Victor CUTMASTER User manual

VictorThermalDynamics.com
CUTMASTER®20mm
PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AJ Issue Date: February 14, 2014 Manual No.: 0-5078

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 distribu-
tor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.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, Inc.
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, excel-
lent 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 plasma and 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™ 20mm
SL60 1Torch™
Operating Manual Number 0-5078
Published by:
Victor Technologies, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victortechnologies.com
Copyright 2008, 2009, 2010, 2011, 2012 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: September 26, 2008
Revision Date: February 14, 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................................................................................1-9
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 ..............................................................3-1
3.04 Gas Connections ........................................................................................3-2
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 SL60 Torch Cutting ....................................................4T-9
4T.08 Recommended Cutting Speeds for SL60 Torch With Exposed Tip........4T-10
4T.09 Recommended Cutting Speeds for SL60 Torch With Shielded Tip........4T-12
PATENT INFORMATION.....................................................................................................4T-14
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 (SL60) ................................................................6-7
6.10 Torch Consumable Parts (SL100) ..............................................................6-8
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, 380/400/415V UNITS............................................... A-6
APPENDIX 6: Publication History ....................................................................................... A-8

CUTMASTER 20MM
Manual 0-5078 GENERAL INFORMATION 1-1
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 em-
phasis or is helpful in efficient operation of
the system.
CAUTION
Aprocedure which, if not properly followed,
may cause damage to the equipment.
!
WARNING
Aprocedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
WARNING
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed
in a box such as this.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF
PLASMAARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric
and magnetic emissions that may interfere
with the proper function of cardiac pacemak-
ers, hearing aids, or other electronic health
equipment. Persons who work near plasma
arc cutting applications should consult their
medical health professional and the manufac-
turer 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.
• 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 Mercry
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 in-
formation 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com-
bustible 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.
Wash hands after 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.

CUTMASTER 20MM
GENERAL INFORMATION Manual 0-5078
1-2
• 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, Publica-
tions.
• Disconnectpowersourcebeforeperformingany
service or repairs.
• ReadandfollowalltheinstructionsintheOperat-
ing 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mate-
rial 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 under-
water 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 dis-
sipated. 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pro-
tective 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hel-
met or shield. Also always wear safety glasses
with side shields, goggles or other protective eye
wear.
• Wearweldingglovesandsuitableclothingto
protect your skin from the arc rays and sparks.
• Keephelmetandsafetyglassesingoodcondition.
Replace lenses when cracked, chipped or dirty.
• Protectothersintheworkareafromthearcrays.
Use protective booths, screens or shields.
• Usetheshadeoflensassuggestedinthefollowing
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.
LEAD WARNING
WARNING: This product contains chemicals, includ-
ing 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

CUTMASTER 20MM
Manual 0-5078 INFORMATIONS GÉNÉRALES 1-3
3. NIOSH, SAFETYAND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATIONAND EDUCATIONALEYEAND 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 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, 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 PRO-
CESSES, 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 Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED 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 BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900Arch Street, Philadelphia, PA19103
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERSAND 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 RESPIRA-
TORY 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“aver-
tissement”sontutiliséspourmettreenreliefdesinfor-
mations à caractère important. Ces mises en relief sont
classiéescommesuit:
NOTE
Touteopération,procédureourenseigne-
mentgénéralsurlequelilimported’insister
davantageouquicontribue àl’efcacitéde
fonctionnement du système.
ATTENTION
Touteprocédurepouvantrésulterl’endom-
magementdumatérielencasdenon-respect
delaprocédureenquestion.
!
AVERTISSEMENT
Touteprocédurepouvantprovoquerdesbles-
suresdel’opérateuroudesautrespersonnes
se trouvant dans la zone de travail en cas de
non-respectdelaprocédureenquestion.
AVERTISSEMENT
Fournit l'information concernant des dom-
mages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”cardia-
que,lesappareilsauditif,ouautrematériel

CUTMASTER 20MM
INFORMATIONS GÉNÉRALES Manual 0-5078
1-4
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,compre-
nez et suivez tous les avertissements, toutes
lesprécautionsdesécuritéettouteslesconsi-
gnesavantd’utiliserlematériel.Composezle
+ 603-298-5711 ou votre distributeur local si
vous avez des questions.
FUMÉE et GAZ
Lafuméeetles gazproduitsparleprocédédejetde
plasmapeuvent présenterdesrisquesetdesdangers
desanté.
• Eloigneztoutefuméeetgazdevotrezonederespi-
ration.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.
• 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.
• AVERTISSEMENT: Ce produit contient des produits
chimiques, notamment du plomb, reconnu par l'État
delaCaliforniepourcauserdesmalformationscongé-
nitales 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’opéra-
teur 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endom-
magée.
• 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tra-
vail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ammablenesetrouvesurlelieudetravail.Proté-
gez 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.