Thermal Dynamics Cutmaster 82 Service Manual

Art # A-08839_AB

600

v

460

400

v

v

82

™

CUTMASTER

PLASMA CUTTING SYSTEM

Service Manual

Rev. AH Date: May 29, 2009 Manual # 0-4980
Operating Features:

!

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™ 82
SL100 1Torch™
Operating Manual Number 0-4980

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

Copyright 2007, 2008, 2009 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

Original Publication Date: October 7, 2007
Revision Date: May 29, 2009

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

i

This Page Intentionally Blank

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.................................................................................................1-2

1.04 Note, Attention et Avertissement ................................................................1-3

1.05 Precautions De Securite Importantes .........................................................1-3

1.06 Documents De Reference ...........................................................................1-5

1.07 Declaration of Conformity ...........................................................................1-6

1.08 Statement of Warranty ................................................................................1-7

SECTION 2 SYSTEM:INTRODUCTION .................................................................................2-1

2.01 How To Use This Manual ............................................................................2-1

2.02 Equipment Identification .............................................................................2-1

2.03 Receipt Of Equipment .................................................................................2-1

2.04 Power Supply Specifications .......................................................................2-2

2.05 Input Wiring Specifications ..........................................................................2-3

2.06 Power Supply Features ...............................................................................2-4

SECTION 2 TORCH:INTRODUCTION ..................................................................................2T-1

2T.01 Scope of Manual ....................................................................................... 2T-1

2T.02 General Description ..................................................................................2T-1

2T.03 Specifications ........................................................................................... 2T-1

2T.04 Options And Accessories .......................................................................... 2T-2

2T.05 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 Gas Connections ........................................................................................ 3-4

SECTION 3 TORCH: INSTALLATION .................................................................................... 3T-1

3T.01 Torch Connections .................................................................................... 3T-1

3T.02 Setting Up Mechanical Torch .................................................................... 3T-1

SECTION 4 SYSTEM: OPERATION ........................................................................................4-1

4.01 Front Panel Controls / Features .................................................................. 4-1

4.02 Preparations for Operation ..........................................................................4-2

SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1

4T.01 Torch Parts Selection ................................................................................ 4T-1

4T.02 Cut Quality ................................................................................................ 4T-2

4T.03 General Cutting Information ...................................................................... 4T-2

4T.04 Hand Torch Operation ............................................................................... 4T-3

4T.05 Gouging .................................................................................................... 4T-7

4T.06 Mechanized Torch Operation ....................................................................4T-8

4T.07 Parts Selection for Manual and Mechanized Torch Cutting ...................... 4T-9

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip 4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T-13

PATENT INFORMATION ...................................................................................................... 4T-16

TABLE OF CONTENTS

SECTION 5 SYSTEM:SERVICE ..............................................................................................5-1

5.01 General Maintenance .................................................................................5-1

5.02 Maintenance Schedule ............................................................................... 5-2

5.03 Common Faults ...........................................................................................5-2

5.04 Fault Indicator .............................................................................................5-3

5.05 Basic Troubleshooting Guide ...................................................................... 5-4

5.06 Power Supply Basic Parts Replacement.....................................................5-6

5.07 Circuit Fault Isolation ..................................................................................5-8

5.08 Main Input and Internal Power Problems ..................................................5-12

5.09 Pilot Arc Problems ....................................................................................5-15

5.10 Main Arc and Controls Problems ..............................................................5-17

5.11 CNC Interface Problems ........................................................................... 5-17

5.12 Test Procedures ........................................................................................5-18

SECTION 5 TORCH:SERVICE .............................................................................................. 5T-1

5T.01 General Maintenance ............................................................................... 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts ........................ 5T-2

SECTION 6:PARTS LISTS .......................................................................................................6-1

6.01 Introduction .................................................................................................6-1

6.02 Ordering Information ................................................................................... 6-1

6.03 Power Supply Replacement ........................................................................6-1

6.04 Major External Replacement Parts .............................................................6-2

6.05 Front Panel Replacement Parts .................................................................. 6-3

6.06 Left Side Replacement Parts .....................................................................6-4

6.07 Right Side Replacement Parts ...................................................................6-5

6.08 Options and Accessories ............................................................................6-6

6.09 Replacement Parts for Hand Torch ............................................................6-7

6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads .......6-8

6.11 Torch Consumable Parts Manual and Mechanized Torches ..................... 6-10

SECTION 7: REPLACEMENT PROCEDURES .......................................................................7-1

7.01 Scope ..........................................................................................................7-1

7.02 Anti-Static Handling Procedures ................................................................. 7-1

7.03 Parts Replacement - General Information ..................................................7-1

7.04 Major External Parts ..................................................................................7-2

7.05 Front Panel Parts Replacement .................................................................. 7-3

7.06 Left Side Internal Parts Replacement .........................................................7-4

7.07 Rear Panel Parts Replacement ..................................................................7-5

7.08 Right Side Internal Parts Replacement .......................................................7-7

TABLE OF CONTENTS

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM) ........................................ A-1

APPENDIX 2: DATA TAG INFORMATION .............................................................................. A-2

APPENDIX 3: TORCH PIN - OUT DIAGRAMS ...................................................................... A-3

APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................... A-4

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ....................................................... A-6

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS .............................................................. A-8

APPENDIX 7: Publication History ......................................................................................... A-10

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

TABLE OF CONTENTS

cutmaster 82

!

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

• 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 chlo­rinated solvents and cleansers. Remove all sources of these
vapors.

• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.

Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of
the health equipment to determine whether a hazard
exists.

To prevent possible injury, read, understand and follow
all warnings, safety precautions and instructions before
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.

• 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 work­place.

Manual 0-4980 1-1 GENERAL INFORMATION

cutmaster 82

• Do not cut or weld on containers that may have held combus­tibles.

• Provide a fire watch when working in an area where fire hazards
may exist.

• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more
information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsec­tion 1.03, Publications, in this manual.

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infra red light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.

• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or
other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use 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.

10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards As­sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY 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

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.).

HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO­TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-4980

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 :

cutmaster 82

• 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:

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

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.

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.

• 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 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.

Manual 0-4980 1-3 GENERAL INFORMATION

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

cutmaster 82

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 enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de mal­formations fœtales ou d’autres problèmes de reproduction.

Il faut s e l a v e r les mains a p r è s t o u t e manipulatio n .

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)

• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.

• 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.

GENERAL INFORMATION 1-4 Manual 0-4980

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ameri­can National Standards Institute), 1430 Broadway, New York, NY
10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO­TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

cutmaster 82

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM­MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À
LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT
RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les
Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection As­sociation, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE 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

Manual 0-4980 1-5 GENERAL INFORMATION

cutmaster 82

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive
73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* For environments with increased hazard of electrical shock, Power Supplies bearing the mark conform to EN50192 when used in conjunction

with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to

ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous
testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire ,

England PR6 7BX

GENERAL INFORMATION 1-6 Manual 0-4980

cutmaster 82

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser

that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and
workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon
notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications,
instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.

Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the
time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation
will provide instructions on the warranty procedures to be implemented.

Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of
sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

CUTMASTER™ 39 4 Years 1 Year

CUTMASTER™ 52 4 Years 1 Year

CUTMASTER™ 82 4 Years 1 Year

CUTMASTER™ 102 4 Years 1 Year

CUTMASTER™ 152 4 Years 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 Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned
for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such
as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything
done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered
by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as
expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics
product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective September 4, 2007

Manual 0-4980 1-7 GENERAL INFORMATION

cutmaster 82

GENERAL INFORMATION 1-8 Manual 0-4980

cutmaster 82

!

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication

or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:

WARNING

A WARNING gives information regarding
possible personal injury.

CAUTION

A CAUTION refers to possible equipment dam­age.

NOTE

2.02 Equipment Identification

The unit’s identication number (specication or

part number), model, and serial number usually
appear on a data tag attached to the rear panel.
Equipment which does not have a data tag such

as torch and cable assemblies are 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 1 for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against
the invoice to make sure it is complete and in­spect the equipment for possible damage due to
shipping. If there is any damage, notify the car-

rier immediately to le a claim. Furnish complete

information concerning damage claims or ship­ping errors to the location in your area listed in
the inside back cover of this manual.

Include all equipment identication numbers as

described above along with a full description of
the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging
the equipment when using bars, hammers, etc., to
un-crate the unit.

A NOTE offers helpful information concerning
certain operating procedures.

Additional copies of this manual may be
purchased by contacting Thermadyne at the
address and phone number in your area listed
in the inside back cover of this manual. Include
the Owner’s Manual number and equipment

identication numbers.

Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermal Dynamics web site listed below and
clicking on Thermal Dynamics and then on the
Literature link:
http://www.thermal-dynamics.com

Manual 0-4980 2-1 INTRODUCTION

cutmaster 82

22.5"

0.57 m

43 lb / 19.5 kg

10.75"

273 mm

16.375"

416 mm

Art # A-07941

6"

150 mm

24"

0.6 m

6"

150 mm

6"

150 mm

Art # A-07925

2.04 Power Supply Specifications

CutMaster 82 Power Supply Specifications

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power

Input Power Cable

Output Current 20 - 80 Amps, Continuously Adjustable

Power Supply Gas

Filtering Ability

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz

Cable for 208/230V input power includes molded plug.

CutMaster 82 Power Supply Duty Cycle *

Power Supply includes input cable.

Particulates to 5 Microns

Ambient Temperature

Duty Cycle Ratings @ 40° C (104° F)
Opperating Range 0° - 50° C

IEC

Rating

IEC

Rating

IEC

Rating

Duty Cycle 40% 60% 100%

All Units

Current

DC Voltage

80 Amps 65 Amps 50 Amps

112 106 100

* 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

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.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

INTRODUCTION 2-2 Manual 0-4980

2.05 Input Wiring Specifications

CutMaster 82 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I1eff Fuse (amps)

208 60 16 75 48 100 6

cutmaster 82

Flexible Cord

(Min. AWG)

1 Phase

3 Phase

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.

230 60 17 72 46 100 6
460 60 20 44 28 50 10
208 60 16 40 26 50 8
230 50/60 16 39 25 50 10
380 50/60 11.8 18 12 20 12
400 50/60 11.8 18 12 20 12
460 60 17 21 14 25 12
600 60 9.6 16 10 20 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTES

Manual 0-4980 2-3 INTRODUCTION

cutmaster 82

Handle and Leads Wrap

Torch Leads Receptacle

Control Panel

Art # A-07942

Work Cable
and Clamp

Art # A-07981

Input Power Cord

Port for Optional Automation
Interface Cable

Gas Inlet Port

Filter Assembly

Input Power Selection

2.06 Power Supply Features

INTRODUCTION 2-4 Manual 0-4980

cutmaster 82

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" /
16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating
instructions and maintenance procedures for the
1Torch Models SL60/Manual and SL100/Mecha­nized Plasma Cutting Torches. Service of this
equipment is restricted to properly trained person-

nel; 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

2T.03 Specifications

A. Torch Configurations

1. Hand/Manual Torch, Models

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

2. Mechanized Torch, Model

The standard machine torch has a positioning
tube with rack & pinch block assembly.

Plasma torches are similar in design to the auto­motive spark plug. They consist of negative and
positive sections separated by a center insulator.
Inside the torch, the pilot arc starts in the gap
between the negatively charged electrode and
the positively charged tip. Once the pilot arc has
ionized the plasma gas, the superheated column of

gas ows through the small orice in the torch tip,

which is focused on the metal to be cut.
A single torch lead provides gas from a single
source to be used as both the plasma and second-

ary gas. The air ow is divided inside the torch

head. Single - gas operation provides a smaller
sized torch and inexpensive operation.

NOTE

Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch
operation.

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

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors
Machine Torches are available as follows:

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

Manual 0-4980 2T-1 INTRODUCTION

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through
torch.

cutmaster 82

!

A-00002

Workpiece

Power

Supply

+

_

C

B

A

F. Torch Ratings

Manual Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

peak

Mechanized Torch Ratings

peak

100% @ 60 Amps @ 400 scfh

)

100% @ 100 Amps @ 400 scfh

)

G. Gas Requirements

Manual and Mechanized Torch Gas

Specications

104° F

40° C

60 Amps

500V

7kV

104° F

40° C

120 Amps

500V

7kV

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an ex­tremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
and then blown away.

While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
of plasma gas in Zone C.

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with oxygen (O2).

NOTE

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

H. Direct Contact Hazard

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

2T.04 Options And Accessories

For options and accessories, see section 6.

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.

Zone A channels a secondary gas that cools the torch.
This gas also assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for
a fast, slag - free cut.

INTRODUCTION 2T-2 Manual 0-4980

cutmaster 82

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

PIP Switch

Shield Cup

To ATC

CNC Start

PIP Switch

Shield Cup

PIP Switch

Shield Cup

Remote Pendant

Automation Torch

To ATC

To ATC

Art # A-08168

B. Gas Distribution

The single gas used is internally split into plasma
and secondary gases.

The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.

The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot
arc creates a path for the main arc to transfer to the
work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con­nected to the workpiece via the work cable and to
the torch through a pilot wire.

E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
is open.

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4980 2T-3 INTRODUCTION

Parts - In - Place Circuit Diagram for Machine

Torch

cutmaster 82

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4980

cutmaster 82

!

SECTION 3 SYSTEM:

INSTALLATION

3.01 Unpacking

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

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

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

3.02 Lifting Options

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

WARNING

Do not touch live electrical parts.

Disconnect input power cord before moving unit.

FALLING EQUIPMENT can cause serious personal injury and can damage equipment.

HANDLE is not for mechanical lifting.

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

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

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

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Manual 0-4980 3-1 INSTALLATION

cutmaster 82

Art # A-07984_AB

Single-Phase (1ø) and Jumper Settings

L1

L2

L3

L4

Jumper L1 -L4

Jumper
L2-L3

L1

L2

L3

GND

L4

Art # A-07983_AB

Three-Phase (3ø) and Jumper Settings

L1

L2

L3

L4

Jumper L1 -L4

L1

L2

L3

GND

L4

Store copper jumper in spare parts box

3.03 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. Check the Voltage Selector
at the rear of the unit for correct setting 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.

Most units are shipped from the factory with a 230Volt input power cable wired to the input contactor in

the single - phase conguration. The following illustrations and directions are for changing that con­guration to a different voltage and or to three - phase operation or back again if a change had already

been made.

Single Phase Input Power Wiring

Three Phase Input Power Wiring

NOTE

There is only one jumper setting that changes between the single and three phase settings. To change from single
phase to three phase, the jumper connected to L2 needs to be removed and placed on the other L3 connection so both
ends of the jumper are attached to the same electrical point. See previous illustrations.

A. Connections to Single Phase Input Power

WARNING

Disconnect input power from the power supply and input cable before attempting this procedure.

These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power
Supply to Single - Phase input power.

1. Remove the Power Supply cover per instructions found in section 5.

2. Disconnect the original input power cable from the main input contactor and the chassis ground
connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original
power cable out of the power supply.

INSTALLATION 3-2 Manual 0-4980

cutmaster 82

4. If the power cable being used is not the factory - supplied cable, use a three - conductor input
power cable for the voltage desired and strip back the insulation on the individual wires.

5. Pass the cable being used through the access opening in the back panel of the power supply. Re-

fer to Section 2 for power cable specications.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2).

6. Connect the wires as follows.

• Set Jumper wires on the contactor. See previous illustrations.

• Green / Yellow wire to Ground.

• Remaining wires to L1 and L2 input. It does not matter what order these wires are attached. 7.

With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

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

B. Connections to Three Phase Input Power

WARNING

Disconnect input power from the power supply and input cable before attempting this procedure.

These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power
Supply to Three - Phase input power.

1. Remove the Power Supply cover per instructions found in section 5.

2. Disconnect the original input power cable from the main input contactor and the chassis ground
connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original
power cable out of the power supply.

4. Using a customer supplied four - conductor input power cable for the voltage desired, strip back
the insulation on the individual wires.

5. Pass the cable being used through the access opening in the back panel of the power supply. Re-

fer to Section 2 for power cable specications.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2).

6. Connect the wires as follows.

• Set Jumper wires on the contactor. See illustration.

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2 and L3 input. It does not matter what order these wires are at-

tached. See the previous illustrations.

7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

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

Manual 0-4980 3-3 INSTALLATION

cutmaster 82

Art # A-07943

Hose Clamp

Regulator/Filter
Assembly

Inlet Port

Gas Supply
Hose

1/4 NPT or ISO-R
to 1/4” (6mm) Fitting

3.04 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high pressure cylinders. Refer to the following two

subsections if an optional air line lter is to be installed.

1. Connect the air line to the inlet port. The illustration shows typical ttings as an example.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not
use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in
the torch.

Air Connection to Inlet Port

INSTALLATION 3-4 Manual 0-4980

cutmaster 82

Art # A-07944

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Regulator/Filter
Assembly

Inlet Port

Gas Supply
Hose

Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for improved ltering with compressed air, to keep moisture and

debris out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet Port.

2. Attach the Filter Assembly to the lter hose.

3. Connect the air line to the Filter. The illustration shows typical ttings as an example.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the
torch. Connect as follows:

Optional Single - Stage Filter Installation

Manual 0-4980 3-5 INSTALLATION

cutmaster 82

Regulator
Input

Gas Supply
Hose

1/4 NPT to 1/4”
(6mm) Fitting

Regulator/Filter
Assembly

2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)

Two Stage
Filter
Assembly

Art # A-07945_AC

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter is also for use on compressed air shop systems. Filter removes

moisture and contaminants to at least 5 microns.

Connect the air supply as follows:

1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied

with the lter assembly.

NOTE

For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions. Do Not
use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in
the torch.

2. Connect the two stage lter outlet hose to the inlet port of the Regulator / Filter Assembly.

3. Use customer - supplied ttings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose
barbed tting is shown as an example.

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

INSTALLATION 3-6 Manual 0-4980

Optional Two - Stage Filter Installation

1. Refer to the manufacturer’s specications for installation and maintenance procedures for high

pressure regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign mate-

rial. Briey 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 ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm) I.D.

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not
use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in
the torch.

NOTE

cutmaster 82

1

2

Art # A-07885

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Sup­ply. Connect only the Thermal Dynamics model
SL60 / Manual or SL100 / Mechanical Torch to
this power supply. Maximum torch leads length
is 100 feet / 30.5 m, including extensions.

WARNING

Disconnect primary power at the source
before connecting the torch.

1. Align the ATC male connector (on the

torch lead) with the female receptacle.
Push the male connector into the female
receptacle. The connectors should push
together with a small amount of pressure.

2. Secure the connection by turning the lock-

ing nut clockwise until it clicks. DO NOT

use the locking nut to pull the connection
together. Do not use tools to secure the
connection.

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON

(up) position.

2. Put the Function Control switch in the SET

position.

3. Place a welding lter lens in front of the

torch and turn on the air. Do not start an
arc!

Any oil or moisture in the air will be visible

on the lens.

3T.02 Setting Up Mechanical Torch

NOTE

An adapter is required to be installed in the power
supply if converting a hand torch system to oper­ate a machine torch.

WARNING

Disconnect primary power at the source be­fore disassembling the torch or torch leads.

The mechanical torch includes a positioning tube
with rack and pinch block assembly.

1. Mount the torch assembly on the cutting
table.

2. To obtain a clean vertical cut, use a square
to align the torch perpendicular to the sur­face of the workpiece.

Connecting the Torch to the Power Supply

3. The system is ready for operation.

Manual 0-4980 3T-1 INSTALLATION

cutmaster 82

A-02585

Workpiece

Square

Pinch Block
Assembly

Mechanical Torch Set - Up

3. The proper torch parts (shield cup, tip, start

cartridge, and electrode) must be installed
for the type of operation. Refer to Section
4T.07, Torch Parts Selection for details.

INSTALLATION 3T-2 Manual 0-4980

SECTION 4 SYSTEM:

+

A

+

PSI BAR

MAX MAX

MIN MIN

!

1 2

3

4

5

6

7

8

9

Art# A-07886

MIN

MAX

10

PSI BAR

MAX MAX

MIN MIN

80

75

70

65

5.5

85 5.9

90 6.3

5.2

4.8

4.5

Art # A-08170

OPERATION

4.01 Front Panel Controls /
Features

See Illustration for numbering Identification

1. Output Current Control

Sets the desired output current. Output settings up
to 60 Amps may be used for drag cutting (with the
torch tip contacting the workpiece) or higher for
standoff cutting.

2. Function Control

Function Control Knob, Used to select between the
different operating modes.

cutmaster 82

SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster
restarting of the Pilot Arc for uninterrupted cutting.

LATCH Used for longer hand held
cuts. Once a cutting arc is established, the torch
switch can be released. The cutting arc will remain
on until the torch is lifted away from the work
piece, the torch leaves the edge of the work piece
the torch switch is activated again or if one of the
system interlocks is activated.

3. On Off Power Switch

ON / OFF Switch controls input power
to the power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure

Control is used in the "SET"
mode to adjust the air/gas pressure. Pull the knob
out to adjust and push in to lock.

5. AC Indicator

Steady light indicates power supply is ready for op-

eration. Blinking light indicates unit is in protective
interlock mode. Shut unit off, shut off or disconnect
input power, correct the fault, and restart the unit.
Refer to Section 5 for details.

Manual 0-4980 4-1 OPERATION

6. Temp Indicator

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

7. Gas Indicator

Indicator is ON when minimum input gas pressure
for power supply operation is present. Minimum
pressure for power supply operation is not sufficient
for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. !Fault Error Indicator

Indicator is ON when Fault circuit is active. See sec­tion 5 for explanations of fault lights.

10. Pressure Indicators

The Indicators will illuminate
according to the pressure set by the Pressure Control
Knob (number 4).

cutmaster 82

Art # A-04509

A

+

PSI BAR

MAX MAX

MIN MIN

!

1

2

Art# A-07946

MIN

MAX

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 (80 amps maximum).
Refer to Section 4T.07 and following for torch parts
selection.

Torch Connection

Check that the torch is properly connected. Only
Thermal Dynamics model SL60 / Manual or SL100 /
Mechanical 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

Power On

Place the Power Supply ON / OFF switch to the ON
(up) position. AC indicator turns on. Gas

indicator turns on if there is sufficient gas pres­sure for power supply operation and the cooling
fans turn on.

NOTE

Minimum pressure for power supply operation is
lower than minimum for torch operation.

The cooling fans will turn on as soon as the unit
is turned on. After the unit is idle for ten (10)
minutes the fans will turn off. The fans will come
back on as soon as the torch switch (Start Signal)
is activated or if the unit is turned off, then turned
on again. If an over temperature condition occurs,
the fans will continue to run while the condition
exists and for a ten (10) minute period once the
condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control

knob to the SET position. Gas will

ow.

2. For Standoff cutting, adjust gas pressure

from 70 - 85 psi / 4.8 - 5.9 bar (LED's

in center of control panel). Refer to the
Standoff chart for pressure setting details.

Ensure source meets requirements (refer to Section

2). Check connections and turn air supply on.

Connect Work Cable

Clamp the work cable to the workpiece or cutting
table. The 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.

OPERATION 4-2 Manual 0-4980

cutmaster 82

STANDOFF

CutMaster 82 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional

25'

(7.6 m)

SL60

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

SL100

(Mechanized Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

3. For Drag cutting, adjust gas pressure from

75 - 95 psi / 5.2 - 6.5 bar (LED's in center

of control panel). Refer to the Drag Cutting
chart for pressure setting details.

DRAG

CutMaster 82 Gas Pressure

Settings

Leads Length

Up to 25'

(7.6 m)

SL60

(Hand Torch)

80 psi

5.5 bar

Typical Cutting Speeds

Cutting speeds vary according to torch output am­perage, the type of material being cut, and opera­tor skill. Refer to Section 4T.08 and following for
greater details.

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

Postflow

Release the trigger to stop the cutting arc. Gas con­tinues to flow for approximately 20 seconds. During
post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.
The main arc transfers to the workpiece if the torch
tip is within transfer distance to the workpiece.

Shutdown

Turn the ON / OFF switch to OFF
(down). All Power Supply indicators shut off.
Unplug the input power cord or disconnect input
power. Power is removed from the system.

Each

additional 25'

(7.6 m)

Add 5 psi

0.4 bar

Select Current Output Level

1. Place the Function Control Knob in one of
the three operating positions available:

RUN ,

RAPID AUTO RESTART

or LATCH . Gas ow stops.

2. Set the output current to desired amperage
with the Output Current Control Knob.

Cutting Operation

When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the
RUN position, there is a brief delay in restarting
the pilot arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the work­piece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the
workpiece. (Use the 'Rapid Auto Restart' position
when cutting expanded metal or gratings, or in
gouging or trimming operations when an uninter­rupted restart is desired). And with the knob in the
LATCH position the main cutting arc will be main­tained after the torch switch is released.

Manual 0-4980 4-3 OPERATION

cutmaster 82

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4980

cutmaster 82

A-03510_AB

Electrode

Start Cartridge

Tip

Shield Cup

Torch Head

SECTION 4 TORCH:

OPERATION

4T.01 Torch Parts Selection

Depending on the type of operation to be done
determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter
Cartridge

NOTE

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

Change the torch parts for a different operation as
follows:

WARNING

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

NOTE

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

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

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

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

4. Install the starter cartridge and desired tip

for the operation into the torch head.

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

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

Manual 0-4980 4T-1 OPERATION

cutmaster 82

Kerf Width

Cut Surface
Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

!

4T.02 Cut Quality

NOTES

Cut quality depends heavily on setup and
parameters such as torch standoff, alignment with
the workpiece, cutting speed, gas pressures, and
operator ability.

Cut quality requirements differ depending on
application. For instance, nitride build - up and
bevel angle may be major factors when the sur­face will be welded after cutting. Dross - free cut-

ting is important when nish cut quality is desired

to avoid a secondary cleaning operation. The
following cut quality characteristics are illustrated

in the following gure:

Bottom Dross Buildup

Molten material which is not blown out of the cut
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after
cutting.

Kerf Width

The width of the cut (or the width of material re­moved during the cut).

Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.

4T.03 General Cutting Information

WARNINGS

Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.

Cut Quality Characteristics

Cut Surface

The desired or specified condition (smooth or rough)
of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.

Bevel Angle

The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0°
bevel angle.

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.

Frequently review the Important Safety Pre­cautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure
no part of the operator’s body comes into
contact with the workpiece while the torch
is activated.

CAUTION

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

NOTE

Handle torch leads with care and protect them
from damage.

Piloting

Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.

OPERATION 4T-2 Manual 0-4980

cutmaster 82

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

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.

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.

4T.04 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE

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

Side Characteristics Of Cut

To make a square - edged cut along an inside
diameter of a circle, the torch should move coun­terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.

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.

Manual 0-4980 4T-3 OPERATION

cutmaster 82

A-00024_AB

Shield Cup

Torch

Standoff Distance

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

A-02986

Trigger

Trigger Release

3

4

Art # A-03383

Trigger

2

1

Trigger Release

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

2. Depending on the cutting operation, do one
of the following:
a. For edge starts, hold the torch perpen-

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

b. For standoff cutting, hold the torch 1/8

- 3/8 in (3-9 mm) from the workpiece as

shown below.

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

3. Hold the torch away from your body.

4. Slide the trigger release toward the back

5. Bring the torch within transfer distance to

Standoff Distance

of the torch handle while simultaneously
squeezing the trigger. The pilot arc will
start.

the work. The main arc will transfer to the
work, and the pilot arc will shut off.

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

The gas preflow and postflow are a characteristic

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

OPERATION 4T-4 Manual 0-4980

cutmaster 82

A-03539

Non-Conductive

Straight Edge
Cutting Guide

A-02986

Trigger

Trigger Release

3

4

Art # A-03383

Trigger

2

1

Trigger Release

Shield Cup With Straight Edge

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 - conduc-

tive.

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.

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

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

NOTE

The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.

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.

4. Keep the torch in contact with the work­piece during the cutting cycle.

5. Hold the torch away from your body.

Manual 0-4980 4T-5 OPERATION

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

9. Follow normal recommended cutting
practices as provided in the power supply

operator's manual.

NOTE

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

cutmaster 82

A-02986

Trigger

Trigger Release

Piercing With Hand Torch

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

NOTE

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

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

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

4. Hold the torch away from your body.

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

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

NOTES

The gas preflow and postflow are a characteristic
of the power supply and not a function of the
torch.

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

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 standoff height

• Proper work cable connection

OPERATION 4T-6 Manual 0-4980

cutmaster 82

!

35°

Workpiece

Torch Head

Standoff Height

A-00941_AB

4T.05 Gouging

WARNINGS

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

Disconnect primary power to the system be­fore disassembling the torch, leads, or power
supply.

CAUTION

Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
plastic, and metal.

Check torch parts. The torch parts must
correspond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection.

Lead Angle

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

Gouging Angle and Standoff Distance

Gouging Parameters

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

CAUTION

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.

Standoff Distance

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

Slag Buildup

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

Manual 0-4980 4T-7 OPERATION

cutmaster 82

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch

The mechanized torch can be activated by remote
control pendant or by a remote interface device
such as CNC.

1. To start a cut at the plate edge, position the
center of the torch along the edge of the
plate.

Travel Speed

Proper travel speed is indicated by the trail of the
arc which is seen below the plate. The arc can be
one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended
for the best cut using air plasma on stainless or
aluminum.

2. Leading Arc

The leading arc is directed in the same direction as
torch travel. A five degree leading arc is generally
recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc­tion as torch travel.

For optimum smooth surface quality, the travel
speed should be adjusted so that only the leading
edge of the arc column produces the cut. If the travel
speed is too slow, a rough cut will be produced as
the arc moves from side to side in search of metal
for transfer.

Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.

Piercing With Machine Torch

To pierce with a machine torch, the arc should be
started with the torch positioned as high as possible
above the plate while allowing the arc to transfer
and pierce. This standoff helps avoid having molten
metal blow back onto the front end of the torch.

When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
enabled until the arc penetrates the bottom of the
plate. As motion begins, torch standoff should be
reduced to the recommended 1/8 - 1/4 inch (3-6
mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and the
tip as soon as possible. Spraying or dipping the
shield cup in anti - spatter compound will minimize
the amount of scale which adheres to it.

Mechanized Torch Operation

OPERATION 4T-8 Manual 0-4980

4T.07 Parts Selection for Manual and Mechanized Torch Cutting

Start

Cartridge

9-8213

Electrode

9-8215

Tips:

20A 9-8205
30A 9-8206
40A 9-8207
60A 9-8252

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag
70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

Tips:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

CUTTING

CUTTING

Art # A-08065_AC

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

NOTE
CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
CutMaster 102 uses 100A and less
CutMaster 152 uses 120A and less

cutmaster 82

Manual 0-4980 4T-9 OPERATION

cutmaster 82

4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed

Tip

Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 70 4.8 90 245 0.00 0.19 4.8

0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 70 4.8 90 245 0.10 0.19 4.8

0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 70 4.8 90 245 0.20 0.19 4.8

0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.19 4.8

0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 70 4.8 90 245 0.50 0.19 4.8

0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 70 4.8 90 245 0.75 0.19 4.8

0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.00 0.25 6.4

0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 70 4.8 90 245 0.10 0.25 6.4

0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 70 4.8 90 245 0.20 0.25 6.4

0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 70 4.8 90 245 0.30 0.25 6.4

0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 70 4.8 90 245 0.50 0.25 6.4

0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 70 4.8 90 245 0.80 0.25 6.4

0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 70 4.8 90 245 NR NR NR

OPERATION 4T-10 Manual 0-4980

cutmaster 82

Type Torch: Mechanized With Exposed Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 70 4.8 115 340 0.00 0.19 4.8

0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8

0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8

0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 70 4.8 115 340 0.20 0.19 4.8

0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.19 4.8

0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 70 4.8 115 340 0.40 0.19 4.8

0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 70 4.8 115 340 0.60 0.19 4.8

0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 70 4.8 115 340 0.75 0.19 4.8

0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 70 4.8 115 340 NR NR NR

Type Torch: Mechanized With Exposed Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4

0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 70 4.8 115 340 0.80 0.25 6.4

0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 70 4.8 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 70 4.8 115 340 NR NR NR

Manual 0-4980 4T-11 OPERATION

cutmaster 82

Type Torch: Mechanized With Exposed Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 70 4.8 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 70 4.8 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 70 4.8 115 340 NR NR NR

NOTES

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

OPERATION 4T-12 Manual 0-4980

cutmaster 82

4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded

Tip

Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 70 4.8 90 245 0.00 0.2 5.1

0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 70 4.8 90 245 0.10 0.2 5.1

0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 70 4.8 90 245 0.20 0.2 5.1

0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.2 5.1

0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 70 4.8 90 245 0.50 0.2 5.1

0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 70 4.8 90 245 0.75 0.2 5.1

0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 70 4.8 90 245 0.75 0.20 5.1

0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 70 4.8 90 245 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 70 4.8 90 245 0.00 0.20 5.1

0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 70 4.8 90 245 0.10 0.20 5.1

0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 70 4.8 90 245 0.20 0.20 5.1

0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 70 4.8 90 245 0.30 0.20 5.1

0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 70 4.8 90 245 0.50 0.20 5.1

0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 70 4.8 90 245 0.80 0.20 5.1

0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 70 4.8 90 245 NR NR NR

0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 70 4.8 90 245 NR NR NR

Manual 0-4980 4T-13 OPERATION

cutmaster 82

Type Torch: Mechanized With Shielded Tip Type Material: Mild Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 70 4.8 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 70 4.8 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 70 4.8 115 340 0.50 0.2 5.1

0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.2 5.1

0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 70 4.8 115 340 0.75 0.2 5.1

0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR

Type Torch: Mechanized With Shielded Tip Type Material: Stainless Steel

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 70 4.8 115 340 0.00 0.2 5.1

0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1

0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1

0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 70 4.8 115 340 0.20 0.2 5.1

0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 70 4.8 115 340 0.30 0.2 5.1

0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 70 4.8 115 340 0.75 0.25 6.4

0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 70 4.8 115 340 1.00 0.25 6.4

0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

OPERATION 4T-14 Manual 0-4980

cutmaster 82

Type Torch: Mechanized With Shielded Tip

Type Material: Aluminum

Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height

Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm

0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 70 4.8 115 340 0.00 0.25 6.4

0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 70 4.8 115 340 0.10 0.25 6.4

0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 70 4.8 115 340 0.20 0.25 6.4

0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 70 4.8 115 340 0.30 0.25 6.4

0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 70 4.8 115 340 0.40 0.25 6.4

0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.25 6.4

0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 70 4.8 115 340 0.75 0.25 6.4

0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR

0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR

1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 70 4.8 115 340 NR NR NR

NOTES

* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

Manual 0-4980 4T-15 OPERATION

cutmaster 82

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
9-8213 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

OPERATION 4T-16 Manual 0-4980

cutmaster 82

Catalog # Description Patent(s)

9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending

The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:

Catalog # Description

9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap

Manual 0-4980 4T-17 OPERATION

cutmaster 82

This Page Intentionally Blank

OPERATION 4T-18 Manual 0-4980

SECTION 5 SYSTEM:

5.01 General Maintenance

cutmaster 82

SERVICE

Manual 0-4980 5-1 SERVICE

cutmaster 82

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, worn or when cut performance has demi­nished.

2. Check plasma and secondary supply and pres­sure.

3. Purge plasma gas line to remove any moisture
build-up.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air
flow.

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

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

Six Months or Every 720 Cutting Hours:

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

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

3. Check all contactor points for severe arcing or
pits, replace if necessary.

5.03 Common Faults

Problem - Symptom Common Cause

Insufficient
Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics
parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics
parts used

1. Cutting speed too slow.

2. Torch standoff too high from
workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics
parts used

6. Incorrect gas pressure

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

4. Vacuum dust and dirt out of the entire machine.

CAUTION

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

SERVICE 5-2 Manual 0-4980

Difficult Starting 1. Worn torch parts.

2. Non - Genuine Thermal Dynamics
parts used.

3. Incorrect gas pressure.

cutmaster 82

A

+

PSI BAR

MAX MAX

MIN MIN

!

1

2

3

4

Art# A-07988

MIN

MAX

0

1

2

3

4

5

6

7

5

S

LO

HI

Art # A-08316

5.04 Fault Indicator

At initial power up, two lights will temporarily illu­minate for 2-3 seconds to show the version of software
used.

To determine the first digit, count the function indicators
left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to
top, 0 through 7. In the example below the Temp indica­tor and 75 psi indicators are on indicating the version
would be 2.3.

Explanation of Faults

" UNDER PRESSURE: Indicates that operating pres-

sure is set too low and power supply output
power will be disabled.

INPUT POWER: Indicates primary line voltage is

outside the operating limits of the power supply
as selected by the setting of INPUT VOLTAGE
SELECTION SWITCH at the rear of the unit. Low
is 208/230 VAC and high is 460 VAC.

PART IN PLACE: Indicates that the shield cup is not

properly installed or tightened.

START ERROR: Indicates that the START SIGNAL

was active (ie. Torch Trigger depressed, hand
held pendant switch on or CNC signal for torch
on) during one of three conditions:

When the !"Fault" indicator is on or blinking it
will be accompanied by one of the pressure indica­tor lights depending on what the Fault is. Only one
of these faults will be displayed at one time. If more
than one fault exists, when the first fault is corrected
and cleared, the next fault will then be displayed. It
is possible to have a fault indicated in the function
indicators and another fault indictated in the pres­sure indicators. The following table shows each of
the Faults possible.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

Manual 0-4980 5-3 SERVICE

85 Shorted Torch

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE

Fault explantions are covered in the following
tables.

1) During initial power up when ON/OFF
switch is turned to ON position

2) When fault which had been disabling the
system is cleared.

3) When the FUNCTION CONTROL SWITCH
Mode is moved from SET position to any of
the other three (3) modes of operation.

CONSUMABLES MISSING: Indicates that the elec-

trode, start cartridge or tip is missing or exces­sively worn.

SHORTED TORCH: Indicates the torch or lead has

a shorted condition between positive and nega­tive leads.

INTERNAL ERROR: Indicates a microprocessor er-

ror.

OVER PRESSURE: Indicates that operating pressure

is set too high. The Error Indicator will not flash
when the pressure is above 95 PSI. This LED will
remain on and the system will operate but pilot
starting and cut performance may be affected.

NOTE

The cooling fans will turn on as soon as the unit
is turned on. After the unit is idle for ten (10)
minutes the fans will turn off. The fans will come
back on as soon as the torch switch (Start Signal)
is activated or if the unit is turned off, then turned
on again. If an over temperature condition occurs,
the fans will continue to run while the condition
exists and for a ten (10) minute period once the
condition is cleared.

cutmaster 82

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 Possible Cause Recommended Action

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

1. Primary power disconnect is in
OFF position.

2. Primary fuses / breakers are
blown or tripped.

3. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

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

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

FAULT indicator
flashing, 65 PSI
indicator flashing

TEMPERATURE
indicator on.
FAULT indicator
flashing.

GAS indicator off,
FAULT and MIN
pressure indicators
flashing.

FAULT and 70 PSI
indicators flashing.

1. INPUT VOLTAGE SELECTION
SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air flow through or around the
unit is obstructed.

2. Duty cycle of the unit has been
exceeded

3. Failed components in unit

1. Gas supply not connected to
unit.

2. Gas supply not turned on.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL
regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to
power supply.

3. Problem in torch and leads PIP
circuit.

4. Failed components in unit.

1. Turn off power to unit then set INPUT VOLTAGE SELECTION
SWITCH to match primary input voltage.

2. Have qualified person check primary voltage to insure it
meets unit requirements see section 2.04.

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

1. Refer to clearance information – section 2.04

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.

4. Adjust regulator to set air pressure - see section 4.02.

5. 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.

FAULT and 75 PSI
indicators flashing.

SERVICE 5-4 Manual 0-4980

1. Start signal is active when
ON/OFF SWITCH is turned to ON
position.

2. Problem in the torch and leads
switch circuit.

3. Failed components in unit.

1. Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low
Release the START signal source

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

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

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI
indicators flashing.
Gas flow is cycling on
and off.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter
cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads
switch circuit.

6. Failed components in unit.

1. Tighten shield cup by hand. Do not overtighten.

2. Turn off power supply. Remove shield cup. Install missing
parts.

3. Turn off power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.

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

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

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

cutmaster 82

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

FAULT and 85 PSI
indicators flashing.

No Fault lights on, no
arc in torch.

FAULT and 85 PSI
indicators flashing

Pilot arc is on but
cutting arc will not
establish

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

2. CNC Contoller device not
providing Start signal.

3. Failed components in unit.

1. Upper O-Ring on torch head is in
wrong position.

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5
blinks per second.

6. Power Supply Failure (Standard
rate of blinking)

1. Failed components in unit. 1. Return to an authorized service center for repair.

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that

1. Work cable not connected to
work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Take Torch and Leads (Remote Pendant) to Authorized
Repair Facility.

2. Contact Controller manufacturer.

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

1. Remove shield cup from torch; check upper O-Ring
position; correct if necessary.

2. Turn off power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service
center for repair.

5. Release torch switch and reactivate.

6. Return to autorized service center for repair or replacement.

does not clear the fault, return to an authorized service center
for repair.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

Torch cutting is
diminished

Manual 0-4980 5-5 SERVICE

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. 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 82

!

Upper
Screws

Lower
Screws

Lower
Screws

Art # A-07947

Slots

Art # A-07989

1

2

3

4

5

6mm

5.06 Power Supply Basic Parts
Replacement

WARNING

Disconnect primary power to the system before
disassembling the torch, leads, or power supply.

This section describes procedures for basic parts replace­ment. For more detailed parts replacement procedures,
refer to the Power Supply Service Manual.

A. Cover Removal

1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection 5.02),
and either cleaned or replaced.

1. Remove power from the power supply; turn off
the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Re­moval" in this section.

3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.

4. Hold a wrench or similar tool against the lock­ing ring on the filter assembly fitting, then pull
on the hose to release it. (Numbers 2 and 3 in the
following illustration).

2. Carefully pull the Cover up and away from the
unit.

B. Cover Installation

1. Reconnect the ground wire, if necessary.

2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage the
lower screws.

3. Tighten lower screws.

4. Reinstall and tighten the upper screws.

SERVICE 5-6 Manual 0-4980

cutmaster 82

Art # A-07990

Filter Element

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

5. Remove the fitting from the filter element as­sembly by inserting a 6 mm hex wrench into
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previous
illustration.

6. Disconnect the input line from the filter element
assembly.

7. Remove the filter element assembly through the
rear opening.

NOTE

If replacing or cleaning just the filter element refer
to the following illustration for disassembly.

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

Optional Single-Stage Filter Element Replacement

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

8. Install the new or cleaned assembly by reversing
these procedures.

9. Turn on the air supply and check for leaks before
reinstalling the cover.

Optional Single-Stage Filter Element

Replacement

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

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

1. Remove power from power supply.

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

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE

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

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

3. Disconnect gas supply hose.

Manual 0-4980 5-7 SERVICE

cutmaster 82

!

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Upper
Screws

Lower
Screws

Lower
Screws

Art # A-07947

Slots

Optional Two-Stage Filter Element

Replacement

The Two-Stage Air Filter has two Filter Elements. When
the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unac­ceptable. Refer to Section 6, Parts List, for replacement
filter element catalog number.

1. Shut off primary input power.

2. Shut off air supply and bleed down system.

WARNING

Always turn off the air supply and bleed the sys­tem before disassembling the Filter Assembly as
injury could result.

3. Loosen the two bolts on the top of the Filter As­sembly enough to allow the Filter Elements to
move freely.

4. Note the location and orientation of the old Filter
Elements.

5.07 Circuit Fault Isolation

WARNING

The following procedures should not be attempted
by anyone who has not had proper training or
authorized to do so.

A. Cover Removal

1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

Note

The upper screws and lower screws are not the
same. Do not mix them. The upper screws are
for threading into the plastic of the front and rear
panels. DO NOT use the finer threaded lower
screws for this.

5. Slide out the old Filter Elements.

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the
Filter Assembly, with the same orientation as
noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torque
each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper
torque may damage the gasket.

2. Carefully pull the Cover up and away from the
unit.

8. Slowly apply air pressure to the assembly, check­ing for leaks.

NOTE

A small amount of air leakage from the bottom
fitting is normal.

This completes the parts replacement procedures.

SERVICE 5-8 Manual 0-4980

cutmaster 82

B. Cover Installation

1. Reverse previous procedures for cover installa­tion.

NOTE

When installing the upper screws, attempt to
reuse the original threads. The easaiest way to
do this is by turning the screw counter-clockwise
until you feel the threads lign up, then begin to
turn the screw clockwise to tighten to 15-18 in.
lbs.. Do not over tighten.

C. Pre Power Up Tests

Prior to applying primary line power to the unit,
perform the following checks to prevent component
failure or blowing primary fuses. The troubleshoot­ing guide will assume these tests were done and no
failure was found or that any failures found were
corrected.

1. Main Contactor (W1) Check – Section 5.11 A

2 Input Diode Module Test – Section 5.11 B

3 Input Capacitor Pcb Test –Section 5.11 C

4 IGBT Modules Test – Section 5.11 D

5 Output Diode Module Test – Section 5.11 E

6 Pilot IGBT Test – Section 5.11 F

If all of the Pre Power-Up Tests are ok, proceed with
the trouble shooting guide.

CAUTION

Due to the close proximity of the Main Pcb to the
Capacitor Pcb, It is recommended to use an insu­lated meter probe when making measurements on
the J2 connector on the Main Pcb. Do not short
between the pins. Do not short to the Capacitor
Pcb connections.

3. Set the Power Supply controls as follows:

• ON/OFF SWITCH to OFF position

• Turn FUNCTION CONTROL SWITCH to SET
position

• CURRENT CONTROL POTENTIOMETER to
MAXIMUM position, fully clockwise.

E. Main Input and Internal Power Test

1. Connect Primary Line power to the unit.

2. Turn the ON/OFF SWITCH ( SW1) to ON position
and observe the following:

• Software version is displayed (See section 5.04

Fault Indicators)

After approx. three (3) seconds

• Inrush relay on PCB1 energizes, starting pre-

charging of working capacitors.

• W1 energizes

• AC and GAS Indicators come on

• Gas flows

• Fans turn on

3. Adjust the pressure regulator to set the gas pres­sure as specified in charts.

STANDOFF

CutMaster 82 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional

25'

(7.6 m)

SL60

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

SL100

(Mechanized Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

D. Initial Set up Conditions

This section is to help isolate the defective circuit
before troubleshooting, identify symptoms, and test
the unit for proper operation. Follow the instructions
as given to identify the possible symptom(s) and the
defective circuit. After repairs are complete, run the
following tests again to verify that the unit is fully
operational.

1. Connect gas supply to rear of Power Supply.

2. Turn on gas supply and set operating pressure
per pressure setting label on power supply.

Manual 0-4980 5-9 SERVICE

DRAG

CutMaster 82 Gas Pressure

Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional 25'

(7.6 m)

SL60

(Hand Torch)

80 psi

5.5 bar

Add 5 psi 0.4

bar

cutmaster 82

4. Turn FUNCTION CONTROL SWITCH to RUN
position

• Solenoid turns off, gas stops flowing (pressure

display may increase slightly when gas is not
flowing)

This completes the Main Input and Internal Power Test.
If the above are all correct then proceed to the next section
"F. Pilot Arc Test". If the unit does not function as stated
above, then note the symptom and proceed to Section
"5.07, Main Input and Internal Power Problems".

F. Pilot Arc Test

1. Activate or depress the torch switch (Activate
START signal) to establish a pilot arc and note
the following

• Gas solenoid opens

• Gas flows

• After two seconds the gas solenoid closes

and gas stops flowing momentarily, then gas
solenoid re-opens and gas resumes flowing

• DC LED comes on

• Pilot arc is established

2. Open the torch switch (Remote Pendant switch
or remove CNC start signal)

• Gas continues to flow

• DC LED goes off

G. Main Arc and Controls Test

Connect work Cable to the work piece, Close torch
switch (Pendant switch or activate CNC Start) to es­tablish a pilot arc. Bring torch to within 1/8” – 3/8”
of the work piece to establish main cutting arc.

• Main Cutting Arc Establishes

• On Main Pcb D59 turns off and D78 turns
on

1. Clamp DC ammeter around the work cable. Out­put will be 80 amps.

2. While cutting, adjust the CURRENT CONTROL
POTENTIOMETER from maximum setting to
minimum setting.

• Current adjusts from 80amps down to 20

amps

3. Set the CURRENT CONTROL POTENTIOM­ETER to maximum position.

• Current adjusts from 20 amps up to 80 amps

4. While cutting, touch the tip of the torch to the
work piece, This is called Drag Mode.

• Tip Saver circuit will activate, current drops

to 60 amps.

5. Lift tip off the plate approx 1/4”

• Tip Saver circuit deactivates, current goes back

to 80 amps

After 20 second post flow time

• Gas solenoid closes

• Gas flow stops

This completes the Pilot Arc Test. If the above are all
correct then proceed to the next section "G, Main Arc
and Controls Test". If the unit does not function as stated
above, then note the symptom and proceed to Section
"5.08, Pilot Arc Problems".

6. While cutting keep the torch switch closed, bring
the torch off the edge of the material.

• Cutting arc extinguishes

• Gas solenoid closes

• Gas flow stops momentarily then restarts

when solenoid opens

• Pilot arc ignites

7. Open the torch switch

• DC LED turns off

After 20 second post flow time

• Gas solenoid closes

• Gas flow stops

8. Set the FUNCTION CONTROL SWITCH to
RAPID AUTO RESTART mode.

SERVICE 5-10 Manual 0-4980

cutmaster 82

9. Close torch switch (Pendant switch or activate
CNC Start) to establish a pilot arc. Bring torch to
within 1/8” – 3/8” of the work piece to establish
main cutting arc.

10. While cutting keep the torch switch closed and
bring the torch off the edge of the material.

• Pilot Arc re-ignites immediately

11. Open the torch switch

• DC LED turns off

After 20 second post flow time

• Gas solenoid closes

• Gas flow stops

12. Set the FUNCTION CONTROL SWITCH to
LATCH mode

13. Start a cut, and release the torch switch

• Main cutting arc will remain on until the torch

is lifted away from the plate approx ¾” or until
the torch is brought off the edge of the metal

Once the arc has extinguished

• DC LED turns off

After 20 second post flow time

• Gas solenoid closes

• Gas flow stops

This completes the Main Arc and Controls Test. If the
above are all correct then proceed to the next section
"H CNC Interface Test." If the unit does not function as
stated above, then note the symptom and proceed to
Section "5.09, Main Arc and Controls Problems".

H. CNC INTERFACE TEST

If the unit has one of the two factory supplied options
for CNC interface installed, proceed with this section,
otherwise the tests are complete.

1. Connect an ohmmeter between J2-12 to J2-14
(START signal). Position the torch to pilot. Check
the OK-TO-MOVE signal by connecting a jumper
between J2-3 and J2-4 (START signal).

3. Remove jumper from J6.

• OK-TO-MOVE signal off (Meter shows no
continuity)

• Gas continues to flow

• DC LED goes off

After 20 second Post flow time

• Gas solenoid closes

• Gas flow stops

If the unit has the Basic CNC Interface harness the
test is complete. If the unit does not function as
stated above, then note the symptom and proceed
to Section "5.10 CNC Interface Problems".If the unit
has the Automation Interface PCB installed, continue
with this section.

4. There are three (3) ARC VOLTs signals available
from the J6 connector.

a) J2-9 (+) to J2-7 (-)

b) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-

nector with jumper installed between pins 1
and 2) = ARC VOLTS divided by 50

c) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-

nector with jumper installed between pins 2
and 3) = ARC VOLTS divided by 16

Measure the voltage between these points while pi­loting (Open Circuit Voltage) and while cutting. The
voltages should approx as listed below

Open Circuit Voltage Cutting Voltage

a) 300 VDC 100 VDC

b) 6 VDC 2 VDC

c) 19 DVC 6 VDC

This completes the CNC Interface Test. If the above are all
correct then the unit is functioning correctly. If the unit
does not function as stated, then note the symptom and
proceed to Section "5.10, CNC Interface Problems".

• Pilot arc is established

2. Bring the torch to the work piece and transfer to
cutting arc.

• OK-TO-MOVE signal is present. (Meter shows

continuity)

Manual 0-4980 5-11 SERVICE

cutmaster 82

Art # A-07984_AB

Single-Phase (1ø) and Jumper Settings

L1

L2

L3

L4

Jumper L1 -L4

Jumper
L2-L3

L1

L2

L3

GND

L4

Art # A-07983_AB

Three-Phase (3ø) and Jumper Settings

L1

L2

L3

L4

Jumper L1 -L4

L1

L2

L3

GND

L4

Store copper jumper in spare parts box

5.08 Main Input and Internal Power
Problems

A. Primary input line fuse blows as soon as

primary disconnect is closed.

1. Primary input cable installed incorrectly.

a) Check wiring of primary power cable to the

contactor. See illustration below.

2. W1 jumpers installed incorrectly

a) Check jumper installation for correct phase

being used.

Single Phase Input Power Wiring

B. Primary line fuses blow immediately after

ON/OFF SWITCH (SW1) is turned to ON
position.

1. Shorted Input Diode Module

a) Check per section 5.11B

2. Shorted Input Capacitor Pcb

a) Check per section 5.11C

C. Gas flows with ON/OFF SWITCH in OFF

position

1. Foreign debris has lodged in gas solenoid.

a) Replace gas solenoid. This is a problem caused

by improperly filtered air supply. Customer
needs to add filtration to air supply prior to
unit inlet.

D. All front panel indicators are off, fans

do not run. Main Contactor W1 does not
close.

1. Primary power not connected.

a) Check that cable is connected to primary

power.

Three Phase Input Power Wiring

3 W1 contactor points are stuck closed

a) Check per section 5.11A

4. Primary plug not wired correctly.

a) Check manufacturer's plug installation instruc-

tions.

5. Primary input cable is defective.

a) Check cable for shorts.

2. Primary line fuse/breaker is blown/tripped.

a) Replace fuse or reset breaker.

3. Defective ON/OFF SWITCH

a) Check continuity

4. Defective Main Pcb

a) Measure Main Pcb power supply voltages at

the following test points

GND1 to +12V = 12VDC

GND1 to +48V = 48 VDC

Replace Main Pcb if not correct

5. Defective Ribbon Cable

a) Check continuity

6. Defective Logic

a) Replace Logic Pcb

SERVICE 5-12 Manual 0-4980

E. INPUT POWER FAULT.

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

AC LED on, FAULT Indicator and 65 PSI LED is

flashing.

1. INPUT VOLTAGE SELECTOR SWITCH (SW2)
set for incorrect voltage

a) Set SW2 to correspond to the primary line volt-

age. Turn SW1 to OFF position then back to
ON position to clear the error.

2. Defective SW2

a) Check continuity

cutmaster 82

3. Primary line voltage out of tolerance range.

4. Defective Main Pcb

If not correct, replace Main PCB assembly

5. Defective Logic assembly

F. PARTS-IN-PLACE (PIP) FAULT. The FAULT

Indicator and 70 PSI LED is flashing.

1. Shield Cup loose

2. Torch not properly connected to power supply

3. Problem with torch and leads PIP circuit

a) Connect unit to voltage with unit specifications.

See section "2.04 Power supply specifications".
If using a generator, connect unit to a wall re­ceptacle to see if problem is corrected.

a) Measure voltage on Main Pcb between test

point GND1 to J2-22. 460 VAC input = approx
3 VDC 230 VAC input = approx 1.5 VDC

b) With all power removed from the unit, discon-

nect the ribbon cable from J2 connector on
Main Pcb. Check continuity between J2-34 to
test point GND 1. With SW2 in LOW position
continuity should be present, with SW2 in the
HIGH position. It should read open

a) Replace Logic PCB

a) Hand tighten the shield cup to close the PIP

switch

a) Insure torch ATC is securely fastened to unit.

a) Check continuity of torch PIP circuit at ATC

pins 1 & 2.

4. Defective Logic Pcb

a) Measure the voltage on Main Pcb between J2-17

to test point GND1 for 12VDC. If the voltage
is less than 2VDC, Replace Logic Pcb

5. Defective Main Pcb

a) Replace Main Pcb

G. TRIGGER LOCKED DURING POWER UP

FAULT. The FAULT Indicator and 75 PSI
LED is flashing.

1. Start signal is active when SW1 is turned to ON
position.

a) Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low

Release the START signal source

2. Problem in the torch and leads switch circuit

a) Check continuity of torch switch circuit at ATC

pins 3 & 4. See previous illustration.

3. Short in CNC cable

a) Check continuity

4. Defective Logic Pcb (PCB3)

a) Measure voltage at Main PCB between J2-16

to test point GND1 for 12VDC. If voltage is
present, replace Logic PCB

5. Defective Main PCB

a) Replace Main PCB.

Manual 0-4980 5-13 SERVICE

cutmaster 82

H. TIP MISSING FAULT. The FAULT Indicator

and 80 PSI LED is flashing. Gas solenoid
cycles on and off.

1. Torch Shield Cup is loose.

a) Tighten shield cup by hand. Do not over

tighten.

2. Torch tip, electrode, or starter cartridge missing.

a) Turn off power supply. Replace missing

part(s).

3. Starter Cartridge is stuck.

a) Turn off power supply. Bleed down the system.

Remove the shield cup, tip,start cartridge and
electrode. Check the lower end unit of the
start cartridge for free movement. Replace
the cartridge if the lower end unit does not
move freely.

3. Fan(s) not turning

a) Measure voltage at plug between J7-1 to J7-

2 and between J81 to J8-2 on Main Pcb for
12VDC If voltage is present replace fan.

4. Defective Main PCB

a) Measure voltage at plug between J7-1 to J7-

2 and between J8-1 to J8-2 on Main Pcb for
12VDC. If voltage is missing at either recep­tacle, replace Main PCB.

5. Defective Logic PCB

a) Replace Logic PCB

J. AC LED on, TEMP, GAS, DC LED's are off,

FAULT Indicator is flashing. MIN PRESSURE

LED is flashing. Gas is not flowing

1. Gas supply not connected to unit

a) Connect gas supply to unit

2. Gas supply not turned on

a) Turn gas supply on

4. Open conductor in torch leads

a) Check continuity

5. Defective Main PCB

b) Measure voltage at Main Pcb between J2-2

to test point GND1 for 12VDC. If voltage is
present, replace Main PCB

6. Defective Logic PCB

a) Replace Logic PCB

I. AC LED on, yellow TEMP LED is on, red

FAULT Indicator is flashing.

1. Air flow through unit is restricted

a) Provide adequate airflow. See Ventillation

Clearance Requirements section 2.04.

2. Exceeded duty cycle of the power supply.

3. Gas supply pressure too low.

a) Set gas supply pressure to 95-120psi

4. Air Pressure Control Regulator set too low.

a) Adjust AIR PRESSURE CONTROL to set

pressure as specified in section 4.02 Setting
Operational Pressure.

K. INTERNAL ERROR

FAULT Indicator and 90 PSI Indicator flashing

1. There has been a microprocessor problem.

a) Turn ON/OFF SWITCH to OFF position and

then turn to ON position to clear the error

L. MAX PRESSURE ERROR

MAX Pressure LED is lit.

1. Gas pressure set too high

a) Reduce gas pressure

2. Defective Logic PCB

a) Replace Logic PCB

a) Allow unit to remain on, but at idle, with fan

running to cool power supply. See Power Sup­ply Specifications section 2.04 for duty cylcle
information.

SERVICE 5-14 Manual 0-4980

cutmaster 82

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

M. AC LED on, TEMP LED off, GAS LED on,

Gas does not flow in SET mode using a
hand torch or a machine torch without
remote solenoid.

1. Defective gas solenoid (SOL1)

a) Measure voltage on Main Pcb between J5-1 to

J5-3 for 12 VDC. If voltage is present, change
SOL 1

2. Defective Logic Pcb

a) Measure on Main PCB between J2-12 to test

point GND1 for 12VDC. If voltage is present,
replace Main PCB.

3. Defective Main PCB

a) Replace Main PCB

N. AC LED on, TEMP LED off, GAS LED on,

Gas does not flow in SET mode using a
machine torch with remote solenoid.

Disconnect the gas solenoid SOL1 from the back of

the ATC connector.

If Gas DOES NOT flow out of SOL1 when the unit is

in SET mode :

6. Defective Logic PCB

a) Measure on Main PCB between J2-11 to GND1

for less than 2VDC. If voltage is 12vdc, replace
Logic PCB.

O. Cannot adjust gas pressure in the SET

mode

1. Inlet gas pressure is too low

a) Increase inlet gas pressure to 95-120 psi

2. Faulty regulator

a) Replace Regulator

5.09 Pilot Arc Problems

A. AC LED on, TEMP LED off, GAS LED on.

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

1. Problem in the torch and leads switch circuit (or
remote pendant or CNC signal missing

a) For hand torches, Check continuity of torch

switch circuit at ATC pins 3 & 4.

1. Defective gas solenoid (SOL1)

a) Measure voltage on Main PCB between J5-1 to

J5-3 for 12 VDC. If voltage is present, change
SOL 1

2. Defective Logic PCB

a) Measure on Main PCB between J2-12 to test

point GND1 for 12VDC. If voltage is present,
replace Main PCB.

3. Defective Main PCB

a) Replace Main PCB

If gas DOES flow out of SOL1 when the unit is in SET

mode, reconnect SOL1 to the ATC connector.

4. Defective torch solenoid.

a) Measure the coil terminals of the torch mounted

gas solenoid SOL2 for 24vac. If present, re­place SOL2.

5. Defective Main PCB

a) Measure on Main PCB between J2-20 to GND1

for less than 2VDC.

If voltage is 12VDC replace Main PCB

b) Measure on Main PCB between J2-11 to GND1

for less than 2VDC. If voltage is less than
2VDC replace Main PCB

b) For machine torches using a remote pendant,

Check continuity of Pendant switch circuit

c) For CNC input see section "5.07 H Tip Missing

Fault"

2. Defective Logic PCB

a) Jumper on Main PCB between J2-16 and test

point GND1. If gas does not flow, replace
Logic PCB

b) With Torch Switch closed, measure voltage

on Main PCB between test points GND1 to
I_DMD1 for 1.4VDC. Replace Logic PCB if
voltage is not present.

Manual 0-4980 5-15 SERVICE

cutmaster 82

Upper Groove
with Vent Holes
Must Remain Open

Threads

Upper O-Ring
in Correct Groove

Lower O-Ring

Art # A-03725

Negative / Plasma Lead

4 Torch Switch

3 Torch Switch

2 PIP

1 PIP

Pilot Lead

Art # A-08124

3. Defective Main PCB

a) With Torch Switch closed, measure voltage

on Main PCB between test points GND1 to
I_DMD1 for 1.4 VDC. Replace Main PCB if
voltage is present.

B. SHORTED TORCH FAULT

After torch switch is closed, gas flows for two (2)
seconds then momentarily shuts off then back
on, FAULT INDICATOR flashes, and 85 PSI LED
flashes.

1. Upper O-Ring on torch head is in the wrong posi­tion.

a) Remove shield cup from torch; check position

of the upper o-ring and correct if needed.

4. Shorted Torch

a) Disconnect torch from unit. With consumables

removed from the torch, Check continuity of
torch at ATC, between negative/plasma lead
connection to pilot lead connection.

C. AC LED on, TEMP LED off, GAS LED on,

gas flowing, DC LED off, Fault Indicators
off, No arc in torch

1. Defective Logic PCB

2. Torch start cartridge is stuck.

a) Turn off power supply. Bleed down the system.

Remove the shield cup, tip,start cartridge and
electrode. Check the lower end unit of the
start cartridge for free movement. Replace
the cartridge if the lower end unit does not
move freely.

3. Worn or faulty torch parts

a) Inspect torch consumables parts. Replace if

necessary.

a) Measure voltage at Main PCB between test

point GND1 to J2-10.

Voltage is normally 12VDC and should drop to less
than 2VDC two (2) seconds after torch switch is
depressed. If voltage does not drop replace Logic
PCB

b) While pilot arc is established, measure voltage

on Main PCB between test points GND1 to
I_DMD1 for 1.4 VDC. If voltage is low or not
present, replace Logic PCB.

2. Defective Main PCB

a) a) Measure voltage at Main PCB between test

point GND1 to J2-10.

Voltage is normally 12VDC and should drop to less
than 2VDC two (2) seconds after torch switch is de­pressed. If voltage does not drop to less than 2VDC
for approx one (1) second then replace Main PCB

D. AC LED on, TEMP LED off, GAS LED on,

gas flowing, DC LED on, Fault Indicators
off, No arc in torch.

1. Defective Main PCB

a) Install jumper on Main PCB between test point

GND1 to terminal TIP1.

SERVICE 5-16 Manual 0-4980

b) Close torch switch. If Pilot starts, replace Main

PCB

cutmaster 82

E. AC LED on, TEMP LED off, GAS LED on,

gas flowing, DC LED on, Fault Indicators
off, Pilot Arc is intermittent.

1. Defective Logic PCB

a) Measure for 12VDC on Main PCB between

test Point GND1 to J2-8. If 12VDC is present,
replace Logic PCB

2. Defective Main PCB

a) Replace Main PCB

F. INTERNAL ERROR FAULT INDICATOR AND

90 PSI INDICATOR FLASHING

1. There has been a microprocessor problem.

a) Turn ON/OFF SWITCH to OFF position and

then turn to ON position to clear the error

5.10 Main Arc and Controls
Problems

A. Main arc will not establish, LED D59 on

Main PCB remains on while pilot arc is
striking the work piece.

1. Work Cable not connected.

a) Connect cable to work piece

2. Work cable open / broken.

a) Check continuity of work cable. Insure connec-

tion of cable to clamp is secure.

B. Main arc transfers but current cannot be

adjusted

1. Defective Logic PCB

a) While main arc is transferred,measure voltage

on Main PCB between test points GND1 to
I_DMD1.

D. With CURRENT CONTROL

POTENTIOMETER set at maximum, output
current is only 60 amps.

1. Tip is touching the work piece, Drag mode.

a) Lift tip off work piece

2. Defective Pilot IGBT on Main PCB

a) Check per section 4.10I

E. In RAPID AUTO RESTART mode, with

torch switch closed, the pilot does not
start immediately when the cutting arc
extinguishes

1. Defective Logic PCB

a) Replace Logic PCB

F. INTERNAL ERROR FAULT INDICATOR AND

90 PSI INDICATOR FLASHING

1. There has been a microprocessor problem.

a) Turn ON/OFF SWITCH to OFF position and

then turn to ON position to clear the error

5.11 CNC Interface Problems

A. Nothing happens when jumper is installed

between J2-3 to J2-4.

1. Defective Automation Interface PCB (PCB4)

a) Measure voltage on PCB4 between J1-6 to J1-8

for 12VDC.

If 12VDC is present replace PCB4

2. Defective Main PCB

a) Measure voltage on Main PCB between J1-6 to

J1-8 for less than 2VDC.

If voltage is less than 2VDC, replace PCB1

b) Adjust CURRENT CONTROL POTENTIOM-

ETER from maximum to minimum. Voltage
should vary from 4VDC at max to 1 VDC at
min

If voltage does not vary with CURRENT CONTROL

POTENTIOMETER, Replace Logic PCB

2. Defective Main PCB

a) Replace Main PCB

C. In LATCH mode, when the torch switch is

released the arc shuts off immediately.

1. Defective Logic PCB

a) Replace Logic PCB

Manual 0-4980 5-17 SERVICE

B. No OK-TO-MOVE signal while cutting.

1. Defective Main Pcb (PCB1)

a) Measure voltage on PCB4 between J1-1 to J1-3

for 12VDC while cutting.

If 12VDC is present, replace PCB1

2. Defective Automation Interface PCB (PCB4)

a) Measure voltage on PCB4 between J1-1 to J1-3

for less than 2VDC while cutting.

If voltage is less than 2VDC, replace PCB4.

cutmaster 82

L4

L3

L2

L1

T4

T3

T2

T1

Actuator Arm

Cover Screws

Input

CutMaster 52 & 82

W1 contactor wired for 1PH

Main Contactor

Jumpers

Actuator Button

C. ARC VOLTS signals are low or not present

1. Defective Automation Interface PCB (PCB4)

a) Replace PCB4

5.12 Test Procedures

A. Main Contactor (W1) Test

1. Check continuity between:

L1 to T1

L2 to T2

L3 to T3

L4 to T4

The contacts should be open – no continuity.

B. Input Diode Module Test

1. Using an ohmmeter perform the tests in the
chart

Input Diode Module

Meter (+) Meter (-) Indication

AC1 MTH 2 Forward Bias
AC2 MTH 2 Forward Bias

AC3 MTH 2 Forward Bias
MTH 2 AC1 Reverse Bias
MTH 2 AC2 Reverse Bias
MTH 2 AC3 Reverse Bias
MTH 5 AC1 Forward Bias
MTH 5 AC2 Forward Bias
MTH 5 AC3 Forward Bias

AC1 MTH 5 Reverse Bias

AC2 MTH 5 Reverse Bias

AC3 MTH 5 Reverse Bias

2. If the test reveals a failed component, replace
Main PCB and perform main contactor test – Sec­tion 5.11A

2. Retest continuity between terminals while engag­ing the contacts manually. This can be done by
pushing down on the recessed actuator button on
the top of W1 or pushing down on the actuator
arm on the side of W1.

L1 to T1

L2 to T2

L3 to T3

L4 to T4

The contacts should be closed – Continuity

3. Visually check W1 contact points. To take the
cover off, remove the two cover screws shown in
the previous illustration. Replace if contacts are
stuck together or show excessive arcing

C. Input Capacitor PCB Test

1. Using an ohmmeter check continuity between the
following points:

Input Capacitors

Meter + Meter - Indication

MTH 2 MTH 4 Charging
MTH 4 MTH 5 Open
MTH 6 MTH 5 Charging

Most meters will show a charging action. Initially a
low resistance will be shown and then the resistance
will start to increase. If the meter probes are reversed
the reading will decrease to zero, then start charging
in the opposite polarity.

2. If a short is found replace Capacitor PCB assem­bly.

3. Check continuity between the following points

Input relays Indication
MTH 2 MTH 6 Open
MTH 4 MTH 6 Open
MTH 4 MTH 5 Open

4. If a short is found, replace Capacitor PCB assem­bly

SERVICE 5-18 Manual 0-4980

D. IGBT Modules Test

1. Disconnect transformer wires from Main PCB
terminals PRI 1 (A) and PRI 4 (D).

2. Using an ohmmeter perform the following
checks

IGBT A
Meter (+) Meter (-) Indication
PRI 1 (A) MTH 2 Forward Bias
PRI 1 (A) MTH 4 Reverse Bias

MTH 2 PRI 1 (A) Reverse Bias

MTH 4 PRI 1 (A) Forward Bias
PRI 2 (B) MTH 2 Forward Bias
PRI 2 (B) MTH 4 Reverse Bias

MTH 2 PRI 2 (B) Reverse Bias

MTH 4 PRI 2 (B) Forward Bias

IGBT B
Meter (+) Meter (-) Indication
PRI 3 (C) MTH 6 Forward Bias
PRI 3 (C) MTH 5 Reverse Bias

MTH 6 PRI 3 (C) Reverse Bias

MTH 5 PRI 3 (C) Forward Bias
PRI 4 (D) MTH 6 Forward Bias
PRI 4 (D) MTH 5 Reverse Bias

MTH 6 PRI 4 (D) Reverse Bias

MTH 5 PRI 4 (D) Forward Bias

3. If the test reveals a failed component, replace
Main Pcb and perform main contactor test – Sec­tion 5.11A. If no problem is found, reconnect the
transformer wires to Main PCB.

cutmaster 82

E. Output Diode Module Test

1. Disconnect transformer wires from Main PCB
terminal SEC 1.

2. Using an ohmmeter perform the tests in the
chart

Output Diode Module

Meter (+) Meter (-) Indication

SEC 1 WORK 1 Forward Bias
SEC 1 CHOKE 1 Reverse Bias

WORK 1 SEC 1 Reverse Bias

CHOKE 1 SEC 1 Forward Bias

SEC 2 WORK 1 Forward Bias

SEC2 CHOKE 1 Reverse Bias

WORK 1 SEC2 Reverse Bias

CHOKE 1 SEC 2 Forward Bias

3. If the test reveals a failed component, replace
Main Pcb. If no problem is found, reconnect the
transformer wires to Main PCB.

Manual 0-4980 5-19 SERVICE

cutmaster 82

MTH8

MTH7 MTH5

MTH6

MTH1

MTH3

MTH4

MTH2

J3*

*J3 CONNECTOR PINOUT

1

2

3

Art # A-08841

F. Pilot IGBT Test

1. Disconnect wire from Main PCB terminal TIP1

2. Measure continuity on Main PCB between test point GND1 to terminal TIP1

3. If the test reveals a failed component, replace Main PCB. If no problem is found, reconnect wire to Main
PCB.

Signal Information

Many of the signal listed will be low voltage signals that will be in one of two states: +12VDC (High) or 0VDC
(Low) with respect to pcb common.. When a signal name is preceded by the “/” mark, it denotes that the signal
is an active low. For example:

/OVERTEMP – This signal is normally High but when an over temperature fault exists, this line will change
state to a Low.

SERVICE 5-20 Manual 0-4980

cutmaster 82

CAPACITOR PCB SIGNALS Signal Source-Destination

J1-1 Capacitor bank A+

J1-5 Capacitor bank A-

J2-1 Capacitor Bank B+

J2-5 Capacitor Bank B-

J3-1 +12 VDC M-C

J3-2 /460 Active low for 460VAC input M-C

J3-3 /230 Active low for 230VAC input M-C

MTH1,2 Capacitor bank A+

MTH3,4 Capacitor bank A-

MTH6,8 Capacitor Bank B+

MTH 5,7 Capacitor Bank B-

Manual 0-4980 5-21 SERVICE

cutmaster 82

D5

D3

D2

D4

D6

D7

D8

D9

D10

D11

D12

D13

D14

D1

TP3

TP4

TP1

J1*

TP7

TP6

T

P5

LOGIC PCB LAYOUT

PCB3

1

4

37

40

*J1 Pinout

TP2

Art # A-08179

LOGIC PCB SIGNALS (Same for MAIN PCB J2) Signal Source/Destination

J1-1 -VOUT (-) OUTPUT VOLTAGE M-L

J1-2 /TIP VOLTS Active high when tip is installed M-L

J1-3 TIP_SEN Approx. 100VDC while cutting with tip not in M-L
contact w/work piece, Active low when tip
contact work during cut (Drag Mode)

J1-4 /460V_IN Active low with 460vac primary input voltage L-M

J1-5 /230V_IN Active low with 230vac primary input voltage L-M

J1-6 CUR_SET Current demand signal. Variable 1-4VDC L-M

J1-7 /RAR Active low when in Rapid Auto Restart mode L-M

J1-8 /INRUSH Active low after inrush time expires L-M

SERVICE 5-22 Manual 0-4980

cutmaster 82

J1-9 /W1_ON Active low to enable W1 contactor L-M

J1-10 SHDN Active low enables PWM circuit

J1-11 /TRCH_SOL Active low to enable Torch Solenoid L-M

J1-12 /SOL_ON Active low to enable Power Supply solenoid L-M

J1-13 /OK_TO_MOVE Active low to enable OK_TO_MOVE (CNC) L-M

J1-14 /FAN_ON Active low to enable fans L-M

J1-15 /LATCH_ACTIVE Active low when Latch mode is active during cut L-M

J1-16 /TRCH_SW Active low = START is active -Torch switch, CNC M-L

J1-17 /PIP Active low = PARTS IN PLACE satisfied M-L

J1-18 AC_ON Pulse signal M-L

J1-19 CSR Active high during main transfer M-L

J1-20 /TORCH_SOL_DETECTED Active low for torch with remote solenoid M-L

J1-21 /OVERTEMP Active low when over temperature M-L

J1-22 V_IN Input Voltage signal M-L
3VDC = 460 VAC / 1.5VDC = 230VAC

J1-23 +12VDC M-L

J1-24 +12VDC M-L

J1-25 GND M-L

J1-26 GND M-L

J1-27 Not Used

J1-28 Not Used

J1-29 MAIN_BD_ID Voltage level to identify Main PCB = 1.1VDC M-L

J1-30 Not Used

J1-31 Not Used

J1-32 Not Used

J1-33 Not Used

J1-34 For Factory Use M-L

J1-35 For Factory Use M-L

J1-36 For Factory Use M-L

J1-37 For Factory Use M-L

J1-38 GND M-L

J1-39 For Factory Use M-L

J1-40 Not Used

Manual 0-4980 5-23 SERVICE

cutmaster 82

LED INDICATORS

NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE

D1 +12VDC

D2 MAX PRESSURE X.7 Over Pressure

D3 90 PSI X.6 Internal Error

D4 85 PSI X.5 Shorted torch

D5 80 PSI X.4 Tip Missing

D6 75 PSI X.3 Start Signal active during power up

D7 70 PSI X.2 Parts-In-Place Fault (PIP)

D8 65 PSI X.1 Input Power Fault

D9 MIN PRESSURE X.0 Low Pressure

D10 AC 1.X

D11 OVERTEMP 2.X

D12 GAS 3.X

D13 DC 4.X

D14 ERROR 5.X

TEST POINTS

TP1 Common

TP2 +12VDC

TP3 +5VDC

TP4 +3.3DCV

TP5 0.5 to 5 VDC / 0 - 100 psi

TP6 +1.8VDC

TP7 Potentiometer Current Demand (0-3.3VDC)

SERVICE 5-24 Manual 0-4980

cutmaster 82

This Page Intentionally Blank

Manual 0-4980 5-25 SERVICE

cutmaster 82

J10 J9

J8

J7

J6

J5

D78

J14

D59

GND2

+48V1

CHOKE1

SEC2

SEC1

TIP1

PRI_3

J4 J3

*J2

TP8

TP7

J13

J12

TP

2

TP

1

J1

TP3

+12V1

+12V2

+48V2

TP6

PRI_2

TP5

AC3

AC1

AC2

WORK_1

PRI_1

PRI_4

J11

Art # A-08518_AB

1

39

40

2

*J2 PINOUT

MAIN PCB SIGNALS

J1-1 L1 Primary AC Line

J1-2 Not used

J1-3 Not used

J1-4 Not used

SERVICE 5-26 Manual 0-4980

cutmaster 82

J1-5 L2 Primary AC Line

J3-1 /230VAC

J3-2 Common

J4 For factory use

J5-1 +12VDC

J5-2 Not used

J5-3 /SOLENOID

J6-1 24VAC Supply for W1

J6-2 24VAC Return

J7-1 +12VDC

J7-2 /FAN

J8-1 +12VDC

J8-2 /FAN

J9-1 /PIP

J9-2 Common

J9-3 /TORCH SWITCH (Start)

J9-4 Common

J9-5 Torch solenoid 24VAC supply

J9-6 Not Used

J9-7 Torch solenoid 24VAC return

J10-1 /OK-TO-MOVE

J10-2 Not used

J10-3 /OK-TO-MOVE

J10-4 Not used

J10-5 Common

J10-6 Common

J10-7 Not used

J10-8 /START (Torch Switch)

J11-1 Jumper installed

J11-2 Jumper installed

J12-1 +12VDC

J12-2 /460VAC

J12-3 /230VAC

GND2 Common
GND3 Common
+12V1 +12VDC
+48V1 +48VDC
I_DMD1 0-4VDC Current Demand Signal

LED INDICATORS

D59 PCR Indicates Pilot IGBT gate signal is on
D78 CSR Indicates cutting arc has been established

MAIN PCB TEST POINTS

GND1 Common

Manual 0-4980 5-27 SERVICE

cutmaster 82

This Page Intentionally Blank

SERVICE 5-28 Manual 0-4980

cutmaster 82

Upper Groove
with Vent Holes
Must Remain Open

Threads

Upper O-Ring
in Correct Groove

Lower O-Ring

Art # A-03725

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

SECTION 5 TORCH:

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 pilot arc initiation and the overall cut quality of
the torch.

WARNINGS

Disconnect primary power to the system before
disassembling the torch or torch leads.

It is recommended to apply a very light film of o­ring lubricant (Catalog # 8-4025) to the o-rings on a
weekly basis.

Torch Head O-Ring

DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.

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

CAUTION

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

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

ATC O-Ring

NOTE

DO NOT use other lubricants or grease, they may

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

Manual 0-4980 5T-1 SERVICE

cutmaster 82

Art # A-08067

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

Good Tip

Worn Tip

A-03406

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNINGS

Disconnect primary power to the system before
disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE

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

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

NOTE

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

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

Example of Tip Wear

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

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

Shield Cups

3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector is
threaded snugly against the shield cup body. In
shielded drag cutting operations (only), there may
be an O-ring between the shield cup body and
drag shield cap. Do not lubricate the O-ring.

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

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into

the torch head.

9. 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.

This completes the parts replacement procedures.

SERVICE 5T-2 Manual 0-4980

cutmaster 82

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

Section 6.03 Complete Power Supply Replacement

Section 6.04 Replacement Parts

Section 6.05 Options and Accessories

Section 6.06 Left Side Replacement Parts

Section 6.07 Right Side Replacement Parts

Section 6.08 Options and Accessories

Section 6.09 Replacement Parts for Hand Torch

Section 6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads

Section 6.11 Torch Consumable Parts Manual and Mechanized Torches

NOTE

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

B. Returns

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.

Qty Description Catalog #

1 CutMaster 82 Power Supply
208/230 - 460VAC, Single or 3 Phase, 60Hz,
with input power cable and plug 3-1130-1
460VAC, Single or 3 Phase, 60Hz,
with input power cable 3-1130-2
600VAC, 3 Phase, 60Hz,
with input power cable 3-1130-5

Manual 0-4980 6-1 PARTS LIST

cutmaster 82

Art # A-08120

3

2

4

5

1

3

6.04 Major External Replacement Parts

Item # Qty Description Catalog #

1 1 Cover with labels 9-0128
2 1 Base Enclosure Assembly 9-0118
3 1 Tube, roll handle 9-0121
4 1 Front Panel 9-0127
5 1 Rear Panel 9-0101

NOTE

Illustration may vary slightly from unit.

PARTS LIST 6-2 Manual 0-4980

cutmaster 82

Art # A-08123

1

2

3

6.05 Front Panel Replacement Parts

Item# Qty Description Ref. Catalog #

1 1 Output Current Control and Function Control Knobs 9-8527

2 1 Toggle - On/Off Switch SW1 9-0109

3 1 Work Cable with Clamp, 20 Ft / 6.1 m 9-0184

NOTE

Illustration may vary slightly from unit.

Manual 0-4980 6-3 PARTS LIST

cutmaster 82

1

2

3

4

56

Art # A-08122

6.06 Left Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Main PCB Assembly PCB1 9-0125

2 1 Logic PCB PCB3 9-0107*
3 1 Center Chassis Molded Plastic 9-0102
4 1 Fan, MOT1,MOT2 9-0104

5 1 Transformer, Main Non 600V T1 9-0199
5 1 Transformer, Main 600V Only T1 9-0170
6 1 Inductor, Output L1 9-0105
Not Shown:
1 Power Cable Strain Relief, for all units 9-0111

1 Input Power Cable 230 V with plug, 9-8596

1 Input Power Cable 460/600V 9-8593
1 Hi/Lo voltage selection switch 9-0110

NOTE:

*9-0107 Logic PCB, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will
be needed to replace not only the Logic PCB (9-0107) but the regulator (9-0115) as well. Another way to tell if
the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting. If there is a
transducer and wire harness instead of the tube, the kit is not needed.

NOTE

Illustration may vary slightly from unit.

PARTS LIST 6-4 Manual 0-4980

cutmaster 82

1

2

3

5

6

7

Art # A-08121

4

8

6.07 Right Side Replacement Parts

Item # Qty Description Ref Catalog #

1 1 Contactor, 4 Pole 9-8587

2 1 Solenoid, 12V 9-0114
3 1 Spare Parts Box 7-3267
4 1 Spare Parts Box Cover 7-3266
5 1 Console Quick Disconnect 9-0161
6 1 Regulator, with knob and mounting nut 9-0115*
7 1 Assembly, PCB, Input Capacitors 9-0126

8 1 Filter, Auto Drain 9-0116

NOTE:

*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be
needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed
is to see if the regulator has a small diameter tube coming out of the bottom fitting. If there is a transducer and
wire harness instead of the tube, the kit is not needed.

Illustration may vary slightly from unit.

Manual 0-4980 6-5 PARTS LIST

NOTE

cutmaster 82

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

6.08 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable ( 50 ft / 15.2 m ) with Clamp 9-8529
1 Multi - Purpose Cart 7-8888
1 Automation Interface Kit 9-8310
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313
1 Nylon Dust Cover 9-7071

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

PARTS LIST 6-6 Manual 0-4980

cutmaster 82

7

5

6

3

4

2

Art # A-07993_AB

1

8

6.09 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O - Ring 8-3487
6 1 Small O - Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60, 20 - foot Leads Assembly with ATC connector 4-7834
1 SL60, 50 - foot Leads Assembly with ATC connector 4-7835
1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836
1 SL100 , 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103

Manual 0-4980 6-7 PARTS LIST

cutmaster 82

6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O - Ring 8-3487
3 1 Small O - Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
6 1 11” / 279 mm Rack 9-7041
7 1 11” / 279 mm Mounting Tube 9-7043
8 1 End Cap Assembly 9-7044
9 2 Body, Mounting, Pinch Block 9-4513
10 1 Pin, Mounting, Pinch Block 9-4521
11 1 Torch Holder Sleeve 7-2896
12 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE

* Does not include Control Cable Adapter or Through - Hole Protector.

PARTS LIST 6-8 Manual 0-4980

cutmaster 82

A-07994

6

1

4

2

3

5

7

8

9

10

12

11

10

Manual 0-4980 6-9 PARTS LIST

cutmaster 82

Start

Cartridge

9-8213

Electrode

9-8215

Tips:

20A 9-8205
30A 9-8206
40A 9-8207
60A 9-8252

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag
70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

Tips:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

CUTTING

CUTTING

Art # A-08065_AC

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

NOTE
CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
CutMaster 102 uses 100A and less
CutMaster 152 uses 120A and less

6.11 Torch Consumable Parts Manual and Mechanized Torches

PARTS LIST 6-10 Manual 0-4980

cutmaster 82

!

SECTION 7: REPLACEMENT

PROCEDURES

7.01 Scope

This section describes parts replacement procedures
which may be performed on the CutMaster 52 Power
Supply.

Under no circumstances are field repairs to be attempted
on Printed Circuits or other subassemblies of this unit.
Evidence of unauthorized repairs may void the factory
warranty.

7.02 Anti-Static Handling
Procedures

A. General

Caution

PC Boards can be irreparably damaged by im­proper handling due to electrostatic discharge
(ESD).

Replacement PC Boards are shipped in a protective en­closure to prevent damage from electrostatic discharge
(ESD) during shipping. A ground strap is included with
each replacement board to prevent static damage during
installation.

B. Procedure

1. Open the wrist strap and unwrap the first two
folds of the band. Wrap the adhesive side firmly
around your wrist.

2. Unroll the rest of the band and peel the liner from
the copper foil at the opposite end.

3. Attach the copper foil to a convenient and ex­posed electrical ground.

4. Connect the equipment primary cable ground to
the same electrical ground as the wrist strap.

5. Open the equipment enclosure and remove the
failed PC board.

6. Carefully open the ESD protective bag and re­move the replacement PC Board.

7. Install the replacement PC Board in the equip­ment and make all necessary connections.

8. Place the failed PC Board in the ESD protective
bag and seal for return shipping.

9. Replace the power supply cover.

10. Remove the grounding wrist strap from your
wrist and from the electrical ground connection
before reconnecting primary power to the equip­ment.

7.03 Parts Replacement - General
Information

WARNINGS

Read and understand these instructions and
the instructions on the grounding wrist strap
package before opening the equipment enclo­sure or removing the replacement PC board
from its protective enclosure.

Disconnect primary power to the system
before disassembling the torch, torch leads,
or power supply enclosure.

Where these instructions include specific
torquing instructions, failure to torque prop­erly will cause component damage.

Do not operate the equipment or test equip­ment under power while wearing the ground­ing wrist strap.

The parts replacement procedures described in this
manual, except for filter replacement, require that the
Power Supply be disassembled. The part to be replaced
will determine to what extent the Power Supply must
be disassembled.

Before removing any connection mark each wire with
the connection designation. When reassembling make
sure the wires go to the proper terminals.

Note the routing of wires and make sure the wires are put
back in the same place when re-assembling the unit.

Each subsection is referenced to Section 6 for parts lists
and overall detailed drawings.

WARNING

Disconnect primary power from the source
before opening or disassembling the power
supply.

Manual 0-4980 7-1 PARTS REPLACEMENT

cutmaster 82

Upper
Screws

Lower
Screws

Lower
Screws

Art # A-07947

Slots

7.04 Major External Parts

A. Cover Removal

Tools required: T20 Torx Driver

1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
in the bottom of the cover.

Note

The upper screws and lower screws are not the
same. Do not mix them. The upper screws are
for threading into the plastic of the front and rear
panels. DO NOT use the finer threaded lower
screws for this.

C. Tube Handle Replacement

Tools required: T20 Torx Driver

1. Disconnect the Torch and Leads from the unit.

2. Remove the cover per subsection 7.04 A.

3. Remove the screws securing the tube handles to
the base of the unit.

NOTE

Some of the earliest manufactured units have Tube
Handles tha are joined together under the base of
the unit. Later versions are not joined together.

4. Remove the power supply from the Tube Han­dles.

5. Replace the Tube Handles by reversing the above
steps.

6. Reinstall the power supply cover.

D. Disconnecting Front and Rear Panels from

the base

In many of the replacement procedures, it may be help­ful to disconnect the front or rear panel from the base in
order to allow more room to access the parts.

2. Carefully pull the Cover up and away from the
unit.

B. Cover Installation

1. Reverse previous procedures for cover installa­tion.

When installing the upper screws, attempt to
reuse the original threads. The easaiest way to
do this is by turning the screw counter-clockwise
until you feel the threads lign up, then begin to
turn the screw clockwise to tighten. Do not over

tighten.

NOTE

Tools required: T20 Torx Driver

1. Remove the cover per subsection 7.04 A.

2. For earlier models remove the Tube Handles
per subsection 7.04 C. The earlier model Tube
Handles join together under the base. Later mod­els do not and there is enough room to perform
this procedure without removing them.

3. While grasping the panel close to the base, pull
the panel directly from the base to release the
locking tabs..

4. To re-engage the panel, position the panel so that
the locking tabs are above the base, then push the
panel back onto the base until the locking tabs
engage the mating holes in the base.

5. For complete removal of panel, disconnect any
other item still attached to the panel and another
component of the power supply.

PARTS REPLACEMENT 7-2 Manual 0-4980

cutmaster 82

2

3

1

Art # A-08150

7.05 Front Panel Parts Replacement

Refer to section 6.05 for Front Panel Replacement Parts
and overall detailed drawing.

A. Current Control Potentiometer (A) Knob

Replacement

Tools required: Flat Screw Driver

1. Turn the potentiometer fully clockwise and note
the location of the pointer mark on the knob.

2. Loosen the screw securing the Current Control
Knob to the potentiometer shaft and remove the
knob.

3. Replace the knob on the potentiometer shaft with
the pointer in the same position as noted in step

1.

B. Function Control Switch Knob

Replacement

Tools required: Flat Screw Driver

1. Turn the Function Control Switch until the
pointer on the knob is in the LATCH position.

2. Loosen the screw securing the knob to the switch
shaft and remove the knob.

3. Replace the knob on the switch shaft with the
pointer in the position noted in step 1.

C. Replacing Gas Hoses

Tools required: T20 Torx Driver

1. Remove the cover per subsection 7.04A

2. Push the gas fitting locking ring back. A small
open end wrench works well for this.

D. Air Regulator Replacement

Tools required: T20 Torx Driver

1. Remove the cover per subsection 7.04A

2. Remove the three (3) air hoses from the regulator
per subsection 7.05-C

3. Pull the Air Regulator adjusting knob from the
shaft.

4. Loosen and remove the locking nut securing the
Air Regulator to the front Panel, then remove the
regulator.

5. Install replacement Air Regulator by reversing
the above steps.

6. Reinstall the power supply cover

E. Gas Solenoid Replacement

Tools required: T20 Torx Driver, Flat Screw Driver

1. Remove the cover per subsection 7:04A

2. Disconnect J5 connector from the Main PCB.

3. Remove the air hose from Gas Solenoid per sub­section 7.05-C

4. The Solenoid utilizes the same type locking fit­ting as the gas hoses. Using a flat blade screw
driver, push the locking ring towards the Sole­noid while pulling the Solenoid away from the
ATC.

5. Install the replacement Gas Solenoid by reversing
the above steps

6. Reinstall the power supply cover

F. Logic PCB (PCB3) Replacement

3. Pull the hose from the fitting.

4. Replace the hose by pushing the hose back into
the fitting until it fully seats. Check it by pull­ing on the hose. If done correctly it will not pull
out.

5. Reinstall the power supply cover

Manual 0-4980 7-3 PARTS REPLACEMENT

Tools required: T20 Torx Driver Flat Screw Driver, ½”
wrench

1. Remove the cover per subsection 7.04A

2. Remove the two large and one small gas hoses
from the pressure regulator per subsection

7.05C.

3. Unplug the connector J2 from the Main PCB.

4. Remove the Current Control Potentiometer Knob
and nut securing the potentiometer shaft to the
front panel per subsection 7.05A

5. Remove the Function Control Switch Knob and
the nut securing the switch shaft to the front
panel per subsection 7.05B.

6. Pull the top of the front panel forward slightly
and carefully remove the Logic PCB from the
unit.

cutmaster 82

Switch

4

3

2

1

Art # A-08169

7. Install the replacement Logic PCB by reversing
the above steps.

8. Reinstall the power supply cover.

G. ON/OFF Switch (SW1) Replacement

Tools required: T20 Torx Driver

1. Remove the cover per subsection 7.04A

2. Disconnect the wires on the rear of the switch,
noting the location and orientation of each wire
as shown below.

3. Squeeze together the clips on the back of the
switch, then remove the switch through the front
panel.

4. Install the replacement switch by reversing the
above steps.

5. Reinstall the power supply cover

H. Work Cable Replacement

7.06 Left Side Internal Parts
Replacement

A. Fan Replacement

Tools required: T20 Torx Driver

1. Remove the Cover per subsection 7.04A

2. Unplug J7 and J8 connectors from Main PCB.

3. Carefully feed the fan wires through the center
chassis wire slot.

4. Remove the fan by pushing the fan retaining
clips apart and pulling the fan out of the center
chassis.

5. On the replacement fan(s) note the direction of
air flow as labeled on the fan housing and orient
so fan will blow air into the unit.

6. Install replacement fan by reversing the above
steps.

7. Reinstall the power supply cover

B. Main Transformer (T1) Replacement

Tools required: T20 Torx Driver, ½” Nut Driver

1. Remove the Cover per subsection 7.04A

2. Remove the Tube Handle per subsection 7.04C

3. Remove the two large and one small gas hoses
per subsection 7.05C

Tools required: T20 Torx Driver

1. Remove the Cover per subsection 7.04A.

2. Disconnect the work cable from the WORK1
terminal on the Main PCB.

3. Squeeze the top and bottom of the Work Cable
Strain Relief and remove from the front panel.

4. Install the replacement Work Cable by reversing
the above steps.

5. Reinstall the power supply cover

4. Remove the Gas Solenoid per subsection 7.05E

5. Disconnect the transformer wires from terminals
PRI 1 (A), PRI 2 (B), PRI 3 (C), PRI 4 (D), SEC1,
SEC2 on the Main PCB.

6. Disconnect J2 & J3 connectors from Main PCB.

7. Remove the two screws securing the Center
Chassis to the base.

8. Loosen the two screws on the Input Power Cable
strain relief.

9. Disengage the Rear panel from the base per sec­tion 7.04D.

10. Guide the rear panel back six (6) inches away
from the base.

11. Guide the Center Chassis towards the center of
the base to disengage the bottom locking tabs
securing the Chassis to the base.

12. Carefully guide the Center Chassis up far enough
to lay the Chassis down to the right side of the
unit.

PARTS REPLACEMENT 7-4 Manual 0-4980

cutmaster 82

Art # A-07989

1

2

3

4

5

6mm

13. Remove the two screws securing the Main Trans­former to the base.

14. Remove the Main Transformer, carefully guiding
all its wires through from the right side of the
unit.

15. Install replacement Transformer by reversing the
above steps.

16. Reinstall the power supply cover

C. Output Inductor (L1)

Tools required: T20 Torx Driver, ½” Nut Driver

1. Remove the Cover per subsection 7.04A

2. Remove the Tube Handle per subsection 7.04C

3. Remove the two large and one small gas hoses
per subsection 7.05-C

4. Remove the Gas Solenoid per subsection 7.05-E

5. Disconnect J2 & J3 connectors from Main PCB.

6. Disconnect Output Inductor wire from terminal
Choke1 on the Main PCB.

7.07 Rear Panel Parts Replacement

A. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection 5.02),
and either cleaned or replaced.

1. Remove power from the power supply; turn off
the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Re­moval" in this section.

3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
illustration.

4. Hold a wrench or similar tool against the locking
ring on the filter assembly fitting, then pull on
the hose to release it. (Numbers 2 and 3 in the
following illustration).

7. Disconnect Output inductor wire from ATC con­nector.

8. Remove the two screws securing the Center
Chassis to the base.

9. Loosen the two screws on the Input Power Cable
strain relief.

10. Disengage the Rear panel from the base per sec­tion 7.04D.

11. Guide the rear panel back six (6) inches away
from the base.

12. Guide the Center Chassis towards the center of
the base to disengage the bottom locking tabs
securing the Chassis to the base.

13. Carefully guide the Center Chassis up far enough
to lay the Chassis down towards the right side
of the unit.

14. Remove the two screws securing the Output
Inductor to the base.

15. Remove the Output Inductor, carefully guid­ing its wires through from the right side of the
unit.

16. Install replacement Output Inductor by reversing
the above steps.

17. Reinstall the power supply cover.

Manual 0-4980 7-5 PARTS REPLACEMENT

5. Remove the fitting from the filter element as­sembly by inserting a 6 mm hex wrench into

cutmaster 82

Art # A-07990

Filter Element

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previous
illustration.

6. Disconnect the input line from the filter element
assembly.

7. Remove the filter element assembly through the
rear opening.

NOTE

If replacing or cleaning just the filter element refer
to the following illustration for disassembly.

C. Input Power Cable Replacement

Tools required: T20 Torx Driver, Phillips Head Screw­driver, Flathead Screwdriver,

1. Remove the Cover per subsection 7.04A

2. Disconnect the input cable wires from the W1
contactor terminals and ground lug.

3. Loosen the two screws in the cable strain relief

4. Remove cable through the rear panel.

5. Install replacement Input Power Cable by revers­ing above steps.

6. Reinstall the power supply cover

D. Optional Single-Stage Filter Element

Replacement

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

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

8. Install the new or cleaned assembly by reversing

9. Turn on the air supply and check for leaks before

B. Voltage Selection Switch Replacement

Tools required: T20 Torx Driver, 9/16” wrench

1. Remove the Cover per subsection 7.04A

2. Disconnect J3 from the Logic PCB

3. Remove retaining nut securing the switch to the

4. Feed the wires and connectors out of the panel

5. Install replacement filter by reversing above

these procedures.

reinstalling the cover.

rear panel.

steps.

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.

Optional Single-Stage Filter Element Replacement

PARTS REPLACEMENT 7-6 Manual 0-4980