Tweco 102 User Manual

100

CUTMASTER™ 102

PLASMA CUTTING SYSTEM

208-

230V

400V

460V 600V

Operating
Manual

Art # A-08618_AC

Revision: AN Issue Date: February 10, 2014 Manual No.: 0-4997

VictorThermalDynamics.com

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our
customer and will strive to provide you with the best service and reliability in the industry. This product
is backed by our extensive warranty and world-wide service network. To locate your nearest distributor
or service agency call 1-800-426-1888, or visit us on the web at www.VictorThermalDynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your
Victor Thermal Dynamics product. Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Pre­cautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for
Victor Technologies.

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

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

!

WARNING

Read and understand this entire Manual and your employer’s safety 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® 102
SL100 1Torch™
Operating Manual Number 0-4997

Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.victorthermaldynamics.com

Copyright 2008, 2009, 2010, 2012, 2013 by
Victor Technologies International, Inc.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negli­gence, accident, or any other cause.

Original Publication Date: May 30, 2008
Revision Date: February 10, 2014

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 ..........................................................................1-6

1.07 Declaration of Conformity ...........................................................................1-7

1.08 Statement of Warranty ................................................................................ 1-8

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 Opening the Contactor Cover .....................................................................3-1

3.04 Primary Input Power Connections ..............................................................3-2

3.05 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

TABLE OF CONTENTS

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

4T.05 Gouging ....................................................................................................4T-6

4T.06 Mechanized Torch Operation ...................................................................4T-7

4T.07 Parts Selection for SL100 Torch Cutting ..................................................4T-9

4T.08 Recommended Cutting Speeds for SL100 Torch With Exposed Tip ......4T-10

4T.09 Recommended Cutting Speeds for SL100 Torch With Shielded Tip ......4T-14

PATENT INFORMATION .....................................................................................................4T-18

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

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 Replacement Power Supply Parts ..............................................................6-2

6.05 Options and Accessories ............................................................................6-2

6.06 Replacement Parts for Hand Torch ...........................................................6-3

6.07 Replacement Parts - for Machine Torches with Unshielded Leads ............6-4

6.08 Replacement Shielded Machine Torch Leads Assemblies ........................ 6-6

6.09 Torch Consumable Parts (SL100) ..............................................................6-7

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

SECTION 1:

CUTMASTER 102

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.

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.

• 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.

WARNING

Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.

1.02 Important Safety Precautions

!

WARNING

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

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

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

• 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.

• WARNING: This product contains chemicals, including
lead, known to the State of California to cause birth de­fects and other reproductive harm.

handling.

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.

Wash hands after

Manual 0-4997 GENERAL INFORMATION

1-1

CUTMASTER 102

• 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ammablematerial

in the workplace. Any material that cannot be removed
must be protected.

• Ventilateallammableorexplosivevaporsfromthe

workplace.

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

combustibles.

• Providearewatchwhenworkinginanareawhere

fire hazards may exist.

• Hydrogengasmaybeformedandtrappedunder

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

NOISE

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

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

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

• Forinformationonhowtotestfornoise,seeitem1in

Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

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

• Toprotectyoureyes,alwayswearaweldinghelmet

or shield. Also always wear safety glasses with side
shields, goggles or other protective eye wear.

• Wearweldingglovesandsuitableclothingtoprotect

your skin from the arc rays and sparks.

• Keephelmetandsafetyglassesingoodcondition.

Replace lenses when cracked, chipped or dirty.

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

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.

!

WARNING

WARNING: This product contains chemicals, including lead,

known to the State of California to cause birth defects and
other reproductive harm.

Wash hands after handling.

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

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

GENERAL INFORMATION Manual 0-4997

1-2

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

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT­TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018

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

CUTMASTER 102

!

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.

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
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

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 :

AVERTISSEMENT

Fournit l'information concernant des dommages
possibles de choc électrique. Des avertissements
seront enfermés dans une boîte de ce type.

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.

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.

Manual 0-4997 INFORMATIONS GÉNÉRALES

La fumée et les gaz produits par le procédé de jet de plasma
peuvent présenter des risques et des dangers de santé.

• Eloigneztoutefuméeetgazdevotrezonede respiration.

• Utilisezun appareilrespiratoire àalimentation enair si

FUMÉE et GAZ

Gardez votre tête hors de la plume de fumée provenant du
chalumeau.

l’aération fournie ne permet pas d’éliminer la fumée et les
gaz.

1-3

CUTMASTER 102

• Lessortesdegazetdefuméeprovenantdel’arcdeplasma

dépendent du genre de métal utilisé, des revêtements se
trouvant sur le métal et des différents procédés. Vous devez
prendre soin lorsque vous coupez ou soudez tout métal
pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Liseztoujours lesches 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.

• Débranchez l’alimentationélectriqueavant touttravail

d’entretien ou de réparation.

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

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé à
l’arc de plasma produit du métal, des étincelles, des scories
chaudes pouvant mettre le feu aux matières combustibles ou

provoquerl’explosiondefuméesinammables.

• Soyezcertainqu’aucunematièrecombustibleouinamma-

ble 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inam­mables 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enammé.

• AVERTISSEMENT: Ce produit contient des produits chimi-

ques, notamment du plomb, reconnu par l'État de la Califor­nie pour causer des malformations congénitales et d'autres
dommages touchant le système reproductif.

Se laver les

mains après manipulation.

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.)

INFORMATIONS GÉNÉRALES Manual 0-4997

1-4

CUTMASTER 102

!

RAYONS D’ARC DE PLASMA

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

• Pourprotégervosyeux,porteztoujoursuncasqueouun

écran de soudeur. Portez toujours des lunettes de sécurité
munies de parois latérales ou des lunettes de protection ou
une autre sorte de protection oculaire.

• Portezdes gantsde soudeuret unvêtement protecteur

approprié pour protéger votre peau contre les étincelles et
les rayons de l’arc.

• Maintenezvotrecasqueetvoslunettesdeprotectionenbon

état. Remplacez toute lentille sale ou comportant fissure ou
rognure.

• Protégezlesautrespersonnes setrouvantsurlazone de

travail contre les rayons de l’arc en fournissant des cabines
ou des écrans de protection.

• 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.

AVERTISSEMENT

AVERTISSEMENT : Ce produit contient des produits chimi-

ques, notamment du plomb, reconnu par l'État de la Californie
pour causer des malformations congénitales et d'autres dom­mages touchant le système reproductif.

Se laver les mains

après manipulation.

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 dúez 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an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.

Manual 0-4997 INFORMATIONS GÉNÉRALES

1-5

CUTMASTER 102

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

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’Asso-

ciationdesGazComprimés(CompressedGasAssociation),1235JeffersonDavisHighway,Suite501,Arlington,VA22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures

deSoudage(NationalWeldingSupplyAssociation),1900ArchStreet,Philadelphia,PA19103

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

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

GENERAL INFORMATION Manual 0-4997

1-6

CUTMASTER 102

1.07 Declaration of Conformity

Manufacturer: Victor Technologies
Address: 16052 Swingley Ridge Road, Suite 300
Chesterfield, MO 63033
USA

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ammabilitytestingforallprinted-circuitboardsused.

* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff
guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing 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.

*UL60974-1:2012ArcWeldingEquipment;Part1:WeldingPowerSources

* CSA E60974-1: 2012 Arc Welding Equipment - Part 1: Welding Power Sources

* IEC 60974-1: 2012 Arc Welding Equipment - Part 1: Welding Power Sources

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

Manufacturers responsible representative: Joe Mueller
Vice President/America's Sales and Marketing
Victor Technologies International, Inc.
16052 Swingley Ridge Road, Suite 300
Chesterfield, MO 63033
USA

Manual 0-4997 GENERAL INFORMATION

1-7

CUTMASTER 102

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies, Inc. warrants to the original

retail purchaser that new Victor 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, Victor Technologies, Inc. shall, upon notification thereof and substantiation that the product has
been stored operated and maintained in accordance with Victor 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.

Victor 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. Victor Technologies, Inc. must be notified within 30 days of any
failure, at which time Victor Technologies, Inc.will provide instructions on the warranty procedures to be implemented.

Victor Technologies, Inc. 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 Victor Thermal Dynamics
Distributor.

LIMITED WARRANTY PERIOD

Product

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 Victor Technologies, Inc.:

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.

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

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

LIMITATION OF LIABILITY: Victor Technologies, Inc. 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 Victor 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 Victor 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 Victor Thermal Dynamics product.

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

Effective September 4, 2007

GENERAL INFORMATION Manual 0-4997

1-8

CUTMASTER 102

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification 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:

NOTE

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

2.02 Equipment Identification

The unit’s identification number (specification 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 identified only by the
specification or part number printed on loosely attached card
or the shipping container. Record these numbers on the bottom
of page i for future reference.

2.03 Receipt Of Equipment

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

CAUTION

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

!

WARNING

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

WARNING

Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.

Additional copies of this manual may be purchased by
contacting Victor Technologies International at the address
and phone number in your area listed on the back cover of this
manual. Include the Owner’s Manual number and equipment
identification 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.victorthermaldynamics.com

Manual 0-4997 INTRODUCTION

2-1

CUTMASTER 102

2.04 Power Supply Specifications

CutMaster 102 Power Supply Specifications

Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz

230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Single Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Three Phase, 50/60 Hz

600 VAC (540 - 630), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas

Filtering Ability

Ambient Tempera­ture

All Units Duty Cycle 60% 80% 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.

Particulates to 5 Microns

CutMaster 102 Power Supply Duty Cycle *

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

Current 100 80 70

DC Voltage 120 112 108

IEC IEC IEC

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

10.75"

273 mm

Art # A-08358

16.375"

416 mm

63 lb / 28.6 kg

30.5"

774.7 m

24"

610 mm

6"

150 mm

Art # A-07925_AB

150 mm

6"

150 mm

6"

INTRODUCTION Manual 0-4997

2-2

2.05 Input Wiring Specifications

CutMaster 102 Power Supply Input Cable Wiring Requirements

Input
voltage

Volts Hz kVA I max I1eff Fuse

1
Phase

208 50/60 20.6 99 76 100 4 Type W
230 50/60 21.9 95 74 100 4 Type W
460 50/60 27.6 60 46 60 6

3
Phase

208 50/60 17.7 49 38 60 6
230 50/60 17.9 45 36 60 6
380 50/60 18.4 28 22 32 10
400 50/60 18.7 27 22 32 10
460 50/60 23.1 29 22 30 10
600 50/60 22.8 22 17 25 12

Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

Freq Power

Input

CUTMASTER 102

Suggested Sizes

Flexible Cord

(amps)

(Min. AWG)

NOTE

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations

refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle.

Manual 0-4997 INTRODUCTION

2-3

CUTMASTER 102

Handle and Leads Wrap

and Clamp

2.06 Power Supply Features

Art # A-08359

Control Panel

To rch Leads Receptacle

Input Power Selection

Filter Assembly

Gas Inlet Port

Input Power Cord

Work Cable

Port for Optional Automation
Interface Cable

Art # A-08360

INTRODUCTION Manual 0-4997

2-4

CUTMASTER 102

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and
maintenance procedures for the 1Torch Models SL100/Manual
and SL100/Mechanized Plasma Cutting Torches. Service of
this equipment is restricted to properly trained personnel;
unqualified personnel are strictly cautioned against attempting
repairs or adjustments not covered in this manual, at the risk
of voiding the Warranty.

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

2T.02 General Description

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

A single torch lead provides gas from a single source to be
used as both the plasma and secondary gas. The air flow is
divided inside the torch head. Single - gas operation provides
a smaller sized torch and inexpensive operation.

NOTE

Refer to Section "2T.05 I ntrod ucti on t o
Plasma" on page 2T-2, for a more detailed descrip­tion of plasma torch operation.

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

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

2. Mechanized Torch, Model

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

15.875" / 403 mm

9.285" / 236 mm

1.375" / 35 mm

1.75" /

44.5 mm

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

0.625" /
16 mm

4.95" / 126 mm

Art # A-03322_AB

1.175" / 30 mm

Art # A-02998

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.

Manual 0-4997 INTRODUCTION

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 VDC circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

F. Torch Ratings

Temperature

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Duty Cycle

peak

Manual Torch Ratings

104° F

40° C

100% @ 100 Amps @ 400 scfh

120 Amps

)

500V

7kV

2T-1

CUTMASTER 102

Mechanized Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

G. Gas Requirements

Gas (Plasma and Secondary) Compressed Air

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and

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

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

peak

Manual and Mechanized Torch Gas

Operating Pressure

Refer to NOTE

Gouging)

100% @ 100 Amps @ 400 scfh

)

Specications

!

WARNING

NOTE

104° F

40° C

120 Amps

500V

7kV

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

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.

_

Power

Supply

+

A

B

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.

Workpiece

C

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.

A-00002

INTRODUCTION Manual 0-4997

2T-2

CUTMASTER 102

Remote Pendant

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.

To Control

Torch Switch

Cable Wiring

PIP Switch

A-02997

Torch Trigger

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

To AT C

PIP Sw itch

CNC Start

Sh ield Cup

To AT C

To AT C

PIP Sw itch

Automation To rch

PIP Sw itch

Sh ield Cup

Art # A-08168

Sh ield Cup

Parts - In - Place Circuit Diagram for Machine Torch

Manual 0-4997 INTRODUCTION

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CUTMASTER 102

This Page Intentionally Blank

INTRODUCTION Manual 0-4997

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CUTMASTER 102

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.

3.03 Opening the Contactor Cover

The input power cord is connected to the main contactor, the contactor is located inside a box with a snap on cover. The cover
is held in place with two or more snap lock tabs. To remove the cover release the front latch and tilt the cover up about ½ inch.
Then squeeze both sides of the cover and lift it straight up. See the Primary Input Power Connections section for the necessary
changes to the Contactor. Remember to replace the Contactor Cover when the changes are complete.

1

2

1

2

Art# A-11478

Contactor cover

Manual 0-4997 INSTALLATION

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CUTMASTER 102

3.04 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.

The following illustration and directions are for changing phase of the power supply.

Input Power Cable Connections

Single-Phase (1ø) and Jumper Settings

Store copper jumpers on base plate

L1

L2

L3

L4

GND

Single and Three Phase Input Power Wiring

NOTE

There are two jumpers used for the single phase 230V setting and none for three phase.

Three-Phase (3ø)

L1

L2

L3

L4

GND

Art # A-08493

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.

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. Refer to Section 2 for
power cable specifications.

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).

INSTALLATION Manual 0-4997

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CUTMASTER 102

6. Connect the wires as follows.

• ConnectBusBarJumpersonthecontactorasshowninpriorillustrationandonlabelinthepowersupply.

• Green/YellowwiretoGround.

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

8. Reinstall the Power Supply cover per instructions found in section 5.

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. Refer to Section 2 for
power cable specifications.

CAUTION

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

6. Connect the wires as follows.

• WirestoL1,L2andL3input.Itdoesnotmatterwhatorderthesewiresareattached.Seepreviousillustrationand

on label in the power supply.

• Green/YellowwiretoGround.

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

8. Reinstall the Power Supply cover per instructions found in section 5.

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 0-4997 INSTALLATION

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CUTMASTER 102

Regulator/Filter

3.05 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 filter is to be installed.

1. Connect the air line to the inlet port. The illustration shows typical fittings 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.

Assembly

Inlet Port

Hose Clamp

1/4 NPT or ISO-R

Gas Supply
Hose

to 1/4” (6mm) Fitting

Art # A-07943

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering 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 filter hose.

3. Connect the air line to the Filter. The illustration shows typical fittings 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:

INSTALLATION Manual 0-4997

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