Il s’allume instantanément quand on l’amorce.
2.1 Couper l’alimentation avant de démonter la torche.
2.2 Ne pas saisir la pièce à couper de la trajectoire de coupage.
2.3 Se protéger entièrement le corps.
3. Tension dangereuse. Risque de choc électrique ou de brûlure.
3.1 Porter des gants isolants. Remplacer les gants quand ils sont humides ou endommagés.
3.2 Se protéger contre les chocs en s’isolant de la pièce et de la terre.
3.3 Couper l’alimentation avant l’entretien. Ne pas toucher les pièces sous tension.
4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées.
4.2 Utiliser une ventilation forcée ou un extracteur local pour dissiper les fumées.
4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.
5. Les rayons d’arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.
6. Suivre une formation.
Seul le personnel qualifié a le droit de faire fonctionner cet équipement. Utiliser exclusivement les torches indiquées dans le manual. Le personnel non qualifié et les enfants doivent se tenir à l’écart.
7. Ne pas enlever, détruire ni couvrir cette étiquette.
La remplacer si elle est absente, endommagée ou usée.
Art # A-13294
GENERAL INFORMATION 0700 400 908
14
Page 15
CUTMASTER 30+

SECTION 2 SYSTEM: INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just product(s) listed on page i.
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by regis­tering on the ESAB web site listed below and clicking on "Product Support" / "ESAB Documentation": / "Download Library", then navigate to "Plasma Equipment" and then "Manual". You must rst be logged in.
http://www.esab.com
2.02 Equipment Identication
The unit’s identication number (specication or part number), model, and serial number appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identied only by the specication or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

ETL
Included items:
• CutMaster 30+ Power Supply
• SL60™ Torch and Leads
• Work Lead with Work Clamp
• Spare Parts Kit ( 2 Electrodes, 2 Cutting Tips, 1 Gouging Tip, 1 Shield Cap, 1 Start Cartridge, 1 Shield Cup Body, 1 Deector Shield Cup, 1 Stando Cutting Guide and 1 Shield cup)
• 50 Amp to 20 Amp Adapter
• 20 Amp to 15 Amp Adapter
• Quick Start Guide
• Air tting 1/4" NPT Milton type D
Move the equipment to the installation site before un-boxing the unit. Use care to avoid damaging the equipment when opening the box.
CE
Included items:
• CutMaster 30+ Power Supply
• SL60™ Torch and Leads
• Work Lead with Work Clamp
• Spare Parts Kit ( 2 Electrodes, 2 Cutting Tips, 1 Gouging Tip, 1 Shield Cap, 1 Start Cartridge, 1 Shield Cup Body, 1 Deector Shield Cup, 1 Stando Cutting Guide and 1 Shield cup)
• Air tting 1/4" NPT EU type
• Quick Start Guide
0700 400 908 INTRODUCTION
15
Page 16
CUTMASTER 30+
2.04 Power Supply Specications ETL
CM 30+ 120-240 VAC 1 Phase Power Supply Specications
Input Power 120 - 240 VAC, Single Phase, 50/60 Hz
1 Phase Input Power Cable ETL
Output Current 10 - 30 Amps, Continuously Adjustable
Power Supply Gas Filtering Ability Particulates to 5 Microns
Inlet Pressure 90-125 PSI (6.2-8.6 bar / 620-862 Kpa)
2.04.01 Additional Power Supply Specications
Ambient Air Temperature
120 VAC Units
208-240 VAC Units
Power Supply includes 3 M single phase 12AWG 3/C input cable with NEMA
CM 30+ Power Supply Duty Cycle *
6-50P Plug
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Rating
Duty Cycle* 40% 60% 100%
Current
DC Voltage
Duty Cycle* 40% 60% 100%
Current
DC Voltage
25 Amps** 21 Amps 16 Amps
120 120 120
30 Amps 25 Amps 20 Amps
120 120 120
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is higher than shown in this chart. ** NOTE: 25 Amps is for a 20 Amp circuit ONLY! DO NOT exceed a 21 Amp output setting on a 15 Amp circuit!
INTRODUCTION 0700 400 908
16
Page 17
2.05 Input Wiring Specications ETL
1 Phase Input Cable Wiring Requirements
1 Phase Cutmaster 30+ Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1e
120 / 15A 50/60 3.02 25.5 19.6 15 12 AWG
120 / 20A 50/60 3.7 30.3 19.1 20 12 AWG
Fuse
(amps)
CUTMASTER 30+
Flexible Cord
(Min. AWG)
1 Phase
208 50/60 4.3 21 13.2 50 12 AWG
220 50/60 4.3 19.9 12.6 50 12 AWG
230 50/60 4.2 19 12 50 12 AWG
240 50/60 4.2 18.2 11.5 50 12 AWG
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE!
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.
0700400951
NOTE!
Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the amperage accordingly.
CM 30+ Cut Capacity
Recommended Pierce Maximum
0.4" (10 mm) 0.4" (10 mm) 0.63" (16 mm)
0700 400 908 INTRODUCTION
17
Page 18
CUTMASTER 30+
2.06 Power Supply Specications CE
CM 30+ 230 VAC 1 Phase Power Supply Specications
Input Power 230 VAC, Single Phase, 50 Hz
1 Phase Input Power Cable CE
Output Current 10 - 30 Amps, Continuously Adjustable
Power Supply Gas Filtering Ability Particulates to 5 Microns
Inlet Pressure 90-125 PSI (6.2-8.6 bar / 620-862 Kpa)
2.06.01 Additional Power Supply Specications
CM 30+ Power Supply Duty Cycle *
Ambient Air Temperature
230 VAC Units
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is higher than shown in this chart.
Power Supply includes 3 M single phase 2.5mm² input
Duty Cycle* 40% 60% 100%
Current
DC Voltage
cable with Schuko plug
Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
Rating
30 Amps 25 Amps 20 Amps
120 120 120
2.07 Input Wiring Specications CE
1 Phase Input Cable Wiring Requirements
1 Phase Cutmaster 30+ Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1e
1 Phase
INTRODUCTION 0700 400 908
18
230 50 4.2 19 12 32 2.5mm
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE!
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.
Fuse
(amps)
Flexible Cord
(Min. AWG)
Page 19
CUTMASTER 30+

2.08 Generator Recommendations

When using generators to power the CM 30+ Plasma Cutting System, the following ratings are a minimum and are to be used along with the ratings previously listed.
CM 30+ Generator Specications
Generator Output Rating CM 30+ Output Current Arc Characteristic
3 kW / 120V 20 A on 15 A circuit Full
5 kW / 120V 25 A on 20 A circuit Full
5 kW / 230V 30 A Full
NOTE: If Generator is equipped with an idle mode it will need to be in "Run" mode to operate at 30 amps.
NOTE!
Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the amperage accordingly.
CM 30+ Cut Capacity
Recommended Pierce Maximum
0.4" (10 mm) 0.4" (10 mm) 0.63" (16 mm)

2.09 Power Supply Features

Handle and Leads Wrap
0700 400 908 INTRODUCTION
Control Panel
Torch Leads Receptacle
Work Lead Receptacle
19
Page 20
CUTMASTER 30+
Input Power Main Switch
Input Power Cord
Weights and Dimensions
311.21 mm
Gas Inlet Port
8”
203.29 mm
12.25"
18.82"
478.07 mm
24.25 lb / 11 kg
Power Supply Dimensions & Weight
INTRODUCTION 0700 400 908
20
Page 21
Clearances for Operation and Ventilation
6"
150 mm
CUTMASTER 30+
15"
381 mm
15"
381 mm
Ventilation Clearance Requirements
6"
150 mm
0700 400 908 INTRODUCTION
21
Page 22
CUTMASTER 30+
This Page Intentionally Blank
INTRODUCTION 0700 400 908
22
Page 23

SECTION 2 TORCH: INTRODUCTION

!!
!!

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Model SL60™ Plasma Cutting Torch. Ser vice of this equipment is restricted to properly trained personnel; unqualied personnel are strictly cau­tioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete under­standing of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

CAUTION
Torch Leads are exible but internal wires can be broken. Do not exceed a 2" radius bend and avoid repeated tight bends when possible.
Refer to the Appendix Pages for additional specications as related to the Power Supply used.
CUTMASTER 30+
D. Parts - In - Place (PIP)
Torch Head has built - in switch
27.5±1.5 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream through torch.
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
Duty Cycle
Maximum
Current
Voltage (V
Arc Striking
Voltage
G. Gas Requirements
) 500V
peak
Manual Torch Gas Specifications
104° F
40° C
100% @ 60 Amps @ 400
scfh
60 Amps
500V
2T.03 Specications
A. Torch Congurations
1. Hand/Manual Torch, Models
The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly.
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
B. Hand Torches are available as follows:
• 20 ft / 6.1 m 7-5200
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
0700 400 908 INTRODUCTION
Art # A-03322_AB
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
WARNING
This Torch is not to be used with oxygen (O2). The SL60QD torch should not be used on an HF system.
NOTE!
Operating pressure varies with torch model, oper­ating amperage, and torch leads length. Refer to gas pressure settings charts for each model.
H. Direct Contact Hazard
For stando tip the recommended stando is 3/16 inches / 4.7 mm.
90 - 120 psi
6.2 - 8.3 bar
5 - 8.3 SCFM 300 - 500 scfh 142 - 235 lpm
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INTRODUCTION 0700 400 908
24
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CUTMASTER 30+

SECTION 3 SYSTEM: INSTALLATION

3.01 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.

3.02 Lifting Options

The Power Supply includes handles for hand lifting only. Be sure unit is lifted and transported safely and securely.
WARNING
Do not touch live electrical parts. Disconnect input power cord before moving unit. FALLING EQUIPMENT can cause serious personal injury and can damage equipment. HANDLES are not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handles, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
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3.03 Gas Connections

Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders.
1. Connect the air line to the quick connect inlet port. The following illustration shows typical gas line with quick connect ttings as an example.
NOTE!
For a secure seal, apply thread sealant to the tting threads, according to manufacturer’s instructions.. Do not use Teon tape as a thread sealer, as small particles of the tape may break o and block the small air passages in the torch.
Applying Thread Sealant
Air Connection to Inlet Port
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!
!
!!
2. IF using high pressure cylinders, or your supply pressure exceeds 125 psi, you MUST use regulator to lower pressure to between 90-125 psi before introducing air to the system.
WARNING
Failure to regulate inbound air pressure below 125 psi may cause damage to the unit.

3.04 Primary Input Power Connections

CAUTION
Check your power source for correct voltage before connecting the unit to input power. The primar y power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specied in Section 2.
Power Cords Included With the Power Supply
Power cords come attached on all systems. For North America it will come with a 50 amp plug for use
on 208-240V/50A circuit. For Europe it will come with a 2.5mm cable and a Schuko plug for use on a 230V circuit.
Also included for ETL systems ONLY, are two adapters. One is a cable with a 120V/20A NEMA 5-20P plug which attaches to the power supply input cord via a NEMA 6-50R plug. The other is a NEMA 5-20R to NEMA 5-15P adapter plug that attaches to the other adapter.
CAUTION
When using the 120V/20A adapter cord (ETL systems ONLY ), do not exceed a current output setting of 25 Amps on the power supply or the input power circuit breaker may trip.
CAUTION
The equipment (CE system ONLY ) is intended for use only in premises having a service current capacity equal to or greater than 100A per phase.
WARNING
When using the 15A adapter in conjunction with the 20A adapter (ETL systems ONLY), extreme caution should be used to not exceed a current output setting of 21 Amps on the power supply. Failure to do so may result in the input power circuit breaker tripping or branch circuit overheating.
Input Voltage Rated Output Amps (RMS) input at
120 V, 15 A Circuit (ETL) 21 A, 120 V 25.5 3.1
120 V, 20 A Circuit (ETL) 25 A, 120 V 30.3 3.7
208-240 V, 50 A Circuit (ETL) 30 A, 120 V 18.2-21 4.2
230 V (CE) 30 A, 120 V 19 4.2
0700 400 908 INSTALLATION
rated output, 60 Hz,
kVA
single-phase
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CUTMASTER 30+
ETL ONLY
0700400951

3.05 Work Lead Connections

Connect the Work Lead to the power supply and the work piece.
1. Attach the Dinse type connection of the work lead to the power supply front panel as shown below.
2. Push in and turn clockwise to the right until tight.
3. Connect the work clamp to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the work piece; do not connect to the part to be cut o.
3
2
1
See section 3T for torch installation.
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SECTION 3 TORCH:
INSTALLATION

3T.01 Torch Connections

Connect the torch to the Power Supply. Connect only the ESAB model SL60 torch to this power supply. Maximum torch leads length is 50 feet/15m, including extensions.
WARNING
Disconnect primary power at the source before connecting the torch.
1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together. Do not use tools to secure the connection.
Connecting the Torch to the Power Supply
0700 400 908 INSTALLATION
1
2
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INSTALLATION 0700 400 908
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SECTION 4 SYSTEM: OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identication
CUTMASTER 30+
4
1
2
1. Control Knob
To select the Menu or change values.
To adjust the cutting current:
• Turn clockwise to increase the cutting current.
• Turn counterclockwise to reduce the cutting current.
To select an option in the menu displayed, press the control knob to enter the menu screen. After entering the menu screen, the options are highlighted in sequence at each turn.
30A
120V 66.7PSI
2T
3
• To select the icon on the menu screen and exit menu screen.
• To change the selection.
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2. Work lead Dinse type receptacle
Align Dinse type connector on work lead with receptacle, press in and turn clockwise to the right until tight.
3. Torch Quick Disconnect Receptacle
Torch Leads are connected here by aligning the connectors, pressing in and turning locking ring clock­wise-to-the-right to secure. Connection should only be snug with no tools used.
Negative / Plasma
8 - Open
7 - Open
6 - Open
5 - Open
Pilot
4 - Switch
8 7
6 5
2 1
3 - Switch
4 3
2 - PIP
1 - PIP
1 2 3 4 5 6 7 8
4. LCD screen
The front panel has an LCD screen to display the cutting mode, cutting current, cutting voltage, air pressure, and error information.
WELCOME SCREEN
The welcome screen is displayed for 3 seconds while the equipment turns ON.
PIP Switch
Trigger Switch
Electrode
After the welcome screen, the model name is displayed for 3 seconds.
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MAIN SCREEN
Current
30A
Arc Cutting Voltage
Cutting mode
MENU SCREEN
To enter the menu screen, press the control knob. In the menu screen, the user may adjust the cutting mode, trigger mode, and gas purge. To exit the menu screen, rotate the control knob to main screen.
1) CUTTING MODE SELECTION SCREEN
To enter the cutting mode selection, press the control knob, the cutting mode is highlighted.
To change the selection, press the knob, the cutting mode changes between plate cutting mode and grid cutting mode.
To conrm the selection, rotate the control knob to exit cutting mode selection menu.
120V PSI
66.7
2T
Output air pressure
Gas purge
Trigger mode
30A
120V PSI
0700 400 908 OPERATION
2T
66.7
30A
120V PSI
66.7
2T
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CUTMASTER 30+
2) TRIGGER MODE SELECTION SCREEN
To enter the cutting mode selection, press the control knob to enter menu screen. Turn the knob clockwise to enter trigger mode screen. The trigger mode is highlighted. To change the selection, press the knob, the trigger mode changes between2T(normal) mode and 4T (lock mode) mode. Rotate the control knob to exit the trigger mode selection screen to conrm the selection.
Note that 4T trigger mode is only available at plate cutting mode. When grid cutting mode is selected, 4T trigger mode can’t be selected.
30A
66.7
2T
PSI
120V
3) GAS PURGE SCREEN
To enter gas purge, press the control knob to enter menu screen. Turn the knob clockwise to enter gas purge screen.
Press the control knob to active the gas purge, press control knob again to stop the gas purge, rotate the control knob to exit the gas purge screen.
30A
120V PSI
2T
66.7
30A
120V PSI
30A
120V PSI
66.7
4T
66.7
2T
OPERATION 0700 400 908
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Error screen
CUTMASTER 30+
There are several error warnings screens to indicate errors. When an error happens, the communication screen will display and cut o the output until the error is cleared.
1) OVERHEATING COMMUNICATION SCREEN
The cutting equipment is protected by a temperature sensor. The overheating communication screen is displayed if the machine is overheated, which normally occurs if the equipment work cycle is exceeded.
If the overheating communication screen displays the machine output shall be deactivated. Let the equipment ON to allow the internal components to cool down. When the equipment is cool enough, the overheating communication screen disappears automatically.
Notice that the main switch must remain in the I position, so that the fan continues to operate and allow the equipment to cool down enough.
2) AIR PRESSURE COMMUNICATION SCREEN
The air pressure communication screen is displayed when the output air pressure is out of range.
3) TORCH INSTALLATION OR COVER ASSEMBLY COMMUNICATION SCREEN
The torch installation or incorrect cover assembly communication screen is displayed when the torch or torch consumable is not installed correctly.
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4) ELECTRODE OR NOZZLE INSTALLATION COMMUNICATION SCREEN
The electrode or cutting nozzle installation communication screen is displayed when the electrode or cutting nozzle is not installed correctly or wear seriously. Check or replace the worn cutting nozzle and electrode.
5) UNDER VOLTAGE COMMUNICATION SCREEN
The under voltage communication screen is displayed when the input voltage is under 85 V, check that the input voltage is not less than 100 V.
(6) START ERROR COMMUNICATION SCREEN
Start signal is active when ON/ OFF SWITCH is turned to ON position.
Start can be active for the following:
• Hand torch switch held closed
OPERATION 0700 400 908
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Art # A-04509

4.02 Preparations for Operation

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.
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 at 230V or 25 amps at 120V). Refer to Section 4T.01 for torch parts order.
Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics models SL60 Manual Torches may be connected to this Power Supply. See Section 3T.01 of this manual.
Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Air Source
Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.
Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The work cable clamp 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 o.
Power ON
Place the Power Supply main switch to the I (right) position. LCD turns ON. The Main Board performs several tests to determine the system is ready to operate.
If there are no issues detected the output current setting will be displayed from 10 to 30 amps.
The cooling fan will turn ON for one second as the unit is turned ON and will auto to run when the unit is working normally.
Set Operating Pressure
Gas pressure cannot be set at the power supply and must be set at the source, from 90 - 125 PSI / 6.2 - 8.6 bar / 620 - 862 Kpa.
NEVER EXCEED 125 PSI / 8.62 bar / 862 kPa.
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Cutting Operation
Once the cutting arc is established, it should continue to cut until the trigger is released, the torch is moved too far from the work piece or the duty cycle has been exceeded causing the system to go into an over temperature mode. In the rst two instances release the torch trigger, ensure that the torch tip is close to the work piece, activate the trigger and reestablish the cutting arc. In the event of an over temperature fault, release the trigger, allow the unit to run so it will cool down. When the fault clears you can begin cutting again.
Typical Cutting Speeds
Cutting speeds vary according to torch output amperage, gas pressure, the type of material being cut, and operator skill.
Output current setting or cutting speeds may be reduced to allow slower cutting when follow­ing a line, or using a template or cutting guide while still producing cuts of excellent quality. As thickness of metal being cut increases cutting speed will need to slow. The opposite is true. As thickness of metal being cut decreases, allowable cutting speed can increase.
Postow
Release the trigger to stop the cutting arc. Gas continues to ow for approximately 30 seconds. During post - ow, if the user quickly presses and releases the trigger, the gas will shut o. If the user continues to hold the trigger and not release it, the pilot arc starts. The main arc will transfer to the workpiece if the torch tip is within transfer distance.
Shutdown
Turn the main switch to O, to the left as you face the unit from the rear. After a short delay all Power Supply indicators and fan shut OFF. Unplug the input power cord or disconnect input power. Power is removed from the system.
NOTE!
To maximize the longevity of the internal electronics, allow the power supply to continue running (without cutting) for a few minutes before turning OFF. This will allow them to cool faster.
OPERATION 0700 400 908
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A-03510_AB

SECTION 4 TORCH: OPERATION

CUTMASTER 30+

4T.01 Torch Parts Selec tion

Depending on the type of operation to be done determines the torch parts to be used.
Type of operation:
Drag cutting, stando cutting or goug­ing
Torch parts:
Shield Cup, Cutting Tip, Electrode and Start Cartridge
NOTE!
Refer to Section 4T.07 and following for additional information on torch parts.
Change the torch parts for a dierent operation as follows:
WARNING
Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies.
NOTE!
The shield cup holds the tip and start cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup assembly from the torch head.
2. Remove the Electrode by pulling it straight out of the Torch Head.
Large O-Ring
Torch Head
Electrode
Small O-Ring
3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.
4. Install the start car tridge and desired tip for the operation into the torch head.
5. Hand tighten the shield cup assembly until it is seated on the torch head, being careful to not cross thread the shield cup while screwing onto the torch. Once it reaches end of threads, no need to further tighten, as the O-rings maintain seals and proper gas ows to front of torch. If resistance is felt when install­ing the cup, check the threads before proceeding.

4T.02 Hand Torch Operation

Stando Cutting With Hand Torch
NOTE!
For best performance and parts life, always use the correct parts for the type of operation.
1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protec­tion. Choose the holding technique that feels most comfortable and allows good control and movement.
NOTE!
The tip should never come in contact with the workpiece except during drag cutting operations with the drag shield in place. See the consum­able chart on your parts kit box for diagram.
Start Cartridge
Tip
Shield Cup
Torch Parts
0700 400 908 TORCH OPERATION
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A-00024_AB
1/8" - 3/8" (3 - 9mm)
Art # A-04034
2. Depending on the cutting operation, do one of the following:
a. For edge starts, hold the torch per-
pendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.
b. For stando cutting, hold the torch
1/8 - 3/8 in (3-9 mm) from the work­piece as shown below.
Tr igger
1
2
Tr igger Release
3
Torch
Shield Cup
Stando Distance
Standoff Distance
3. Hold the torch away from your body.
4. Slide the trigger release toward the back of the torch handle while simultaneous­ly squeezing the trigger. The pilot arc will start.
Trigger
4
Art # A-03383
6. Cut as usual. Simply release the trigger assembly to stop cutting.
7. Follow normal recommended cutting practices as provided in the power supply operator's manual.
NOTE!
When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.
8. For a consistent stando height from the workpiece, install the stando guide by sliding it onto the torch shield cup. In­stall the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During oper­ation, position the legs of the stando guide against the workpiece.
Trigger Release
A-02986
5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic
Shield Cup
Standoff Guide
Torch Tip
Workpiece
of the power supply and not a function of the torch.
TORCH OPERATION 0700 400 908
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Shield Cup With Straight Edge
t # A-03383
Tr igger
The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.
WARNING The straight edge must be non - conductive.
CUTMASTER 30+
5. Slide the trigger release toward the back of the torch handle while simultaneous­ly squeezing the trigger. The pilot arc will start.
Trigger
Non-Conductive
Straight Edge Cutting Guide
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface.
Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4" (6 mm) thick or less.
NOTE!
For best parts performance and life, always use the correct parts for the type of operation.
1. Install the drag cutting tip and set the output current.
2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protec­tion. Choose the holding technique that feels most comfortable and allows good control and movement.
3. Keep the torch in contact with the work­piece during the cutting cycle.
4. Hold the torch away from your body.
Trigger Release
A-02986
6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic of the power supply and not a function of the torch.
1
2
Tr igger Release
3
4
Ar
7. Cut as usual. Simply release the trigger assembly to stop cutting.
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8. Follow normal recommended cutting practices as provided in the power supply operator's manual.
NOTE!
When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.
Piercing With Hand Torch
1. Hold the torch away from your body.
2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.
NOTE!
The tip should never come in contact with the workpiece except during drag cutting operations.
3. Angle the torch slightly to direct blow­back particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.
4. In a portion of the unwanted metal start the pierce o the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.
5. Slide the trigger release toward the back of the torch handle while simultaneous­ly squeezing the trigger. The pilot arc will start.
Trigger
Trigger Release
A-02986
6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
NOTE!
The gas preow and postow are a characteristic of the power supply and not a function of the torch.
7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.
Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:
• Torch parts wear
• Air quality
• Line voltage uctuations
• Torch stando height
• Proper work cable connection
Rolling Pierce
A technique that can work on thinner materials is a rolling pierce. A Rolling Pierce begins cutting with the torch head placed at an angle to the work surface. Splatter/dross are blown away from the work area as the torch cuts. The torch head rotates towards vertical as the cut grows deeper and pierces the workpiece.
Art # A-13353
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4T.03 Gouging

!!
!
!!
35°
Workpiece
Torch Head
Standoff Height
A-00941_AB
WARNING
Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the op­erator’s body comes in contact with the workpiece when the torch is activated. Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTION
Sparks from plasma gouging can cause damage
!
to coated, painted or other surfaces such as glass, plastic, and metal. Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.07, Torch Parts Selection.
Gouging Parameters
Gouging performance depends on parame­ters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (stando).
CUTMASTER 30+
Lead Angle
The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.
Gouging Angle and Stando Distance
CAUTION
Touching the torch tip or shield cup to the work surface will cause excessive parts wear.
Torch Travel Speed
NOTE!
Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.
Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).
Current Setting
Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.
0700 400 908 TORCH OPERATION
Stando Distance
The tip to work distance aects gouge qual­ity and depth. Stando distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller stando distances may result in a severance cut rather than a gouge. Stando distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.
Slag Buildup
Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle, or stando height.
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TORCH OPERATION 0700 400 908
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5.01 General Maintenance

CUTMASTER 30+

SECTION 5 SYSTEM: SERVICE

Warning! Disconnect input power before maintaining.
Visually inspect the torch body, consumables and Quick Connect
Replace all broken parts
Maintain more often if used under severe conditions
Each Use
Visual check of torch tip and electrode
Weekly
Visually inspect the cables and leads. Replace as needed
3 Months
Clean exterior of power supply

5.02 Maintenance Schedule

NOTE!
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Check plasma and secondary supply and pressure/ow.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air ow.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Inspect input power cable for damage or exposed wires, replace if necessary.
0700 400 908 SERVICE
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!!
Six Months or Every 720 Cutting Hours:
1. Check cables and hoses for leaks or cracks, replace if necessary.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

5.03 Common Faults

Problem ­Symptom
Insufficient Penetration
Main Arc
Extinguishes
Excessive
Dross
Formation
Short Torch
Parts Life
Difficult Starting
Common Cause
1. Cutting speed too fast.
2. Torch tilted too much.
3. Metal too thick.
4. Worn torch parts.
5. Cutting current too low.
6. Non - Genuine Thermal Dynamics parts used.
7. Incorrect gas pressure. Line pressure 90-125 psi (6.2-8.6 bar / 620-862 Kpa).
1. Cutting speed too slow.
2. Torch standoff too high from workpiece.
3. Cutting current too high.
4. Work cable disconnected.
5. Worn torch parts.
6. Non - Genuine Thermal Dynamics parts used.
7. Line voltage drop due to extension cord or supply line being too long.
1. Cutting speed too slow.
2. Torch standoff too high from workpiece.
3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine Thermal Dynamics parts used.
6. Incorrect gas pressure.
1. Oil or moisture in air source.
2. Exceeding system capability (material too thick).
3. Excessive pilot arc time
4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics parts used.
1. Worn torch parts.
2. Non - Genuine Thermal Dynamics parts used.
3. Incorrect gas pressure.
4. Line voltage too low.
5. Wrong parts for current selection.
6. Hose restriction.
SERVICE 0700 400 908
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5.04 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.
CUTMASTER 30+
Problem ­Symptom
Main Switch is ON but the LCD does not light
Overheating communication screen
Air pressure communication screen
Torch installation or cover assembly communication screen
Possible Cause Recommended Action
1. Primary power disconnect is in OFF position.
2. Primary fuses / breakers are blown or tripped.
3. Faulty components in unit.
1. Air ow through or around the unit is obstructed.
2. Duty cycle of the unit has been exceeded.
3. Failed components in unit.
1. Gas supply not connected to unit.
2. Gas supply not turned ON.
3. Gas supply pressure too low.
4. Failed components in unit.
1. Shield Cup loose.
2. Torch not properly connected to power supply.
3. Problem in torch and leads PIP circuit.
4. Failed components in unit.
1. Turn primary power disconnect switch to ON position.
2. a) Have qualied person check primary fuses / breakers. b) Connect unit to known good primary power receptacle.
3. Return to authorized service center for repair or replacement.
1. Refer to clearance information – see Section "2.04 Power Supply Specications" on page 16.
2. Allow unit to cool.
3. Return to authorized service center for repair or replacement.
1. Connect gas supply to unit.
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi. Set leads length to match the actual length being used.
4. Return to authorized service center for repair or replacement.
1. Hand tighten the shield cup until it is snug.
2. Insure torch ATC is securely fastened to unit.
3. Replace torch and leads or return to authorized service center for repair or replacement.
4. Return to authorized service center for repair or replacement.
0700 400 908 SERVICE
47
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CUTMASTER 30+

5.05 Power Supply Basic Parts Replacement

Optional Single-Stage Filter Element Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement lter element catalog number.
1. Remove power from power supply.
2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single-Stage Filter Element Replacement
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 rst.
7. Replace Housing on Cover.
8. Reattach gas supply. Check for leaks.
NOTE!
If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.
This completes the parts replacement procedures.
SERVICE 0700 400 908
48
Page 49

SECTION 5 TORCH: SERVICE

!
Lower O-Ring
Art # A-03725
#8-0525
CUTMASTER 30+

5T.01 General Maintenance

NOTE!
Refer to Previous “Section 5: System” for com­mon and fault indicator descriptions.
Cleaning Torch
Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can aect the pilot arc initiation and the overall cut quality of the torch.
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned with electrical contact cleaner using a cot­ton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.
Upper Groove with Vent Holes Must Remain Open
Upper O-Ring in Correct Groove
Threads
Torch Head O-Ring
ATC Male Connector
Gas Fitting
CAUTION
!
Dry the torch thoroughly before reinstalling.
O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male Connector requires lubrication on a sched­uled basis. This will allow the O-Rings to remain pliable and provide a proper seal. The O-Rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems.
It is recommended to apply a very light lm of O-Ring lubricant (Catalog # 8-4025) to the O-Rings on a weekly basis.
0700 400 908 SERVICE
Art #A-03791_AB
ATC O-Ring
NOTE!
DO NOT use other lubricants or grease, they may not be designed to operate within high tempera­tures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.
O-Ring
49
Page 50
CUTMASTER 30+
Art # A-08067
Good Tip
Worn Tip
Spring-Loaded
Spring-Loaded
/
Art # A-03284
5T.02 Inspection and Replacement of
Consumable Torch Parts
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE!
The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE!
Slag built up on the shield cup that cannot be removed may eect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace if damaged.
4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orice). Clean or replace the tip if necessary.
A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end tting for free motion. Replace if nec­essary.
Lower End Fitting Full Compression
6. Pull the Electrode straight out of the Torch Head. Check the face of the elec­trode for excessive wear. Refer to the following gure.
Lower End Fitting at Reset Full Extension
Art # A-08064_AC
New Electrode
Shield Cups
3. On torches with a shield cup body and a shield cap or deector, ensure that the cap or deector is threaded snugly
7. Reinstall the Electrode by pushing it
against the shield cup body. In shielded drag cutting operations (only), there may be an O-Ring between the shield
8. Reinstall the desired starter cartridge
cup body and drag shield cap. Do not lubricate the O-Ring.
Shield
Cup Body
Drag Shield Cap
9. Hand tighten the shield cup until it is
This completes the parts replacement procedures.
O-Ring No. 8-3488
SERVICE 0700 400 908
50
Art # A-03878
Worn Electrode
Electrode Wear
straight into the torch head until it clicks.
and tip into the torch head.
seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.
Page 51
CUTMASTER 30+

SECTION 6: PARTS LISTS

6.01 Introduction

A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

6.03 Power Supply Replacement

6.04 Replacement Parts
6.05 Options and Accessories
6.06 Replacement Parts for SL60 Hand Torch
6.07 Torch Consumable Parts (SL60)
NOTE!
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
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 power supply. Address all inquiries to your authorized distributor.
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, input power cable, input power cable adapters (2), gas pressure regulator / lter, SL60 Torch, spare parts kit, and operating manual.
Qty Description Catalog #
1 CUTMASTER 30+ Plasma cutting machine
package ESAB ETL 0559130001
1 CUTMASTER 30+ Plasma cutting machine package ESAB CE 0559130004
0700 400 908 PARTS LIST
51
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CUTMASTER 30+

6.04 Replacement Parts

Item # Qty Description Catalog #
1 1 TOP HANDLE KIT 0464565880
2 1 HANDLE COVER 0465952001 3 1 PANEL, RH CM40 ESAB 0559094440 4 1 ASS'Y PANEL FRONT CM30+/40+ 0700400929 5 1 PANEL, LH CM30+ ESAB 0700400932 6 1 ASS'Y, PANEL REAR CM30+/40+ ESAB 0700400935 7 1 TOP PANEL 0465951001 8 1 ASS'Y PCB DISPLAY CM30+ 0700400936 9 1 Main PCBA board assembly 0700400937 10 1 Control PCBA board assembly 0700400938 11 1 EMI PCBA board assembly 0700400939 12 1 Inbuilt air regulator assembly, AW2000-02D 0700400940 13 1 Fan, 0.61A, RUNDA 0700400941 14 1 Adapter connector Y shape, 8MM-8MM-G1/4 0700400942 15 1 Adapter connector L shape, 8MM-G1/8 0700400943 16 1 Pressure sensor, XGZP6161D102V 0700400944 17 1 Power switch, 690V 20A 0700400945 18 1 Input cable ETL, 3.3 MM2, 3.5 M 0700400946 19 1 Solenoid assembly, V3221-08E4 0700400947 20 1 Air tting EU Type 1/4 NPT (not shown) 0700400997 21 1 Air tting Milton type D 1/4 NPT (not shown) 0700400917 22 1 Input cable CE, 2.5 MM2, 3.5 M (not shown) 0700400990 23 16 Screw, black, full thread, M5X12 0700400995 24 12 Screw, black, self-tapping, 4.8X16 0700400996
PARTS LIST 0700 400 908
52
Page 53
CUTMASTER 30+
(Cat.

6.05 Options and Accessories

Qty Description Catalog #
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 Work Cable #8 with 50mm Dinse plug 9-9692 1 Multi - Purpose Cart 7-8888 1 Shoulder strap kit 0445197880
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single - Stage Filter Kit
0700 400 908 PARTS LIST
53
Page 54
CUTMASTER 30+

6.06 Replacement Parts for SL60 Hand Torch

Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 2 1 Trigger Assembly Replacement Kit 9-7034 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219 5 1 Large O-Ring 8-3487 6 1 Small O-Ring 8-3486 7 Leads Assemblies with ATC connectors (includes switch assemblies) 1 SL100, 20 - foot / 6.1m Leads Assembly with ATC connector 4-7836 1 SL100, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7837 8 1 Switch Kit 9-7031 9 1 Complete SL60 20'/6.1m torch assembly (not shown) 7-5200
1
8
2
4
5 6
3
7
Art # A-07993_AB
PARTS LIST 0700 400 908
54
Page 55

6.07 Torch Consumable Parts (SL60)

0700400998 REV AA
CUTMASTER 30+
A
0700 400 908 PARTS LIST
55
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CUTMASTER 30+
This Page Intentionally Blank
PARTS LIST 0700 400 908
56
Page 57
Production Code
Type of Power Supply (Note 1)

APPENDIX 1: DATA TAG INFORMATION

Manufacturer's Name and/or Logo, Location
Regulatory Standard Covering This Type of Power Supply
CUTMASTER 30+
Serial Number
Output Current Type
Plasma Cutting Symbol
Rated No­Load Voltage
Input Power Symbol
Degree of Protection
NOTES:
1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectier, DC output.
2. Indicates input voltages for this power supply. Most power supplies carry a label on the bottom of the unit showing input voltage requirements for the power supply as built.
3. Top row: Duty cycle values. Duty cycle values meet or exceed the IEC specied rating. Second row: Rated cutting current values. Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas of the power supply.
Input Power Specications (Phase, AC or DC Hertz Rating)
Conventional Load Current
Rated Supply
Conventional Load Voltage
Rated Supply Voltage (Note 2)
Country of Manufacturer
Output Range (Amperage/ Voltage)
Duty Cycle Factor
Regulatory Standard Covering This Type of Power Supply
Rated Maximum Supply Current
Maximum Eective Supply Current
Standard Symbols
AC
DC
Phase
Ø
Duty Cycle Data (Note 3)
Manufacturer's Revision Level
0700 400 908 APPENDIX
57
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CUTMASTER 30+
3 - Switch
2- Orange / PIP

APPENDIX 2: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram
Negative / Plasma
4 - Green / Switch
3 - White / Switch
1 - Black / PIP
Pilot
4 3
2 1
ATC Male Connector
Front View
8 7
6
5
8 - Open
7 - Open
6 - Open
5 - Open
8 - Open
7 - Open
6 - Open
5 - Open
ATC Female Receptacle
Front View
8 7
6 5
Pilot
Negative / Plasma
4 - Switch
4 3
2 1
2 - PIP
1 - PIP
A-03701_AB
APPENDIX 0700 400 908
58
Page 59

APPENDIX 3: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram
Torch: SL60 Leads: Torch Leads with ATC Connector Power Supply: CM30+
Torch
Head
PIP
Switch
Torch
Switch
Pilot
Torch
Leads
Black
Orange
Green
White
Negative / Plasma
Male
ATC Leads
Connector
ATC Female
Receptacle
1
2
5
6
4
3
8
7
1
2
5
6
4
3
8
7
CUTMASTER 30+
Power Supply
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
0700 400 908 APPENDIX
59
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ESAB / esab.com
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