0mm 12mm ™ CUTMASTER PLASMA CUTTING SYSTEM 30 20 40 Art A-10399 Operating Manual Rev.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new 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 worldwide service network. To locate your nearest distributor or service provider visit us at www.thermadyne.com on the web.
! WARNINGS Read and understand this entire Operating 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.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION .............................................................................1-1 1.01 1.02 1.03 1.04 Notes, Cautions and Warnings ................................................................................. 1-1 Important Safety Precautions ................................................................................... 1-1 Publications..............................................................................................................
Figures and Tables SECTION 1: GENERAL INFORMATION .............................................................................1-1 Table 1-1 - Protective Filters .................................................................................................... 1-3 SECTION 2 SYSTEM: INTRODUCTION .............................................................................2-1 Figure 2-1 - Power Source Dimensions & Weight....................................................................
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CUTMASTER 10MM, 12MM SECTION 1: GENERAL INFORMATION ! WARNING PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
CUTMASTER 10MM, 12MM ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy 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 workpiece or other parts of the welding circuit. • Repair or replace all worn or damaged parts.
CUTMASTER 10MM, 12MM Recommended Protective Filters for Electric Welding Description of Process Approximate Range of Welding Current in Amps Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 400 12 Greater than 400 13 Manual Metal Arc Welding - covered electrodes (MMAW) Less than or equal to 150 10 150 to 250 11 250 to 300 12 300 to 400 13 Greater than 400 14 Gas Metal Arc Welding (GMAW) (MIG) other than Aluminium and Stainless Steel Gas Metal Arc Welding (GMAW) (MIG) Alu
CUTMASTER 10MM, 12MM 1.03 CYLINDERS CAN EXPLODE Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. • Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs. • Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.
CUTMASTER 10MM, 12MM 1.04 Declaration of Conformity Manufacturer: Address: Thermadyne Company 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
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CUTMASTER 10MM, 12MM SECTION 2 SYSTEM: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification This Operating Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
CUTMASTER 10MM, 12MM 2.05 Power Source Specifications CutMaster 10mm Plant Part No. 1-4730-6 CUTMASTER 10mm Power Source Specifications Input Power 240 VAC (+/-15%), 1 Phase, 50/60Hz Output Current 20-30 Amps @ 240VAC CUTMASTER 10mm Power Source Duty Cycle (Note 1) Ambient Temperature 104° F (40° C) Duty Cycle 40% @ 240VAC Rated Current 30 Amps @ 240V SL60 Torch Gas Requirements (See Section 2T.02) Note 1. Duty Cycle is the percentage of time the system can be operated without overheating.
CUTMASTER 10MM, 12MM 9" (228.6mm) 30 20 CUTMASTER 40 A ® 18.5" (469.9mm) Art # A-10216 7" (177mm) 26lb / 11.8kg Figure 2-1 - Power Source Dimensions & Weight NOTE Weight includes torch & leads, input power cord, and work cable with clamp. CAUTION Provide clearance for proper air flow through the Power Source. Operation without proper air flow will inhibit proper cooling and reduce duty cycle.
CUTMASTER 10MM, 12MM 2.06 Input Wiring Specifications CUTMASTER 10mm Input Power Requirements Input Power Input Current Input Current Input Suggested Sizes (See Note) Voltage Frequency (kVA) Max (Amps) I1eff (Amps) Fuse (Amps) (Volts-AC) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 240 50/60 3.8 15.6 9.9 16 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application. Check local requirements for your situation in this regard.
CUTMASTER 10MM, 12MM 2.
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CUTMASTER 10MM, 12MM SECTION 2 TORCH: INTRODUCTION 2T.01 Scope of Operating Manual This manual contains descriptions, operating instructions and maintenance procedures for the SL60 Plasma Cutting Torch. 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.
CUTMASTER 10MM, 12MM 2T.03 Introduction to Plasma A. Plasma Gas Flow B. Gas Distribution Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically 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.
CUTMASTER 10MM, 12MM SECTION 3: INSTALLATION 3.01 Unpacking 1. Use the packing lists to identify and account for each item. A. Contents List for CutMaster 10mm Plant Description Part No. 1-4730-6 Quantity CM 10mm Power Source 1 Work cable and clamp 5m (installed) 1 Carry bag 1 SL60 Torch 1 (Including SL60 Torch 20 ft/6.2m w/ATC, consumables set, spare parts kit) Shoulder Strap 1 Operating Manual 1 B. Contents List for CutMaster 12mm Plant Description Part No.
CUTMASTER 10MM, 12MM 3.03 Air Supply Connections A. Connecting Air Supply to Unit B. Using Industrial Compressed Air In Gas Cylinders The connection is the same for compressed air or industrial compressed air in gas cylinders. When using industrial compressed air in gas cylinders as the gas supply: 1. Connect the gas line to the compressed air inlet port at the appropriate pressure. 1.
CUTMASTER 10MM, 12MM SECTION 4 SYSTEM: OPERATION 4.01 Control Panel AC Indicator DC Indicator (Ready) On/Off Switch Air Inlet, 1/4” NPT Power Cord Air Indicator Overheat Indicator 30 20 CUTMASTER ® 40 A 12mm Art # A-10218 Figure 4-1 - Front Control Panel Figure 4-2 - Rear Controls 1. ON/OFF Switch (Power Switch/Lamp) Controls input power to the Power Source. I is ON (Red Lamp), O is OFF. 2. (A) Output Current Control Sets the desired output current.
CUTMASTER 10MM, 12MM 4.02 Preparations for Operating At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling Power Source, torch parts, or torch and leads assemblies. NOTE All consumables must be correctly installed and maintained to ensure correct operation. A. Torch Parts Selection Check the torch for proper assembly and appropriate torch parts.
CUTMASTER 10MM, 12MM B. Torch Connection Check that the torch is properly connected. 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 the unit per Section "2.05 Power Source Specifications" on page 2-2. 2. Connect the input power cable (or CLOSE the main disconnect switch) to supply power to the system. D. Gas Selection Ensure gas source meets requirements listed in Section "H.
CUTMASTER 10MM, 12MM 4.03 Sequence of Operation The following is a typical sequence of operation for this Power Source. 1. Place the ON/OFF switch on the Power Source to ON (up) position (Red indicator lamp is illuminated). a. AC indicator turns ON; fan turns ON. NOTE During initial power up, there will be a delay of about 2 seconds before the AC Indicator light will illuminate and the pre-flow gas and fan starts.
CUTMASTER 10MM, 12MM NOTE When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. DO NOT attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components. Trigger 1 2 Trigger Release • Drag Cutting With a Hand Torch Drag cutting works best on metal 1/4" (6mm) thick or less.
CUTMASTER 10MM, 12MM 4.04 Cut Quality NOTE Cut Surface Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability. The desired or specified condition (smooth or rough) of the face of the cut. Nitride Build-Up Refer to Appendix pages for additional information as related to the Power Source used. Cut quality requirements differ depending on application.
CUTMASTER 10MM, 12MM 4.05 General Cutting Information Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left. WARNING Disconnect primary power at the source before disassembling the power source, torch, or torch leads.
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CUTMASTER 10MM, 12MM 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.
CUTMASTER 10MM, 12MM A. Every three months Check external air filter, replace if necessary. 1. Shut OFF input power; turn OFF the gas supply. Bleed down the gas supply. Check air filter and replace if necessary. NOTE Leave internal ground wire in place. B. Every six months 1. Check the in-line air filter(s), clean or replace as required. 2. Check cables and hoses for leaks or cracks, replace if necessary. 3. Check all contactor points for severe arcing or pits, replace if necessary. 4.
CUTMASTER 10MM, 12MM C. Air indicator OFF. 1. Gas pressure too low. Check supply pressure. D. TEMP indicator ON, (AC indicator 1. Unit air flow obstructed. a. ON). Check for blocked air flow around the unit and correct condition. 2. Fan blocked. a. Check for blocked status and correct condition. 3. Unit is overheated. a. Keep the machine plugged in and turned ON for five minutes. This will allow the fan to run and cool the machine. 4. Faulty components in unit. a.
CUTMASTER 10MM, 12MM H. Output is restricted, and can not be controlled. 1. Input or output connection is poor. a. Check all input and output connection leads. 2. Working cable connection to workpiece is poor. a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece. 3. Faulty components in unit. a. Have an Accredited CIGWELD service provider repair or replace as required. I. Cutting output is unstable or inadequate. 1. Input or output connection is poor. a.
CUTMASTER 10MM, 12MM L. Torch cuts but not well. 1. Current control is set too low. a. Increase the current setting. 2. Torch is being moved too fast across workpiece. a. Reduce cutting speed. 3. Excessive oil or moisture in torch. a. Hold torch 1/8 inch (3mm) from clean surface while purging and observe oil or moisture buildup (DO NOT activate torch). If there are contaminants in the gas, additional filtering may be needed. 4. Torch parts worn. a.
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CUTMASTER 10MM, 12MM SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE Refer to previous "Section 5 System" for common and fault indicator descriptions. Cleaning Torch Upper Groove with Vent Holes Must Remain Open Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the arc initiation and the overall cut quality of the torch.
CUTMASTER 10MM, 12MM 3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. 5T.02 Inspection and Replacement of Consumable Torch Parts Good Tip Worn Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Source is ON. A-09791 Figure 5-4 - Tip Wear 4. Remove the starter cartridge.
CUTMASTER 10MM, 12MM SECTION 6: PARTS LIST 6.01 Introduction C. Ordering Information Order replacement parts by part number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor. 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.
CUTMASTER 10MM, 12MM 6.03 SL60 Replacement Parts Item # Qty Description Part No 1 2 3 1 1 1 1 1 1 Electrode, 30-120 Amp Start Cartridge Tip, 40A Drag (fitted) Tip, 40A Standoff Shield Cup SL60 Torch w/20 ft (6,2m) leads (not shown) OTD9/8215 OTD9/8213 OTD9/8207 OTD9/8208 OTD9/8218 OTD7/5204 4 N/S Art# A-09345 Torch Head Electrode Start Cartridge Tip Shield Cup Parts 6-2 - Electrode Parts 6.
A-1 AC 240 VAC INPUT 50/60Hz 1 2 L 2 1 3 4 V+ AC AC V- G V- AC AC V+ S D 4 3 1 2 1 2 CURRENT CONTROL DC AIR OT A 1 2 DRIVE SIGNAL 7 6 5 4 3 2 1 1 2 U_D G G +15V-15V S G +15V-15V S G S D 2 1 3 2 1 + - S G 6 5 4 3 2 1 XFIF/IN/OUT FEEDBACK SIGNAL 1 2 3 4 1 2 3 4 1 2 3 4 1 2 HFOUT N/A +24V D 3 2 1 3 2 1 G 1 2 3 4 + - S G 2 1 2 1 S D_port 4 3 2 1 + HF/QF + WV OUTPUT WV OUTPUT 1 2 DC 24V TRANSF IFB 5 4 3 2 1 SOURCE&TIP FEEDBACK SIGNAL 7 6 5 4 3 2
Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne Company warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER® plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton, TX 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
Asia Pacific Regional Headquarters 71 Gower Street Preston, Victoria, Australia, 3072 Telephone: +61 3 9474 7400 FAX: +61 3 9474 7391 Email: enquiries@thermadyne.com.au www.thermadyne.
