Rev. AA Date: October 30, 2008 Manual # 0-5118
Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We
are proud to have you as our customer and will strive to provide
you with the best service and reliability in the industry. This
product is backed by our extensive warranty and world-wide
service network. To locate your nearest distributor or service
agency call 1-800-426-1888, or visit us on the web at www.
thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product.
Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the
entire manual, especially the Safety Precautions. They will help
you to avoid potential hazards that may exist when working with
this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and
Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through marketleading, 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
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2008 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Original Publication Date: October 30, 2008
Record the following information for Warranty purposes:
Where Purchased:_________________________________________________
APPENDIX 5: SYSTEM SCHEMATIC, 400V UNITS .............................................................. A-6
APPENDIX 6: Publication History ........................................................................................... A-8
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover
This Page Intentionally Blank.
TABLE OF CONTENTS
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
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
CUTMASTER 35mm, 40mm
• 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:
• Always read the Material Safety Data Sheets (MSDS) that
should be supplied with the material you are using. These
MSDSs will give you the information regarding the kind and
amount of fumes and gases that may be dangerous to your
health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications
in this manual.
• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible
or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlo
rinated solvents and cleansers. Remove all sources of these
vapors.
• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
-
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of
the health equipment to determine whether a hazard
exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-5711 or
your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can
be dangerous and hazardous to your health.
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 Manu
al.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma
arc.
-
• 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.
Manual 0-5118 1-1 GENERAL INFORMATION
• 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 work
place.
-
CUTMASTER 35mm, 40mm
GENERAL INFORMATION 1-2 Manual 0-5118
• 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.
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
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 Sub
section 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The
plasma arc process produces very bright ultra violet and infra red
light. These arc rays will damage your eyes and burn your skin if
you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles
or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your
skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protec
tive 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.
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 PROTECTION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
-
FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2,
FIRE PREVENTION IN THE USE OF
CUTTING AND WELDING PROCESSES, obtainable from
American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. AWS Standard A6.0,
WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
8. NFPA Standard 51,
OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain
-
able from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3
-
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain
able from the National Welding Supply Association, 1900
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer,
birth defects and other reproductive harm. Wash hands after han-dling. (California Health & Safety Code § 25249.5 et seq.)
Arch Street, Philadelphia, PA 19103
-
14. American Welding Society Standard AWSF4.1, RECOM-
!
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable
from the American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général
sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans
la zone de travail en cas de non-respect de la procédure
en question.
1.05 Precautions De Securite Importantes
CUTMASTER 35mm, 40mm
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
-
votre tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma
dépendent du genre de métal utilisé, des revêtements se trouvant
sur le métal et des différents procédés. Vous devez prendre soin
lorsque vous coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée et les
gaz de votre lieu de travail, consultez l’article 1 et les documents
cités à la page 5.
• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez toute
source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe, produit
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un
“pacemaker” cardiaque, les appareils auditif, ou autre
matériel de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le
manufacturier de matériel de santé pour déterminer
s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le +
603-298-5711 ou votre distributeur local si vous avez
des questions.
Manual 0-5118 1-3 GENERAL INFORMATION
de la fumée ou des gaz pouvant contenir des éléments reconnu
dans L’état de la Californie, qui peuvent causer des défauts de
naissance et le cancer. (La sécurité de santé en Californie et la
code sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au
jet de plasma requiert et produit de l’énergie électrique haute tension.
Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail
ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.
CUTMASTER 35mm, 40mm
GENERAL INFORMATION 1-4 Manual 0-5118
• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page
• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de con
signes.
5,
article 9.)
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:
Les incendies et les explosions peuvent résulter des scories chaudes,
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma
produit du métal, des étincelles, des scories chaudes pouvant mettre
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables
ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfer
mer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium
sous l’eau ou sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.
• Maintenez votre casque et vos lunettes de protection en bon
état. Remplacez toute lentille sale ou comportant fissure ou
rognure.
• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des
écrans de protection.
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux
sonores supérieurs aux limites normalement acceptables. Vous
dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter
une perte permanente de l’ouïe.
-
• Pour protéger votre ouïe contre les bruits forts, portez des
tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de
travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit,
consultez l’article 1, page 5.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.
Il f aut se laver l e s mai n s aprè s toute m anipul a tion.
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes
ayant été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS
DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible
auprès du Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY
10018
CUTMASTER 35mm, 40mm
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO
TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre
les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUD
AGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
-
-
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUD
AGE, disponible auprès de l’Association Nationale de Fournitures
de Soudage (National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET
TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRA
TOIRE, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
-
-
Manual 0-5118 1-5 GENERAL INFORMATION
CUTMASTER 35mm, 40mm
GENERAL INFORMATION 1-6 Manual 0-5118
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.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive
89/336/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.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in conjunction
with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing 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: Steve Ward
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Operations Director
CUTMASTER 35mm, 40mm
1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail
purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty are free of
defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal
Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance
with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair
or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship
within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics
Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the
date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
CUTMASTER™ 10mm
Power Supply Components
(Parts and Labor)
3 Years1 Year
Torch and Leads
(Parts and Labor)
CUTMASTER™12mm3 Years1 Year
CUTMASTER™ 20mm3 Years1 Year
CUTMASTER™ 25mm3 Years1 Year
CUTMASTER™ 35mm3 Years1 Year
CUTMASTER™ 40mm
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon
ndustry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product
returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
3 Years1 Year
LIMITATION OF LIABILITY: Thermal Dynamics Corporation 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 customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 the
goods covered by or furnished by Thermal Dynamics 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 liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal
Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007
Manual 0-5118 1-7 GENERAL INFORMATION
CUTMASTER 35mm, 40mm
This Page Intentionally Blank
GENERAL INFORMATION 1-8 Manual 0-5118
CUTMASTER 35mm, 40mm
!
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just
specication or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be
purchased by contacting Thermadyne at the
address and phone number in your area listed
in the inside back cover of this manual. Include
the Owner’s Manual number and equipment
identication numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermal Dynamics web site listed below and
clicking on Thermal Dynamics and then on the
Literature link:
http://www.thermal-dynamics.com
2.02 Equipment Identification
The unit’s identication number (specication
or part number), model, and serial number
usually 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 identied only by the specication or part
number printed on loosely attached card or the
shipping container. Record these numbers on the
bottom of page 1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it
against the invoice to make sure it is complete
and inspect the equipment for possible damage
due to shipping. If there is any damage, notify
the carrier immediately to le a claim. Furnish
complete information concerning damage claims
or shipping errors to the location in your area
listed in the inside back cover of this manual.
Include all equipment identication numbers as
described above along with a full description of
the parts in error.
Move the equipment to the installation site
before un-crating the unit. Use care to avoid
damaging the equipment when using bars,
hammers, etc., to un-crate the unit.
Manual 0-5118 2-1 INTRODUCTION
CUTMASTER 35mm, 40mm
INTRODUCTION 2-2 Manual 0-5118
CutMaster 35 Power Supply Specifications
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable
Power Supply includes input cable.
Output Current
30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
Particulates to 5 Microns
CutMaster 35 Power Supply Duty Cycle *
Ambient Temperature
Duty Cycle Ratings @ 40° C (104° F)
Opperating Range 0° - 50° C
All Units
Duty Cycle
60%80%
100%
Current
1008070
IEC
IECIEC
DC Voltage
120120116
* 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.
CutMaster 40 Power Supply Specifications
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power Cable
Power Supply includes input cable.
Output Current
30 - 120 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
Particulates to 5 Microns
CutMaster 35 Power Supply Duty Cycle *
Ambient Temperature
Duty Cycle Ratings @ 40° C (104° F)
Opperating Range 0° - 50° C
All Units
Duty Cycle
N/A80%100%
Current
120100
IECIECIEC
DC Voltage
128124
* 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. **Using a 208/230 VAC input will
reduce this duty cycle to 50%
2.04 Power Supply Specifications
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.
NOTE
CUTMASTER 35mm, 40mm
30.5"
774.7 m
63 lb / 28.6 kg
10.75"
273 mm
16.375"
416 mm
Art # A-08358
6"
150 mm
24"
0.6 m
6"
150 mm
6"
150 mm
Art # A-07925
Power Supply Dimensions & Weight Ventilation Clearance Requirements
2.05 Input Wiring Specifications
CutMaster 35mm Power Supply Input Cable Wiring Requirements
Input voltageFreqPower InputSuggested Sizes
Flexible Cord
VoltsHzkVAI maxI effFuse (amps)
(AWG)
3805018.428253210
3 Phase
4005018.727243210
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
CutMaster 40mm Power Supply Input Cable Wiring Requirements
Input voltageFreqPower InputSuggested Sizes
Flexible Cord
3 Phase
VoltsHzkVAI maxI effFuse (amps)
38050233532408
(AWG)
4005023.63431408
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.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle.
Manual 0-5118 2-3 INTRODUCTION
CUTMASTER 35mm, 40mm
Handle and Leads Wrap
Torch Leads Receptacle
Control Panel
Art # A-08359
Work Cable
and Clamp
Art # A-08547
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly
2.06 Power Supply Features
INTRODUCTION 2-4 Manual 0-5118
CUTMASTER 35mm, 40mm
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
Art # A-03322_AB
Art # A-02998
1.75" /
44.5 mm
1.375" / 35 mm
15.875" / 403 mm
0.625" /
16 mm
4.95" / 126 mm
1.175" / 30 mm
9.285" / 236 mm
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating
instructions and maintenance procedures for
the 1Torch Models SL100/Manual and SL100/
Mechanized Plasma Cutting Torches. Service of
this equipment is restricted to properly trained
personnel; unqualied 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
Plasma torches are similar in design to the automotive spark plug. They consist of negative and
positive sections separated by a center insulator. Inside the torch, the pilot arc starts in the
gap between the negatively charged electrode
and the positively charged tip. Once the pilot
arc has ionized the plasma gas, the superheated
column of gas ows through the small orice in
the torch tip, which is focused on the metal to be
cut.
A single torch lead provides gas from a single
source to be used as both the plasma and secondary gas. The air ow is divided inside the
torch head. Single - gas operation provides a
smaller sized torch and inexpensive operation.
NOTE
Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch
operation.
Refer to the Appendix Pages for additional
specifications as related to the Power Supply
used.
2T.03 Specifications
A. Torch Configurations
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.
2. Mechanized Torch, Model
The standard machine torch has a positioning
tube with rack & pinch block assembly.
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20 ft / 6.1 m, with ATC connectors
• 50 ft / 15.2 m, with ATC connectors
Machine Torches
• 5 foot / 1.5 m, with ATC connectors
• 10 foot / 3.05 m, with ATC connectors
• 25 foot / 7.6 m, with ATC connectors
• 50 foot / 15.2 m, with ATC connectors
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
are available as follows:
D. Parts - In - Place (PIP)
Torch Head has built - in switch
Manual 0-5118 2T-1 INTRODUCTION
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream
through torch.
CUTMASTER 35mm, 40mm
INTRODUCTION 2T-2 Manual 0-5118
!
A-00002
Workpiece
Power
Supply
+
_
C
B
A
F. Torch Ratings
Manual Torch Ratings
CUTMASTER 35mm
Ambient Temperature
Duty Cycle100% @ 100 Amps @ 400 scfh
Maximum Current100 Amps
Voltage (V
Arc Striking Voltage7kV
Ambient Temperature
Duty Cycle100% @ 120 Amps @ 400 scfh
Maximum Current120 Amps
Voltage (V
Arc Striking Voltage7kV
)500V
peak
Manual Torch Ratings
CUTMASTER 40mm
)500V
peak
104° F
40° C
104° F
40° C
G. Gas Requirements
2T.04 Options And Accessories
For options and accessories, see section 6.
2T.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The
metal to be cut or removed is melted by the heat
of the arc and then blown away.
While the goal of plasma arc cutting is separation
of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone
B, where a pilot arc between the electrode and the
torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through
the column of plasma gas in Zone C.
Manual and Mechanized Torch Gas Specifications
Gas (Plasma and Secondary)Compressed Air
Operating Pressure
Refer to NOTE
Maximum Input Pressure125 psi / 8.6 bar
Gas Flow (Cutting and Gouging)
60 - 95 psi
4.1 - 6.5 bar
300 - 500 scfh
142 - 235 lpm
WARNING
This torch is not to be used with oxygen
(O2).
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 standoff tip the recommended standoff is 3/16
inches / 4.7 mm.
Typical Torch Head Detail
By forcing the plasma gas and electric arc through
a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted
plasma arc is shown in Zone C. Direct current
(DC) straight polarity is used for plasma cutting,
as shown in the illustration.
Zone A channels a secondary gas that cools the
torch. This gas also assists the high velocity plasma
gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.
CUTMASTER 35mm, 40mm
A-02997
Torch Trigger
PIP Switch
Shield Cup
To Control
Cable Wiring
Torch Switch
PIP Switch
Shield Cup
To ATC
CNC Start
PIP Switch
Shield Cup
PIP Switch
Shield Cup
Remote Pendant
Automation Torch
To ATC
To ATC
Art # A-08168
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.
The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot
arc creates a path for the main arc to transfer to
the work.
D. Main Cutting Arc
DC power is also used for the main cutting arc.
The negative output is connected to the torch electrode through the torch lead. The positive output
is connected to the workpiece via the work cable
and to the torch through a pilot wire.
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit. When the shield cup is properly installed, it
closes a switch. The torch will not operate if this
switch is open.
Parts - In - Place Circuit Diagram for Hand Torch
Manual 0-5118 2T-3 INTRODUCTION
Parts - In - Place Circuit Diagram for Machine
Torch
CUTMASTER 35mm, 40mm
This Page Intentionally Blank
INTRODUCTION 2T-4 Manual 0-5118
CUTMASTER 35mm, 40mm
!
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 a handle 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.
HANDLE is 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.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other ve
hicle.
-
Manual 0-5118 3-1 INSTALLATION
CUTMASTER 35mm, 40mm
INSTALLATION 3-2 Manual 0-5118
Art # A-08548
Input Power Cable Connections
Three-Phase (3ø)
GND
L1
L2
L3
L4
3.03 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.
The following illustration and directions are for wiring three phase input power.
Three Phase Input Power Wiring
A. Connections to Three Phase Input Power
WARNING
Disconnect input power from the power supply and input cable before attempting this procedure.
These instructions are for replacing the input power and or cable for 400 VAC Power Supply to
Three - Phase input power.
1. Remove the Power Supply cover per instructions found in section 5.
2. Disconnect the original input power cable from the main input contactor and the chassis
ground connection.
3. Loosen the through - hole protector on the back panel of the power supply. Pull the original
power cable out of the power supply.
4. Using a customer supplied four - conductor input power cable for the voltage desired, strip
back the insulation on the individual wires.
5. Pass the cable being used through the access opening in the back panel of the power supply.
Refer to Section 2 for power cable specications.
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2).
6. Connect the wires as follows.
• Wires to L1, L2 and L3 input. It does not matter what order these wires are attached. See
previous illustration and on label in the power supply.
• Green / Yellow wire to Ground.
7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.
8. Reinstall the Power Supply cover.
9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.
10. Connect the input power cable (or close the main disconnect switch) to supply power.
CUTMASTER 35mm, 40mm
Art # A-07943
Hose Clamp
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
3.04 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders. Refer to the following
two subsections if an optional air line lter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical ttings 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 air passages in the torch.
Air Connection to Inlet Port
Installing Optional Single - Stage Air Filter
An optional lter kit is recommended for improved ltering 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 lter hose.
3. Connect the air line to the Filter. The illustration shows typical ttings as an example.
Manual 0-5118 3-3 INSTALLATION
CUTMASTER 35mm, 40mm
INSTALLATION 3-4 Manual 0-5118
Art # A-07944
Hose Clamp
1/4 NPT to 1/4"
(6mm) Fitting
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
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 air passages
in the torch. Connect as follows:
Optional Single - Stage Filter Installation
CUTMASTER 35mm, 40mm
Art # A-07945_AB
Regulator/Filter
Assembly
Regulator
Input
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Gas Supply
Hose
1/4 NPT to 1/4”
(6mm) Fitting
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line lter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied
with the lter assembly.
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 air passages
in the torch.
2. Connect the two stage lter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied ttings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose
barbed tting is shown as an example.
Optional Two - Stage Filter Installation
Manual 0-5118 3-5 INSTALLATION
CUTMASTER 35mm, 40mm
Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specications for installation and maintenance procedures for
high pressure regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign
material. Briey 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
pressure 100 psi (6.9 bar) and ows of at least 300 scfh (141.5 lpm). For Maximum pressures
and Flows refer to the "Gas Requirements" chart in section 2T.03.
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure 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 air passages
in the torch.
INSTALLATION 3-6 Manual 0-5118
1
2
Art # A-07885
SECTION 3 TORCH:
INSTALLATION
CUTMASTER 35, 40mm
3T.01 Torch Connections
If necessary, connect the torch to the Power
Supply. Connect only the Thermal Dynamics
model SL100 / Manual or SL100 / Mechanical
Torch to this power supply. Maximum torch
leads length is 100 feet / 30.5 m, 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.
1. Put the ON / OFF switch in the
ON (up) position.
2. Put the Function Control switch in the
SET position.
3. Place a welding lter lens in front of the
torch and turn on the air. Do not start
an arc!
Any oil or moisture in the air will be visible
on the lens.
3T.02 Setting Up Mechanical Torch
NOTE
An adapter is required to be installed in the
power supply if converting a hand torch system
to operate a machine torch.
WARNING
Disconnect primary power at the source
before disassembling the torch or torch
leads.
Connecting the Torch to the Power Supply
3. The system is ready for operation.
Check Air Quality
To test the quality of air:
The mechanical torch includes a positioning
tube with rack and pinch block assembly.
1. Mount the torch assembly on the cutting
table.
2. To obtain a clean vertical cut, use a
square to align the torch perpendicular to
the surface of the workpiece.
Manual 0-5118 3T-1 INSTALLATION
CUTMASTER 35mm, 40mm
A-02585
Workpiece
Square
Pinch Block
Assembly
Mechanical Torch Set - Up
3. The proper torch parts (shield cup, tip,
start cartridge, and electrode) must be
installed for the type of operation. Refer
to Section 4T.07, Torch Parts Selection
for details.
INSTALLATION 3T-2 Manual 0-5118
SECTION 4 SYSTEM:
+
A
+
PSI BAR
MAX MAX
MIN MIN
!
12
3
4
5
6
7
8
9
Art# A-07886
MIN
MAX
10
PSIBAR
MAXMAX
MINMIN
80
75
70
65
5.5
855.9
906.3
5.2
4.8
4.5
Art # A-08170
OPERATION
4.01 Front Panel Controls /
Features
See Illustration for numbering Identification
1. Output Current Control
Sets the desired output current. Output settings
up to 60 Amps may be used for drag cutting (with
the torch tip contacting the workpiece) or higher
for standoff cutting.
2. Function Control
Function Control Knob, Used to select between
the different operating modes.
CUTMASTER 35mm, 40mm
SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.
RUN Used for general cutting operations
RAPID AUTO RESTART Allows for faster
restarting of the Pilot Arc for uninterrupted cutting.
LATCH Used for longer hand held
cuts. Once a cutting arc is established, the torch
switch can be released. The cutting arc will remain on until the torch is lifted away from the
work piece, the torch leaves the edge of the work
piece the torch switch is activated again or if one
of the system interlocks is activated.
3. On Off Power Switch
ON / OFF Switch controls input power
to the power supply. Up is ON, down is OFF.
4. Air/Gas Pressure Control
The Pressure
"SET" mode to adjust the air/gas pressure. Pull
the knob out to adjust and push in to lock.
Control is used in the
6. Temp Indicator
Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let
the unit cool before continuing operation.
7. Gas Indicator
Indicator is ON when minimum input gas pressure for power supply operation is present. Minimum pressure for power supply operation is not
sufficient for torch operation.
8. DC Indicator
Indicator is ON when DC output circuit is active.
9. !Fault Error Indicator
Indicator is ON when Fault circuit is active. See
section 5 for explanations of fault lights.
10. Pressure Indicators
5. 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.
The Indicators will illuminate
according to the pressure set by the Pressure Control Knob (number 4).
Manual 0-5118 4-1 OPERATION
CUTMASTER 35mm, 40mm
OPERATION 4-2 Manual 0-5118
Art # A-04509
A
+
PSI BAR
MAX MAX
MIN MIN
!
1
2
Art# A-07946
MIN
MAX
4.02 Preparations for Operation
Power On
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 (120 amps maximum).
Refer to Section 4T.07 and following for torch parts
selection.
Torch Connection
Check that the torch is properly connected. Only
Thermal Dynamics model SL100 / Manual or
SL100 / Mechanical Torches may be connected
to this Power Supply. See Section 3T of this
manual.
Place the Power Supply ON / OFF switch to the
ON (up) position. AC indicator turns on.
Gas indicator turns on if there is sufficient gas
pressure for power supply operation and the cooling fans turn on.
NOTE
Minimum pressure for power supply operation
is lower than minimum for torch operation.
The cooling fans will turn on as soon as the unit
is turned on. After the unit is idle for ten (10)
minutes the fans will turn off. The fans will
come back on as soon as the torch switch (Start
Signal) is activated or if the unit is turned off,
then turned on again. If an over temperature
condition occurs, the fans will continue to run
while the condition exists and for a ten (10)
minute period once the condition is cleared.
Set Operating Pressure
1. Place the Power Supply Function Control
knob to the SET position. Gas will
ow.
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, Specications.
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 toSection
2). Check connections and turn air supply on.
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.
2. For Standoff cutting, adjust gas pressure
from 70 - 85 psi / 4.8 - 5.9 bar (LED's
in center of control panel). Refer to the
Standoff chart for pressure setting details.
CUTMASTER 35mm, 40mm
STANDOFF
Gas Pressure Settings
SL100
(Mechanized Torch)
Leads
Length
Up to 25'
(7.6 m)
Each
Additional
25' (7.6 m)
SL100
(Hand Torch)
75 psi
5.2 bar
Ad 5 psi
0.4 bar
SL100 SV
(Automation Torch)
75 psi
5.5bar
Add 5 psi
0.4 bar
3. For Drag cutting, adjust gas pressure
from 75 - 95 psi / 5.2 - 6.5 bar (LED's
in center of control panel). Refer to the
Drag Cutting chart for pressure setting
details.
DRAG (60 amps or less)
Gas Preassure Settings
SL100
Leads Length
Up to 25'
(7.6 m)
Each
Additional
25' (7.6 m)
(Hand Torch)
80 psi
5.5 bar
Ad 5 psi
0.4 bar
Select Current Output Level
1. Place the Function Control Knob in one
of the three operating positions available:
Cutting Operation
When the torch leaves the workpiece during cutting operations with the Function Control Knob in
the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves
the workpiece the pilot arc restarts instantly, and
the cutting arc restarts instantly when the pilot
arc contacts the workpiece. (Use the 'Rapid Auto
Restart' position when cutting expanded metal or
gratings, or in gouging or trimming operations
when an uninterrupted restart is desired). And
with the knob in the LATCH position the main
cutting arc will be maintained after the torch
switch is released.
Typical Cutting Speeds
Cutting speeds vary according to torch output
amperage, the type of material being cut, and operator skill. Refer to Section 4T.08 and following
for greater details.
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.
Postflow
Release the trigger to stop the cutting arc. Gas
continues to flow for approximately 20 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.
RUN ,
RAPID AUTO RESTART
or LATCH . Gas ow stops.
2. Set the output current to desired amperage with the Output Current Control
Knob.
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 0-5118 4-3 OPERATION
CUTMASTER 35mm, 40mm
This Page Intentionally Blank
OPERATION 4-4 Manual 0-5118
A-03510_AB
Electrode
Start Cartridge
Tip
Shield Cup
Torch Head
SECTION 4 TORCH:
OPERATION
4T.01 Torch Parts Selection
Depending on the type of operation to be done
determines the torch parts to be used.
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter
Cartridge
NOTE
Refer to Section 4T.07 and following for
additional information on torch parts.
Change the torch parts for a different 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 starter cartridge
in place. Position the torch with the shield cup
facing upward to keep these parts from falling
out when the cup is removed.
CUTMASTER 35mm, 40mm
Torch Parts
(Drag Shield Cap & Shield Cup Body Shown)
3. Install the replacement Electrode by pushing it straight into the torch head until it
clicks.
4. Install the starter cartridge 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. If resistance
is felt when installing the cup, check the
threads before proceeding.
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.
Manual 0-5118 4T-1 OPERATION
CUTMASTER 40mm
OPERATION 4T-2 Manual 0-5118
Kerf Width
Cut Surface
Bevel Angle
Top Edge
Rounding
Cut Surface
Drag Lines
Dross
Build-Up
Top
Spatter
A-00007
!
4T.02 Cut Quality
NOTES
Cut quality depends heavily on setup and
parameters such as torch standoff, alignment
with the workpiece, cutting speed, gas pressures,
and operator ability.
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel
angle may be major factors when the surface will
be welded after cutting. Dross - free cutting is
important when nish cut quality is desired to
avoid a secondary cleaning operation. The following cut quality characteristics are illustrated
in the following gure:
Bottom Dross Buildup
Molten material which is not blown out of the
cut area and resolidifies on the plate. Excessive
dross may require secondary cleanup operations
after cutting.
Kerf Width
The width of the cut (or the width of material
removed during the cut).
Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.
4T.03 General Cutting Information
WARNINGS
Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.
Cut Quality Characteristics
Cut Surface
The desired or specified condition (smooth or
rough) of the face of the cut.
Nitride Build - Up
Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material is to be welded after the cutting process.
Bevel Angle
The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a
0° bevel angle.
Top - Edge Rounding
Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.
Frequently review the Important Safety
Precautions at the front of this manual. Be
sure the operator is equipped with proper
gloves, clothing, eye and ear protection.
Make sure no part of the operator’s body
comes into contact with the workpiece while
the torch is activated.
CAUTION
Sparks from the cutting process can cause
damage to coated, painted, and other surfaces
such as glass, plastic and metal.
NOTE
Handle torch leads with care and protect them
from damage.
Piloting
Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.
CUTMASTER 35mm, 40mm
Right Side
Cut Angle
Left Side
Cut Angle
A-00512
A-00024_AB
Shield Cup
Torch
Standoff Distance
1/8" - 3/8" (3 - 9mm)
Torch Standoff
Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as
well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff
will generally result in a more square cut.
Edge Starting
For edge starts, hold the torch perpendicular to
the workpiece with the front of the tip near (not
touching) the edge of the workpiece at the point
where the cut is to start. When starting at the edge
of the plate, do not pause at the edge and force the
arc to "reach" for the edge of the metal. Establish
the cutting arc as quickly as possible.
Direction of Cut
In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of
gas. This swirl effect results in one side of a cut
being more square than the other. Viewed along
the direction of travel, the right side of the cut is
more square than the left.
tant cleanup can be accomplished by scraping,
not grinding.
4T.04 Hand Torch Operation
Standoff 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.
Side Characteristics Of Cut
To make a square - edged cut along an inside
diameter of a circle, the torch should move counterclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch
should travel in a clockwise direction.
Dross
When dross is present on carbon steel, it is commonly referred to as either “high speed, slow
speed, or top dross”. Dross present on top of
the plate is normally caused by too great a torch
to plate distance. "Top dross" is normally very
easy to remove and can often be wiped off with
a welding glove. "Slow speed dross" is normally
present on the bottom edge of the plate. It can vary
from a light to heavy bead, but does not adhere
tightly to the cut edge, and can be easily scraped
off. "High speed dross" usually forms a narrow
bead along the bottom of the cut edge and is very
difficult to remove. When cutting a troublesome
steel, it is sometimes useful to reduce the cutting
speed to produce "slow speed dross". Any resul-
2. Depending on the cutting operation, do one
of the following:
a. For edge starts, hold the torch perpen-
dicular 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 standoff cutting, hold the torch 1/8
- 3/8 in (3-9 mm) from the workpiece
as shown below.
Standoff Distance
Manual 0-5118 4T-3 OPERATION
CUTMASTER 40mm
OPERATION 4T-4 Manual 0-5118
A-02986
Trigger
Trigger Release
3
4
Art # A-03383
Trigger
2
1
Trigger Release
Shield Cup
Workpiece
Standoff Guide
Art # A-04034
Torch Tip
A-03539
Non-Conductive
Straight Edge
Cutting Guide
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.
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 preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
8. For a consistent standoff height from the
workpiece, install the standoff 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 standoff guide against
the workpiece.
Shield Cup With Straight Edge
The drag shield cup can be used with a non conductive straight edge to make straight cuts by
hand.
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.
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.
NOTE
WARNING
The straight edge must be non - conductive.
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
A-02986
Trigger
Trigger Release
3
4
Art # A-03383
Trigger
2
1
Trigger Release
Drag cutting works best on metal 1/4" (6 mm)
thick or less.
NOTE
Drag cutting can only be performed at 60 amps
or less.
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.
4. Keep the torch in contact with the workpiece during the cutting cycle.
5. Hold the torch away from your body.
6. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
CUTMASTER 35mm, 40mm
8. Cut as usual. Simply release the trigger
assembly to stop cutting.
9. 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.
7. 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 preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
Piercing With Hand Torch
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 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.
2. 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.
3. In a portion of the unwanted metal start
Manual 0-5118 4T-5 OPERATION
CUTMASTER 40mm
OPERATION 4T-6 Manual 0-5118
A-02986
Trigger
Trigger Release
!
the pierce off the cutting line and then
continue the cut onto the line. Hold the
torch perpendicular to the workpiece
after the pierce is complete.
4. Hold the torch away from your body.
5. Slide the trigger release toward the back
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.
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.
NOTES
The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.
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.
4T.05 Gouging
WARNINGS
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
(standoff).
CAUTION
7. Clean spatter and scale from the shield
cup and the tip as soon as possible.
Touching the torch tip or shield cup to the work surface
will cause excessive parts wear.
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 standoff height
• Proper work cable connection
CUTMASTER 35mm, 40mm
35°
Workpiece
Torch Head
Standoff Height
A-00941_AB
Torch Travel Speed
NOTE
Re fer to App endix 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.
Pressure Setting
Even though the setting is within the specified
range, if the torch does not pilot well the pressure
may need to be reduced.
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.
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
standoff height.
4T.06 Mechanized Torch Operation
Cutting With Mechanized Torch
The mechanized torch can be activated by remote
control pendant or by a remote interface device
such as CNC.
1. To start a cut at the plate edge, position
the center of the torch along the edge of
the plate.
Travel Speed
Proper travel speed is indicated by the trail of the
arc which is seen below the plate. The arc can be
one of the following:
1. Straight Arc
A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended
for the best cut using air plasma on stainless
or aluminum.
2. Leading Arc
The leading arc is directed in the same direction as torch travel. A five degree leading arc
is generally recommended for air plasma on
mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direction as torch travel.
Gouging Angle and Standoff Distance
Standoff Distance
The tip to work distance affects gouge quality
and depth. Standoff distance of 1/8 - 1/4 inch
(3 - 6 mm) allows for smooth, consistent metal
removal. Smaller standoff distances may result
in a severance cut rather than a gouge. Standoff
distances greater than 1/4 inch (6 mm) may result
in minimal metal removal or loss of transferred
main arc.
Manual 0-5118 4T-7 OPERATION
CUTMASTER 40mm
OPERATION 4T-8 Manual 0-5118
Standoff Distance
Straight Arc
Trailing Arc
Leading Arc
Direction of Torch Travel
A-02586
Mechanized Torch Operation
Piercing With Machine Torch
To pierce with a machine torch, the arc should
be started with the torch positioned as high as
possible above the plate while allowing the arc
to transfer and pierce. This standoff helps avoid
having molten metal blow back onto the front end
of the torch.
When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
enabled until the arc penetrates the bottom of the
plate. As motion begins, torch standoff should be
reduced to the recommended 1/8 - 1/4 inch (3-6
mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and the
tip as soon as possible. Spraying or dipping the
shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.
For optimum smooth surface quality, the travel
speed should be adjusted so that only the leading
edge of the arc column produces the cut. If the
travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search
of metal for transfer.
Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer
cut. The power source output should be reduced
also. Refer to the appropriate Control Module
Operating Manual for any Corner Slowdown
adjustments that may be required.
4T.07 Parts Selection for SL100Torch Cutting
Start
Cartridge
9-8213
Electrode
9-8215
Tips:
20A 9-8205
30A 9-8206
40A 9-8207
60A 9-8252
Tip Gouging A 9-8225 (40 Amps Max.)
Tip Gouging B 9-8226 (50 - 100 Amps)
Tip Gouging C 9-8227 (60 - 120 Amps)
Tip Gouging D 9-8228 (60 - 120 Amps)
Tip Gouging E 9-8254 (60 - 120 Amps)
Shield Cap, Gouging
9-8241
Shield Cap, Drag
40A 9-8244
40A 9-8208
50-55A 9-8209
60A 9-8210
70A 9-8231
80A 9-8211
90/100A 9-8212
120A 9-8253
Shield Cap, Drag
50-60A 9-8235
Shield Cap, Drag
70-100A 9-8236
Shield
Cup Body,
9-8237
70-120A
50-60A
40A
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
Tip:
Tips:
Tips:
Tips:
DRAG TIP
CUTTING
40-120A
GOUGING
CUTTING
CUTTING
CUTTING
Art # A-08065_AC
DRAG SHIELD
CUTTING
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Standoff Guide
9-8281
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
Standoff Guide
9-8281
STANDOFF
CUTTING
DRAG SHIELD
CUTTING
STANDOFF CUTTING
Shield Cap, Deflector
9-8243
Shield
Cup Body,
9-8237
Shield Cup
9-8218
O-Ring No. 8-3488
Standoff Guide
9-8251
NOTE
CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
CutMaster 102 uses 100A and less
CutMaster 152 uses 120A and less
CUTMASTER 35mm, 40mm
Manual 0-5118 4T-9 OPERATION
CUTMASTER 40mm
OPERATION 4T-10 Manual 0-5118
4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip
Type Torch: SL100 With Exposed TipType Material: Mild Steel
Type Plasma Gas: AirType Secondary Gas: Single Gas Torch
ThicknessTipOutputAmperage Speed (Per Minute)StandoffPlasma Gas PressFlow (CFH)PiercePierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) InchesMetersInches mmpsi*barPlasma Total** Delay (Sec) Inches mm
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709;
D499620; D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8241 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8243 Shield Cap US Pat No(s) 6914211; D493183
Other Pat(s) Pending
9-8235 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8236 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
9-8238 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8239 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8244 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:
Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap
CUTMASTER 35mm, 40mm
Manual 0-5118 4T-19 OPERATION
CUTMASTER 40mm
This Page Intentionally Blank
OPERATION 4T-20 Manual 0-5118
SECTION 5 SYSTEM:
Warning!
Disconnect input power before maintaining.
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the torch body tip,
electrode, start cartridge and shield cup
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Replace all
broken parts
Visually check and
Carefully clean the
interior
Maintain more often
if used under severe
conditions
Art # A-07938_AB
5.01 General Maintenance
CUTMASTER 35mm, 40mm
SERVICE
Manual 0-5118 5-1 SERVICE
CUTMASTER 35mm, 40mm
SERVICE 5-2 Manual 0-5118
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/flow.
3. Purge plasma gas line to remove any moisture
build-up.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate
air flow.
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.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as
required
2. Check cables and hoses for leaks or cracks,
replace if necessary.
3. Check all contactor points for severe arcing or
pits, replace if necessary.
4. Vacuum dust and dirt out of the entire machine.
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 -
SymptomCommon Cause
Insufficient
Penetration
Main Arc
Extinguishes
Excessive Dross
Formation
Short Torch Parts
Life
Difficult Starting 1. Worn torch parts.
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
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
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
2. Non - Genuine Thermal Dynamics
parts used.
3. Incorrect gas pressure.
5.04 Fault Indicator
A
+
PSI BAR
MAX MAX
MIN MIN
!
1
2
3
4
Art# A-07988
MIN
MAX
0
1
2
3
4
5
6
7
5
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software
used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second
digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the
Temp indicator and 75 psi indicators are on indicating
the version would be 2.3.
CUTMASTER 35mm, 40mm
When the !"Fault" indicator is on or blinking it
will be accompanied by one of the pressure indicator lights depending on what the Fault is. The
following table explains each of those Faults.
Pressure
Fault
Indicator
MaxOver Pressure
90Internal Error
85Shorted Torch
80Consumables Missing
75Start Error
70Parts in Place
65Input Power
MinUnder Pressure
Fault explanations are covered in the following
tables.
NOTE
Manual 0-5118 5-3 SERVICE
CUTMASTER 35mm, 40mm
SERVICE 5-4 Manual 0-5118
5.05 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.
Problem -
SymptomPossible CauseRecommended Action
ON / OFF Switch
is on but the A/C
Indicator does not
light
Fault indicator
flashing, 65 PSI
indicator flashing
TEMPERATURE
indicator on.
FAULT indicator
flashing.
GAS LED off,
FAULT and MIN
pressure indicators
flashing.
FAULT and 70 PSI
indicators flashing.
FAULT and 75 PSI
indicators flashing.
1. Primary power disconnect is in
OFF position.
2. Primary fuses / breakers are
blown or tripped.
3. Units internal fuse blown.
4. Faulty components in unit.
1. Improper Input Voltage.
2. Primary input voltage problem.
3. Faulty components in unit.
1. Air flow 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. AIR PRESSURE CONTROL
regulator set too low.
5. 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. Start signal is active when
ON/OFF SWITCH is turned to
ON position.
2. Problem in the torch and leads
switch circuit.
3. Failed components in unit.
1. Turn primary power disconnect switch to ON position.
2. a) Have qualified person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle
3. a) Replace fuse.
b) If fuse blows again, return to authorized service center
for repair or replacement.
4. Return to authorized service center for repair or replace ment.
1. Check for proper primary input voltage.
2. Have qualified person check primary voltage to insure it
meets unit requirements see section 2.05.
3. Return to authorized service center for repair or replace ment.
1. Refer to clearance information – section 2.04
2. Allow unit to cool.
3. Return to authorized service center for repair or replace ment.
1. Connect gas supply to unit.
2. Turn gas supply on.
3. Set air supply inlet pressure to unit to 120 psi.
4. Adjust regulator to set air pressure - see section 4.02.
5. Return to authorized service center for repair or replace ment.
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 replace ment.
1. Start can be active for one of the following:
• Hand torch switch held closed
• Hand pendant switch held closed
• CNC START signal is active low
• Release the START signal source
2. Replace torch and leads or return to authorized service
center for repair or replacement.
3. Return to authorized service center for repair or replace ment.
CUTMASTER 35mm, 40mm
Problem Symptom
FAULT & 80 PSI
indicators flashing.
Gas flow is cycling
on and off.
Nothing happens
when torch switch
or remote switch
is closed ( Or CNC
START signal is
active) No gas
flow, DC LED OFF.
FAULT and 85 PSI
indicators flashing.
Possible CauseRecommended Action
1. Torch shield cup is loose.
2. Torch tip, electrode or starter
cartridge missing.
3. Torch starter cartridge is stuck.
4. Open conductor in torch leads.
5. Problem in the torch and leads
switch circuit.
6. Failed components in unit.
1. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).
2. CNC Controller device not
providing Start signal.
3. Failed components in unit.
1. Upper O-Ring on torch head is
in wrong position.
2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
5. Temporary Short indicated by 5
blinks per second.
6. Power Supply Failure (Standard
rate of blinking)
1. Tighten shield cup by hand. Do not overtighten.
2. Turn off power supply. Remove shield cup. Install missing
parts.
3. Turn off power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if
fitting does not move freely.
4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Replace torch and leads or return to authorized service
center for repair or replacement.
6. Return to authorized service center for repair or
1. Take Torch and Leads (Remote Pendant) to Authorized
Repair Facility.
2. Contact Controller manufacturer.
3. Return to authorized service center for repair or replace ment.
1. Remove shield cup from torch; check upper O-Ring position;
correct if necessary.
2. Turn off power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if
fitting does not move freely.
3. Inspect torch consumable parts. Replace if necessary.
4. Replace torch and leads or return to an authorized service
center for repair.
5. Release torch switch and reactivate.
6. Return to autorized service center for repair or replacement.
No Fault lights on,
no arc in torch.
Fault and 90 PSI
indicators flashing
Pilot arc is on but
cutting arc will not
establish
Torch cutting is
diminished
1. Failed components in unit.1. Return to an authorized service center for repair.
1. Internal Error1. Turn the ON / OFF switch OFF then back ON again. If that
does not clear the fault, return to an authorized service
center for repair.
1. Work cable not connected to
work piece.
2. Work cable/connector broken.
3. Failed components in unit.
1. Incorrect current setting.
2. Worn torch consumables.
3. Poor work cable connection to
work piece.
4. Torch being moved too fast.
5. Excessive oil or water in torch.
6. Failed components in unit.
1. Connect work cable.
2. Replace work cable.
3. Return to an authorized service center for repair.
1. Check and adjust to proper setting.
2. Check torch consumables and replace as needed.
3. Check the connection of the Work Lead to the work piece.
4. Reduce cutting speed.
5. Refer to "Check air quality" in section 3 Torch.
6. Return to an authorized service center for repair.
Manual 0-5118 5-5 SERVICE
CUTMASTER 35mm, 40mm
SERVICE 5-6 Manual 0-5118
Art # A-08429
Lower
Screws
Lower
Screws
Slots
Upper
Screws
Art # A-07989
1
2
3
4
5
6mm
5.06 Power Supply Basic Parts
Replacement
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power
supply.
This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.
A. Cover Removal
1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.
C. Filter Element Assembly Replacement
The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should
be checked per the Maintenance Schedule (Subsection
5.02), and either cleaned or replaced.
1. Remove power from the power supply; turn off
the gas supply and bleed down the system.
2. Remove the system cover. See "A Cover Removal" in this section.
3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.
4. Hold a wrench or similar tool against the locking ring on the filter assembly fitting, then pull
on the hose to release it. (Numbers 2 and 3 in
the following illustration).
2. Carefully pull the Cover up and away from the
unit.
B. Cover Installation
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage
the lower screws.
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.
CUTMASTER 35mm, 40mm
Art # A-07990
Filter Element
Art # A-02476
Filter
Element
(Cat. No. 9-7741)
Housing
Cover
Barbed
Fitting
Spring
Assembled Filter
O-ring
(Cat. No. 9-7743)
5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previous illustration.
6. Disconnect the input line from the filter element
assembly.
7. Remove the filter element assembly through the
rear opening.
NOTE
If replacing or cleaning just the filter element
refer to the following illustration for disassembly.
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 filter 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.
8. Install the new or cleaned assembly by reversing
these procedures.
9. Turn on the air supply and check for leaks before
reinstalling the cover.
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 first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.
Manual 0-5118 5-7 SERVICE
CUTMASTER 35mm, 40mm
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
Optional Two-Stage Filter Element
Replacement
The Two-Stage Air Filter has two Filter Elements.
When the Filter Elements become dirty the Power
Supply will continue to operate but cut quality may
become unacceptable. Refer to Section 6, Parts List,
for replacement filter element catalog number.
1. Shut off primary input power.
2. Shut off air supply and bleed down system.
WARNING
Always turn off the air supply and bleed the
system before disassembling the Filter Assembly
as injury could result.
3. Loosen the two bolts on the top of the Filter
Assembly enough to allow the Filter Elements
to move freely.
4. Note the location and orientation of the old
Filter Elements.
5. Slide out the old Filter Elements.
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the
Filter Assembly, with the same orientation as
noted in Step 4 above.
7. Hand tighten the two bolts evenly, then torque
each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket.
8. Slowly apply air pressure to the assembly,
checking for leaks.
NOTE
A small amount of air leakage from the bottom
fitting is normal.
This completes the parts replacement procedures.
SERVICE 5-8 Manual 0-5118
Upper Groove
with Vent Holes
Must Remain Open
Threads
Upper O-Ring
in Correct Groove
Lower O-Ring
Art # A-03725
ATC Male Connector
Art #A-03791
Gas Fitting
O-Ring
SECTION 5 TORCH:
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 affect
the pilot arc initiation and the overall cut quality
of the torch.
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
CUTMASTER 35mm, 40mm
SERVICE
Torch Head O-Ring
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.
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 film of oring lubricant (Catalog # 8-4025) to the o-rings on
a weekly basis.
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.
Manual 0-5118 5T-1 SERVICE
CUTMASTER 35, 40mm
Art # A-08067
Drag Shield Cap
Shield
Cup Body
O-Ring No. 8-3488
Art # A-03878
Good Tip
Worn Tip
A-03406
Art # A-08064
Spring-Loaded
Lower End Fitting
Full Compression 1/8”
Spring-Loaded
Lower End Fitting at Rest /
Full Extension
Worn Electrode
New Electrode
Art # A-03284
5T.02 Inspection and Replacement
of Consumable Torch Parts
WARNINGS
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 effect the performance of the
system.
2. Inspect the cup for damage. Wipe it clean or
replace if damaged.
Shield Cups
4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice).
Clean or replace the tip if necessary.
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration.
Check the lower end fitting for free motion.
Replace if necessary.
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector
is threaded snugly against the shield cup body.
In shielded drag cutting operations (only), there
may be an O-ring between the shield cup body
and drag shield cap. Do not lubricate the Oring.
SERVICE 5T-2 Manual 0-5118
6. Pull the Electrode straight out of the Torch
Head. Check the face of the electrode for excessive wear. Refer to the following figure.
Electrode Wear
CUTMASTER 35mm, 40mm
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:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
Section 6.06 Replacement Parts for Hand Torch
Section 6.07 Replacement Parts - for Machine Torches with Unshielded Leads
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,
gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 35mm Non CE Power Supply with 400VAC, 3 phase input power cable 3-1330-3
1 CutMaster 40mm Non CE Power Supply with 400VAC, 3 phase input power cable 3-1730-3
1 CutMaster 35mm CE Power Supply with 400VAC, 3 phase input power cable 3-1330-4
1 CutMaster 40mm CE Power Supply with 400VAC, 3 phase input power cable 3-1730-4
Manual 0-5118 6-1 PARTS LIST
CUTMASTER 35mm, 40mm
PARTS LIST 6-2 Manual 0-5118
Art # A-02476
Filter
Element
(Cat. No. 9-7741)
Housing
Cover
Barbed
Fitting
Spring
Assembled Filter
O-ring
(Cat. No. 9-7743)
First & Second
Stage
Cartridges
(as marked)
Art # A-02942
6.04 Replacement Power Supply Parts
Qty Description Catalog #
1 Regulator 9-0115
1 Filter Assembly Replacement Element 9-0116
1 CutMaster 35mm Input Power Cord for 380/400 V Power Supply 9-0216
1 CutMaster 40mm Input Power Cord for 380/400 V Power Supply 9-0217
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 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable ( 50 ft / 15.2 m ) with Clamp 9-8529
1 ` Automation Harness 9-8385
1 Automation Interface Kit 9-8311
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313
1 Nylon Dust Cover 9-7071
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit
CUTMASTER 35mm, 40mm
6.06 Replacement Parts for 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 Leads Assembly with ATC connector 4-7836
1 SL100 , 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103
Manual 0-5118 6-3 PARTS LIST
CUTMASTER 35mm, 40mm
PARTS LIST 6-4 Manual 0-5118
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O - Ring 8-3487
3 1 Small O - Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042
NOTE
* Does not include Control Cable Adapter or Through - Hole Protector.
Refer to Section 6.09 for Replacement Shielded Leads Assemblies.
CUTMASTER 35mm, 40mm
A-07994
6
1
4
2
3
5
7
8
9
10
12
11
10
Manual 0-5118 6-5 PARTS LIST
CUTMASTER 35mm, 40mm
PARTS LIST 6-6 Manual 0-5118
A-03684
1
Torch Continuity
('PIP') Switch
Remote Pendant Adapter is
present on Mechanized leads only.
1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
1 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847
1 25 - foot / 7.6 m Leads Assembly with ATC Connector 4-7848
1 50 - foot / 15.2 m Leads Assembly with ATC Connector 4-7849
6.09 Torch Consumable Parts (SL100)
CUTMASTER 35mm, 40mm
Manual 0-5118 6-7 PARTS LIST
CUTMASTER 35mm, 40mm
This Page Intentionally Blank
PARTS LIST 6-8 Manual 0-5118
CUTMASTER 35mm, 40mm
ACTION:
ON / OFF switch to ON
RESULT:
AC indicator ON.
Fan(s) ON.
GAS indicator ON
when input
pressure is adequate
for power supply operation.
Power circuit ready.
ACTION:
Protect eyes and activate torch.
RESULT:
Gas flows briefly, then stops.
Gas restarts.
DC indicator ON
Pilot arc established.
Art #A-07979
ACTION:
Unplug input
power cord or
open external
disconnect.
RESULT:
No power to system.
ACTION:
Connect work cable to workpiece.
Set output amperage.
RESULT:
System is ready
for operation.
ACTION:
RUN /
Rapid Auto Restart /
SET / LATCH switch
to SET
RESULT:
Gas flows to set
pressure.
ACTION:
RUN / Rapid Auto Restart /
SET / LATCH
switch to RUN
(for most applications)
or to
Rapid Auto Restart
(for gouging, trimming,
or expanded metal
applications)
or to
LATCH
is used for specific applications
(torch switch can be released
after main arc transfer).
RESULT: Gas flow stops.
ACTION:
Release torch trigger.
RESULT:
Main arc stops.
Gas flow stops after post - flow.
ACTION:
ON / OFF switch
to OFF
RESULT:
All indicators off.
Power supply fan(s) shuts off.
ACTION:
Close external
disconnect switch.
RESULT:
Power to system.
ACTION:
Torch moved within
transfer distance of workpiece.
RESULT:
Main arc transfers.
Pilot arc off.
PILOT ARC
ACTION:
Torch moved away from work (while
still activated).
RESULT:
Main arc stops.
Pilot arc automatically
restarts.
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
Manual 0-5118 A-1 APPENDIX
CUTMASTER 35mm, 40mm
APPENDIX A-2 Manual 0-5118
1/3
f
f
1
2
West Lebanon, NH USA 03784
Made in USA
Model:
U
1
1
1
1max1eff
I
I
U
2
3Ø
3Ø1Ø
1Ø
S/N
U
0
=
X
Standard Symbols
Ø
AC
DC
Phase
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
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.
I
Art # A-03288
Date of Mfr:
Output Range (Amperage/
Voltage)
Type of Power
Supply (Note 1)
Output Current Type
Rated NoLoad Voltage
Plasma Cutting
Symbol
Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code
Conventional
Load Voltage
Regulatory Standard Covering
This Type of Power Supply
Duty Cycle Data (Note 3)
Duty Cycle Factor
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Input Power
Symbol
Rated Supply
Voltage (Note 2)
Rated Maximum
Supply Current
Maximum Effective
Supply Current
Degree of Protection
Manufacturer's Electrical
Schematic File Number
and Revision Level
APPENDIX 2: DATA TAG INFORMATION
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
1
2
3
4
5
6
7
8
5
6
7
8
1
2
3
4
ATC Female Receptacle
Front View
Pilot
Pilot
6 - Open
7 - Open
8 - Open
5 - Open
Negative /
Plasma
6 - Open
7 - Open
5 - Open
2 - PIP
3 - Switch
4 - Switch
1 - PIP
4 - Green /
Switch
2- Orange /
PIP
3 - White /
Switch
1 - Black /
PIP
Negative /
Plasma
8 - Ground
ATC Male Connector
Front View
A-03701
ATC Female Receptacle
Front View
ATC Male Connector
Front View
Negative / Plasma
3 - White Pendant
Connector
4- Black Pendant
Connector
2 - Orange /
PIP
1 - Black /
PIP
Pilot
2 - PIP
1 - PIP
6 - Open
7 - Open
5 - Open
8 - Ground
8 - Green Pendant
Connector
Ground
5 - White /
Not Used
7 - Green /
Not Used
6 - Open
UNSHIELDED MACHINE TORCH
3 - Switch
4 - Switch
Art # A-03799
Negative / Plasma
Pilot
1
2
3
4
5
6
7
8
5
6
8
1
2
3
4
7
A. Hand Torch Pin - Out Diagram
B. Mechanized (Machine) Torch Pin - Out Diagram
CUTMASTER 35mm, 40mm
Manual 0-5118 A-3 APPENDIX
CUTMASTER 35mm, 40mm
APPENDIX A-4 Manual 0-5118
Torch: SL60 / SL100 Hand Torch
Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle
Pilot
Negative / Plasma
Power
Supply
PIP
Switch
Male
ATC Leads
Connector
ATC Female
Receptacle
Pilot
Negative / Plasma
Black
Orange
Torch
Leads
Torch
Head
To Power Supply
Circuitry
Art # A-03797
1
2
5
6
4
3
8
7
1
2
5
6
4
3
8
7
Torch
Switch
Green
White
To Power Supply
Circuitry
Torch: Unshielded Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector
Power Supply: with ATC Female Receptacle
Pilot
Negative / Plasma
Power
Supply
To Remote Control
Remote
Pendant
Connector
PIP
Switch
Not
Used
Male
ATC Leads
Connector
ATC Female
Receptacle
Pilot Lead
Negative / Plasma Lead
Torch
Leads
Torch
Head
Art # A-03798
1
2
5
6
4
3
8
7
To Power Supply
Circuitry
Green
To Power Supply
Circuitry
1
2
5
6
4
3
8
7
Black
White
Green
Black
Orange
White
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
B. Mechanized Torch Connection Diagram
CUTMASTER 35mm, 40mm
This Page Intentionally Blank
Manual 0-5118 A-5 APPENDIX
CUTMASTER 35mm, 40mm
APPENDIX A-6 Manual 0-5118
Art # A-08534
5
5
4
4
DD
CC
BB
AA
+12VDC
+12VDC
+12VDC
24VAC
+12VDC
+12VDC
+12VDC
_
INRUSH
RESISTORS
FAN
3.3VDC
TXD
RXD
Q2
D
SERIAL PORT
*CM 35mm C7 & C10
not installed
_
/400
8
9
7A
L1
L2
L3
L4
T1
T2
T3
T4
PCB1
+
+
+
+
Q1
24VAC RET
5
PRIMARY
AC INPUT
400VAC 3PH
6
/SOLENOID
CM 35mm 19X2371 / CAT# 9-0108
CM 40mm 19X2416 / CAT# 9-0125
MAIN PCB
7
/INRUSH
D1
L1
L2
L3
GND
C
D
B
A
_
Q2
_
B
CM 35mm 19X2478 / CAT# 9-0192
CM 40mm 19X2545 / CAT# 9-0202
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
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Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
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Via Bolsena 7
20098 S. Giuliano
Milan, Italy
Tel: (39) 0236546801
Fax: (39) 0236546840
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139