Thermal Dynamics CUTMASTER 40 PLASMA CUTTING SYSTEM Instruction manual

OUTPUT MAX OUTPUT

VOLTAGE

INPUT POWER

40

CUTMASTER® 40

PLASMA CUTTING SYSTEM

OPERATING
MANUAL

120-

240V

Revision: AE Issue Date: 29 June, 2020

esab.com

Art # A-14036_AB

Manual No.: 0-5557

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.esab.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 produc t 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 ESAB.

We distinguish ourselves from our competition through market-leading, dependable products
that have stood the test of time. We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support, together with excellence in
sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.

!!

WARNING

Read and understand this entire Manual and your employer’s safety prac tices before installing, operating, or
servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer
assumes no liability for its use.

Plasma Cutting Power Supply
CutMaster® 40
SL60™ 1Torch™
Operating Manual Number 0-5557

Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207

www.esab.com

© Copyright 2019 by
Thermal Dynamics an ESAB brand.

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.

For Material Print Specications, refer to document 47x1961
Original Publication Date: 15 November, 2019
Revision Date: 29 June, 2020

See website for Warranty Information.

Record the following information for Warranty purposes:

Where Purchased:_______________________________ _____________________

Purchase Date:__________________________ ____________________________

Power Supply Serial #:_______________________________ _________________

Torch Serial #:______________________________ _________________________

i

i

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully
familiar with the principles of operation and safe practices for arc welding
and cutting equipment, we urge you to read our booklet, “Precautions and
Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do
NOT permit untrained persons to install, operate, or maintain this equip­ment. Do NOT attempt to install or operate this equipment until you have
read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to
read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty mainte­nance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.

!

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

PROTECT YOURSELF AND OTHERS!

OPERATING.

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOUR-

NISSEUR.

MISE EN GARDE

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionne­ment et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage,
nous vous suggérons de lire notre brochure « Precautions and Safe Practices for
Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux per-

sonnes non qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement.

Ne tentez PAS d’installer ou d’opérer cet équipement avant de lire et de bien com­prendre ces instructions. Si vous ne comprenez pas bien les instructions, commu­niquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire
les Règles de Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagne­ment et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions

fournies. Vous devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne

fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées
doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il
est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le
Distributeur Autorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant.

L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte,

un entretien fautif, des dommages, une réparation incorrecte ou une modication par une personne autre que le

fabricant ou un centre de service désigné par le fabricant.

!

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION

AVANT D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

EU DECLARATION OF CONFORMITY

According to

The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016

The EMC Directive 2014/30/EU, entering into force 20 April 2016

The RoHS Directive 2011/65/EU, entering into force 2 January 2013

Type of equipment

PLASMA CUTTING SYSTEM

Type designation etc.

CutMaster 40, from serial number 007-XXXXXX

Brand name or trade mark

Thermal Dynamics, an ESAB brand

Manufacturer or his authorised representave

Name, address, telephone No:

OZAS-ESAB Ltd.
ul. A. Struga 10,
45-073 Opole, Poland
Phone: [phone], FAX + 48 77 4019 201.

The following harmonised standard in force within the EEA has been used in the design:

IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 + AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electro­magnetic compatibility (EMC) requirements

Additional Information: Restrictive use, Class A equipment, intended for use in location other than

residential.

By signing this document, the undersigned declares as manufacturer, or the manufactur­er’s authorised representative, that the equipment in question complies with the safety
requirements stated above.

Date Signature Position

10 February, 2020

Flavio Santos General Manager

Accessories and

Adjacencies

2020

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1: GENERAL INFORMATION.......................................................... 11

1.01 Notes, Cautions and Warnings ................................................................................. 11

SECTION 1 : INFORMATIONS GÉNÉRALES ................................................... 13

1.01 Remarques, avertissements et mises en garde ........................................................ 13

SECTION 2 SYSTEM: INTRODUCTION ......................................................... 15

2.01 How To Use This Manual .......................................................................................... 15

2.02 Equipment Identication ......................................................................................... 15

2.03 Receipt Of Equipment .............................................................................................. 15

2.04 Power Supply Specications CSA ............................................................................. 16

2.04.01 Additional Power Supply Specications 16

2.05 Input Wiring Specications CSA ...............................................................................17

2.06 Power Supply Specications CE ...............................................................................18

2.06.01 Additional Power Supply Specications 18

2.07 Input Wiring Specications CE .................................................................................18

2.08 Generator Recommendations .................................................................................. 19

2.09 Power Supply Features ............................................................................................ 19

SECTION 2 TORCH: INTRODUCTION ........................................................... 23

2T.01 Scope of Manual ...................................................................................................... 23

2T.02 General Description ................................................................................................. 23

2T.03 Specications .........................................................................................................23

SECTION 3 SYSTEM: INSTALLATION ........................................................... 25

3.01 Unpacking ............................................................................................................... 25

3.02 Lifting Options ......................................................................................................... 25

3.03 Gas Connections ...................................................................................................... 26

3.04 Primary Input Power Connections ........................................................................... 27

3.05 Work Lead Connections ........................................................................................... 28

SECTION 3 TORCH:

INSTALLATION ......................................................................................... 25

3T.01 Torch Connections.................................................................................................... 25

SECTION 4 SYSTEM: OPERATION ............................................................... 27

4.01 Front Panel Controls / Features ................................................................................27

4.02 Preparations for Operation ......................................................................................28

SECTION 4 TORCH: OPERATION .................................................................. 31

4T.01 Torch Parts Selection ............................................................................................... 31

4T.02 Hand Torch Operation .............................................................................................. 31

4T.03 Gouging................................................................................................................... 35

4T.04 PATENT INFORMATION ............................................................................................. 37

TABLE OF CONTENTS

SECTION 5 SYSTEM: SERVICE ..................................................................... 39

5.01 General Maintenance .............................................................................................. 39

5.02 Maintenance Schedule ............................................................................................ 39

5.03 Common Faults ........................................................................................................40

5.04 Fault Indicator .........................................................................................................41

5.05 Basic Troubleshooting Guide .................................................................................... 42

5.06 Power Supply Basic Parts Replacement ................................................................... 44

SECTION 5 TORCH: SERVICE ...................................................................... 45

5T.01 General Maintenance .............................................................................................. 45

5T.02 Inspection and Replacement of Consumable Torch Parts ......................................... 46

SECTION 6: PARTS LISTS ........................................................................... 47

6.01 Introduction ............................................................................................................ 47

6.02 Ordering Information ..............................................................................................47

6.03 Power Supply System Replacement ......................................................................... 47

6.04 Replacement Power Supply Parts ............................................................................ 48

6.05 Options and Accessories ..........................................................................................48

6.06 External Replacement Parts ................................................................................... 49

6.07 Replacement Parts for SL60 Hand Torch .................................................................. 50

6.08 Replacement Parts for SL60QD Hand Torch ............................................................. 51

6.09 Torch Consumable Parts (SL60) ................................................................................52

APPENDIX 1: DATA TAG INFORMATION ...................................................... 53

APPENDIX 2: TORCH PIN  OUT DIAGRAMS ................................................ 54

APPENDIX 3: TORCH CONNECTION DIAGRAMS ........................................... 55

CUTMASTER 40

!!

!!

SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information.
These highlights are categorized as follows:

NOTE!

An operation, procedure, or background information which requires additional emphasis or is helpful in
ecient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

WARNING

Gives information regarding possible electrical shock injury.

0-5557 GENERAL INFORMATION

11

CUTMASTER 40

WARNING

1. Cutting sparks can cause explosion
or fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby and
ready to use.

1.3 Do not use a drum or other closed
container as a cutting table.

2. Plasma arc can injure and burn;
point the nozzle away from
yourself. Arc starts instantly when
triggered.

2.1 Turn o power before disassembling
torch.

2.2 Do not grip the workpiece near the
cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric
shock or burn.

3.1 Wear insulating gloves. Replace
gloves when wet or damaged.

3.2 Protect from shock by insulating
yourself from work and ground.

3.3 Disconnect power before servicing.
Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local
exhaust to remove the fumes.

4.3 Do not operate in closed spaces.
Remove fumes with ventilation.

5. Arc rays can burn eyes and injure
skin.

5.1 Wear correct and appropriate
protective equipment to protect
head, eyes, ears, hands, and body.
Button shirt collar. Protect ears from
noise. Use welding helmet with the
correct shade of filter.

6. Become trained.

Only qualified personnel should
operate this equipment. Use torches
specified in the manual. Keep
non-qualified personnel and children
away.

7. Do not remove, destroy, or cover
this label.

Replace if it is missing, damaged,
or worn.

AVERTISSEMENT

1. Les étincelles de coupage peuvent
provoquer une explosion ou un
incendie.

1.1 Ne pas couper près des matières
inflammables.

1.2 Un extincteur doit être à proximité
et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre
contenant fermé comme table de
coupage.

2. L’arc plasma peut blesser et brûler;
éloigner la buse de soi. Il s’allume
instantanément quand on l’amorce.

2.1 Couper l’alimentation avant de
démonter la torche.

2.2 Ne pas saisir la pièce à couper de la
trajectoire de coupage.

2.3 Se protéger entièrement le corps.

3. Tension dangereuse. Risque de
choc électrique ou de brûlure.

3.1 Porter des gants isolants. Remplacer
les gants quand ils sont humides ou
endommagés.

3.2 Se protéger contre les chocs en
s’isolant de la pièce et de la terre.

3.3 Couper l’alimentation avant
l’entretien. Ne pas toucher les pièces
sous tension.

4. Les fumées plasma peuvent être
dangereuses.

4.1 Ne pas inhaler les fumées.

4.2 Utiliser une ventilation forcée ou un
extracteur local pour dissiper les
fumées.

4.3 Ne pas couper dans des espaces clos.
Chasser les fumées par ventilation.

5. Les rayons d’arc peuvent brûler les
yeux et blesser la peau.

5.1 Porter un bon équipement de
protection pour se protéger la tête,
les yeux, les oreilles, les mains et le
corps. Boutonner le col de la chemise.
Protéger les oreilles contre le bruit.
Utiliser un masque de soudeur avec
un filtre de nuance appropriée.

6. Suivre une formation.

Seul le personnel qualifié a
le droit de faire fonctionner cet
équipement. Utiliser exclusivement
les torches indiquées dans le manual.
Le personnel non qualifié et les
enfants doivent se tenir à l’écart.

7. Ne pas enlever, détruire ni couvrir
cette étiquette.

La remplacer si elle est absente,
endommagée ou usée.

Art # A-13294

GENERAL INFORMATION 0-5557

12

CUTMASTER 40

!!

!!

SECTION 1 : INFORMATIONS GÉNÉRALES

1.01 Remarques, avertissements et mises en garde

Le présent manuel est ponctué de remarques, d’avertissements et de mises en garde qui attirent
l’attention sur des informations importantes. Ces repères sont classés comme suit :

REMARQUE:

Fonction, procédé ou renseignement de base qui nécessite une plus grande attention ou contribue au
bon fonctionnement du système.

ATTENTION

Procédé qui, s’il n’est pas suivi correctement, peut endommager l’équipement.

AVERTISSEMENT

Procédé qui, s’il n’est pas suivi correctement, peut causer des lésions à l’utilisateur ou aux personnes
dans la zone d’exploitation.

AVERTISSEMENT

Fournit des renseignements relatifs à d’éventuelles blessures se devant à une décharge électrique.

0-5557 GENERAL INFORMATION

13

CUTMASTER 40

WARNING

1. Cutting sparks can cause explosion
or fire.

1.1 Do not cut near flammables.

1.2 Have a fire extinguisher nearby and
ready to use.

1.3 Do not use a drum or other closed
container as a cutting table.

2. Plasma arc can injure and burn;
point the nozzle away from
yourself. Arc starts instantly when
triggered.

2.1 Turn o power before disassembling
torch.

2.2 Do not grip the workpiece near the
cutting path.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric
shock or burn.

3.1 Wear insulating gloves. Replace
gloves when wet or damaged.

3.2 Protect from shock by insulating
yourself from work and ground.

3.3 Disconnect power before servicing.
Do not touch live parts.

4. Plasma fumes can be hazardous.

4.1 Do not inhale fumes.

4.2 Use forced ventilation or local
exhaust to remove the fumes.

4.3 Do not operate in closed spaces.
Remove fumes with ventilation.

5. Arc rays can burn eyes and injure
skin.

5.1 Wear correct and appropriate
protective equipment to protect
head, eyes, ears, hands, and body.
Button shirt collar. Protect ears from
noise. Use welding helmet with the
correct shade of filter.

6. Become trained.

Only qualified personnel should
operate this equipment. Use torches
specified in the manual. Keep
non-qualified personnel and children
away.

7. Do not remove, destroy, or cover
this label.

Replace if it is missing, damaged,
or worn.

AVERTISSEMENT

1. Les étincelles de coupage peuvent
provoquer une explosion ou un
incendie.

1.1 Ne pas couper près des matières
inflammables.

1.2 Un extincteur doit être à proximité
et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre
contenant fermé comme table de
coupage.

2. L’arc plasma peut blesser et brûler;
éloigner la buse de soi. Il s’allume
instantanément quand on l’amorce.

2.1 Couper l’alimentation avant de
démonter la torche.

2.2 Ne pas saisir la pièce à couper de la
trajectoire de coupage.

2.3 Se protéger entièrement le corps.

3. Tension dangereuse. Risque de
choc électrique ou de brûlure.

3.1 Porter des gants isolants. Remplacer
les gants quand ils sont humides ou
endommagés.

3.2 Se protéger contre les chocs en
s’isolant de la pièce et de la terre.

3.3 Couper l’alimentation avant
l’entretien. Ne pas toucher les pièces
sous tension.

4. Les fumées plasma peuvent être
dangereuses.

4.1 Ne pas inhaler les fumées.

4.2 Utiliser une ventilation forcée ou un
extracteur local pour dissiper les
fumées.

4.3 Ne pas couper dans des espaces clos.
Chasser les fumées par ventilation.

5. Les rayons d’arc peuvent brûler les
yeux et blesser la peau.

5.1 Porter un bon équipement de
protection pour se protéger la tête,
les yeux, les oreilles, les mains et le
corps. Boutonner le col de la chemise.
Protéger les oreilles contre le bruit.
Utiliser un masque de soudeur avec
un filtre de nuance appropriée.

6. Suivre une formation.

Seul le personnel qualifié a
le droit de faire fonctionner cet
équipement. Utiliser exclusivement
les torches indiquées dans le manual.
Le personnel non qualifié et les
enfants doivent se tenir à l’écart.

7. Ne pas enlever, détruire ni couvrir
cette étiquette.

La remplacer si elle est absente,
endommagée ou usée.

Art # A-13294

GENERAL INFORMATION 0-5557

14

CUTMASTER 40

SECTION 2 SYSTEM: INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just product(s) listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and
warnings.

Additional copies of this manual may be purchased by contacting ESAB at the address and phone
number in your area listed on back cover of this manual. Include the Operating Manual number and
equipment identication numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by go­ing to the ESAB web site listed below and clicking on "Product Support" / "ESAB Documentation": /
"Download Library", then navigate to "Plasma Equipment" and then "Manual".

http://www.esab.com

2.02 Equipment Identication

The unit’s identication number (specication or part number), model, and serial number usually appear
on a data tag attached to the bottom. Equipment which does not have a data tag such as torch and
cable assemblies are identied only by the specication or part number printed on loosely attached
card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

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 on the back cover of this manual.

Include all equipment identication numbers as described above, along with a full description of the
parts in error.

CSA / UL

Included items:

• CutMaster 40 Power Supply

• SL60™ Torch and Leads

• Work Lead with Work Clamp

• Spare Parts Kit ( 2 Electrodes, 2 Stando
Tips, 1 Gouging Tip, 1 Shield Cap and
1 Shield cup)

• 50 Amp to 20 Amp Adapter

• 20 Amp to 15 Amp Adapter

• Operating Manual

• Quick Start Guide

Move the equipment to the installation site before un-boxing the unit. Use care to avoid damaging
the equipment when opening the box.

0-5557 INTRODUCTION

CE

Included items:

• CutMaster 40 Power Supply

• SL60™ Torch and Leads

• Work Lead with Work Clamp

• Spare Parts Kit ( 2 Electrodes, 2 Stando
Tips, 1 Gouging Tip, 1 Shield Cap and
1 Shield cup)

• 1/4" NPT to female BSP Adapter.

• Operating Manual

• Quick Start Guide

15

CUTMASTER 40

2.04 Power Supply Specications CSA

CM 40 120-240 VAC 1 Phase Power Supply Specications

Input Power 120 - 240 VAC, Single Phase, 50/60 Hz

1 Phase Input Power Cable CSA

Output Current 15 - 40 Amps, Continuously Adjustable

Power Supply Gas Filtering Ability Particulates to 5 Microns

Inlet Pressure 90-125 PSI (6.2-8.6 bar / 620-862 Kpa)

2.04.01 Additional Power Supply Specications

CM 40 Power Supply Duty Cycle *

Ambient Air Temperature

120 VAC Units

208-240 VAC Units

Power Supply includes 9' single phase 12AWG 3/C input cable with NEMA

Duty Cycle Ratings @ 40° C (104° F)

Duty Cycle* 30% 60% 100%

Current

DC Voltage

Duty Cycle* 40% 60% 100%

Current

DC Voltage

6-50P Plug

Operating Range 0° - 50° C

Rating

27 Amps** 20 Amps 15 Amps

92 93 89

40 Amps 30 Amps 20 Amps

135 130 135

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is higher than
shown in this chart.
** NOTE: 27 Amps is for a 20 Amp circuit ONLY!
DO NOT exceed a 20 Amp output setting on a 15 Amp circuit!

INTRODUCTION 0-5557

16

2.05 Input Wiring Specications CSA

1 Phase Input Cable Wiring Requirements

1 Phase CutMaster 40 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I1e

120 / 15A 50/60 2.3 19.3 13.6 15 12 AWG

120 / 20A 50/60 3.1 25.3 18.3 20 12 AWG

Fuse

(amps)

CUTMASTER 40

Flexible Cord

(Min. AWG)

1 Phase

208 50/60 6.1 29.2 18.5 50 12 AWG

220 50/60 6.1 27.9 17.6 50 12 AWG

230 50/60 6.0 26.1 16.5 50 12 AWG

240 50/60 6.0 25.1 15.9 50 12 AWG

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTE!

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.

Art# A-14359

NOTE!

Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the
amperage accordingly.

CM 40 Cut Capacity

Recommended Pierce Maximum

1/2" (12.7mm) 1/2" (12.7mm) 1" (25.4mm)

0-5557 INTRODUCTION

17

CUTMASTER 40

2.06 Power Supply Specications CE

CM 40 240 VAC 1 Phase Power Supply Specications

Input Power 230 VAC, Single Phase, 50 Hz

1 Phase Input Power Cable CE

Output Current 15 - 40 Amps, Continuously Adjustable

Power Supply Gas Filtering Ability Particulates to 5 Microns

Inlet Pressure 90-125 PSI (6.2-8.6 bar / 620-862 Kpa)

2.06.01 Additional Power Supply Specications

CM 40 Power Supply Duty Cycle *

Ambient Air Temperature

230VAC Units

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the output voltage (DC) is higher than
shown in this chart.

Power Supply includes 2.5M single phase 2.5mm² input

Duty Cycle* 35% 60% 100%

Current

DC Voltage

cable with Schuko plug

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

Rating

40 Amps 30 Amps 20 Amps

135 130 135

2.07 Input Wiring Specications CE

1 Phase Input Cable Wiring Requirements

1 Phase CutMaster 40 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I1e

1 Phase 230 CE 50 6.0 26.1 15.5 50

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTE!

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.

INTRODUCTION 0-5557

18

Fuse

(amps)

Flexible Cord

(Min. AWG)

2.5mm

CUTMASTER 40

2.08 Generator Recommendations

When using generators to power the CM40 Plasma Cutting System, the following ratings are a
minimum and are to be used along with the ratings previously listed.

CM 40 Generator Specications

Generator Output Rating CM 40 Output Current Arc Characteristic

3 kW / 120V 20A on 15A circuit Full

5 kW / 120V 27A on 20A circuit Full

6.8 kW 40A Full

NOTE: If Generator is equipped with an idle mode it will need to be in "Run" mode to operate at 40 amps.

NOTE!

Due to circuitry, age and condition two generators with the same ratings may produce dierent results. Adjust the
amperage accordingly.

CM 40 Cut Capacity

Recommended Pierce Maximum

1/2" (12.7mm) 1/2" (12.7mm) 1" (25.4mm)

2.09 Power Supply Features

Handle and Leads Wrap

Art # A-14041

0-5557 INTRODUCTION

Control Panel

Work Lead Receptacle

Torch Leads Receptacle

19

CUTMASTER 40

Input Power ON/OFF Switch

Input Power Cord

Weights and Dimensions

Gas Inlet Port

Art # A-14042

8”

203.29 mm

Art # A-14039

12.25"

311.21 mm

18.82"

478.07 mm

29 lb / 13.154 kg

Power Supply Dimensions & Weight

INTRODUCTION 0-5557

20

Clearances for Operation and Ventilation

6"

150 mm

CUTMASTER 40

15"

381 mm

Art # A-14040

15"

381 mm

Ventilation Clearance Requirements

6"

150 mm

0-5557 INTRODUCTION

21

CUTMASTER 40

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INTRODUCTION 0-5557

22

SECTION 2 TORCH: INTRODUCTION

!!

!!

2T.01 Scope of Manual

This manual contains descriptions, operating
instructions and maintenance procedures for the
1Torch Model SL60™ Plasma Cutting Torch. Ser vice
of this equipment is restricted to properly trained
personnel; unqualied personnel are strictly cau­tioned against attempting repairs or adjustments
not covered in this manual, at the risk of voiding
the Warranty.

Read this manual thoroughly. A complete under­standing of the characteristics and capabilities
of this equipment will assure the dependable
operation for which it was designed.

2T.02 General Description

CAUTION

Torch Leads are exible but internal wires can
be broken. Do not exceed a 2" radius bend and
avoid repeated tight bends when possible.

Refer to the Appendix Pages for
additional specications as related
to the Power Supply used.

CUTMASTER 40

D. Parts - In - Place (PIP)

Torch Head has built - in switch

15 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream
through torch.

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum

Current

Voltage (V

Arc Striking

Voltage

G. Gas Requirements

) 500V

peak

Manual Torch Gas Specifications

104° F

40° C

100% @ 60 Amps @ 400

scfh

60 Amps

500V

2T.03 Specications

A. Torch Congurations

1. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch
handle. The hand torches include a torch
handle and torch trigger assembly.

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Hand Torches are available as follows:

• 20 ft / 6.1 m

• 50 ft / 15.2 m

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

0-5557 INTRODUCTION

Art # A-03322_AB

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and

Gouging)

WARNING

This Torch is not to be used with oxygen (O2).
The SL60QD torch should not be used on an HF
system.

NOTE!

Operating pressure varies with torch model,
operating amperage, and torch leads length. Refer
to gas pressure settings charts for each model.

H. Direct Contact Hazard

For stando tip the recommended stando
is 3/16 inches / 4.7 mm.

90 - 120 psi

6.2 - 8.3 bar

5 - 8.3 SCFM

300 - 500 scfh

142 - 235 lpm

23

CUTMASTER 40

This Page Intentionally Blank

INTRODUCTION 0-5557

24

CUTMASTER 40

SECTION 3 SYSTEM: INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account for each item.

2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor
and / or shipping company before proceeding with the installation.

3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name,
in the information block at the front of this manual.

3.02 Lifting Options

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

WARNING

Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLES are not for mechanical lifting.

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

• Lift unit by the handles, using two hands. Do not use straps for lifting.

• Use optional cart or similar device of adequate capacity to move unit.

0-5557 INSTALLATION

25

CUTMASTER 40

3.03 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high pressure cylinders.

1. Connect the air line to the quick connect inlet port. The following illustration shows typical
gas line with quick connect ttings as an example.

Art # A-14048_AB

Air Connection to Inlet Port

NOTE!

1/4" NPT to 1/4" female BSP adapter provided for European units if preferred.

INSTALLATION 0-5557

26

CUTMASTER 40

!!

3.04 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before connecting the unit to input power. The primar y power source, fuse,
and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring
requirements as specied in Section 2.

Power Cords Included With the Power Supply

Power cords come attached on all systems. For North America it will come with a 50 amp plug for use

on a 240V/50A circuit. For Europe it will come with a 2.5mm cable and a Schuko plug for use on a
230V circuit. . .

Also included for CSA systems ONLY, are two adapters. One is a cable with a 120V/20A NEMA 5-20P
plug which attaches to the power supply input cord via a NEMA 6-50R plug. The other is a 5-20R to
5-15P adapter plug that attaches to the other adapter.

CAUTION

When using the 120V/20A adapter cord (CSA systems ONLY ), do not exceed
a current output setting of 27 Amps on the power supply or the input power
circuit breaker may trip.

WARNING

When using the 15A adapter in conjunction with the 20A adapter (CSA
systems ONLY), extreme caution should be used to not exceed a current
output setting of 20 Amps on the power supply. Failure to do so may result
in the input power circuit breaker tripping or branch circuit overheating.

Input Voltage Rated Output Amps (RMS) input at

120V, 15A Circuit (CSA) 20A, 93V 19.3 2.3

120V, 20A Circuit (CSA) 27A, 92V 25.3 3.1

208-240V, 50A Circuit (CSA) 40A, 135V 25-29 6.0

230V, (CE) 40A, 135V 26 6.0

CSA ONLY

0-5557 INSTALLATION

rated output, 60 Hz,

kVA

single-phase

Art# A-14359

27

CUTMASTER 40

3.05 Work Lead Connections

Connect the Work Lead to the power supply and the work piece.

1. Attach the Dinse type connection of the work lead to the power supply front panel as shown
below. Push in and turn clockwise to the right until tight.

2. Connect the work clamp to the workpiece or cutting table. The area must be free from oil,
paint and rust. Connect only to the main part of the work piece; do not connect to the part
to be cut o.

3

2

1

Art# A-14043

See section 3T for torch installation.

INSTALLATION 0-5557

28

CUTMASTER 40

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the ESAB model SL60 or SL60QD™
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.

Art # A-14044

Connecting the Torch to the Power Supply

0-5557 INSTALLATION

1

2

25

CUTMASTER 40

This Page Intentionally Blank

INSTALLATION 0-5557

26

SECTION 4 SYSTEM: OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identication

2

1

CUTMASTER 40

3
4
5
6

7

8

Art # A-14045

1. Current Control Knob

Knob used to adjust current output.

2. Numeric Display

• Displays software revision at start up

• Displays amperage values (Factory default)

• Displays Status Codes

3. AC Indicator

Steady light indicates power supply is ready for operation. No light indicates there is no input
voltage, the input voltage is outside of operating range, or there is an internal fault.

4. DC Indicator

Indicator is ON when DC output circuit is active.

0-5557 OPERATION

27

CUTMASTER 40

5. Gas Pressure Indicator

Indicator will be ON to show any gas pressure but not whether it is adequate or not. Check the
inlet gas pressure. It should be between 90 - 125 PSI / 6.2 - 8.6 bar / 620 - 862 Kpa. NEVER EXCEED

150 PSI / 10.34 bar / 1034 Kpa.

6. Over Temp Indicator

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

7. Work Lead Dinse type receptacle

Align Dinse type connector on work lead with receptacle, press in and turn clockwise to the
right until tight.

8. Torch Quick Disconnect Receptacle

Torch Leads are connected here by aligning the connectors, pressing in and turning locking ring
clockwise-to-the-right to secure. Connection should only be snug with no tools used.

4.02 Preparations for Operation

At the start of each operating session:

WARNING

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

Torch Parts Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond
with the type of operation, and with the amperage output of this Power Supply (40 amps maximum
at 240V or 27 amps at 120V). Refer to Section 4T.01 for torch parts order.

Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics models SL60, SL60QD™ /
Manual Torches may be connected to this Power Supply. See Section 3T of this manual.

Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets
the power requirements for the unit per Section 2, Specications.

2. Connect the input power cable (or close the main disconnect switch) to supply power to the
system.

Air Source

Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.

OPERATION 0-5557

28

CUTMASTER 40

Art # A-04509

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 o.

Power ON

Place the Power Supply ON / OFF switch to the ON (right) position. AC indicator turns ON.
The Main Board performs several tests to determine the system is ready to operate. During the
self-tests the digital display rst shows the rmware revision number which includes decimals.

1.1.0 is an example of a production released code revision that may be displayed.

If there are no issues detected the output current setting will be displayed from 15 to 40 amps.
Should a problem be detected the status code in letter format or Exx will display. Refer to Section
5 for fault / status code explanations.

The cooling fan will turn ON as soon as the unit is turned ON and will continue to run until the
power is turned OFF.

Set Operating Pressure

Gas pressure cannot be set at the power supply and must be set at the source, from 90 - 125 PSI
/ 6.2 - 8.6 bar / 620 - 862 Kpa.

NEVER EXCEED 150 PSI / 10.34 bar / 1034 Kpa.

Cutting Operation

Once the cutting arc is established, it should continue to cut until the trigger is released, the torch
is moved too far from the work piece or the duty cycle has been exceeded causing the system
to go into an over temperature mode. In the rst two instances release the torch trigger, ensure
that the torch tip is close to the work piece, activate the trigger and reestablish the cutting arc.
In the event of an over temperature fault, release the trigger, allow the unit to run so it will cool
down. When the fault clears you can begin cutting again.

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, gas pressure, the type of material
being cut, and operator skill.

Output current setting or cutting speeds may be reduced to allow slower cutting when following
a line, or using a template or cutting guide while still producing cuts of excellent quality.

0-5557 OPERATION

29

CUTMASTER 40

Postow

Release the trigger to stop the cutting arc. Gas continues to ow for approximately 10 seconds.
During post - ow, if the user quickly presses and releases the trigger, the gas will shut o. If the
user continues to hold the trigger and not release it, the pilot arc starts. The main arc will transfer
to the workpiece if the torch tip is within transfer distance.

Shutdown

Turn the ON / OFF switch to OFF, to the left as you face the unit from the rear. After a short delay
all Power Supply indicators and fan shut OFF. Unplug the input power cord or disconnect input
power. Power is removed from the system.

NOTE!

To maximize the longevity of the internal electronics, allow the power supply to continue running (without cutting) for
a few minutes before turning OFF. This will allow them to cool faster.

OPERATION 0-5557

30

A-03510_AB

SECTION 4 TORCH: OPERATION

CUTMASTER 40

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, stando cutting or goug­ing

Torch parts:

Shield Cup, Cutting Tip, Electrode and
Start Cartridge

NOTE!

Refer to Section 4T.07 and following for additional
information on torch parts.

Change the torch parts for a dierent operation
as follows:

WARNING

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

NOTE!

The shield cup holds the tip and start cartridge
in place. Position the torch with the shield cup
facing upward to keep these parts from falling out
when the cup is removed.

1. Unscrew and remove the shield cup
assembly from the torch head.

2. Remove the Electrode by pulling it
straight out of the Torch Head.

3. Install the replacement Electrode by
pushing it straight into the torch head
until it clicks.

4. Install the start car tridge and desired tip
for the operation into the torch head.

5. Hand tighten the shield cup assembly
until it is seated on the torch head. If
resistance is felt when installing the cup,
check the threads before proceeding.

4T.02 Hand Torch Operation

Stando Cutting With Hand Torch

NOTE!

For best performance and parts life, always use
the correct parts for the type of operation.

1. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to the
torch head for maximum control or near
the back end for maximum heat protec­tion. Choose the holding technique that
feels most comfortable and allows good
control and movement.

NOTE!

The tip should never come in contact with the
workpiece except during drag cutting operations.

Large O-Ring

Torch Head

Electrode

Start Cartridge

Small O-Ring

Tip

Shield Cup

Torch Parts

0-5557 TORCH OPERATION

31

CUTMASTER 40

1/8" - 3/8" (3 - 9mm)

Art # A-04034

2. Depending on the cutting operation, do
one of the following:

a. For edge starts, hold the torch per-

pendicular to the workpiece with
the front of the tip on the edge of
the workpiece at the point where
the cut is to start.

b. For stando cutting, hold the torch

1/8 - 3/8 in (3-9 mm) from the work­piece as shown below.

Torch

Shield Cup

Stando Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back
of the torch handle while simultaneous­ly squeezing the trigger. The pilot arc
will start.

Trigger Release

Standoff Distance

Trigger

A-02986

Tr igger

1

2

Tr igger Release

3

4

Art # A-03383

6. Cut as usual. Simply release the trigger
assembly to stop cutting.

7. Follow normal recommended cutting
practices as provided in the power
supply operator's manual.

NOTE!

When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
damage components.

8. For a consistent stando height from the
workpiece, install the stando guide by
sliding it onto the torch shield cup. In­stall the guide with the legs at the sides
of the shield cup body to maintain good
visibility of the cutting arc. During oper­ation, position the legs of the stando
guide against the workpiece.

5. Bring the torch within transfer distance
to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a characteristic

Shield Cup

Standoff Guide

Torch Tip

Workpiece

of the power supply and not a function of the
torch.

TORCH OPERATION 0-5557

32

Shield Cup With Straight Edge

t # A-03383

Tr igger

The drag shield cup can be used with a non
conductive straight edge to make straight cuts
by hand.

WARNING
The straight edge must be non - conductive.

CUTMASTER 40

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.

Non-Conductive

Straight Edge
Cutting Guide

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when
cutting 3/16 inch (4.7 mm) solid metal with
relatively smooth surface.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 1/4" (6
mm) thick or less.

NOTE!

For best parts performance and life, always use
the correct parts for the type of operation.

1. Install the drag cutting tip and set the
output current.

2. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to the
torch head for maximum control or near
the back end for maximum heat protec­tion. Choose the holding technique that
feels most comfortable and allows good
control and movement.

Trigger

Trigger Release

A-02986

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 preow and postow are a characteristic
of the power supply and not a function of the
torch.

1

2

Tr igger Release

3

4

Ar

8. Cut as usual. Simply release the trigger
assembly to stop cutting.

0-5557 TORCH OPERATION

33

CUTMASTER 40

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.

5. Slide the trigger release toward the back
of the torch handle while simultaneous­ly squeezing the trigger. The pilot arc
will start.

Trigger

Piercing With Hand Torch

1. Hold the torch away from your body.

2. The torch can be comfortably held in
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch,
the hand may be positioned close to
the torch head for maximum control or
near the back end for maximum heat
protection. Choose the technique that
feels most comfortable and allows good
control and movement.

NOTE!

The tip should never come in contact with the
workpiece except during drag cutting operations.

3. Angle the torch slightly to direct blow­back particles away from the torch tip
(and operator) rather than directly back
into it until the pierce is complete.

4. In a portion of the unwanted metal start
the pierce o the cutting line and then
continue the cut onto the line. Hold the
torch perpendicular to the workpiece
after the pierce is complete.

Trigger Release

A-02986

6. Bring the torch within transfer distance
to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.

NOTE!

The gas preow and postow are a characteristic
of the power supply and not a function of the
torch.
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. Clean spatter and scale from the shield
cup and the tip as soon as possible.
Spraying the shield cup in anti - spatter
compound will minimize the amount of
scale which adheres to it.

Cutting speed depends on material, thickness,
and the operator’s ability to accurately follow the
desired cut line. The following factors may have
an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage uctuations

• Torch stando height

• Proper work cable connection

TORCH OPERATION 0-5557

34

4T.03 Gouging

!!

!!

!!

35°

Workpiece

Torch Head

Standoff Height

WARNING

Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that
all safety precautions at the front of this manual
have been followed. Make sure no part of the op­erator’s body comes in contact with the workpiece
when the torch is activated.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.

CAUTION

Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
plastic, and metal.
Check torch parts. The torch parts must
correspond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection.

Gouging Parameters

Gouging performance depends on parame­ters such as torch travel speed, current level,
lead angle (the angle between the torch and
workpiece), and the distance between the
torch tip and workpiece (stando).

Lead Angle

CUTMASTER 40

The angle between the torch and workpiece
depends on the output current setting and
torch travel speed. The recommended lead
angle is 35°. At a lead angle greater than 45°
the molten metal will not be blown out of
the gouge and may be blown back onto the
torch. If the lead angle is too small (less than
35°), less material may be removed, requiring
more passes. In some applications, such as
removing welds or working with light metal,
this may be desirable.

Gouging Angle and Stando Distance

CAUTION

Touching the torch tip or shield cup to the work
surface will cause excessive parts wear.

Torch Travel Speed

NOTE!

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

Optimum torch travel speed is dependent
on current setting, lead angle, and mode of
operation (hand or machine torch).

Current Setting

Current settings depend on torch travel
speed, mode of operation (hand or machine
torch), and the amount of material to be
removed.

0-5557 TORCH OPERATION

Stando Distance

The tip to work distance aects gouge qual­ity and depth. Stando distance of 1/8 - 1/4
inch (3 - 6 mm) allows for smooth, consistent
metal removal. Smaller stando distances
may result in a severance cut rather than a
gouge. Stando distances greater than 1/4
inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.

Slag Buildup

Slag generated by gouging on materials such
as carbon and stainless steels, nickels, and
alloyed steels, can be removed easily in most
cases. Slag does not obstruct the gouging
process if it accumulates to the side of the
gouge path. However, slag build - up can
cause inconsistencies and irregular metal
removal if large amounts of material build
up in front of the arc. The build - up is most
often a result of improper travel speed, lead
angle, or stando height.

35

CUTMASTER 40

Rolling Pierce

A Rolling Pierce begins cutting with the torch head placed at an angle to the work surface. Splatter/
dross are blown away from the work area as the torch cuts. The torch head rotates towards vertical as
the cut grows deeper and pierces the workpiece.

Art # A-13353

TORCH OPERATION 0-5557

36

CUTMASTER 40

4T.04 PATENT INFORMATION

Plasma Cutting Torch Patents

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
9-8214 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

0-5557 TORCH OPERATION

37

CUTMASTER 40

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

Patents Pending for the following:

Quick Disconnect Torch and Quick Disconnect Torch Leads

TORCH OPERATION 0-5557

38

5.01 General Maintenance

CUTMASTER 40

SECTION 5 SYSTEM: SERVICE

Warning!
Disconnect input power before maintaining.

Visually inspect the torch body,
consumables and Quick Connect

Replace all
broken parts

Art# A-14037

Maintain more often
if used under severe
conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the
cables and leads.
Replace as needed

3 Months

Clean
exterior
of power supply

5.02 Maintenance Schedule

NOTE!

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Check plasma and secondary supply and pressure/ow.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air ow.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Inspect input power cable for damage or exposed wires, replace if necessary.

0-5557 SERVICE

39

CUTMASTER 40

!!

Six Months or Every 720 Cutting Hours:

1. Check the in-line air lter(s), clean or replace as required.

2. Check cables and hoses for leaks or cracks, replace if necessary.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere
with sensitive electrical components and cause damage to the unit.

5.03 Common Faults

Problem ­Symptom

Insufficient
Penetration

Main Arc

Extinguishes

Excessive

Dross

Formation

Short Torch

Parts Life

Difficult
Starting

Common Cause

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics parts used

7. Incorrect gas pressure. Line pressure 90-125 psi
(6.2-8.6 bar / 620-862 Kpa.

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics parts used

7. Line voltage drop due to extension cord or supply
line being too long.

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

1. Oil or moisture in air source.

2. Exceeding system capability (material too thick).

3. Excessive pilot arc time

4. Gas pressure too low.

5. Improperly assembled torch.

6. Non - Genuine Thermal Dynamics parts used

1. Worn torch parts.

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

4. Line voltage too low

5. Wrong parts for current selection.

6. Hose restriction.

SERVICE 0-5557

40

CUTMASTER 40

5.04 Fault Indicator

At initial power up, the system goes through a series of self checks before it is ready for use. If during
those checks it detects something is not within proper operating parameters, a fault will occur. If that
happens, an Error Code will illuminate on the digital display. Depending on the type of error it may be
accompanied by one of the indicator lights to the right of the digital display to turn ON or in the case
of a low or high line voltage detection the AC indicator will turn OFF.

The Cutmaster 40 has two types of Fault Codes. One is the Communication Fault. This type of code is
to help you determine what you can do to get the system up and running by correcting a problem like
forgetting to put the consumables in the torch. These will show letters on the digital display.

The other type of Fault Code is the Error Fault for issues with the Power Supply or incoming power
and will show "E0" and a number on the digital display and possibly a fault light such as the AC light
being turned OFF.

Communication Fault Description

Over Temp Overtemp Error will activate if an Over Temperature status has been
detected on the heatsink or transformer. "HI" will show on the 7
segment display and the Over Temp LED will be illuminated.

Parts InPlace Fault Parts In Place Error is activated if the shield cup is removed.

“PIP” will show on the 7-segment display

Parts In Contact Parts In Contact Error is activated when the tip is not in contact with
the electrode during initialization. Most likely to occur if the tip is
missing from the torch. “PIC” will show on the 7-segment display.

Trigger Fault SCC Trigger Fault Error is activated if the trigger is pulled during
machine start up or while another fault is clearing. “SCC” will show
on the 7-segment display.

Gas Fault LoP Gas Fault Error is activated if the consumables do not separate
when the gas is turned on. Most likely due to gas line not attached
or pressure is too high closing the valve. The Gas LED on the front
display will be ashing or not be illuminated.

Error Fault Description

Bus Fault Bus Fault Error is activated if the bus voltage drops below
~360V. Bus voltage will be checked in standby mode only.
“E02” will show on the 7-segment display.

Bias Fault Bias Fault Error is activated if the bias voltage drops below
~13.5V. “E03” will show on the 7-segment display.

Low Line Voltage Fault Low Line Voltage Error is activated if the Input voltage is too low.
“E06” will show on the 7-segment display and the AC LED indicator
on the front display will not be illuminated.

High Line Voltage Fault High Line Voltage Error is activated if the input voltage is too high.
“E07” will show on the 7-segment display and the AC LED indicator
on the front display will not be illuminated.

0-5557 SERVICE

41

CUTMASTER 40

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 ­Symptom

ON / OFF Switch
is ON but the A/C
Indicator does not
light

Fault indicator
showing Error
Code E02

TEMPERATURE
LED ON.
Communication
Fault showing HI

GAS LED OFF,
Communication
Fault showing LoP

FAULT and
Communication
Fault showing PIP

FAULT and
Communication
Fault showing PIC

Possible Cause Recommended Action

1. Primary power disconnect is in OFF
position.

2. Primary fuses / breakers are blown
or tripped.

3. Faulty components in unit.

1. Primary input voltage problem.

2. Faulty components in unit.

1. Air ow through or around the unit is
obstructed.

2. Duty cycle of the unit has been
exceeded.

3. Failed components in unit.

1. Gas supply not connected to unit.

2. Gas supply not turned ON.

3. Gas supply pressure too low.

4. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power
supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter cartridge
missing.

3. Torch start cartridge is stuck.

4. Unit inlet gas pressure is too high
causing continuous gas ow.

5. Open conductor in torch leads.

6. Problem in the torch and leads switch
circuit.

7. Failed components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualied person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle

3. Return to authorized service center for repair or replacement.

1. Have qualied person check primary voltage to insure it meets unit
requirements see Section "2.05 Input Wiring Specications" on page

19.

2. Return to authorized service center for repair or replacement.

1. Refer to clearance information – see Section "2.04 Power Supply
Specications" on page 18

2. Allow unit to cool.

3. Return to authorized service center for repair or replacement.

1. Connect gas supply to unit.

2. Turn gas supply ON.

3. Set air supply inlet pressure to unit to 120 psi. Set leads length to
match the actual length being used.

4. Return to authorized service center for repair or replacement.

1. Hand tighten the shield cup until it is snug.

2. Insure torch ATC is securely fastened to unit.

3. Replace torch and leads or return to authorized service center for
repair or replacement.

4. Return to authorized service center for repair or replacement.

1. Tighten shield cup by hand. Do not over tighten.

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 start cartridge. Check start cartridge lower end tting for
free movement. Replace if tting does not move freely.

4. Decrease gas supply pressure to 125 PSI or less.

5. Replace torch and leads or return to authorized service center for
repair or replacement.

6. Replace torch and leads or return to authorized service center for
repair or replacement.

7. Return to authorized service center for repair or replacement

SERVICE 0-5557

42

Problem -

Symptom

Nothing happens
when torch switch
or remote switch
is closed (Or CNC
START signal is
active). No gas
ow, DC LED OFF.

No Fault lights ON,
no arc in torch.

Pilot arc is ON but
cutting arc will not
establish

Torch cutting is
diminished

Possible Cause Recommended Action

1. Problem in the torch and leads switch
circuit (Remote pendant switch circuit).

2. Failed components in unit.

3. Gas pressure too high.

1. Failed components in unit. 1. 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. Take Torch and Leads (Remote Pendant) to Authorized Repair Facility.

2. Return to authorized service center for repair or replacement.

3. Reduce gas pressure.

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.

CUTMASTER 40

0-5557 SERVICE

43

CUTMASTER 40

5.06 Power Supply Basic Parts Replacement

Optional Single-Stage Filter Element Replacement

These instructions apply to power supplies where the optional Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the Filter Element becomes completely saturated.
The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to
dry. Refer to Section 6, Parts List, for replacement lter element catalog number.

1. Remove power from power supply.

2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter
Element.

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located
inside the Housing.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

6. Wipe inside of housing clean, then insert the replacement Filter Element open side rst.

7. Replace Housing on Cover.

8. Reattach gas supply. Check for leaks.

NOTE!

If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.

This completes the parts replacement procedures.

SERVICE 0-5557

44

SECTION 5 TORCH: SERVICE

!

Lower O-Ring

Art # A-03725

CUTMASTER 40

5T.01 General Maintenance

NOTE!

Refer to Previous “Section 5: System” for com­mon and fault indicator descriptions.

Cleaning Torch

Even if precautions are taken to use only
clean air with a torch, eventually the inside of
the torch becomes coated with residue. This
buildup can aect the pilot arc initiation and
the overall cut quality of the torch.

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned
with electrical contact cleaner using a cot­ton swab or soft wet rag. In severe cases,
the torch can be removed from the leads
and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and
blowing it through with compressed air.

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads

Torch Head O-Ring

ATC Male Connector

Gas Fitting

CAUTION

!

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

An O-Ring on the Torch Head and ATC Male
Connector requires lubrication on a sched­uled basis. This will allow the O-Rings to
remain pliable and provide a proper seal.
The O-Rings will dry out, becoming hard
and cracked if the lubricant is not used on
a regular basis. This can lead to potential
performance problems.

It is recommended to apply a very light lm
of O-Ring lubricant (Catalog # 8-4025) to the
O-Rings on a weekly basis.

0-5557 SERVICE

Art #A-03791_AB

ATC O-Ring

NOTE!

DO NOT use other lubricants or grease, they may
not be designed to operate within high tempera­tures or may contain “unknown elements” that
may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent
performance or poor parts life.

O-Ring
#8-0525

45

CUTMASTER 40

Art # A-08067

Good Tip

Worn Tip

Spring-Loaded

Spring-Loaded

/

Art # A-03284

5T.02 Inspec tion and Replacement of

Consumable Torch Parts

WARNING

Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE!

The shield cup holds the tip and starter cartridge
in place. Position the torch with the shield
cup facing upward to prevent these parts from
falling out when the cup is removed.

1. Unscrew and remove the shield cup
from the torch.

NOTE!

Slag built up on the shield cup that cannot be
removed may eect the performance of the
system.

2. Inspect the cup for damage. Wipe it
clean or replace if damaged.

4. Remove the tip. Check for excessive
wear (indicated by an elongated or
oversized orice). Clean or replace the
tip if necessary.

A-03406

Example of Tip Wear

5. Remove the starter cartridge. Check
for excessive wear, plugged gas holes,
or discoloration. Check the lower end
tting for free motion. Replace if nec­essary.

Lower End Fitting
Full Compression

6. Pull the Electrode straight out of the
Torch Head. Check the face of the elec­trode for excessive wear. Refer to the
following gure.

Lower End Fitting at Reset
Full Extension

Art # A-08064_AC

New Electrode

Shield Cups

3. On torches with a shield cup body and
a shield cap or deector, ensure that
the cap or deector is threaded snugly

7. Reinstall the Electrode by pushing it

against the shield cup body. In shielded
drag cutting operations (only), there
may be an O-Ring between the shield

8. Reinstall the desired starter cartridge

cup body and drag shield cap. Do not
lubricate the O-Ring.

Shield

Cup Body

Drag Shield Cap

9. Hand tighten the shield cup until it is

This completes the parts replacement procedures.

O-Ring No. 8-3488

SERVICE 0-5557

46

Art # A-03878

Worn Electrode

Electrode Wear

straight into the torch head until it clicks.

and tip into the torch head.

seated on the torch head. If resistance
is felt when installing the cup, check the
threads before proceeding.

CUTMASTER 40

SECTION 6: PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable components. The parts lists are arranged as follows:

6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts

6.05 Options and Accessories

6.06 External Replacement Parts

6.07 Replacement Parts for SL60 Hand Torch

6.08 Replacement Parts for SL60QD Hand Torch

6.09 Torch Consumable Parts (SL60™)

NOTE!

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper
authorization will not be accepted.

6.02 Ordering Information

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

6.03 Power Supply System Replacement

The following items are included with the replacement power supply: work cable & clamp, input power
cable, input power cable adapters (2), gas pressure regulator / lter, SL60 Torch, spare parts kit, and
operating manual.

Qty Description Catalog #

1 CutMaster 40 Power Supply UL/CSA

120 -240 VAC, SINGLE Phase, 60Hz,
with input power cable and plug 1-4000-1

1 CutMaster 40Power Supply CE
240 VAC, SINGLE Phase, 60Hz,
with input power cable 1-4000-4

0-5557 PARTS LIST

47

CUTMASTER 40

(Cat.

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Filter Assembly Replacement Element (Factory lter) 9-0116
1 Cable, Pwr 2.5mm 3m EU Type F 9-4435

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Work Cable #8 with 50mm Dinse plug 9-9692
1 Multi - Purpose Cart 7-8888

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single - Stage Filter Kit

PARTS LIST 0-5557

48

CUTMASTER 40

6.06 External Replacement Parts

Item # Qty Description Catalog #

1 1 Top Handle Kit 0464 565 880
2 1 Handle Cover 0465 952 001
3 1 Panel, RH CM40 TD_AEB 9-4440
4 1 Ass'y, Panel Frnt CM40 9-4437
5 1 Panel, LH CM40 TD_AEB 9-4439
6 1 Ass'y, Panel Rear CM40 9-4438

7 1 Top Panel 0465 951 001
8 1 Ass'y, Pcb Display 9-4433
9 1 Kit, Hardware CM40 (not shown) 9-4000

-Includes all the screws/nuts for this system

2

1

2

7

6

5

0-5557 PARTS LIST

Art # A-14465

3

8

4

49

CUTMASTER 40

Art # A-07993_AB

6.07 Replacement Parts for SL60 Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60, 20 - foot / 6.1m Leads Assembly with ATC connector 4-7834
1 SL60, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7835
8 1 Switch Kit 9-7031

1

8

2

4

5

6

3

7

PARTS LIST 0-5557

50

CUTMASTER 40

6.08 Replacement Parts for SL60QD Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Assembly Replacement 7-5681
2 Leads Assemblies with ATC connector and Quick Connectors
1 SL60QD™, 20 - foot Leads Assembly with ATC and QD connectors 4-5620
1 SL60QD™, 50 - foot Leads Assembly with ATC and QD connectors 4-5650
1&2 1 Torch and Leads Assembly, 20 - foot 7-5620
1&2 1 Torch and Leads Assembly, 50 - foot 7-5650

1

0-5557 PARTS LIST

2

Art # A-13248_AB

51

CUTMASTER 40

6.09 Torch Consumable Parts (SL60)

9-8251

PARTS LIST 0-5557

52

9-8244

Art # A-14049_AC

APPENDIX 1: DATA TAG INFORMATION

CUTMASTER 40

Manufacturer's Name and/or
Logo, Location, Model and
Revision Level

Victor Technologies Group, Inc.
2800 Airport Road
Denton, TX 76207

=

U

0

USA

X

I

U

2

Conventional
Load Voltage

U1

Rated Supply
Voltage (Note 2)

CSA E60974-1
ANSI/IEC 60974-1
Class A

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1e

I

1

1Ø

Model: CM40 - CSA/UL

Type of Power
Supply (Note 1)

Plasma Cutting
Symbol

Input Power
Symbol

Input Power
Specications
(Phase, AC or DC
Hertz Rating)

NOTES:

1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectier, DC output.

2. Indicates input voltages for this power supply. Most power
supplies carry a label on the bottom of the unit showing input
voltage requirements for the power supply as built.

3. Top row: Duty cycle values.
Duty cycle values meet or exceed the
IEC specied rating.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas
of the power supply.

Made in Poland

Output Current Type

Rated No­Load Voltage

Degree of Protection

Regulatory Standard Covering
This Type of Power Supply

Ser. No.

Art. No.

I

1

3Ø

Output Range (Amperage/
Voltage)

Duty Cycle Data (Note 3)

Maximum Eective

3Ø1Ø

Supply Current

Manufacturer's Electrical
Schematic File Number
and Revision Level

Standard Symbols

AC

DC

Phase

Ø

Serial Number

Art # A-14369

0-5557 APPENDIX

53

CUTMASTER 40

3 - Switch

2- Orange
PIP

APPENDIX 2: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

Negative /
Plasma

4 - Green /
Switch

3 - White /
Switch

1 - Black /
PIP

ATC Male Connector

Front View

8 - Open

7 - Open

4
3

2

/

1

Pilot

8
7

6
5

6 - Open

5 - Open

8 - Open

7 - Open

6 - Open

5 - Open

ATC Female Receptacle

Front View

8
7

6
5

Pilot

Negative /
Plasma

4 - Switch

4
3

2
1

2 - PIP

1 - PIP

A-03701_AB

APPENDIX 0-5557

54

APPENDIX 3: TORCH CONNECTION DIAGRAMS

Art # A-14446

A. Hand Torch Connection Diagram

Torch: SL60QD / SL60 / SL100 Hand Torch
Leads: Torch Leads with ATC Connector
Power Supply: CM40

Torch

Head

PIP

Switch

Torch

Switch

Pilot

Torch
Leads

Black

Orange

Green

White

Negative / Plasma

Male

ATC Leads

Connector

ATC Female

Receptacle

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

CUTMASTER 40

Power
Supply

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

0-5557 APPENDIX

55

CUTMASTER 40

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APPENDIX 0-5557

56

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