Victor CUTMASTER 102 User manual

100
208/230V
460V 600V
400V
VictorThermalDynamics.com
Art # A-08618_AD
Service
Manual
Revision: AM Issue Date: September 4, 2014 Manual No.: 0-4998
CUTMASTER™102
PLASMA CUTTING SYSTEM

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 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.

!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster® 102
SL100 1Torch™
Service Manual Number 0-4998
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2008, 2009, 2010, 2012, 2013 by
Victor Technologies International, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher 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: September 25, 2008
Revision Date: September 4, 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 ..........................................................................1-5
1.07 Statement of Warranty................................................................................1-6
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-1
4T.03 General Cutting Information......................................................................4T-2
4T.04 Hand Torch Operation ..............................................................................4T-3
4T.05 Gouging ....................................................................................................4T-5
4T.06 Mechanized Torch Operation ...................................................................4T-6
4T.07 Parts Selection for Manual and Mechanized Torch Cutting......................4T-8
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip4T-9
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip4T-11
PATENT INFORMATION...............................................................................................................4T-14

TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE......................................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Maintenance Schedule ...............................................................................5-2
5.03 Common Faults ..........................................................................................5-2
5.04 Fault Indicator .............................................................................................5-3
5.05 Basic Troubleshooting Guide......................................................................5-5
5.06 Circuit Fault Isolation ..................................................................................5-7
5.07 Main Input and Internal Power Problems..................................................5-10
5.08 Pilot Arc Problems ....................................................................................5-15
5.09 Main Arc and Controls Problems ..............................................................5-19
5.10 CNC Interface Problems...........................................................................5-20
5.11 Test Procedures .......................................................................................5-20
SECTION 5 TORCH: SERVICE......................................................................................................5T-1
5T.01 General Maintenance ...............................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts .......................5T-2
SECTION 6: PARTS LISTS ..............................................................................................................6-1
6.01 Introduction .................................................................................................6-1
6.02 Ordering Information...................................................................................6-1
6.03 Power Supply Replacement .......................................................................6-1
6.04 Major External Replacement Parts .............................................................6-2
6.05 Front Panel Replacement Parts..................................................................6-3
6.06 Left Side Replacement Parts .....................................................................6-4
6.07 Right Side Replacement Parts ...................................................................6-5
6.08 Options and Accessories ............................................................................6-6
6.09 Replacement Parts for Hand Torch ...........................................................6-7
6.10 Replacement Parts - for Machine Torches with Unshielded Leads ............6-8
6.11 Torch Consumable Parts (SL100 SV) ......................................................6-10
SECTION 7: REPLACEMENT PROCEDURES ...............................................................................7-1
7.01 Scope..........................................................................................................7-1
7.02 Anti-Static Handling Procedures.................................................................7-1
7.03 Parts Replacement - General Information ..................................................7-1
7.04 Major External Parts ..................................................................................7-1
7.05 Front Panel Parts Replacement..................................................................7-2
7.06 Left Side Internal Parts Replacement .........................................................7-4
7.07 Rear Panel Parts Replacement ..................................................................7-6
7.08 Right Side Internal Parts Replacement.......................................................7-8
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, 208/460V UNITS................................................................ A-6
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS....................................................................... A-8
APPENDIX 7: PUBLICATION HISTORY ....................................................................................... A-10

CUTMASTER 102
Manual 0-4998 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 informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the op-
erating area.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARD-
OUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons
who work near plasma arc cutting applications
should consult their medical health professional
and the manufacturer of the health equipment to
determine whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions and
instructions before using the equipment. Call
1-603-298-5711 or your local distributor if you
have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process
can be dangerous and hazardous to your health.
• Keepallfumesandgasesfromthebreathingarea.Keep
your head out of the welding fume plume.
• Useanair-suppliedrespiratorifventilationisnotadequate
to remove all fumes and gases.
• Thekindsoffumesandgasesfromtheplasmaarcdepend
on the kind of metal being used, coatings on the metal,
and the different processes. You must be very careful
when cutting or welding any metals which may contain
one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• AlwaysreadtheMaterialSafetyDataSheets(MSDS)that
should be supplied with the material you are using. These
MSDSs will give you the information regarding the kind
and amount of fumes and gases that may be dangerous
to your health.
• Forinformationonhowtotestforfumesandgases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Usespecialequipment,suchaswater ordowndraft
cutting tables, to capture fumes and gases.
• Donotusetheplasmatorchinanareawherecombustible
or explosive gases or materials are located.
• Phosgene,atoxicgas,isgeneratedfromthevaporsof
chlorinated solvents and cleansers. Remove all sources
of these vapors.
• 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.
• Extracaremustbetakenwhentheworkplaceismoistor
damp.

CUTMASTER 102
GENERAL INFORMATION Manual 0-4998
1-2
• 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 infra
red light. These arc rays will damage your eyes and burn your
skin if you are not properly protected.
• Toprotectyoureyes,alwayswearaweldinghelmetor
shield. Also always wear safety glasses with side shields,
goggles or other protective eye wear.
• Wearweldingglovesandsuitableclothingtoprotectyour
skin from the arc rays and sparks.
• Keephelmetandsafetyglassesingoodcondition.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per
ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
!
WARNING
WARNING: This product contains chemicals, including lead,
known to the State of California to cause birth defects and other
reproductive harm. Wash hands after handling.
1.03 Publications
Refer to the following standards or their latest revisions for
more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainablefromtheSuperintendentof Documents,U.S.
GovernmentPrintingOfce,Washington,D.C.20402
2. ANSIStandardZ49.1,SAFETYINWELDINGANDCUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
3. NIOSH,SAFETYANDHEALTHINARCWELDINGANDGAS
WELDINGANDCUTTING,obtainablefromtheSuperintendent
ofDocuments,U.S.GovernmentPrintingOfce,Washington,
D.C. 20402
4. ANSIStandardZ87.1,SAFEPRACTICESFOROCCUPATION
ANDEDUCATIONALEYEANDFACEPROTECTION,obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
8. NFPA Standard 51, OXYGEN-FUELGASSYSTEMSFOR
WELDING,CUTTINGANDALLIEDPROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

CUTMASTER 102
Manual 0-4998 INFORMATIONS GÉNÉRALES 1-3
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 Associa-
tion,1235JeffersonDavisHighway,Suite501,Arlington,VA
22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND
CUTTING,obtainablefromtheCanadianStandardsAssociation,
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W 1R3
13.NWSAbooklet,WELDINGSAFETYBIBLIOGRAPHYobtainable
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED
SAFEPRACTICESFORTHEPREPARATIONFORWELDINGAND
CUTTINGOFCONTAINERSAND PIPINGTHATHAVEHELD
HAZARDOUSSUBSTANCES,obtainablefromtheAmerican
Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTEC-
TION, obtainable from American National Standards Institute,
1430 Broadway, New York, NY 10018
1.04 Note, Attention et Avertissement
Danscemanuel,lesmots“note,”“attention,”et“avertissement”
sont utilisés pour mettre en relief des informations à caractère
important.Cesmisesenreliefsontclassiéescommesuit:
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter l’endomma-
gement du matériel en cas de non-respect de la
procédure en question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
AVERTISSEMENT
Fournit l'information concernant des dommages
possibles de choc électrique. Des avertissements
seront enfermés dans une boîte de ce type.
1.05 Precautions De Securite
Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉ-
RIEL 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 magné-
tique qui peuvent interférer la fonction propre d’un
“pacemaker” cardiaque, les appareils auditif, ou
autre matériel de santé electronique. Ceux qui tra-
vail 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 bles-
sures possibles, lisez, comprenez et suivez tous les
avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma
peuventprésenterdesrisquesetdesdangersdesanté.
• 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.

CUTMASTER 102
INFORMATIONS GÉNÉRALES Manual 0-4998
1-4
• 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.
• Ceproduitcontientdesproduitschimiques,notamment
du plomb, reconnu par l'État de la Californie pour causer
des malformations congénitales et d'autres dommages
touchant le système reproductif. Se laver les mains après
manipulation.
CHOC ELECTRIQUE
Leschocsélectriquespeuventblesseroumêmetuer.Lepro-
cédéaujetdeplasmarequiertetproduitdel’énergieélectrique
hautetension.Cetteénergieélectriquepeutproduiredeschocs
graves, voire mortels, pour l’opérateur et les autres personnes
sur le lieu de travail.
• Netouchezjamaisunepièce“soustension”ou“vive”;portez
des gants et des vêtements secs. Isolez-vous de la pièce
de travail ou des autres parties du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendommagée.
• Prenezdessoinsparticulierslorsquelazonedetravailest
humide ou moite.
• MontezetmaintenezlematérielconformémentauCode
électriquenationaldesEtats-Unis.(Voirlapage5, article
9.)
• Débranchezl’alimentationélectriqueavanttouttravail
d’entretien ou de réparation.
• LisezetrespecteztouteslesconsignesduManueldeconsi-
gnes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé à
l’arc de plasma produit du métal, des étincelles, des scories
chaudes pouvant mettre le feu aux matières combustibles ou
provoquerl’explosiondefuméesinammables.
• Soyezcertainqu’aucunematièrecombustibleouinamma-
ble ne se trouve sur le lieu de travail. Protégez toute telle
matièrequ’ilestimpossiblederetirerdelazonedetravail.
• Procurezunebonneaérationdetouteslesfuméesin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 dissiper. Le gas
hydrogèneaccumuléexploserasienammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos
yeux et brûler votre peau. Le procédé à l’arc de plasma produit
une lumière infra-rouge et des rayons ultra-violets très forts.
Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si
vous ne vous protégez pas correctement.
• Pourprotégervosyeux,porteztoujoursuncasqueouun
écran de soudeur. Portez toujours des lunettes de sécurité
munies de parois latérales ou des lunettes de protection ou
une autre sorte de protection oculaire.
• Portezdesgantsdesoudeuretunvêtementprotecteur
approprié pour protéger votre peau contre les étincelles et
les rayons de l’arc.
• Maintenezvotrecasqueetvoslunettesdeprotectionenbon
état.Remplaceztoutelentillesaleoucomportantssure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:

CUTMASTER 102
Manual 0-4998 INFORMATIONS GÉNÉRALES 1-5
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
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 dúez 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.
!
AVERTISSEMENT
AVERTISSEMENT :Ceproduitcontientdesproduitschimiques,
notamment du plomb, reconnu par l'État de la Californie pour
causer des malformations congénitales et d'autres dommages
touchant le système reproductif. Se laver les mains après
manipulation.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes
ayant été faites à celles-ci pour de plus amples renseignements :
1. OSHA,NORMESDESÉCURITÉDUTRAVAILETDEPRO-
TECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du
SuperintendentofDocuments,U.S.GovernmentPrinting
Ofce,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Ofce,Washington,D.C.20402
4. NormeANSIZ87.1, PRATIQUESSURESPOURLA PRO-
TECTIONDESYEUXETDUVISAGEAUTRAVAILETDANS
LES ECOLES, disponible de l’Institut Américain des Normes
Nationales(AmericanNationalStandardsInstitute),1430
Broadway, New York, NY 10018
5. NormeANSIZ41.1,NORMESPOURLESCHAUSSURES
PROTECTRICES, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS
DEL’EMPLOIDEPROCÉDÉSDECOUPEETDESOUDAGE,
disponible auprès de l’American National Standards Institute,
1430 Broadway, New York, NY 10018
7. NormeA6.0del’AssociationAméricaineduSoudage(AWS),
LESOUDAGEET LACOUPEDE CONTENEURSAYANT
RENFERMÉDESPRODUITSCOMBUSTIBLES,disponible
auprès de la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection
contrelesIncendies(NFPA),LESSYSTEMESÀGAZAVEC
ALIMENTATIONENOXYGENEPOURLESOUDAGE,LA
COUPEETLESPROCÉDÉSASSOCIÉS,disponibleauprèsde
la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
9. Norme70delaNFPA,CODEELECTRIQUENATIONAL,dis-
ponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
10.Norme51BdelaNFPA,LESPROCÉDÉSDECOUPEETDE
SOUDAGE,disponibleauprèsdelaNationalFireProtection
Association, Batterymarch Park, Quincy, MA 02269
11.BrochureGCAP-1,LAMANIPULATIONSANSRISQUEDES
GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de
l’AssociationdesGazComprimés(CompressedGasAsso-
ciation),1235JeffersonDavisHighway,Suite501,Arlington,
VA 22202
12.NormeCSAW117.2,CODEDESÉCURITÉPOURLESOU-
DAGEETLACOUPE,disponibleauprèsdel’Association
des Normes Canadiennes, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada, M9W 1R3
13.LivretNWSA,BIBLIOGRAPHIE SURLASÉCURITÉDU
SOUDAGE,disponibleauprèsdel’AssociationNationalede
FournituresdeSoudage(NationalWeldingSupplyAssocia-
tion),1900ArchStreet,Philadelphia,PA19103
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONSDEPRATIQUESSURESPOURLA
PRÉPARATIONÀLACOUPEETAUSOUDAGEDECONTE-
NEURS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

CUTMASTER 102
GENERAL INFORMATION Manual 0-4998
1-6
1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Thermal Dynamics® Corporation warrants to the original
retailpurchaserthatnewVictorThermalDynamicsCUTMASTER®plasma cutting systems sold after the effective date of this warranty are free
of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Victor
ThermalDynamicsCorporationshall,uponnoticationthereofandsubstantiationthattheproducthasbeenstoredoperatedandmaintained
inaccordancewithVictorThermalDynamics’specications,instructions,recommendationsandrecognizedindustrypractice,correctsuch
defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Victor Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanshipwithinthetimeperiodssetoutbelow.VictorThermalDynamicsCorporationmustbenotiedwithin30daysofanyfailure,at
which time Victor Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Victor Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods
begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Victor Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER®39 4 Years 1 Year
CUTMASTER®52 4 Years 1 Year
CUTMASTER®82 4 Years 1 Year
CUTMASTER®102 4 Years 1 Year
CUTMASTER®152 4 Years 1 Year
This warranty does not apply to:
1. ConsumableParts,suchastips,electrodes,shieldcups,o-rings,startercartridges,gasdistributors,fuses,lters.
2. Equipmentthathasbeenmodied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 Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Victor Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
TheseremediesmaybeauthorizedbyVictorThermalDynamicsandareFOBWestLebanon,NHoranauthorizedVictorTechnologiesservice
station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: VictorThermalDynamicsCorporationshallnotunderanycircumstancesbeliableforspecialorconsequential
damagessuchas,butnotlimitedto,damageorlossofpurchasedorreplacementgoodsorclaimsofcustomerofdistributors(hereinafter
“Purchaser”)forserviceinterruption.TheremediesofthePurchasersetforthhereinareexclusiveandtheliabilityofVictorThermalDynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of the goods covered by or furnished by Victor Thermal Dynamics whether arising out of contract, negligence, strict tort,
or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Victor
Thermal Dynamics product.
This warranty is invalid if the Victor Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007

CUTMASTER 102
Manual0-4998 INTRODUCTION 2-1
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
ThisOwner’sManualappliestojustspecicationorpart
numbers listed on page i.
To ensure safe operation, read the entire manual, including the
chapter on safety instructions and warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular
attention to the information provided under these headings.
These special annotations are easily recognized as
follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is
helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the op-
erating area.
WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a box
such as this.
Additional copies of this manual may be purchased by
contacting Victor Technologies at the address and phone
number in your area listed in the inside back cover of this
manual.IncludetheOwner’sManualnumberandequipment
identicationnumbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the Victor Thermal
Dynamics web site listed below and clicking on Thermal
Dynamics and then on the Literature link:
http://www.victorthermaldynamics.com
2.02 Equipment Identification
Theunit’sidenticationnumber(specicationorpartnumber),
model, and serial number usually appear on a data tag attached
totherearpanel.Equipmentwhichdoesnothaveadatatag
suchastorchandcableassembliesareidentiedonlybythe
specicationorpartnumberprintedonlooselyattachedcard
or the shipping container. Record these numbers on the bottom
of page i for future reference.
2.03 Receipt Of Equipment
Whenyoureceivetheequipment,checkitagainsttheinvoice
tomakesureitiscompleteandinspecttheequipmentforpos-
sible damage due to shipping. If there is any damage, notify the
carrierimmediatelytoleaclaim.Furnishcompleteinformation
concerning damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Includeallequipmentidenticationnumbersasdescribedabove
along with a full description of the parts in error.
Movetheequipmenttotheinstallationsitebeforeun-crating
theunit.Usecaretoavoiddamagingtheequipmentwhenusing
bars, hammers, etc., to un-crate the unit.

CUTMASTER 102
 INTRODUCTION Manual0-4998
2-2
2.04 Power Supply Specifications
CutMaster 102 Power Supply Specifications
Input Power 208/230VAC(187-253VAC),SinglePhase,50/60Hz
230VAC(187-253VAC),ThreePhase,50/60Hz
380VAC(360-440VAC),ThreePhase,50/60Hz
400VAC(360-440VAC),ThreePhase,50/60Hz
460VAC(414-506VAC),SinglePhase,50/60Hz
460VAC(414-506VAC),ThreePhase,50/60Hz
600VAC(540-630),ThreePhase,50/60Hz
Input Power Cable Power Supply includes input cable.
Output Current 30 - 100 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability
Particulates to 5 Microns
CutMaster 102 Power Supply Duty Cycle *
Ambient Tempera-
ture
DutyCycleRatings@40°C(104°F)
Operating Range 0° - 50° C
AllUnits Duty Cycle 60% 80% 100%
Current 100 80 70
IEC IEC IEC
DC Voltage 120 112 108
*NOTE:Thedutycyclewillbereducediftheprimaryinputpower(AC)islow
ortheoutputvoltage(DC)ishigherthanshowninthischart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications include
calculating an output voltage based upon power supply rated current. To facilitate comparison between power sup-
plies, all manufacturers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight Ventilation Clearance Requirements
30.5"
774.7 m
63 lb / 28.6 kg
10.75"
273 mm
16.375"
416 mm
Art # A-08358
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB

CUTMASTER 102
Manual0-4998 INTRODUCTION 2-3
2.05 Input Wiring Specifications
CutMaster 102 Power Supply Input Cable Wiring Requirements
Input volt-
age
Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff Fuse(amps) Flexible Cord
(Min.AWG)
1 Phase 208 50/60 20.6 99 76 100 4 Type W
230 50/60 21.9 95 74 100 4 Type W
460 50/60 27.6 60 46 60 6
3 Phase 208 50/60 17.7 49 38 60 6
230 50/60 17.9 45 36 60 6
380 50/60 18.4 28 22 32 10
400 50/60 18.7 27 22 32 10
460 50/60 23.1 29 22 30 10
600 50/60 22.8 22 17 25 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
I1max is taken at TDC rated minimum duty cycle.
I1eff is taken at TDC 100% rated duty cycle.

CUTMASTER 102
 INTRODUCTION Manual0-4998
2-4
2.06 Power Supply Features
Handle and Leads Wrap
To rch Leads Receptacle
Control Panel
Art # A-08359
Work Cable
and Clamp
Art # A-08360
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly
Input Power Selection

CUTMASTER 102
Manual0-4998 INTRODUCTION 2T-1
SECTION 2 TORCH:
INTRODUCTION
2T.01 Scope of Manual
This manual contains descriptions, operating instructions and
maintenance procedures for the 1Torch Models SL100/Manual
and SL100/Mechanized Plasma Cutting Torches. Service of
thisequipmentisrestrictedtoproperlytrained personnel;
unqualiedpersonnelarestrictlycautionedagainstattempting
repairs or adjustments not covered in this manual, at the risk
of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the
characteristicsandcapabilitiesofthisequipmentwillassurethe
dependable operation for which it was designed.
2T.02 General Description
Plasma torches are similar in design to the automotive spark
plug. They consist of negative and positive sections separated
by a center insulator. Inside the torch, the pilot arc starts in the
gap between the negatively charged electrode and the positively
charged tip. Once the pilot arc has ionized the plasma gas, the
superheatedcolumnofgasowsthroughthesmalloricein
the torch tip, which is focused on the metal to be cut.
A single torch lead provides gas from a single source to be
usedasboththeplasmaandsecondarygas.Theairowis
divided inside the torch head. Single - gas operation provides
a smaller sized torch and inexpensive operation.
NOTE
Refer to Section "2T.05 Introduction to
Plasma" on page 2T-2, for a more detailed descrip-
tion of plasma torch operation.
Refer to the Appendix Pages for additional specifi-
cations as related to the Power Supply used.
2T.03 Specifications
A. Torch Configurations
1. Hand/Manual Torch, Models
The hand torch head is at 75° to the torch handle.
The hand torches include a torch handle and torch
trigger assembly.
10.125" (257 mm)
3.75"
(95 mm)
1.17" (29 mm)
Art # A-03322_AB
2. Mechanized Torch, Model
The standard machine torch has a positioning
tube with rack & pinch block assembly.
Art # A-02998
1.75" /
44.5 mm
1.375" / 35 mm
15.875" / 403 mm
0.625" /
16 mm
4.95" / 126 mm
1.175" / 30 mm
9.285" / 236 mm
B. Torch Leads Lengths
Hand Torches are available as follows:
• 20ft/6.1m,withATCconnectors
• 50ft/15.2m,withATCconnectors
Machine Torches are available as follows:
• 5foot/1.5m,withATCconnectors
• 10foot/3.05m,withATCconnectors
• 25foot/7.6m,withATCconnectors
• 50foot/15.2m,withATCconnectors
C. Torch Parts
Start Cartridge, Electrode, Tip, Shield Cup
D. Parts - In - Place (PIP)
TorchHeadhasbuilt-inswitch
12 VDC circuit rating
E. Type Cooling
Combination of ambient air and gas stream through torch.
F. Torch Ratings
Manual Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 100 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV
Mechanized Torch Ratings
Ambient
Temperature
104° F
40° C
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 120 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 7kV

CUTMASTER 102
 INTRODUCTION Manual0-4998
2T-2
G. Gas Requirements
Manual and Mechanized Torch Gas
Specications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure
Refer to NOTE
60 - 95 psi
4.1 - 6.5 bar
Maximum Input Pressure 125 psi / 8.6 bar
Gas Flow (Cutting and
Gouging)
300 - 500 scfh
142 - 235 lpm
!
WARNING
This torch is not to be used with oxygen (O2).
NOTE
Operating pressure varies with torch model, operat-
ing amperage, and torch leads length. Refer to gas
pressure settings charts for each model.
H. Direct Contact Hazard
For standoff tip the recommended standoff is 3/16 inches
/ 4.7 mm.
2T.04 Options And Accessories
For options and accessories, see section 6.
2T.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes electri-
cally conductive. The plasma arc cutting and gouging
processes use this plasma to transfer an electrical arc to
the workpiece. The metal to be cut or removed is melted
by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of the
material, plasma arc gouging is used to remove metals to
a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B, where
a pilot arc between the electrode and the torch tip heats and
ionizes the gas. The main cutting arc then transfers to the
workpiece through the column of plasma gas in Zone C.
A-00002
Workpiece
Power
Supply
+
_
C
B
A
Typical Torch Head Detail
By forcing the plasma gas and electric arc through a small
orice,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.
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 start cartridge, around the electrode, and
outthroughthetiporice.
Thesecondarygasowsdownaroundtheoutsideofthe
torch start 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.

CUTMASTER 102
Manual0-4998 INTRODUCTION 2T-3
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.
A-02997
Torch Trigger
PIP Switch Shield Cup
To Control
Cable Wiring
Torch Switch
Parts - In - Place Circuit Diagram for Hand Torch
PIP Sw itch Sh ield Cup
To AT C
CNC Start
PIP Sw itch Sh ield Cup
PIP Sw itch Sh ield Cup
Remote Pendant
Automation To rch
To AT C
To AT C
Art # A-08168
Parts - In - Place Circuit Diagram for Machine Torch

CUTMASTER 102
 INTRODUCTION Manual0-4998
2T-4
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