ESAB Thermal Dynamics CUTMASTER 40 User manual

40 120-
240V
esab.com
OUTPUT MAX OUTPUT VOLTAGE
Art # A-14036_AB
INPUT POWER
Revision: AE Issue Date: 29 June, 2020 Manual No.: 0-5557
OPERATING
MANUAL
CUTMASTER® 40
PLASMA CUTTING SYSTEM

WE APPRECIATE YOUR BUSINESS!
Congratulations on your newThermal Dynamics product. We are proud to have you as our customer
and will strive to provide you with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.To locate your nearest distributor
or service agency call 1-800-426-1888, or visit us on the web at www.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your
Thermal Dynamics product.Your satisfaction with this product and its safe operation is our ultimate
concern.Therefore please take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for ESAB.
We distinguish ourselves from our competition through market-leading, dependable products
that have stood the test of time. We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support, together with excellence in
sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.

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Plasma Cutting Power Supply
CutMaster® 40
SL60™ 1Torch™
Operating Manual Number 0-5557
Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207
www.esab.com
© Copyright 2019 by
Thermal Dynamics an ESAB brand.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether such
error results from negligence, accident, or any other cause.
For Material Print Specications, refer to document 47x1961
Original Publication Date: 15 November, 2019
Revision Date: 29 June, 2020
See website for Warranty Information.
Record the following information for Warranty purposes:
Where Purchased:____________________________________________________
Purchase Date:__________________________ ____________________________
Power Supply Serial #:_______________________________ _________________
Torch Serial #:______________________________ _________________________
!!
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 judgment, the Manufacturer
assumes no liability for its use.
i

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully
familiar with the principles of operation and safe practices for arc welding
and cutting equipment, we urge you to read our booklet, “Precautions and
Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do
NOT permit untrained persons to install, operate, or maintain this equip-
ment. Do NOT attempt to install or operate this equipment until you have
read and fully understand these instructions. If you do not fully understand
these instructions, contact your supplier for further information. Be sure to
read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty mainte-
nance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOUR-
NISSEUR.
MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionne-
ment et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage,
nous vous suggérons de lire notre brochure « Precautions and Safe Practices for
Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux per-
sonnes non qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement.
Ne tentez PAS d’installer ou d’opérer cet équipement avant de lire et de bien com-
prendre ces instructions. Si vous ne comprenez pas bien les instructions, commu-
niquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire
les Règles de Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagne-
ment et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions
fournies. Vous devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne
fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées
doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il
est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le
Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant.
L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte,
un entretien fautif, des dommages, une réparation incorrecte ou une modication par une personne autre que le
fabricant ou un centre de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION
AVANT D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

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EU DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING SYSTEM
Type designation etc.
CutMaster 40, from serial number 007-XXXXXX
Brand name or trade mark
Thermal Dynamics, an ESAB brand
Manufacturer or his authorised representave
Name, address, telephone No:
OZAS-ESAB Ltd.
ul. A. Struga 10,
45-073 Opole, Poland
Phone: [phone], FAX + 48 77 4019 201.
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 + AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electro-
magnetic compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than
residential.
By signing this document, the undersigned declares as manufacturer, or the manufactur-
er’s authorised representative, that the equipment in question complies with the safety
requirements stated above.
Date Signature Position
10 February, 2020
Flavio Santos General Manager
Accessories and
Adjacencies
2020

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TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION.......................................................... 11
1.01 Notes, Cautions andWarnings .................................................................................11
SECTION 1: INFORMATIONS GÉNÉRALES ................................................... 13
1.01 Remarques, avertissements et mises en garde........................................................ 13
SECTION 2 SYSTEM: INTRODUCTION ......................................................... 15
2.01 HowTo Use This Manual .......................................................................................... 15
2.02 Equipment Identication.........................................................................................15
2.03 Receipt Of Equipment..............................................................................................15
2.04 Power Supply Specications CSA............................................................................. 16
2.04.01 Additional Power Supply Specications 16
2.05 InputWiring Specications CSA............................................................................... 17
2.06 Power Supply Specications CE ...............................................................................18
2.06.01 Additional Power Supply Specications 18
2.07 InputWiring Specications CE.................................................................................18
2.08 Generator Recommendations.................................................................................. 19
2.09 Power Supply Features ............................................................................................19
SECTION 2TORCH: INTRODUCTION ........................................................... 23
2T.01 Scope of Manual......................................................................................................23
2T.02 General Description.................................................................................................23
2T.03 Specications .........................................................................................................23
SECTION 3 SYSTEM: INSTALLATION ........................................................... 25
3.01 Unpacking............................................................................................................... 25
3.02 Lifting Options......................................................................................................... 25
3.03 Gas Connections ......................................................................................................26
3.04 Primary Input Power Connections ...........................................................................27
3.05 Work Lead Connections ...........................................................................................28
SECTION 3 TORCH:
INSTALLATION......................................................................................... 25
3T.01 Torch Connections....................................................................................................25
SECTION 4 SYSTEM: OPERATION ............................................................... 27
4.01 Front Panel Controls / Features................................................................................27
4.02 Preparations for Operation ......................................................................................28
SECTION 4TORCH: OPERATION.................................................................. 31
4T.01 Torch Parts Selection ............................................................................................... 31
4T.02 HandTorch Operation..............................................................................................31
4T.03 Gouging...................................................................................................................35
4T.04 PATENT INFORMATION .............................................................................................37

TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE..................................................................... 39
5.01 General Maintenance ..............................................................................................39
5.02 Maintenance Schedule............................................................................................ 39
5.03 Common Faults........................................................................................................ 40
5.04 Fault Indicator .........................................................................................................41
5.05 BasicTroubleshooting Guide.................................................................................... 42
5.06 Power Supply Basic Parts Replacement ...................................................................44
SECTION 5TORCH: SERVICE ...................................................................... 45
5T.01 General Maintenance ..............................................................................................45
5T.02 Inspection and Replacement of ConsumableTorch Parts.........................................46
SECTION 6: PARTS LISTS ........................................................................... 47
6.01 Introduction ............................................................................................................47
6.02 Ordering Information ..............................................................................................47
6.03 Power Supply System Replacement......................................................................... 47
6.04 Replacement Power Supply Parts............................................................................ 48
6.05 Options and Accessories ..........................................................................................48
6.06 External Replacement Parts ...................................................................................49
6.07 Replacement Parts for SL60 HandTorch .................................................................. 50
6.08 Replacement Parts for SL60QD HandTorch .............................................................51
6.09 Torch Consumable Parts (SL60)................................................................................52
APPENDIX 1: DATA TAG INFORMATION...................................................... 53
APPENDIX 2: TORCH PIN  OUT DIAGRAMS ................................................ 54
APPENDIX 3: TORCH CONNECTION DIAGRAMS ........................................... 55