Victor CUTMASTER A40 User manual

VictorThermalDynamics.com
40 208-
230V 460V
Art # A-08838_AD
600V
380-
400V
Operating
Manual
Revision: AQ Issue Date: October 24, 2014 Manual No.: 0-4978
CUTMASTER®A40
AUTOMATED 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 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.

!
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®A40
SL100 ™ SV Automated Torch
Operating Manual Number 0-4978
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
www.victorthermaldynamics.com
Copyright 2008, 2009, 2010, 2011, 2012, 2013, 2014 by
Victor Technologies International, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is pro-
hibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or dam-
age caused by any error or omission in this Manual, whether such error results from negligence,
accident, or any other cause.
Original Publication Date: July 15, 2008
Revision Date: October 24, 2014
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ____________
Purchase Date:______________________________________________
Power Supply Serial #:________________________________________
Torch Serial #:___________________________________ ___________
i

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 Declaration of Conformity............................................................................... 1-7
1.08 Statement of Warranty.................................................................................... 1-8
SECTION 2 SYSTEM: INTRODUCTION .................................................................. 2-1
2.01 How To Use This Manual ................................................................................ 2-1
2.02 Equipment Identification................................................................................. 2-1
2.03 Receipt Of Equipment ..................................................................................... 2-1
2.04 Power Supply Specifications .......................................................................... 2-2
2.05 Input Wiring Specifications............................................................................. 2-3
2.06 Power Supply Features ................................................................................... 2-4
SECTION 2 TORCH: INTRODUCTION ...................................................................2T-1
2T.01 Scope of Manual............................................................................................2T-1
2T.02 General Description .......................................................................................2T-1
2T.03 Specifications ...............................................................................................2T-1
2T.04 Options And Accessories...............................................................................2T-2
2T.05 Introduction to Plasma ..................................................................................2T-2
SECTION 3 SYSTEM: INSTALLATION ................................................................... 3-1
3.01 Unpacking....................................................................................................... 3-1
3.02 Lifting Options ................................................................................................ 3-1
3.03 Power Supply location and Mounting ............................................................. 3-1
3.04 Opening the Contactor Cover.......................................................................... 3-1
3.05 Primary Input Power Connections.................................................................. 3-1
3.06 Gas Connections............................................................................................. 3-4
SECTION 3 TORCH: INSTALLATION..................................................................... 3T-1
3T.01 Torch Connections.........................................................................................3T-1
3T.02 CNC Connection.............................................................................................3T-1
3T.03 Setting Up Automation or Machine Torch ......................................................3T-2
SECTION 4 SYSTEM: OPERATION........................................................................ 4-1
4.01 Front Panel Controls / Features....................................................................... 4-1
4.02 Preparations for Operation.............................................................................. 4-2

TABLE OF CONTENTS
SECTION 4 TORCH: OPERATION ........................................................................ 4T-1
4T.01 Machine and Automated Torch Operation......................................................4T-1
4T.02 Automation Torch Parts Selection..................................................................4T-1
4T.03 Machine and Hand Torch Parts Selection.......................................................4T-2
4T.04 Cut Quality .....................................................................................................4T-3
4T.05 General Cutting Information...........................................................................4T-3
4T.06 Hand Torch Operation....................................................................................4T-4
4T.07 Gouging.........................................................................................................4T-7
4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Ex-
posed Tip.....................................................................................................4T-10
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With
Shielded Tip.................................................................................................4T-22
PATENT INFORMATION .............................................................................................4T-34
SECTION 5 SYSTEM: SERVICE ........................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 Maintenance Schedule.................................................................................... 5-2
5.03 Common Faults............................................................................................... 5-2
5.04 Fault Indicator................................................................................................. 5-3
5.05 Basic Troubleshooting Guide .......................................................................... 5-4
5.06 Circuit Fault Isolation...................................................................................... 5-6
SECTION 5 TORCH: SERVICE ............................................................................5T-1
5T.01 General Maintenance .....................................................................................5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts..............................5T-2
SECTION 6: PARTS LISTS ................................................................................. 6-1
6.01 Introduction.................................................................................................... 6-1
6.02 Ordering Information ...................................................................................... 6-1
6.03 Power Supply Replacement............................................................................ 6-1
6.04 Replacement Power Supply Parts................................................................... 6-2
6.05 Options and Accessories ................................................................................ 6-2
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) 6-4
6.07 Torch Consumable Parts (SL100 SV) Automation .......................................... 6-6
6.08 Torch Consumable Parts Manual (SL60)Torch................................................ 6-7
6.09 Replacement Parts for Hand Torch ................................................................ 6-8

TABLE OF CONTENTS
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, 400V/600V UNITS .............................................. A-8
APPENDIX 7: RAW ARC VOLTAGE ......................................................................A-10
APPENDIX 8: PUBLICATION HISTORY..................................................................A-12

CUTMASTER A40
Manual 0-4978 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 instruc-
tions before using the equipment. Call 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 N i c k e l
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.
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.
• InstallandmaintainequipmentaccordingtoNECcode,
refer to item 9 in Subsection 1.03, Publications.

CUTMASTER A40
1-2 GENERAL INFORMATION Manual 0-4978
• 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 Docu-
ments, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUT-
TING, 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 Print-
ing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-
PATION AND EDUCATIONAL EYE AND FACE PROTEC-
TION, 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 Na-
tional 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

CUTMASTER A40
Manuel 0-4978 INFORMATIONS GÉNÉRALES 1-3
7. AWS Standard A6.0, WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES, obtain-
able 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 PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Com-
pressed Gas Association, 1235 Jefferson Davis High-
way, 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 Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTTING OF CONTAINERS AND
PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES,
obtainable from the American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
1.04 NOTE, ATTENTION ET AVERTISSEMENT
Danscemanuel,lesmots“note,”“attention,”et“avertissement”
sont utilisés pour mettre en relief des informations à caractère
important. Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure
en question.
!
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 mag-
nétique qui peuvent interférer la fonction propre
d’un “pacemaker” cardiaque, les appareils auditif,
ou autre matériel de santé electronique. Ceux qui
travail près d’une application à l’arc au jet de plasma
devrait consulter leur membre professionel de
médication et le manufacturier de matériel de santé
pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les 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 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.

CUTMASTER A40
1-4 INFORMATIONS GÉNÉRALES Manuel 0-4978
• 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prov-
enant des solvants et des produits de nettoyage chlorés.
Eliminez toute source de telle fumée.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé
au jet de plasma requiert et produit de l’énergie électrique haute
tension. Cette énergie électrique peut produire des chocs graves,
voire mortels, pour l’opérateur et les autres personnes sur le
lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous de la
pièce de travail ou des autres parties du circuit de soudage.
• Réparezouremplaceztoutepièceuséeouendommagée.
• Prenezdessoinsparticulierslorsquelazonedetravailest
humide ou moite.
• Montezetmaintenezlematérielconformément auCode
électrique national des Etats-Unis. (Voir la page 5, article
9.)
• Débranchez l’alimentation électrique avant touttravail
d’entretien ou de réparation.
• LisezetrespecteztouteslesconsignesduManueldecon-
signes.
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 alli-
ages 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.

CUTMASTER A40
Manuel 0-4978 INFORMATIONS GÉNÉRALES 1-5
• 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 ob-
servé 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 ac-
ceptables. Vous dúez vous protéger les oreilles contre les bruits
forts afin d’éviter une perte permanente de l’ouïe.
• Pourprotégervotreouïecontrelesbruitsforts,portezdes
tampons protecteurs et/ou des protections auriculaires.
Protégez également les autres personnes se trouvant sur
le lieu de travail.
• Ilfautmesurerlesniveauxsonoresand’assurerqueles
décibels (le bruit) ne dépassent pas les niveaux sûrs.
• Pourdesrenseignementssurlamanièredetesterlebruit,
consultez l’article 1, page 5.
!
AVERTISSEMENT
AVERTISSEMENT : Ce produit contient des produits
chimiques, notamment du plomb, reconnu par
l'État de la Californie pour causer des malforma-
tions 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
PROTECTION DE LA SANTÉ, 29CFR 1910, disponible
auprès du Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402

CUTMASTER A40
1-6 GENERAL INFORMATION Manual 0-4978
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société
Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible
auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES
ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broad-
way, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE,
disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT
RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC
ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Bat-
terymarch 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 Association), 1235 Jefferson Davis Highway, Suite 501, Arlington,
VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des
Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Four-
nitures 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 PRÉPA-
RATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX
, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

CUTMASTER A40
Manual 0-4978 GENERAL INFORMATION 1-7
1.07 DECLARATION OF CONFORMITY
Declaration of Conformity
Application of Council Directive(s): The equipment described in this document 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document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.
Manufacturer: Victor Technologies International Inc.
Address: 16052 Swingley Ridge Road
Suite 300
Chesterfield, MO 63033 U.S.A.
Type of Equipment: Plasma Cutting Power Source
Model /Number: CutMaster A40
Serial Number: Serial numbers are unique with each individual piece of equipment and details description, parts used to manu-
facture a unit and date of manufacture.
Market Release Date: January 1, 2012
Classification: The equipment described in this document 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 difficulties 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 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources. (Supersedes Standard EN 60974-1:2005)
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 the manual and related industry standards, and performs as specified.
Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Victor Technologies. 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 International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: March 18, 2014
Steve Ward
Full Name
V.P. Europe and General Manager
(Position)
(Signature)

CUTMASTER A40
1-8 GENERAL INFORMATION Manual 0-4978
Classication: 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.

CUTMASTER A40
Manual 0-4978 GENERAL INFORMATION 1-9
1.08 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 notification thereof and substantiation that
the product has been stored operated and maintained in accordance with Victor Thermal Dynamics’ specifications, instructions,
recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Victor Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in
material or workmanship within the time periods set out below. Victor Thermal Dynamics Corporation must be notified 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)
U.S. Non U.S.
CUTMASTER®A40 4 Years 3 Years 1 Year
CUTMASTER®A60 4 Years 3 Years 1 Year
CUTMASTER®A80 4 Years 3 Years 1 Year
CUTMASTER®A120 4 Years 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, O-rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based
upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Victor 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 Tech-
nologies International 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 A40
1-10 GENERAL INFORMATION Manual 0-4978
This Page Intentnionally Blank

CUTMASTER A40
Manual 0-4978 INTRODUCTION 2-1
SECTION 2 SYSTEM:
INTRODUCTION
2.01 HOW TO USE THIS MANUAL
This Owner’s Manual applies to just specification or part num-
bers 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 informa-
tion 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 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.
Additional copies of this manual may be purchased by con-
tacting Victor Technologies at the address and phone number
in your area listed on back cover of this manual. Include the
Owner’s Manual number and equipment identification numbers.
Electronic copies of this manual can also be downloaded at no
charge in Acrobat PDF format by going to the Victor Thermal
Dynamics web site listed below and clicking on Thermal Dynam-
ics and then on the Literature link:
http://www.victorthermaldynamics.com
2.02 EQUIPMENT IDENTIFICATION
The unit’s identification number (specification or part number),
model, and serial number usually appear on a data tag attached
to the rear panel. Equipment which does not have a data tag
such as torch and cable assemblies are identified only by the
specification or part number printed on loosely attached card
or the shipping container. Record these numbers on the bottom
of page i for future reference.
2.03 RECEIPT OF EQUIPMENT
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for pos-
sible damage due to shipping. If there is any damage, notify the
carrier immediately to file a claim. Furnish complete information
concerning damage claims or shipping errors to the location in
your area listed in the inside back cover of this manual.
Include all equipment identification numbers as described above
along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when using
bars, hammers, etc., to un-crate the unit.

CUTMASTER A40
2-2 INTRODUCTION Manual 0-4978
2.04 POWER SUPPLY SPECIFICATIONS
CutMaster A40 Power Supply Specifications
Input Power
208 / 230 VAC (187 - 253 VAC), Single Phase, 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, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630 VAC), Three Phase, 60 Hz
Input Power Cable Power Supply includes input cable.
Cable for 208/230V input power includes molded plug.
Output Current 20 - 60 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
CutMaster A40 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Operating Range 0° - 50° C
IEC Rating
All Units
Duty Cycle 40% 60% 100%
Current 60 Amps 50 Amps 30 Amps
DC Voltage 104 100 92
* 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
20.8"
0.528 m
43 lb / 19.5 kg
10"
254 mm
13.78"
350 mm
Art # A-08305
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB

CUTMASTER A40
Manual 0-4978 INTRODUCTION 2-3
2.05 INPUT WIRING SPECIFICATIONS
CutMaster A40 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I1eff Fuse (amps)
Flexible Cord
(Min. AWG)
1 Phase
208 60 10.4 47 30 50 10
230 60 10.8 45 29 50 10
460 60 15.2 31 20 35 12
3 Phase
208 60 5.4 26 17 30 12
230 50/60 5.8 24 16 30 12
380 50/60 6.1 16 11 20 14
400 50/60 6.4 16 11 20 14
460 60 7.4 16 10 20 12
600 60 7.8 13 11 15 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.
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. For hard-wired installations
refer to local or national codes.
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be used
to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or “one-time” fuses like UL Class K5.

CUTMASTER A40
2-4 INTRODUCTION Manual 0-4978
2.06 POWER SUPPLY FEATURES
Art # A-08306
Mounting Rails
Torch Leads
Receptacle
Control Panel
Work Cable
and Clamp
Input Power Cord
Automation Interface
Cable Port
Gas Inlet Port
Filter Assembly
Input Power Selection
Art # A-08318