Victor 42 CUTMASTER User manual

VictorThermalDynamics.com
Operating
Manual
CUTMASTER®42
PLASMA CUTTING SYSTEM
Révision : AJ Issue Date: Oct. 18, 2013 Manual No.: 0-5141
40 230V
120V

!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
Cutmaster®42
SL40 Torch™
Operating Manual Number 0-5141
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victorthermaldynamics.com
Copyright 2010, 2011, 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.
Publication Date: October 15, 2010
Revision Date: October 18, 2013
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ____________
Purchase Date:______________________________________________
Power Supply Serial #:________________________________________
Torch Serial #:___________________________________ ___________
i
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 Pre-
cautions. 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, 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 welding industry.

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.............................................................................................................. 1-3
1.04 Note, Attention et Avertissement.............................................................................. 1-4
1.05 Precautions De Securite Importantes....................................................................... 1-4
1.06 Documents De Reference......................................................................................... 1-6
Declaration of Conformity......................................................................................... 1-7
1.07 Statement of Warranty ............................................................................................. 1-8
SECTION 2 SYSTEM: INTRODUCTION ............................................................................2-1
2.01 Working Principle..................................................................................................... 2-1
2.02 Power Supply Specifications.................................................................................... 2-1
2.03 Input Wiring Specifications ...................................................................................... 2-2
2.04 Power Supply Features............................................................................................. 2-3
SECTION 2 TORCH: INTRODUCTION ............................................................................ 2T-1
2T.01 Scope of Manual..................................................................................................... 2T-1
2T.02 Specifications ........................................................................................................ 2T-1
2T.03 Introduction to Plasma........................................................................................... 2T-2
SECTION 3: INSTALLATION .........................................................................................3-1
3.01 Unpacking ................................................................................................................ 3-1
3.02 Lifting Options.......................................................................................................... 3-1
3.03 Primary Input Power Connections............................................................................ 3-2
3.04 Air Supply Connections............................................................................................ 3-3
SECTION 4 SYSTEM: OPERATION..................................................................................4-1
4.01 Control Panel............................................................................................................ 4-1
4.02 Preparations For Operating....................................................................................... 4-2
4.03 Sequence of Operation ............................................................................................. 4-5
4.04 Cut Quality................................................................................................................ 4-7
4.05 General Cutting Information ..................................................................................... 4-7
SECTION 5 SYSTEM: SERVICE.....................................................................................5-1
5.01 General Maintenance................................................................................................ 5-1
5.02 Basic Troubleshooting Guide.................................................................................... 5-2
SECTION 5 TORCH: SERVICE ..................................................................................... 5T-1
5T.01 General Maintenance.............................................................................................. 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts....................................... 5T-1
SECTION 6: PARTS LISTS ...........................................................................................6-1
6.01 Introduction.............................................................................................................. 6-1
6.02 Power Supply Replacement Parts ............................................................................ 6-2
6.03 SL40 Torch Replacement Parts ................................................................................ 6-3
6.04 Optional Accessories................................................................................................ 6-4
APPENDIX 1: CUTMASTER 42 CIRCUIT DIAGRAM ..............................................................A-1
APPENDIX 2: SL40 TORCH PIN-OUT DIAGRAM..................................................................A-2

Manual 0-5141 1-1 GENERAL INFORMATION
CUTMASTER 42
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 efcient operation of
the system.
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC 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
pacemakers, hearing aids, or other elec-
tronic health equipment. Persons who work
near plasma arc cutting applications should
consult their medical health professional
and the manufacturer of the health equip-
ment 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 Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• AlwaysreadtheMaterialSafetyDataSheets(MSDS)that
should be supplied with the material you are using. These
MSDSs will give you the information regarding the kind
and amount of fumes and gases that may be dangerous
to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Usespecialequipment,suchaswaterordowndraftcut-
ting 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.
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 en-
ergy can cause severe or fatal shock to the operator or others
in the workplace.
• Nevertouchanypartsthatareelectrically“live”or“hot.”
• Weardryglovesandclothing.Insulateyourselffromthe
work piece or other parts of the welding circuit.
• Repairorreplaceallwornordamagedparts.

GENERAL INFORMATION 1-2 Manual 0-5141 Manual 0-5141 1-3 GENERAL INFORMATION
CUTMASTER 42 CUTMASTER 42
• 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re
hazards may exist.
• Hydrogengas maybe formed and trapped underalu-
minum 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protec-
tive 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 infrared
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.Re-
place 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chart.
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 lters may be used when the arc is
hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions for
more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtain-
able from the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, ob-
tainable 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
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
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, Bat-
terymarch 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 HAZ-
ARDOUS SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTEC-
TION, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
AWS F2.2:2001 (R2010), Adapted with permission of the American Welding Society (AWS), Miami, Florida
Guide for Shade Numbers
(from AWS F2.2, Lens Shade Selector)
Shade numbers are given as a guide only and may be varied to suit individual needs.
Process Electrode Size in. (mm) Arc Current (Amperes)
Minimum
Protective
Shade
Suggested*
Shade No.
(Comfort)
Shielded Metal Arc Welding (SMAW)
Less than 3/32 (2.4)
3/32-5/32 (2.4-4.0)
5/32-1/4 (4.0-6.4)
More than 1/4 (6.4)
Less than 60
60-160
160-250
250-550
7
8
10
11
-
10
12
14
Gas Metal Arc Weding (GMAW) and
Flux Cored Arc Welding (FCAW)
Less than 60
60-160
160-250
250-550
7
10
10
10
-
11
12
14
Gas Tungsten arc Welding (GTAW) Less than 50
50-150
150-500
8
8
10
10
12
14
Air Carbon Arc Cutting (CAC-A) (Light)
(Heavy) Less than 500 500-1000 10 11 12 14
Plasma Arc Welding (PAW)
Less than 20
20-100
100-400
400-800
6
8
10
11
6 to 8
10
12
14
Plasma Arc Cutting (PAC)
Less than 20
20-40
40-60
60-80
80-300
300-400
400-800
4
5
6
8
8
9
10
4
5
6
8
9
12
14
* As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade
which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding,
cutting,orbrazingwherethetorchand/ortheuxproducesahighyellowlight,itisdesirabletousea
filter lens that absorbs the yellow or sodium line of the visible light spectrum.
Table 1-1

GENERAL INFORMATION 1-4 Manual 0-5141 Manual 0-5141 1-5 GENERAL INFORMATION
CUTMASTER 42 CUTMASTER 42
Classification: The equipment described in this manual is Class A and intended for industrial use.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided
by the public low-voltage supply system. There may be potential difculties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
1.04 Note, Attention et Avertissement
Danscemanuel,lesmots“note,”“attention,”et“avertisse-
ment”sontutiliséspourmettreenreliefdesinformations
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-res-
pect 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.
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
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 maté-
riel 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respiration.
Gardezvotretêtehorsdelaplumedefuméeprovenantdu
chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si
l’aérationfournienepermetpasd’éliminerlafuméeetles
gaz.
• 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pro-
venantdessolvantsetdesproduitsdenettoyagechlorés.
Elimineztoutesourcedetellefumée.
• AVERTISSEMENT : Ce produitcontient des produits
chimiques, notamment du plomb, reconnu par l'Étatde la
Californie pour causerdes malformations congénitaleset
d'autresdommages touchant le système reproductif.
Se
laver les mainsaprès manipulation.
CHOC ELECTRIQUE
Leschocsélectriquespeuventblesseroumêmetuer.Lepro-
cédéaujetdeplasmarequiertetproduitdel’énergieélectri-
quehautetension.Cetteénergieélectriquepeutproduiredes
chocsgraves,voiremortels,pourl’opérateuretlesautres
personnes sur le lieu de travail.
• Netouchezjamaisunepièce“soustension”ou“vive”;portez
des gants et des vêtements secs. Isolez-vous de la pièce
de travail ou des autres parties du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendommagée.
• Prenezdessoinsparticulierslorsquelazonedetravailest
humide ou moite.
• Montezet maintenezle matérielconformément auCode
électriquenationaldesEtats-Unis.(Voirlapage5,article
9.)
• Débranchez l’alimentation électrique avant tout travail
d’entretienouderéparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
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am-
mable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am-
mables 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dissi-
per.Legashydrogèneaccumuléexploserasienammé.
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accepta-
bles.Vousdú4ezvousprotégerlesoreillescontrelesbruits
fortsan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.

GENERAL INFORMATION 1-6 Manual 0-5141 Manual 0-5141 1-7 GENERAL INFORMATION
CUTMASTER 42 CUTMASTER 42
This page left blank intentionally.
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pro-
duit 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sécu-
ritémuniesdeparoislatéralesoudeslunettesdeprotec-
tion ou une autre sorte de protection oculaire.
• Portezdesgantsdesoudeuretunvêtementprotecteurappro-
prié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 recom-
mendation 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 ltres moins foncés peuvent être utilisés
quand l’arc est caché par moiceau de travail.
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ren-
seignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTEC-
TION DE LA SANTÉ, 29CFR 1910, disponible auprès du Supe-
rintendent 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(Ame-
rican National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO-
TECTRICES, 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, dispo-
nible 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 Ame-
rican 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 ALIMEN-
TATION 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, dispo-
nible auprès de la National Fire Protection Association, Batte-
rymarch Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOU-
DAGE, disponible auprès de la National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
desGazComprimés(CompressedGasAssociation),1235Jef-
ferson 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 SOUDA-
GE, 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 PRÉ-
PARATION 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 RESPIRA-
TOIRE, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-8 Manual 0-5141 Manual 0-5141 1-9 GENERAL INFORMATION
CUTMASTER 42 CUTMASTER 42
Manufacturer: Victor Technologies LTD (Formerly Thermadyne Corporation)
Address: Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Type of Equipment: Plasma Cutter
Model /Number: CUTMASTER 42
Serial Number: Serial numbers are unique with each individual piece of equipment and details description, parts
used to manufacture a unit and date of manufacture.
Market Release Date: 10-10-2013
Classification: The equipment described in this manual is Class A and intended for industrial use.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided
by the public low-voltage supply system. There may be potential difculties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
HarmonizedStandardof“EMCDirective”
EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements
HarmonizedStandardof“LowVoltageDirective”
EN 60974-1:2005 Arc Welding Equipment - Part 1: Welding power sources. (Superseded by Standard EN 60974-1:2012)
Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing
process. This is to ensure the product is safe, when used according to instructions in this manual and related industry stan-
dards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured
product meets or exceeds all design specifications.
Victor Technologies International Inc. has been manufacturing products for more than 30 years, and will continue to achieve
excellence in our area of manufacture.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address: Victor Technologies LTD (Formerly Thermadyne Corporation)
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: 10-10-2013
Steve Ward
Full Name
V.P. Europe and General Manager
(Position)
(Signature)
Declaration of Conformity
Application of Council Directive(s): The equipment described in this manual conforms to all applicable
aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 2006/95/EC) and to
the National legislation for the enforcement of this Directive.
Theequipmentdescribedinthismanualconformstoallapplicableaspectsandregulationsofthe“EMC
Directive”(EuropeanCouncilDirective2004/108/EC)andtotheNationallegislationfortheenforcement
of this Directive.
1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies warrants to the original retail
purchaser that new Thermal Dynamics CUTMASTER®plasma cutting systems sold after the effective date of this warranty are
free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period
stated below, Victor Technologies shall, upon notification thereof and substantiation that the product has been stored operated
and maintained in accordance with Victor Technologies’s 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 Technologies 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 must be notified within 30 days of any
failure, at which time Victor Technologies will provide instructions on the warranty procedures to be implemented.
Victor Technologies 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 Technologies
Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER 42 4 Year 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:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Victor Technologies.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Victor Technologies 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 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 Technologies 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
Technologies 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 Technologies product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective October 15, 2010

GENERAL INFORMATION 1-10 Manual 0-5141
CUTMASTER 42
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CUTMASTER 42
Manual 0-5141 2-1 INTRODUCTION
SECTION 2 SYSTEM: INTRODUCTION
2.01 Working Principle
Rectifier Inverter Transformer Rectifier
Reduce pressure, filter Gas valve Cutting torch Workpiece
Compressed air
Art # A-09204_AB
2.02 Power Supply Specifications
CUTMASTER 42 Power Supply Specifications
Input Power 120 VAC (+-10%), 1Phase, 50/60Hz
208-230 VAC (+-10%), 1Phase, 50/60Hz
Output Current 20 Amps @ 120VAC, 15A
20-27 Amps @ 120VAC, 20A
20-40 Amps @ 230VAC, 20A
CUTMASTER 42 Power Supply Duty Cycle (Note 1)
Ambient Temperature 104° F (40° C)
Duty Cycle 30% @ 120VAC, 40% @ 230VAC
Rated Current 27 Amps @ 120VAC, 40 Amps @ 230V
SL40 Torch Gas Requirements (see section 2T.03)
Notes
1. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is re-
duced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.
2. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause
double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting perfor-
mance and rapid electrode wear. Optional filters provide increased filtering capabilities.
NOTE
IEC Rating is determined as specied by the International Electro-Technical Commission. These
specications 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.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting
with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch,
consumables, and actual cutting operation.

CUTMASTER 42
CUTMASTER 42
INTRODUCTION 2-2 Manual 0-5141 Manual 0-5141 2-3 INTRODUCTION
Art# A-09333_AC
26lb / 11.8kg
7" (177mm)
18.5" (469.9mm)
9" (228.6mm)
CUTMASTER
®
42
120V 15A
120V 20A
230V 20A
A
24
40
20
20
30
27
Figure 2-1: Power Supply Dimensions & Weight
NOTE
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
Provide clearance for proper air ow through the power supply. Operation without proper air ow will
inhibit proper cooling and reduce duty cycle.
2.03 Input Wiring Specifications
CUTMASTER 42 Input Power Requirements
Input Power Input Current Input Current Input Suggested Sizes (See Note)
Voltage Freq. (kVA) Max (Amps) Ieff (Amps) Fuse (Amps)
(Volts-AC) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph
120 50/60 3.3 27.5 15 25
208 50/60 5.0 24 15.4 23
230 50/60 5.0 21.4 13.5 20
240 50/60 5.0 20.8 13 20
Line Voltages with Suggested Circuit Protection
Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation
in this regard.
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is 167° F (75° C).
2.04 Power Supply Features
Air Inlet
Control Panel
Torch Lead
120/230 VAC Power Source
Work Cable and Clamp
Art # A-09334_AC
CUTMASTER
®
42
120V 15A
120V 20A
230V 20A
A
24
40
20
20
30
27
Art# A-09335
Air Inlet
On/Off
Switch
Power Cord

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Manual 0-5141 2T-1 INTRODUCTION
CUTMASTER 42
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instructions and
maintenance procedures for the SL40 Plasma Cutting Torch.
Service of this equipment is restricted to properly trained
personnel;unqualiedpersonnelarestrictlycautionedagainst
attempting repairs or adjustments not covered in this manual,
at the risk of voiding the Warranty. Read this manual thoroughly.
A complete understanding of the characteristics and capabili-
ties of this equipment will assure the dependable operation for
which it was designed.
2T.02 Specifications
A. Torch Configurations
1. Hand Torch, Model SL40
The hand torch head is at 75° to the torch handle. The
hand torches include a torch handle and torch trigger
assembly.
8.3" (210.82mm)
2.6"
(66.04mm)
.96" (24.38mm)
Art # A-09336
B. Torch Leads Lengths
Hand Torches are available as follows:
• 15ft/4.6m.
C. Torch Parts (see Section 6.03)
Starter Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
Torch has built-in switch.
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through torch.
F. Torch Ratings
SL40 Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 40 Amps @ 193 scfh
Maximum Current 40 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 500V
Torch Control Circuit
Voltage 24V
G. Current Ratings
SL40 Current Ratings
SL40 Torch & Leads Up to 40 Amps, DC,
Straight Polarity
NOTE
Power Supply characteristics will determine
material thickness range.
H. Gas Requirements
SL40 Torch Gas Specifications
Gas (Plasma and Secondary) Compressed Air
Minimum Input Pressure 85 psi
5.9 bar
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow 193 scfh
91 lpm
!
WARNING
This torch is not to be used with oxygen
(O
2
). This torch is not to be used with high
frequency starting systems.

CUTMASTER 42
INTRODUCTION 2T-2 Manual 0-5141
2T.03 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
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.
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
Workpiece
Power
Supply
+
_
C
B
A
Typical Torch Head Detail
B. Gas Distribution
The single gas used is internally split into plasma and
secondary gases.
Theplasmagasowsintothetorchthroughthenegative
lead, through the starter cartridge, around the electrode,
and out through the tip orifice.
Thesecondarygasows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 nega-
tive 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.
Torch Trigger
PIP Switch Shield Cup
To Control
Cable Wiring
Torch Switch
Art# A-09595_AB
Parts - In - Place Circuit Diagram for Hand Torch

CUTMASTER 42
Manual 0-5141 3-1 INSTALLATION
SECTION 3: INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
A. Contents List
Description Quantity
CM42 Power source 1
10ft power input cable (installed) 1
120VAC Adapter Pigtail 15A 1
120VAC Adapter Pigtail 20A 1
Work cable and clamp (installed) 1
SL40 Torch (15ft(4.6m)) w/consumables 1
Carry case 1
40A Tip Drag 2
20A Tip Drag 2
40A Tip, Standoff 2
Electrode 2
Gloves 1
Cutting Glasses 1
1/4" Pipe Size NPT female × BSPT male adapter 1
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handle,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.

CUTMASTER 42 CUTMASTER 42
INSTALLATION 3-2 Manual 0-5141 Manual 0-5141 3-3 INSTALLATION
3.03 Primary Input Power Connections
Power Cords Included With Power Supply
Attached to the power supply is an input power cord with a 230 Volt 50 Amp NEMA 6-50P for plug. Supplied adapters allow for
connection of the power supply input cable plug when using 120V input power.
Art# A-09432_AB
Figure 3-1: 120VAC Adapter Pigtail
CAUTION
Check your power source for correct voltage 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 rec-
ommended circuit protection and wiring requirements as specied in Section 2.
Input Voltage (VAC) Rated Output Amps (RMS) input at rated
output, 60 Hz, single-phase kVA
120V, 15A Circuit 20A, 88V 20.4 2.5
120V, 20A Circuit 27A, 91V 28.5 3.5
120V, 30A Circuit 27A, 91V 28.5 3.5
208-230V, 20A Circuit 40A, 96V 23-21.4 4.8
3.04 Air Supply Connections
A. Connecting Air Supply to Unit
The connection is the same for compressed air or industrial compressed air in gas cylinders.
1. Connect the gas line to the compressed air inlet port at the appropriate pressure.
Art# A-09337
Air Inlet
On/Off
Switch
Figure 3-2: Gas Connection to Compressed Air input
B. Using Industrial Compressed Air In Gas Cylinders
When using Industrial compressed air in gas cylinders as the gas supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators.
2. Examinethecylindervalvestobesuretheyarecleanandfreeofoil,greaseoranyforeignmaterial.Brieyopeneach
cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi
(6.9bar)maximumandowsofatleast250scfh(120lpm).
4. Connect gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the tting threads, according to manufacturer's instructions.
Do Not use Teon tape as a thread sealer, as small particles of the tape may break off and block the
small gas passages in the torch.

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CUTMASTER 42
Manual 0-5141 4-1 OPERATION
SECTION 4 SYSTEM: OPERATION
4.01 Control Panel
Art# A-09338-AD
CUTMASTER
®
42
AC Indicator
The Front Panel The Rear Panel
Overheat Indicator
Air Indicator
DC Indicator (Ready)
Air Inlet
On/Off
Switch
Power Cord
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
1. ON / OFF Switch (Power Switch/Lamp)
Controls input power to the power supply. I is ON (Red Lamp), O is OFF.
2. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit opens
frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate input power. Note:
For 120V input power, the unit will automatically limit the output current to a maximum of 27A. For 230V input power, the
maximum output is 40 Amps. Refer to Section 2 for input power requirements.
3. AC Indicator
Steady light indicates power supply is ready for operation.
4. OVERHEAT Indicator (TEMP Indicator)
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Allow the unit to run with the
fan on until the temp indicator turns off.
5. AIR Indicator
AIR light should be ON when there is sufficient gas pressure.
6. READY (DC Indicator)
Indicator is ON when DC output circuit is active.
NOTE
All consumables must be correctly installed and maintained to ensure correct operation.

CUTMASTER 42 CUTMASTER 42
OPERATION 4-2 Manual 0-5141 Manual 0-5141 4-3 OPERATION
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts,
or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of opera-
tion, and with the amperage output of this power supply (40 amps maximum). Use only genuine Thermal Dynamics parts
with this torch.
Art # A-09340-AG
Start Cartridge,
Cat. No. 9-0097
Electrode, Cat. No. 9-0096
Worn Electrode Worn Tip
40 Amp Drag Tip, Cat. No. 9-0093
Shield Cup, Cat. No. 9-0098
40 Amp
Standoff Tip,
Cat. No. 9-0094
NOTE
For 115VAC, 20A Drag Cutting Tip (Cat.No. 9-0091) shall be used (refer to 6.03 SL40 Replacement
Parts).
NOTE
When operating the torch in a normal condition, some gas vents through the gap between the shield
cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal
components may result.
B. Torch Connection
Check that the torch is properly connected.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for
the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure gas source meets requirements listed in section 2T. Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the
mainpartoftheworkpiece;donotconnecttotheparttobecutoff.
Art # A-03387
F. Power On
Place the power supply ON / OFF switch to the ON (I) position. Power indicator turns on.
Art# A-09335
Air Inlet
On/Off
Switch
Power Cord
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
Art# A-09339_AD
Rear Panel with ON/OFF Switch Front Panel With Power ON/OFF Indicator

CUTMASTER 42 CUTMASTER 42
OPERATION 4-4 Manual 0-5141 Manual 0-5141 4-5 OPERATION
G. Select Current Output Level
Set the desired current output level.
A
120V 15A
120V 20A
230V 20A
24
40
20
20
30
27
120V, 15A
24
40
20
20
30
27
2
4
40
4
40
20
20
30
7
27
7
0
0
230V, 20A
24
20
27
24
20
7
27
40
20
30
A
4
30
120V, 20A
40
20
30
30
30
30
A
24
40
4
40
20
20
7
27
7
A
24
2
A
4
2
2
0
40
20
3
0
24
20
A
AA
27
A#09697_AA
4.03 Sequence of Operation
The following is a typical sequence of operation for this
power supply.
1. Place the ON / OFF switch on the power supply to ON
(up) position (Red indicator lamp is illuminated).
a. AC indicator turnson;fanturnson.
NOTE
During initial power up, there will be a delay
of about 2 seconds before the AC Indicator
light will illuminate and the pre-ow gas and
fan starts. The gas will automatically ow
from torch for approximately 10 seconds
(only after the AC Indicator lamp is illu-
minated) (The AC Indicator lamp and fan
turns on approximately 2 seconds after the
ON/OFF switch is enabled), this is a pro-
cess that makes sure all inputs (gas, input
power, torch connection, and torch parts)
are acknowledged for proper operation.
2. Wear protective clothing, including welding gloves and
appropriate eye protection (see table 1-1). Place tip on
work piece and pull trigger. Arc will initiate and start
cutting material.
Standoff Cutting With Hand Torch
NOTE
For best performance and parts life, always
use the correct parts for the type of opera-
tion.
A. The torch can be comfortably held in one hand
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.
NOTE
The tip should never come in contact with
the workpiece except during drag cutting
operations.
B. Depending on the cutting operation, do one of the
following:
a) For drag cutting, place the tip on the plate
holding the torch at a angle to the plate so that
only one edge of the tip is in contact with the
plate. This prevents damage to the tip during
the piercing process.
b) For standoff cutting, hold the torch tip on the
work piece, pull the trigger. After the arc is
initiated lift the tip to 1/8" - 3/8" (3-4mm) off
the work.
A-00024_AB
Shield Cup
Torch
Standoff Distance
1/8" - 3/8" (3 - 9mm)
Standoff Distance
Art # A-09342
Trigger
Trigger Release
3
4
Trigger
2
1
Trigger Release
Art # A-11462
NOTE
When the shield cup is properly installed,
there is a slight gap between the shield cup
and the torch handle. Gas vents through
this gap as part of normal operation. Do
not attempt to force the shield cup to close
this gap. Forcing the shield cup against
the torch head or torch handle can damage
components.