Victor Cutmaster 42 Operating Manual
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Victor Cutmaster 42 Operating Manual

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

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  • Page 1 120V 230V CUTMASTER ® PLASMA CUTTING SYSTEM Operating Manual Révision : AJ Issue Date: Oct. 18, 2013 Manual No.: 0-5141 VictorThermalDynamics.com...
  • Page 2 WE APPRECIATE YOUR BUSINESS! While the information contained in this Manual represents the Manufacturer's best judgement, Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our the Manufacturer assumes no liability for its use.

  • Page 3: Table Of Contents

    SECTION 6: PARTS LISTS ...................6-1 6.01 Introduction ......................6-1 6.02 Power Supply Replacement Parts ................6-2 6.03 SL40 Torch Replacement Parts ................6-3 6.04 Optional Accessories ....................6-4 APPENDIX 1: CUTMASTER 42 CIRCUIT DIAGRAM ..............A-1 APPENDIX 2: SL40 TORCH PIN-OUT DIAGRAM ..............A-2...

  • Page 4: Section 1: General Information

    CUTMASTER 42 SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process 1.01 Notes, Cautions and Warnings can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep Throughout this manual, notes, cautions, and warnings are your head out of the welding fume plume.

  • Page 5: Publications

    CUTMASTER 42 CUTMASTER 42 • Extra care must be taken when the workplace is moist or • Provide a fire watch when working in an area where fire 1.03 Publications damp. hazards may exist. Refer to the following standards or their latest revisions for PLASMA ARC RAYS • Install and maintain equipment according to NEC code, • Hydrogen gas may be formed and trapped under alu- more information: Plasma Arc Rays can injure your eyes and burn your skin.

  • Page 6: Note, Attention Et Avertissement

    CUTMASTER 42 CUTMASTER 42 1.04 Note, Attention et Avertissement Il faut communiquer aux opérateurs et au • Procurez une bonne aération de toutes les fumées inflam- mables ou explosives. personnel TOUS les dangers possibles. Afin Dans ce manuel, les mots “note,” “attention,” et “avertisse- CHOC ELECTRIQUE d’éviter les blessures possibles, lisez, compre- • Ne coupez pas et ne soudez pas les conteneurs ayant pu ment” sont utilisés pour mettre en relief des informations nez et suivez tous les avertissements, toutes Les chocs électriques peuvent blesser ou même tuer. Le pro-...

  • Page 7: Documents De Reference

    CUTMASTER 42 CUTMASTER 42 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 RAYONS D’ARC DE PLASMA Printing Office, Washington, D.C. 20402 Les rayons provenant de l’arc de plasma peuvent blesser vos...

  • Page 8: Declaration Of Conformity

    Victor Technologies will honor warranty claims submitted within the warranty periods listed below. All warranty periods Type of Equipment: Plasma Cutter begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Victor Technologies Model /Number: CUTMASTER 42 Distributor.
  • Page 9 CUTMASTER 42 This page left blank intentionally. GENERAL INFORMATION 1-10 Manual 0-5141...

  • Page 10: Section 2 System: Introduction

    208-230 VAC (+ - 10%), 1Phase, 50/60Hz Output Current 20 Amps @ 120VAC, 15A 20-27 Amps @ 120VAC, 20A 20-40 Amps @ 230VAC, 20A CUTMASTER 42 Power Supply Duty Cycle (Note 1) Ambient Temperature 104° F (40° C) Duty Cycle 30% @ 120VAC, 40% @ 230VAC...

  • Page 11: Input Wiring Specifications

    Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit proper cooling and reduce duty cycle. 2.03 Input Wiring Specifications On/Off Switch Air Inlet CUTMASTER 42 Input Power Requirements Power Cord Input Power Input Current Input Current Input Suggested Sizes (See Note) Voltage Freq.
  • Page 12 This page left blank intentionally...

  • Page 13: Section 2 Torch: Introduction

    CUTMASTER 42 SECTION 2 TORCH: Torch Ratings INTRODUCTION SL40 Torch Ratings Ambient 104° F Temperature 40° C 2T.01 Scope of Manual Duty Cycle 100% @ 40 Amps @ 193 scfh This manual contains descriptions, operating instructions and Maximum Current 40 Amps maintenance procedures for the SL40 Plasma Cutting Torch.

  • Page 14: 03 Introduction To Plasma

    CUTMASTER 42 B. Gas Distribution 2T.03 Introduction to Plasma The single gas used is internally split into plasma and A. Plasma Gas Flow secondary gases. Plasma is a gas which has been heated to an extremely The plasma gas flows into the torch through the negative high temperature and ionized so that it becomes electrically lead, through the starter cartridge, around the electrode, conductive.

  • Page 15: Section 3: Installation

    CUTMASTER 42 SECTION 3: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account for each item. A. Contents List Description Quantity CM42 Power source 10ft power input cable (installed) 120VAC Adapter Pigtail 15A 120VAC Adapter Pigtail 20A Work cable and clamp (installed) SL40 Torch (15ft(4.6m)) w/consumables...

  • Page 16: Primary Input Power Connections

    CUTMASTER 42 CUTMASTER 42 3.03 Primary Input Power Connections 3.04 Air Supply Connections Power Cords Included With Power Supply A. Connecting Air Supply to Unit Attached to the power supply is an input power cord with a 230 Volt 50 Amp NEMA 6-50P for plug. Supplied adapters allow for The connection is the same for compressed air or industrial compressed air in gas cylinders.
  • Page 17 This page left blank intentionally.

  • Page 18: Section 4 System: Operation

    CUTMASTER 42 SECTION 4 SYSTEM: OPERATION 4.01 Control Panel On/Off Air Inlet Switch AC Indicator Power Cord DC Indicator (Ready) Air Indicator Overheat Indicator 120V 15A 120V 20A 230V 20A CUTMASTER ® Art# A-09338-AD The Front Panel The Rear Panel 1.

  • Page 19: Preparations For Operating

    CUTMASTER 42 CUTMASTER 42 B. Torch Connection 4.02 Preparations For Operating Check that the torch is properly connected. At the start of each operating session: C. Check Primary Input Power Source 1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for WARNING the unit per Section 2, Specifications.

  • Page 20: Sequence Of Operation

    CUTMASTER 42 CUTMASTER 42 G. Select Current Output Level 4.03 Sequence of Operation Torch Set the desired current output level. The following is a typical sequence of operation for this power supply. 1. Place the ON / OFF switch on the power supply to ON (up) position (Red indicator lamp is illuminated).

  • Page 21: Cut Quality

    CUTMASTER 42 CUTMASTER 42 Drag Cutting With a Hand Torch 4.04 Cut Quality Top Spatter (Dross) Trigger Top spatter or dross on the top of the cut caused by slow Drag cutting works best on metal 1/4"(6 mm) thick or...
  • Page 22 CUTMASTER 42 Left Side Cut Angle Right Side Cut Angle A-00512 Side Characteristics Of Cut To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

  • Page 23: Section 5 System: Service

    CUTMASTER 42 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements Maintain more often and troubleshooting techniques.

  • Page 24: Basic Troubleshooting Guide

    CUTMASTER 42 CUTMASTER 42 A. Every three months C. Air indicator Check external air filter, replace if necessary. 1. Gas pressure too low. Check supply pressure. 1. Shut off input power; turn off the gas supply. Bleed down the gas supply. Check air filter and replace if necessary.
  • Page 25 CUTMASTER 42 CUTMASTER 42 K. Arc goes out while operating. Arc can’t be restarted when torch trigger is activated. G. Torch cuts but not adequately 1. Incorrect setting of output current control 1. Power Supply is overheated (TEMP indicator ON).
  • Page 26 CUTMASTER 42 This page left blank intentionally. SERVICE Manual 0-5141...

  • Page 27: Section 5 Torch: Service

    CUTMASTER 42 SECTION 5 TORCH: 5T.02 Inspection and Replacement of Consumable Torch Parts SERVICE 5T.01 General Maintenance WARNING NOTE Disconnect primary power to the system before disassembling the torch or torch Refer to Previous "Section 5 System" for leads. common and fault indicator descriptions.
  • Page 28 CUTMASTER 42 Good Tip Worn Tip A-09791 Tip Wear 4. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion. Replace if neces- sary. Art A-09792 5. Pull the electrode straight out of the torch head.

  • Page 29: Section 6: Parts Lists

    CUTMASTER 42 SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. B. Returns If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

  • Page 30: Power Supply Replacement Parts

    CUTMASTER 42 CUTMASTER 42 6.02 Power Supply Replacement Parts 6.03 SL40 Torch Replacement Parts Item # Qty. Description Catalog # Item # Qty. Description Catalog # Control PCB assembly 9-0077 SL40 Torch Front Control PCB assembly 9-0076 w/15ft(4.6m) leads, (not shown)

  • Page 31: Optional Accessories

    CUTMASTER 42 6.04 Optional Accessories Description Cat. No. Standoff Guide for SL40 9-0090 Cutting Guide Bushing, accommodating the use of the SL40 with the cutting guides 7-2915 Torch Cutting Guides / Guides Kits including Carrying Case, Radius/Roller Kit (7-7501), Circle Cutting Guide (7-3291), 7-8910 Magnetic Pivot, Suction Pivot Circle Cutting Guide Kit, 7-3291 Radius/Roller Cutting Guide Kit 7-7501 Filter Body, single stage air filter...

  • Page 32: Appendix 1: Cutmaster 42 Circuit Diagram

    CUTMASTER 42 APPENDIX 1: CUTMASTER 42 CIRCUIT DIAGRAM Art # A-09396_AF Manual 0-5141 APPENDIX...

  • Page 33: Appendix 2: Sl40 Torch Pin-Out Diagram

    CUTMASTER 42 APPENDIX 2: SL40 TORCH PIN-OUT DIAGRAM A. Hand Torch Pin-Out Diagram ATC Male Connector Cutmaster 42 Female Torch Receptacle Front View Front View Negative / Plasma Negative / Plasma 4 - Green / 8 - Open 8 - Ground...
  • Page 34 This page left blank intentionally.
  • Page 35 I N N O V A T I O N T O S H A P E T H E W O R L D ™ U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178 Printed in China © 2012 Victor Technologies International, Inc. www.victortechnologies.com...

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