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: