Victor CUTMASTER User manual

VictorThermalDynamics.com
40 380-
400V
Art # A-09205_AB
Operating
Manual
Revision: AI Issue Date: December 5, 2013 Manual No.: 0-5076
CUTMASTER®12mm
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,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster®12mm
SL60 1Torch™
Operating Manual Number 0-5076
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victorthermaldynamics.com
Copyright 2008, 2009, 2010, 2011, 2012, 2013 by
Victor Technologies International, Inc.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Original Publication Date: September 26, 2008
Revision Date: December 5, 2013
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 Declaration of Conformity......................................................................................... 1-6
1.08 Statement of Warranty ............................................................................................. 1-7
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-6
4T.06 Mechanized Torch Operation .................................................................................. 4T-7
4T.07 Parts Selection for Manual and Mechanized Torch Cutting..................................... 4T-9
4T.08 Recommended Cutting Speeds for SL60 Torch With Exposed Tip ....................... 4T-10
4T.09 Recommended Cutting Speeds for SL60 Torch With Shielded Tip....................... 4T-11

Table of Contents
PATENT INFORMATION ...........................................................................................4T-12
SECTION 5 SYSTEM: SERVICE.....................................................................................5-1
5.01 General Maintenance................................................................................................ 5-1
5.02 Maintenance Schedule.............................................................................................. 5-2
5.03 Common Faults ........................................................................................................ 5-2
5.04 Fault Indicator .......................................................................................................... 5-3
5.05 Basic Troubleshooting Guide.................................................................................... 5-4
5.06 Power Supply Basic Parts Replacement................................................................... 5-6
SECTION 5 TORCH: SERVICE .................................................................................... 5T-1
5T.01 General Maintenance.............................................................................................. 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts....................................... 5T-2
SECTION 6: PARTS LISTS ..........................................................................................6-1
6.01 Introduction.............................................................................................................. 6-1
6.02 Ordering Information................................................................................................ 6-1
6.03 Power Supply Replacement...................................................................................... 6-1
6.04 Replacement Power Supply Parts ............................................................................ 6-2
6.05 Options and Accessories.......................................................................................... 6-2
6.06 Replacement Parts for Hand Torch .......................................................................... 6-3
6.07 Replacement Parts - for Machine Torches with Unshielded Leads ........................... 6-4
6.08 Replacement Shielded Machine Torch Leads Assemblies ........................................ 6-6
6.09 Torch Consumable Parts (SL60)............................................................................... 6-7
6.10 Torch Consumable Parts (SL100)............................................................................. 6-8
APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ...............................................A-1
APPENDIX 2: DATA TAG INFORMATION ..........................................................................A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS.....................................................................A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS ................................................................A-4
APPENDIX 5: SYSTEM SCHEMATIC, 380/400/415V UNITS ....................................................A-6
APPENDIX 6: PUBLICATION HISTORY .......................................................................... A-10
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...........................................REAR COVER

CUTMASTER 12mm
Manual 0-5076 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.
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.
• Disconnectpowersourcebeforeperforminganyservice
or repairs.
• ReadandfollowalltheinstructionsintheOperating
Manual.

CUTMASTER 12mm
1-2 GENERAL INFORMATION Manual 0-5076
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lters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 Superin-
tendent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, obtain-
ablefromAmericanNationalStandardsInstitute, 1430
Broadway, New York, NY 10018
5. ANSIStandard Z41.1,STANDARD FOR MEN’SSAFETY-
TOEFOOTWEAR,obtainablefromtheAmericanNational
StandardsInstitute,1430Broadway,NewYork,NY10018
6. ANSIStandardZ49.2,FIRE PREVENTION IN THE USE OF
CUTTING AND WELDING PROCESSES, obtainable from
AmericanNationalStandardsInstitute,1430Broadway,
New York, NY 10018
7. AWSStandardA6.0,WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
AmericanWeldingSociety,550N.W.LeJeuneRd,Miami,
FL 33126

CUTMASTER 12mm
Manual 0-5076 GENERAL INFORMATION 1-3
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, obtain-
able from the National Fire Protection Association, Battery-
march Park, Quincy, MA 02269
10.NFPAStandard51B,CUTTINGANDWELDINGPROCESSES,
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 Compressed
GasAssociation,1235JeffersonDavisHighway,Suite501,
Arlington, VA 22202
12.CSAStandardW117.2,CODEFORSAFETYINWELDING
AND CUTTING, obtainable from the Canadian Standards As-
sociation,StandardsSales,178RexdaleBoulevard,Rexdale,
Ontario,CanadaM9W1R3
13.NWSAbooklet,WELDINGSAFETYBIBLIOGRAPHYobtain-
ablefromtheNationalWeldingSupplyAssociation,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 PRO-
TECTION, 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.

CUTMASTER 12mm
1-4 GENERAL INFORMATION Manual 0-5076
• Lessortesdegazetdefuméeprovenantdel’arcdeplasma
dépendentdugenredemétalutilisé,desrevêtementsse
trouvantsurlemétaletdesdifférentsprocédés.Vousdevez
prendresoinlorsquevouscoupezou soudeztoutmétal
pouvantcontenirunouplusieursdesélémentssuivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
 baryum  cuivre  sélénium
 béryllium  manganèse vanadium
• Liseztoujours leschesdedonnéessurlasécuritédes
matières(sigleaméricain “MSDS”); celles-ci devraient
êtrefourniesaveclematérielquevousutilisez.LesMSDS
contiennent des renseignements quant à la quantité et la
naturedelafuméeetdesgazpouvantposerdesdangers
de santé.
• Pourdesinformationssurlamanièredetesterlafuméeet
lesgazdevotrelieudetravail,consultezl’article1etles
documents cités à la page 5.
• Utilisezunéquipementspécialtelquedestablesdecoupe
àdébitd’eauouàcourantdescendantpourcapterlafumée
et les gaz.
• N’utilisezpaslechalumeauaujetdeplasmadansunezone
oùsetrouventdesmatièresoudesgazcombustiblesou
explosifs.
• Lephosgène,ungaztoxique,estgénéréparlafuméepro-
venantdessolvantsetdesproduitsdenettoyagechlorés.
Eliminez toute source de telle fumée.
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 12mm
Manual 0-5076 GENERAL INFORMATION 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ltres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 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 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 12mm
1-6 GENERAL INFORMATION Manual 0-5076
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 regula-
tions 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
   Chestereld,MO63033U.S.A.
Type of Equipment: Plasma Cutting Power Source
Model /Number: CutMaster 12mm
SerialNumber:  Serialnumbersareuniquewitheachindividualpieceofequipmentanddetailsdescription,partsused
to manufacture a unit and date of manufacture.
MarketReleaseDate: January1,2012
Classication: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verication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specied.
Rigoroustestingisincorporatedintothemanufacturingprocesstoensurethemanufacturedproductmeetsorexceedsalldesignspecications.
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 12mm
Manual 0-5076 GENERAL INFORMATION 1-7
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 12mm
1-8 GENERAL INFORMATION Manual 0-5076
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™ 1Series 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®10mm 3 Years 1 Year
CUTMASTER®12mm 3 Years 1 Year
CUTMASTER®20mm 3 Years 1 Year
CUTMASTER®25mm 3 Years 1 Year
CUTMASTER®35mm 3 Years 1 Year
CUTMASTER®40mm 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,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 12mm
Manual 0-5076 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 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 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 Thermadyne 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 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
Dynamics 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 12mm
2-2 INTRODUCTION Manual 0-5076
2.04 Power Supply Specifications
CutMaster 12mm Power Supply Specifications
Input Power 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
†NOTE: Some CutMaster 12mm models will only operate on 380-400V. Please check your machine
before attempting to run on any of the other voltages that are listed above.
Input Power Cable Power Supply includes input cable.
Cable for 400V 3 Phase.
Output Current 20 - 40 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
CutMaster 12mm 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%
Ratings Non CE CE Non CE CE Non CE CE
Current 40A 35A 40A 25A 25A
DC Voltage 96 96 94 96 90 90
* 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
22.5"
0.57 m
43 lb / 19.5 kg
10.75"
273 mm
16.375"
416 mm
Art # A-07941
6"
150 mm
24"
610 mm
6"
150 mm
6"
150 mm
Art # A-07925_AB

CUTMASTER 12mm
Manual 0-5076 INTRODUCTION 2-3
2.05 Input Wiring Specifications
CutMaster 12mm Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I max I eff Fuse (amps)
Flexible Cord
(AWG)
3 Phase 380 50/60 5.3 8 5 10 16
400 50/60 5.3 8 5 10 16
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.

CUTMASTER 12mm
2-4 INTRODUCTION Manual 0-5076
2.06 Power Supply Features
Handle and Leads Wrap
To rch Leads Receptacle
Control Panel
Art # A-07942
Work Cable
and Clamp
Art # A-08544
Input Power Cord
Port for Optional Automation
Interface Cable
Gas Inlet Port
Filter Assembly

CUTMASTER 12mm
Manual 0-5076 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 SL60/
Manual and SL100/Mechanized Plasma Cutting Torches.
Service of this equipment is restricted to properly trained
personnel; unqualified 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 as-
sure 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 sepa-
rated 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 ion-
ized the plasma gas, the superheated column of gas flows
through the small orifice 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 flow
is divided inside the torch head. Single - gas operation pro-
vides a smaller sized torch and inexpensive operation.
NOTE
Refer to Section "2T.05 Introduction
to Plasma" on page 2T-2, for a more detailed
description of plasma torch operation.
Refer to the Appendix Pages for additional speci-
fications 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 position-
ing 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
1. Hand Torches are available as follows:
• 20ft/6.1m,withATCconnectors
• 50ft/15.2m,withATCconnectors
2. 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
Starter 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% @ 60 Amps @ 400
scfh
Maximum Current 60 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 12mm
2T-2 INTRODUCTION Manual 0-5076
G. Gas Requirements
Manual and Mechanized Torch Gas Specifications
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 (O
2
).
NOTE
Operating pressure varies with torch model, op-
erating 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
orifice, the torch delivers a high concentration of heat to a
small area. The stiff, constricted plasma arc is shown in
Zone C. Direct current (DC) straight polarity is used for
plasma cutting, as shown in the illustration.
Zone A channels a secondary gas that cools the torch. This
gas also assists the high velocity plasma gas in blowing
the molten metal out of the cut allowing for a fast, slag -
free cut.
B. Gas Distribution
The single gas used is internally split into plasma and
secondary gases.
The plasma gas flows into the torch through the negative
lead, through the starter cartridge, around the electrode,
and out through the tip orifice.
The secondary gas flows down around the outside of the
torch starter cartridge, and out between the tip and shield
cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established between
the electrode and cutting tip. This pilot arc creates a path
for the main arc to transfer to the work.
D. Main Cutting Arc
DC power is also used for the main cutting arc. The nega-
tive output is connected to the torch electrode through
the torch lead. The positive output is connected to the
workpiece via the work cable and to the torch through a
pilot wire.