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Art # A-09347_AE
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CUTMASTER
PLASMA CUTTING SYSTEM
Operating Manual
Rev. AA Date: October 15, 2010 Manual # 0-5141
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
provider visit us on the web at www.cigweld.com.au (Asia
Pacific) www.thermal-dynamics.com (Americas and Europe).
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
advanced products to achieve a safer working environment within
the welding industry.
!
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.
Plasma Cutting Power Supply
CutMaster™ 42
SL40 Torch™
Operating Manual Number 0-5141
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2010 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.
Printed in the United States of America
Publication Date: October 15, 2010
Record the following information for Warranty purposes:
Where Purchased:_______________________________ __________________
Purchase Date:__________________________________ __________________
Power Supply Serial #:___________________________ ___________________
Torch Serial #:___________________________________ _________________
i
TABLE OF CONTENTS
SECTION 1:GENERAL INFORMATION ........................................................................................................1-1
1.01 Notes, Cautions and Warnings ................................................................................. 1-1
1.02 Important Safety Precautions ...................................................................................1-1
1.03 Publications .............................................................................................................. 1-3
1.04 Note, Attention et Avertissement ..............................................................................1-4
1.05 Precautions De Securite Importantes ....................................................................... 1-4
1.06 Documents De Reference .........................................................................................1-6
1.07 Declaration of Conformity......................................................................................... 1-7
1.08 Statement of Warranty .............................................................................................1-8
SECTION 2 SYSTEM:INTRODUCTION ...................................................................................................... 2-1
2.01 Working Principle .....................................................................................................
2.02 Power Supply Specifications .................................................................................... 2-1
2.03 Input Wiring Specifications ......................................................................................2-2
2.04 Power Supply Features ............................................................................................. 2-3
SECTION 2 TORCH:INTRODUCTION ...................................................................................................... 2T-1
2T.01 Scope of Manual
2T.02 Specifications ........................................................................................................ 2T-1
2T.03 Introduction to Plasma ........................................................................................... 2T-2
SECTION 3 SYSTEM:INSTALLATION ........................................................................................................ 3-1
3.01 Unpacking ................................................................................................................3-1
3.02 Lifting Options .......................................................................................................... 3-1
3.03 Primary Input Power Connections ............................................................................ 3-2
3.04 Air Supply Connections ............................................................................................ 3-2
SECTION 4 SYSTEM:OPERATION ..............................................................................................................4-1
4.01 Control Panel ............................................................................................................
4.02 Preparations for Operating ....................................................................................... 4-2
4.03 Sequence of Operation ............................................................................................. 4-4
4.04 Cut Quality ................................................................................................................ 4-6
4.05 General Cutting Information ..................................................................................... 4-7
..................................................................................................... 2T-1
2-1
4-1
SECTION 5 SYSTEM:SERVICE .................................................................................................................. 5-1
5.01 General Maintenance ................................................................................................ 5-1
5.02 Basic Troubleshooting Guide .................................................................................... 5-2
SECTION 5 TORCH:SERVICE
5T.01 General Maintenance ..............................................................................................
5T.02 Inspection and Replacement of Consumable Torch Parts ....................................... 5T-1
SECTION 6:PARTS LISTS .......................................................................................................................... 6-1
6.01 Introduction ..............................................................................................................
6.02 Power Supply Replacement Parts ............................................................................6-2
APPENDIX 1:CIRCUIT DIAGRAM .............................................................................................................A-1
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ............................................................ Rear Cover
...................................................................................................................
5T-1
5T-1
6-1
cutmaster 42
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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.
A procedure which, if not properly followed, may cause
injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNING
• The kinds of fumes and gases from the plasma arc depend on
the kind of metal being used, coatings on the metal, and the
different processes. You must be very careful when cutting
or welding any metals which may contain one or more of the
following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.
• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of 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.)
-
WARNING
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.
• 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.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work
piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or
damp.
• Install and maintain equipment according to NEC code, refer to
item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or
repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma
arc.
• Be sure there is no combustible or flammable material in the
workplace. Any material that cannot be removed must be
protected.
• Ventilate all flammable or explosive vapors from the work
place.
• Do not cut or weld on containers that may have held combus
tibles.
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Manual 0-5141 1-1 GENERAL INFORMATION
cutmaster 42
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Electrode Size
Metal Thickness
Filter
Shade
Welding or Cutting
Operation
Electrode Size
Metal Thickness
Filter
Shade
Torch soldering 2
Gas metal-arc
welding (MIG)
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding
(stick) electrodes
Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in.,
4 to 6.4 mm
12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
• Provide a fire watch when working in an area where fire hazards
may exist.
• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsec
tion 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 infrared light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or
other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective
booths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
*These values apply where the actual arc is clearly
-
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
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 handling. (California
Health & Safety Code § 25249.5 et seq.)
Table 1-1
GENERAL INFORMATION 1-2 Manual 0-5141
cutmaster 42
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, ob
tainable from the American Welding Society, 550 N.W. LeJeune
Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, Washington, D.C.
20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND
EDUCATIONAL EYE AND FACE 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,
AND WELDING PROCESSES, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY 10018
FIRE PREVENTION IN THE USE OF CUTTING
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 obtainable
from the National Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED
SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND
CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTEC
TION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
-
7. AWS Standard A6.0,
WHICH HAVE HELD COMBUSTIBLES, obtainable from American
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51,
ING, CUTTING AND ALLIED PROCESSES, obtainable from the
National Fire Protection Association, Batterymarch Park, Quincy,
MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
WELDING AND CUTTING CONTAINERS
OXYGEN-FUEL GAS SYSTEMS FOR WELD-
Manual 0-5141 1-3 GENERAL INFORMATION
cutmaster 42
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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
• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma
dépendent du genre de métal utilisé, des revêtements se trouvant
sur le métal et des différents procédés. Vous devez prendre soin
lorsque vous coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la 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.
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.
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.
• Ce produit, dans le procéder de soudage et de coupe, produit de
la fumée ou des gaz pouvant contenir des éléments reconnu dans
L’état de la Californie, qui peuvent causer des défauts de naissance
et le cancer. (La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé
au jet de plasma requiert et produit de l’énergie électrique haute
tension. Cette énergie électrique peut produire des chocs graves,
voire mortels, pour l’opérateur et les 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.
• 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
consignes.
5,
article 9.)
GENERAL INFORMATION 1-4 Manual 0-5141
cutmaster 42
INCENDIE ET EXPLOSION
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
renfermer 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 enflamm
é.
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.
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 engend r e des prod u its chi miques , rec onnus par l’é t at
de Californie comme pouvant être à l’origine de cancer, de
malformations fœtales ou d’autres problèmes de reproduction.
Il fa ut se la ve r le s ma in s ap rè s to u te ma n ip ula ti on .
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)
• 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.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* 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.
Manual 0-5141 1-5 GENERAL INFORMATION
cutmaster 42
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. OS HA , NOR ME S DE SÉC UR ITÉ DU TR AVA IL 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
5. Nor me ANSI Z41.1, NORMES POUR LES CHAUSSURES
PROTECTRICES, 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
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE
SOUDAGE, 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 SOUDAGE,
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. No rm e AN SI Z8 8. 2, PR AT IQU ES DE PR OT EC TI ON
RESPIRATOIRE, 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 ELEC TRIQU E NATIONAL ,
disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
GENERAL INFORMATION 1-6 Manual 0-5141
cutmaster 42
S
1.07 Declaration of Conformity
Manufacturer: Thermadyne Company
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.
* AS60974.1 Arc Welding Equipment Welding Power Sources.
For environments with increased hazard of electrical shock, Power Supplies bearing the
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.
Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative in Europe: Steve Ward
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Operations Director
mark conform to EN50192 when used in
Manual 0-5141 1-7 GENERAL INFORMATION
cutmaster 42
1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne Company warrants to the original retail purchaser that new
Thermal Dynamics CUTMASTER® 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, Thermadyne Company shall, upon notification thereof and
substantiation that the product has been stored operated and maintained in accordance with Thermadyne’s 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.
Thermadyne 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. Thermadyne Company must be notified within 30 days of any failure, at which time Thermadyne Company will provide
instructions on the warranty procedures to be implemented.
Thermadyne Company 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 Thermadyne Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER 42 4 Year 1 Year
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 industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermadyne Company:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermadyne 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.
LIMITATION OF LIABILITY: Thermadyne Company 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 Thermadyne 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 Thermadyne 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 Thermadyne
product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective October 15, 2010
GENERAL INFORMATION 1-8 Manual 0-5141
SECTION 2 SYSTEM:
Rectifier
Inverter
Transformer
Rectifier
Reduce pressure, filter
Gas valve Cutting torch
Workpiece
Compressed air
Art # A-09204_AB
INTRODUCTION
2.01 Working Principle
2.02 Power Supply Specifications
CUTMASTER 42 Power Supply Specifications
Input Power 120 VAC (+-10%), 1Phase, 50/60Hz
208-230 VAC (+-10%), 1Phase, 50/60Hz
Output Current 20 Amps @ 120VAC, 15A
20-27 Amps @ 120VAC, 20A
20-40 Amps @ 230VAC, 20A
CUTMASTER 42 Power Supply Duty Cycle (Note 1)
Ambient Temperature 104° F (40° C)
Duty Cycle 30% @ 120VAC, 40% @ 230VAC
Rated Current 27 Amps @ 120VAC, 40 Amps @ 230V
SL40 Torch Gas Requirements (see section 2T.03)
Notes
1. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is reduced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.
2. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause
double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear. Optional filters provide increased filtering capabilities.
NOTE
cutmaster 42
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.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting
with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch,
consumables, and actual cutting operation.
Manual 0-5141 2-1 INTRODUCTION
cutmaster 42
Art# A-09333_AC
26lb / 11.8kg
7" (177mm)
18.5" (469.9mm)
9" (228.6mm)
CUTMAST
ER
®
42
120V 15A
120V 20A
230V 20A
A
24
40
20
20
30
27
Figure 2-1 Power Supply Dimensions & Weight
NOTE
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will
inhibit proper cooling and reduce duty cycle.
2.03 Input Wiring Specifications
CUTMASTER 42 Input Power Requirements
Input Power Input Current Input Current Input Suggested Sizes (See Note)
Voltage Freq. (kVA) Max (Amps) Ieff (Amps) Fuse (Amps)
(Volts-AC) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph
120 50/60 3.3 27.5 15 25
208 50/60 5.0 24 15.4 23
230 50/60 5.0 21.4 13.5 20
240 50/60 5.0 20.8 13 20
Line Voltages with Suggested Circuit Protection
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation
in this regard.
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
NOTE
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is 167° F (75° C).
INTRODUCTION 2-2 Manual 0-5141
2.04 Power Supply Features
Air Inlet
Control Panel
Torch Lead
120/230 VAC Power Source
Work Cable and Clamp
Art # A-09334_AC
CUT
MAST
E
R
®
42
120V 15A
120V 20A
230V 20A
A
24
40
20
20
30
27
Art# A-09335
Air Inlet
On/Off
Switch
Power Cord
cutmaster 42
Manual 0-5141 2-3 INTRODUCTION
This Page left blank intentionally.
cutmaster 42
8.3" (210.82mm)
2.6"
(66.04mm)
.96" (24.38mm)
Art # A-09336
!
SECTION 2TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instructions and maintenance procedures for the SL40 Plasma
Cutting Torch. Service of this equipment is restricted
to properly trained personnel; unqualified 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 Specifications
A. Torch Configurations
1. Hand Torch, Model SL40
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
F. Torch Ratings
SL40 Torch Ratings
Ambient
Temperature
Duty Cycle 100% @ 40 Amps @ 250 scfh
Maximum Current 40 Amps
Voltage (V
Arc Striking Voltage 500V
) 500V
peak
104° F
40° C
G. Current Ratings
SL40 Current Ratings
SL40 Torch & Leads
Up to 40 Amps, DC,
Straight Polarity
NOTE
Power Supply characteristics will determine
material thickness range.
H. Gas Requirements
SL40 Torch Gas Specications
Gas (Plasma and Secondary) Compressed Air
B. Torch Leads Lengths
Hand Torches are available as follows:
• 15 ft / 4.6 m.
C. Torch Parts
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch has built-in switch.
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through
torch.
Minimum Input Pressure
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow
WARNING
85 psi
5.9 bar
193 scfh
91 lpm
This torch is not to be used with oxygen (O2).
This torch is not to be use with high frequency
starting systems.
Manual 0-5141 2T-1 INTRODUCTION
CUTMASTER 42
A-00002
Workpiece
Power
Supply
+
_
C
B
A
Torch Trigge
r
PIP Switch
Shield Cup
To Control
Cable Wiring
Torch Switch
A-09595
2T.03 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 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.
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.
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.
INTRODUCTION 2T-2 Manual 0-5141
Typical Torch Head Detail
Parts - In - Place Circuit Diagram for Hand Torch
cutmaster 42
SECTION 3:
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
A. Contents List
Description Quantity
CM42 Power source 1
10ft power input cable (installed) 1
120VAC Adapter Pigtail 15A 1
120VAC Adapter Pigtail 20A 1
Work cable and clamp (installed) 1
SL40 Torch (15ft(4.6m)) w/consumables 1
Carry case 1
40A Tip Drag 2
20A Tip Drag 2
40A Tip, Standoff 2
Electrode 2
Gloves 1
Cutting Glasses 1
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 handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-5141 3-1 INSTALLATION
cutmaster 42
Art# A-09432_AB
3.03 Primary Input Power Connections
Power Cords Included With Power Supply
Attached to the power supply is an input power cord with a 230 Volt 50 Amp NEMA 6-50P for plug. Supplied adapters
allow for connection of the power supply input cable plug for when using 120V input power.
Figure 3-1 120VAC Adapter Pigtail
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.
Input Voltage (VAC) Rated Output
Amps (RMS) input at rated
output, 60 Hz, single-phase
kVA
120V, 15A Circuit 20A, 88V 20.4 2.5
120V, 20A Circuit 27A, 91V 28.5 3.5
120V, 30A Circuit 27A, 91V 28.5 3.5
208-230V, 20A Circuit 40A, 96V 23-21.4 4.8
3.04 Air Supply Connections
A. Connecting Air Supply to Unit
The connection is the same for compressed air or industrial compressed air in gas cylinders.
1. Connect the gas line to the compressed air inlet port at the appropriate pressure.
INSTALLATION 3-2 Manual 0-5141
cutmaster 42
Art# A-09337
Air Inlet
On/Off
Switch
Figure 3-2 Gas Connection to Compressed Air input
B. Using Industrial Compressed Air In Gas Cylinders
When using Industrial compressed air in gas cylinders as the gas supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas
regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open
each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100
psi (6.9 bar) maximum and flows of at least 250 scfh (120 lpm).
4. Connect gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do
Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas
passages in the torch.
Manual 0-5141 3-3 INSTALLATION
This page left blank intentionally.
4.01 Control Panel
Art# A-09338-AD
CUTMASTER®42
AC Indicator
The Front Panel The Rear Panel
Overheat Indicator
Air Indicator
DC Indicator (Ready)
Air Inlet
On/Off
Switch
Power Cord
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
cutmaster 42
SECTION 4 SYSTEM:
OPERATION
1. ON / OFF Switch (Power Switch/Lamp)
Controls input power to the power supply. I is ON (Red Lamp), O is OFF.
2. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit
opens frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate
input power. Note: For 120V input power, the unit will automatically limit the output current to a maximum of
27A. For 230V input power, the maximum output is 40 Amps. Refer to Section 2 for input power requirements.
3.
4.
5.
AC Indicator
Steady light indicates power supply is ready for operation.
OVERHEAT Indicator (TEMP Indicator)
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Allow the unit to
run with the fan on until the temp indicator turns off.
AIR Indicator
AIR light should be ON when there is sufficient gas pressure.
6.
READY (DC Indicator)
Manual 0-5141 4-1 OPERATION
cutmaster 42
Art # A-09340-AF
Start Cartridge,
Cat. No. 9-0097
Electrode, Cat. No. 9-0096
Worn Electrode
Worn Tip
40 Amp Drag Tip, Cat. No. 9-0093
Shield Cup, Cat. No. 9-0098
40 Amp
Standoff Tip,
Cat. No. 9-0094
Indicator is ON when DC output circuit is active.
NOTE
All consumables must be correctly installed and maintained to ensure correct operation.
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts,
or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type
of operation, and with the amperage output of this power supply (40 amps maximum). Use only genuine Thermal
Dynamics parts with this torch.
NOTE
When operating the torch in a normal condition, some gas vents through the gap between the shield cup
and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
OPERATION 4-2 Manual 0-5141
cutmaster 42
Art # A-03387
Art# A-09335-AB
Air Inlet
On/Off
Switch
Power Cord
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
Art# A-09339_AD
B. Torch Connection
Check that the torch is properly connected.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power require-
ments for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure gas source meets requirements listed in section 2T. Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect
only to the main part of the workpiece; do not connect to the part to be cut off.
F. Power On
Place the power supply ON / OFF switch to the ON (I) position. Power indicator turns on.
Rear Panel with ON/OFF Switch Front Panel With Power ON/OFF Indicator
Manual 0-5141 4-3 OPERATION
cutmaster 42
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
120V, 15A
24
40
20
20
30
27
2
4
230V, 20A
24
20
27
40
20
30
120V, 20A
40
20
30
A
40
40
4
3
0
24
20
A
A
A
27
A#09697_AA
G. Select Current Output Level
Set the desired current output level.
4.03 Sequence of Operation
The following is a typical sequence of operation for this power supply.
1. Place the ON / OFF switch on the power supply to ON (up) position (Red indicator lamp is illuminated).
During initial power up, there will be a delay of about 2 seconds before the AC Indicator light will illuminate
and the pre-flow gas and fan starts. The gas will automatically flow from torch for approximately 10 seconds
(only after the AC Indicator lamp is illuminated) (The AC Indicator lamp and fan turns on approximately 2
seconds after the ON/OFF switch is enabled), this is a process that makes sure all inputs (gas, input power,
torch connection, and torch parts) are acknowledged for proper operation.
2. Wear protective clothing, including welding gloves and appropriate eye protection (see table 1-1). Place tip on
• Standoff Cutting With Hand Torch
a. AC indicator turns on; fan turns on.
NOTE
work piece and pull trigger. Arc will initiate and start cutting material.
OPERATION 4-4 Manual 0-5141
NOTE
A-00024_AB
Shield Cup
Torch
Standoff Distance
1/8" - 3/8" (3 - 9mm)
Art # A-09342
Trigger
Trigger Release
3
4
Trigger
2
1
Trigger Release
Art# A-09341
For best performance and parts life, always use
the correct parts for the type of operation.
A. 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.
B. Depending on the cutting operation, do one of
the following:
a). For drag cutting, place the tip on the plate
holding the torch at a angle to the plate so
that only one edge of the tip is in contact
with the plate. This prevents damage to the
tip during the piercing process.
b). For standoff cutting, hold the torch tip
on the work piece, pull the trigger. After
the arc is initiated lift the tip to 1/8" - 3/8"
(3-4mm) off the work.
cutmaster 42
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.
• Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4"(6 mm) thick
or less.
NOTE
For best parts performance and life, always use
the correct parts for the type of operation.
A. Install the drag cutting tip and set the output
current.
Standoff Distance
Manual 0-5141 4-5 OPERATION
cutmaster 42
Art # A-09342_AB
Trigger
Trigger Release
3
4
Trigger
2
1
Trigger Release
Art# A-09341
Kerf Width
Cut Surface
Bevel Angle
Top Edge
Rounding
Cut Surface
Drag Lines
Dross
Build-Up
Top
Spatter
A-00007
B. 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.
C. Keep the torch in contact with the workpiece
during the cutting cycle.
D. Hold the torch away from your body.
E. Slide the trigger release toward the back of the
torch handle while simultaneously squeezing
the trigger. The arc will start.
3. Complete cutting operation.
NOTE
If the torch is lifted too far from the workpiece
while cutting, the main arc will stop and the
pilot arc will automatically restart.
4. Release the torch trigger.
a. Main arc stops.
5. Set the power supply ON / OFF switch to OFF
(down position).
a. AC indicator
turns OFF.
6. Set the main power disconnect to OFF, or unplug
input power cord.
a. Input power is removed from the system.
4.04 Cut Quality
NOTE
Cut quality depends heavily on setup and
parameters such as torch standoff, alignment
with the workpiece, cutting speed, gas pressures, and operator ability.
OPERATION 4-6 Manual 0-5141
F. Place the torch tip on the work. The main arc
will transfer to the work.
NOTE
The gas preflow and postflow are a characteristic of the power supply and not a function
of the torch.
G. Cut as usual. Simply release the trigger as-
sembly to stop cutting.
H. Follow normal recommended cutting practices
as provided herein.
Refer to appendix pages for additional information as related to the power supply used.
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 finish cut quality
is desired to avoid a secondary cleaning operation. The
following cut quality characteristics are illustrated in the
following figure:
Cut Quality Characteristics
Cut Surface
The desired or specified condition (smooth or rough)
of the face of the cut.
Nitride Build - Up
Right Side
Cut Angle
Left Side
Cut Angle
A-00512
cutmaster 42
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.
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.
4.05 General Cutting Information
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.
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.
WARNING
Disconnect primary power at the source before
disassembling the power supply, torch, or
torch leads.
Frequently review the Important Safety Precautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
Side Characteristics Of Cut
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.\
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.
Manual 0-5141 4-7 OPERATION
cutmaster 42
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 resultant cleanup
can be accomplished by scraping, not grinding.
OPERATION 4-8 Manual 0-5141
SECTION 5 SYSTEM: SERVICE
Warning!
There are extremely dangerous voltage and power levels present inside
this product. Do not attempt to open or repair unless you are a qualified
electrical tradesperson and you have had training in power measurements
and troubleshooting techniques. If major complex subassemblies are faulty,
then the Cutting Power Source must be returned to an Accredited Thermal
Dynamics Service Provider for repair.
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
6 Months
Replace all
broken parts
Visually check and
Carefully clean the
interior
Maintain more often
if used under severe
conditions
Art # A-09343_AC
Clean
exterior
of power supply
C
U
T
M
A
S
T
E
R
®
4
2
C
U
R
R
E
N
T
A
2
0
4
0
3
0
C
U
T
M
A
S
T
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R
®
4
2
C
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4
0
3
0
5.01 General Maintenance
cutmaster 42
Manual 0-5141 5-1 SERVICE
cutmaster 42
!
A. Every three months
Check external air filter, replace if necessary.
1. Shut off input power; turn off the gas supply.
sary.
Leave internal ground wire in place.
B. Every six months
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.
Bleed down the gas supply. Check air filter and replace if neces-
NOTE
5.02 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose
or repair it unless you are an accredited service provider and you have had training in power electronics
measurement and troubleshooting techniques.
Common Faults symptom LED Indicators
A. AC indicator OFF
1. Main input power cord does not connect to power distribution net.
a. Connect the power cord.
2. Power ON/OFF switch in OFF (down) position.
a. Turn switch to ON (up) position.
3. Actual input voltage does not correspond to voltage of unit.
a. Verify that the input line voltage is correct.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
B. AC indicator
1. Indicator blinking (1 sec ON/1 Sec OFF, Gas may also pulse 3 times).
a. Check for missing torch parts or not properly installed. Turn ON/OFF switch to OFF position and
restart the machine by turning the power switch to ON.
2. Indicator blinking (1 sec ON/3 Sec OFF).
blinking
a. Check for worn or sticking torch parts. Replace if necessary.
SERVICE 5-2 Manual 0-5141
cutmaster 42
3. Indicator blinking (3 sec ON/3 Sec OFF).
a. Torch switch was depressed before machine was completely powered up. Turn ON/OFF switch to
OFF position and the restart the machine by turning the power switch to ON.
C. Air indicator
1. Gas pressure too low. Check supply pressure.
D. TEMP indicator
1. Unit air flow obstructed.
a. Check for blocked air flow around the unit and correct condition.
2. Fan blocked.
a. Check for blocked status and correct condition.
3. Unit is overheated.
a. Keep the machine plugged in and turned on for five minutes. This will allow the fan to run and cool
the machine.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
E. Torch will not pilot, when torch trigger is activated.
1. Faulty parts in torch
a. Check torch parts per section 4.02; replace as needed.
OFF
ON, (AC indicator ON)
2. Gas pressure too low
a. Adjust supply pressure to proper setting value.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
F. No cutting output when torch is activated; AC indicator
1. Torch is not connected properly to power supply.
a. Check torch connection to power supply.
2. Working cable not connected to work piece, or connection is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
4. Faulty torch
a. Return for repair or have qualified technician repair.
G. Torch cuts but not adequately
1. Incorrect setting of output current control
ON, gas flows, fan turns.
a.
Manual 0-5141 5-3 SERVICE
Check and adjust to proper setting.
cutmaster 42
2. Working cable connection to work piece is poor.
a.
3. Faulty components in unit
a. Return for repair or have qualified technician repair.
H. Output is restricted, and can not be controlled.
1. Input or output connection is poor.
a. Check all input and output connection leads.
2. Working cable connection to work piece is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per service manual.
I. Cutting output is unstable or inadequate at 120V operation.
1. Low or fluctuating input voltage
a. Turn output current to minimum (20 amps) and suggest using 20A Drag tip.
b. Connect to a dedicated input line voltage.
c. Have electrician check input line voltage under load.
Make sure that work cable has a proper connection to a clean, dry area of the work piece.
2. Input or output connection is poor
a. Check all input and output connection leads.
2. Working cable connection is poor.
a. Make sure that work cable has a proper connection to a clean, dry area of the work piece.
J. Hard to startup
1. Torch parts worn (consumables)
a. Turn off input power, remove shield cup, tip, start cartridge, and electrode and check them all. If the
electrode or cutting tip is worn out, replace them. If the start cartridge does not move freely, replace it. If
there is too much spatter on shield cup, replace it.
K. Arc goes out while operating. Arc can’t be restarted when torch trigger is activated.
1. Power Supply is overheated (TEMP indicator
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond duty cycle
limit.
2. Fan blades blocked (TEMP indicator
a. Check and clear blades.
ON).
ON).
3. Air flow blocked
a. Check for blocked air flow around the unit and correct condition.
4. Gas pressure is too low. (Air indicator
a. Check gas source. Adjust to proper setting value.
SERVICE 5-4 Manual 0-5141
ON when torch trigger is activated.)
cutmaster 42
5. Torch parts worn
a. Check torch shield cup, cutting tip, start cartridge and electrode. Replace as needed.
6. Faulty component in unit
a. Return for repair or have qualified technician repair per service manual.
L. Torch cuts but not well.
1. Current control is set too low.
a. Increase the current setting.
2. Torch is being moved too fast across work piece
a. Reduce cutting speed.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup
(do not activate torch). If there are contaminants in the gas, additional filtering may be needed.
4. Torch parts worn
a. Check torch shield cup, cutting tip, start cartridge and electrode. Replace as needed.
M. Gas in torch pulsates 3 times and then stops. AC indicator light blinking.
1. Torch parts not properly installed in torch. There may have been an attempt to remove torch parts without
turning off ON/OFF power switch to OFF on unit.
a. Check to make sure torch parts are properly installed.
b. Turn ON/OFF switch to OFF and then back to ON.
Manual 0-5141 5-5 SERVICE
This page left blank intentionally.
cutmaster 42
Art# A-09345
Electrode
Start Cartridge
Tip
Shield Cup
Torch Head
Good Tip
Worn Tip
A-09791
SECTION 5 TORCH:
SERVICE
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 arc
initiation and the overall cut quality of the torch.
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads.
Remove the consumable torch parts as follows:
NOTE
The shield cup holds the tip and starter cartridge shield cup 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.
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..
5T.02 Inspection and Replacement of
Consumable Torch Parts
WARNING
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while
the AC indicator light of the Power Supply is
ON.
Consumable Parts
3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean
or replace the tip if necessary.
Tip Wear
Manual 0-5141 5T-1 SERVICE
cutmaster 42
Art A-09792
Worn Electrode
New Electrode
Art # A-09346
Art# A-09817
Electrode
Start Cartridge
Tip
Shield Cup
Torch Head
1
2
3
4
4. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check
the lower end fitting for free motion. Replace if
necessary.
5. Pull the electrode straight out of the torch head.
Check the face of the electrode for excessive wear.
Refer to the following figure.
SL40 Replacement Parts
Item # Description Cat. No
1 Electrode 9-0096
2 Start Cartridge 9-0097
3 Tip, 20A Drag 9-0091
Tip, 40A Drag 9-0093
Tip, 40A Standoff 9-0094
4 Shield Cup 9-0098
N/S SL40 Torch w/ 15ft (4.6m) leads 7-0040
Electrode Wear
6. Reinstall the electrode by pushing it straight into
the torch head until it clicks.
7. Reinstall the desired starter cartridge and tip into
the torch head.
8. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the
cup, check the threads before proceeding.
SERVICE 5T-2 Manual 0-5141
cutmaster 42
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable components.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.
C. Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly, as listed in the
parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your
authorized distributor.
Manual 0-5141 6-1 PART LIST
cutmaster 42
9
5
1
2
11
13
7
3
15
10
14
8
12
6
4
Art# A-09387-AE
16
6.02 Power Supply Replacement Parts
Item # Qty Description Catalog #
1 1 Logic PCB assembly 9-0076
2 1 Control PCB assembly 9-0077
3 1 Main PCB assembly 9-0079
4 1 Regulator 9-0081
5 1 Solenoid assembly 9-0082
6 1 Pressure Switch 9-0075
7 1 Front Panel with Label 9-0071
8 1 Rear Panel with Label 9-0072
9 1 Cover with Labels 9-0080
10 1 Hall Current Sensor 9-0088
11 1 CM42 Cutting Control Knob 9-0073
12 1 CM42 On/Off Switch 9-0074
13 1 ATC Connection 9-0083
14 1 Fan 9-0042
15 1 AC/DC Rectifier 9-0049
16 1 Power Cord 9-0025
17 1 CM42 Carry Case (not shown) 9-0084
18 1 Gloves (not shown) 9-0086
19 1 Glasses (not shown) 9-0087
20 1 Replacement Torch (not shown) 7-0040
21 1 15A Power Cord Adapter(not shown) 9-0026
22 1 20A Power Cord Adapter(not shown) 9-0048
PART LIST 6-2 Manual 0-5141
cutmaster 42
G
DSGDS
G
D S
13456 27
1
23
45
6
7
DRIVE SIGNAL
DRIVE SIGNAL
123
45
12345
HF/QF
123
1
2
1
2
3
4
TEST
WV OUTPUT
123
123
WV OUTPUT
121 2 3 4
FEEDBACK SIGNAL
WORK
TORCH
AC 230V/120V
INPUT 50/60Hz
1
2
34
A
-
+
GAS SOLENOID
1 2
DC 24V
+
-
PILOT
SOURCE&TIP
1
2
U_D
Rev
Revision By Date
A THERMADYNE Company
NOTE:
TITLE:
CUTMASTER 42 230V SINGLE PHASE 50/60Hz
SCHEMATIC
Information proprietary to THERMAL DYNAMICS CORPORATION
Not for Release Reproduction or Distribution without writeen consent
Unless otherwise Specified resistors are in Ohms 1/4W 5%
Capacitors are in Microfarads (UF)
THERMAL DYNAMICS
INDUSTRIAL OARK NO.2
WEST LEBANON,NH03784
603-298-5711
AC
1
V+
2
AC3V-
4
AC
1V+2
AC
3
V-
4
1
2
L?
G
DS
OVER TEMPERATURE
PRESSURE SW
TORCH SW
OT
POWER
DC
CURRENT CONTROL
AIR
1 2 3 4
1 2 3 4
-15V S G
+15V
+
+24V
123
TRANSF IFB
12
D_port
1 2
HFOUT
1
2
N/A
1 2
1
2
123456
XFIF/IN/OUT
1 2 3 4
+
-
S G
+
-
S G
-15V S G+15V
FEEDBACK SIGNAL
12
Art # A-09396_AB
APPENDIX 1:
CIRCUIT DIAGRAM
Manual 0-5141 A-1 APPENDIX
This page left blank intentionally.
This Page Intentionally Blank.
For Use with Thermal Dynamics Manual Literature
(large area) . . .
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Sales Office
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&ORM.OXX © 2010 Thermadyne Industries, Inc. www.thermadyne.com Printed in U.S.A.
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