Cutmaster Plasma

60 208-
460V 600V
230V
CUTMASTER™ 52
PLASMA CUTTING SYSTEM
Operating
Manual
Art # A-08617_AD
Revision: AR Issue Date: February 11, 2014 Manual No.: 0-4961
VictorThermalDynamics.com
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is backed by our extensive warranty and world-wide service network. To locate your nearest distribu-
tor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.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.
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Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for
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! WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply

CutMaster™ 52
SL60 1Torch™
Operating Manual Number 0-4961
Published by:
Victor Technologies International, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.victortechnologies.com
Copyright 2007, 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 negli-
gence, accident, or any other cause.
Original Publication Date: September 4, 2007

Revision Date: February 11, 2014
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................................................................................ 1-6
1.07 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 Opening the Contactor Cover........................................................................... 3-1
3.04 Primary Input Power Connections................................................................... 3-1
3.05 Gas Connections.............................................................................................. 3-3
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
TABLE OF CONTENTS
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 Mechanized Torch With Exposed Tip.....4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip.....4T-13
PATENT INFORMATION.................................................................................. 4T-16
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.................................................................... 6-1
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, 208/460V UNITS................................................ A-6
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS...................................................... A-8
APPENDIX 7: PUBLICATION HISTORY..................................................................A-10
CUTMASTER 52
SECTION 1: To prevent possible injury, read, understand
and follow all warnings, safety precautions
GENERAL INFORMATION and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.
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: GASES AND FUMES
Gases and fumes produced during the plasma cutting
NOTE
process can be dangerous and hazardous to your health.
An operation, procedure, or background
information which requires additional em- • Keep all fumes and gases from the breathing area.
phasis or is helpful in efficient operation of Keep your head out of the welding fume plume.
the system. • 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
CAUTION depend on the kind of metal being used, coatings
A procedure which, if not properly followed, on the metal, and the different processes. You must
may cause damage to the equipment. be very careful when cutting or welding any metals
which may contain one or more of the following:
! WARNING
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
A procedure which, if not properly followed, Beryllium Lead Silver
may cause injury to the operator or others in Cadmium Manganese Vanadium
the operating area. • Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formation regarding the kind and amount of fumes
WARNING and gases that may be dangerous to your health.
Gives information regarding possible electri- • For information on how to test for fumes and
cal shock injury. Warnings will be enclosed gases in your workplace, refer to item 1 in "1.03
in a box such as this. Publications" on page 1-2 in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
1.02 Important Safety Precautions • Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
! WARNING
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN- • WARNING: This product contains chemicals,
GEROUS AND HAZARDOUS TO YOUR including lead, known to the State of California to
HEALTH. cause birth defects and other reproductive harm.
Wash hands after handling.
Plasma arc cutting produces intense electric
and magnetic emissions that may interfere
with the proper function of cardiac pacemak-
ELECTRIC SHOCK
ers, hearing aids, or other electronic health
equipment. Persons who work near plasma Electric Shock can injure or kill. The plasma arc process
arc cutting applications should consult their uses and produces high voltage electrical energy. This
medical health professional and the manufac- electric energy can cause severe or fatal shock to the
turer of the health equipment to determine operator or others in the workplace.
whether a hazard exists.
• Never touch any parts that are electrically “live”
or “hot.”
Manual 0-4961 GENERAL INFORMATION 1-1
CUTMASTER 52
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit. PLASMA ARC RAYS
• Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin.
• Extra care must be taken when the workplace is The plasma arc process produces very bright ultra violet
moist or damp. and infra red light. These arc rays will damage your eyes
• Install and maintain equipment according to NEC and burn your skin if you are not properly protected.
code, refer to item 9 in Section "1.03 Publi- • To protect your eyes, always wear a welding helmet
cations" on page 1-2. or shield. Also always wear safety glasses with side
• Disconnect power source before performing any shields, goggles or other protective eye wear.
service or repairs. • Wear welding gloves and suitable clothing to protect
• Read and follow all the instructions in the Operat- your skin from the arc rays and sparks.
ing Manual. • Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
FIRE AND EXPLOSION Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or • Use the shade of lens as suggested in the following
the plasma arc. per ANSI/ASC Z49.1:
Minimum Protective Suggested
• Be sure there is no combustible or flammable mate-
Arc Current Shade No. Shade No.
rial in the workplace. Any material that cannot be
removed must be protected. Less Than 300* 8 9
• Ventilate all flammable or explosive vapors from 300 - 400* 9 12
the workplace.
400 - 800* 10 14
• Do not cut or weld on containers that may have
held combustibles. * These values apply where the actual arc
is clearly seen. Experience has shown that
• Provide a fire watch when working in an area where
lighter filters may be used when the arc is
fire hazards may exist.
hidden by the workpiece.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
! WARNING
unless the hydrogen gas can be eliminated or dis-
WARNING: This product contains chemicals, includ-
sipated. Trapped hydrogen gas that is ignited will
ing lead, known to the State of California to cause birth
cause an explosion.
defects and other reproductive harm. Wash hands after
handling.
NOISE
1.03 Publications
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits. Refer to the following standards or their latest revisions
for more information:
You must protect your ears from loud noise to prevent
permanent loss of hearing. 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
• To protect your hearing from loud noise, wear pro- ments, U.S. Government Printing Office, Washington,
tective ear plugs and/or ear muffs. Protect others D.C. 20402
in the workplace. 2. ANSI Standard Z49.1, SAFETY IN WELDING AND
• Noise levels should be measured to be sure the CUTTING, obtainable from the American Welding
decibels (sound) do not exceed safe levels. Society, 550 N.W. LeJeune Rd, Miami, FL 33126
• For information on how to test for noise, see item 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
1 in Section "1.03 Publications", in this manual. from the Superintendent of Documents, U.S. Govern-
ment Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION AND EDUCATIONAL EYE AND FACE
1-2 GENERAL INFORMATION Manual 0-4961
CUTMASTER 52
PROTECTION, obtainable from American National NOTE
Standards Institute, 1430 Broadway, New York, NY Toute opération, procédure ou renseigne-
10018
ment général sur lequel il importe d’insister
5. ANSI Standard Z41.1, STANDARD FOR MEN’S davantage ou qui contribue à l’efficacité de
SAFETY-TOE FOOTWEAR, obtainable from the fonctionnement du système.
American National Standards Institute, 1430 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES, ATTENTION
obtainable from American National Standards Insti- Toute procédure pouvant résulter l’endom-
tute, 1430 Broadway, New York, NY 10018 magement du matériel en cas de non-res-
7. AWS Standard A6.0, WELDING AND CUTTING pect de la procédure en question.
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
! AVERTISSEMENT
FOR WELDING, CUTTING AND ALLIED PRO- Toute procédure pouvant provoquer des bles-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269 sures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, non-respect de la procédure en question.
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro- AVERTISSEMENT
tection Association, Batterymarch Park, Quincy, MA
02269 Fournit l'information concernant des dom-
11. CGA Pamphlet P-1, SAFE HANDLING OF COM- mages possibles de choc électrique. Des
PRESSED GASES IN CYLINDERS, obtainable from avertissements seront enfermés dans une
the Compressed Gas Association, 1235 Jefferson Davis boîte de ce type.
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the 1.05 Precautions De Securite
Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W Importantes
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Asso- ! AVERTISSEMENTS
ciation, 1900 Arch Street, Philadelphia, PA 19103
L’OPÉRATION ET LA MAINTENANCE DU
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE MATÉRIEL DE SOUDAGE À L’ARC AU JET
PREPARATION FOR WELDING AND CUTTING DE PLASMA PEUVENT PRÉSENTER DES
OF CONTAINERS AND PIPING THAT HAVE HELD RISQUES ET DES DANGERS DE SANTÉ.
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Coupant à l’arc au jet de plasma produit
Miami, FL 33126 de l’énergie électrique haute tension et des
émissions magnétique qui peuvent interférer
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA- la fonction propre d’un “pacemaker” cardia-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New que, les appareils auditif, ou autre matériel
York, NY 10018 de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma
1.04 Note, Attention et Avertissement devrait consulter leur membre professionel de
médication et le manufacturier de matériel de
Dans ce manuel, les mots “note,” “attention,” et “aver- santé pour déterminer s’il existe des risques
tissement” sont utilisés pour mettre en relief des infor- de santé.
mations à caractère important. Ces mises en relief sont
classifiées comme suit :
Manuel 0-4961 INFORMATIONS GÉNÉRALES 1-3

CUTMASTER 52
Il faut communiquer aux opérateurs et au • Le phosgène, un gaz toxique, est généré par la fumée
personnel TOUS les dangers possibles. Afin provenant des solvants et des produits de nettoyage
d’éviter les blessures possibles, lisez, compre- chlorés. Eliminez toute source de telle fumée.
nez et suivez tous les avertissements, toutes
• AVERTISSEMENT: Ce produit contient des produits
les précautions de sécurité et toutes les consi-
chimiques, notamment du plomb, reconnu par l'État
gnes avant d’utiliser le matériel. Composez le
de la Californie pour causer des malformations congé-
+ 603-298-5711 ou votre distributeur local si
nitales et d'autres dommages touchant le système
vous avez des questions.
reproductif. Se laver les mains après manipulation.
CHOC ELECTRIQUE
FUMÉE et GAZ
Les chocs électriques peuvent blesser ou même tuer. Le
La fumée et les gaz produits par le procédé de jet de
procédé au jet de plasma requiert et produit de l’énergie
plasma peuvent présenter des risques et des dangers
électrique haute tension. Cette énergie électrique peut
de santé.
produire des chocs graves, voire mortels, pour l’opérateur
• Eloignez toute fumée et gaz de votre zone de respi- et les autres personnes sur le lieu de travail.
ration. Gardez votre tête hors de la plume de fumée
• Ne touchez jamais une pièce “sous tension” ou “vive”;
provenant du chalumeau.
portez des gants et des vêtements secs. Isolez-vous
• Utilisez un appareil respiratoire à alimentation en air de la pièce de travail ou des autres parties du circuit
si l’aération fournie ne permet pas d’éliminer la fumée de soudage.
et les gaz.
• Réparez ou remplacez toute pièce usée ou endomma-
• Les sortes de gaz et de fumée provenant de l’arc de gée.
plasma dépendent du genre de métal utilisé, des
• Prenez des soins particuliers lorsque la zone de travail
revêtements se trouvant sur le métal et des différents
est humide ou moite.
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un • Montez et maintenez le matériel conformément au
ou plusieurs des éléments suivants: Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
antimoine cadmium mercure
argent chrome nickel • Débranchez l’alimentation électrique avant tout tra-
arsenic cobalt plomb vail d’entretien ou de réparation.
baryum cuivre sélénium
béryllium manganèse vanadium • Lisez et respectez toutes les consignes du Manuel de
consignes.
• Lisez toujours les fiches 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 INCENDIE ET EXPLOSION
quantité et la nature de la fumée et des gaz pouvant Les incendies et les explosions peuvent résulter des
poser des dangers de santé. scories chaudes, des étincelles ou de l’arc de plasma. Le
• Pour des informations sur la manière de tester la procédé à l’arc de plasma produit du métal, des étincelles,
fumée et les gaz de votre lieu de travail, consultez des scories chaudes pouvant mettre le feu aux matiè-
l’article 1 et les documents cités à la page 5. res combustibles ou provoquer l’explosion de fumées
inflammables.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour • Soyez certain qu’aucune matière combustible ou
capter la fumée et les gaz. inflammable ne se trouve sur le lieu de travail. Proté-
gez toute telle matière qu’il est impossible de retirer
• N’utilisez pas le chalumeau au jet de plasma dans de la zone de travail.
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs. • Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
1-4 INFORMATIONS GÉNÉRALES Manuel 0-4961

CUTMASTER 52
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
BRUIT
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont Le bruit peut provoquer une perte permanente de l’ouïe.
coupées sous l’eau ou sur une table d’eau. NE PAS Les procédés de soudage à l’arc de plasma peuvent
couper les alliages en aluminium sous l’eau ou sur provoquer des niveaux sonores supérieurs aux limites
une table d’eau à moins que le gas hydrogène peut normalement acceptables. Vous dú4ez vous protéger
s’échapper ou se dissiper. Le gas hydrogène accumulé les oreilles contre les bruits forts afin d’éviter une perte
explosera si enflammé. permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections auri-
RAYONS D’ARC DE PLASMA culaires. Protégez également les autres personnes se
Les rayons provenant de l’arc de plasma peuvent bles- trouvant sur le lieu de travail.
ser vos yeux et brûler votre peau. Le procédé à l’arc de • Il faut mesurer les niveaux sonores afin d’assurer que
plasma produit une lumière infra-rouge et des rayons les décibels (le bruit) ne dépassent pas les niveaux
ultra-violets très forts. Ces rayons d’arc nuiront à vos sûrs.
yeux et brûleront votre peau si vous ne vous protégez
pas correctement. • Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
• 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 ! AVERTISSEMENT
protection ou une autre sorte de protection oculaire.
AVERTISSEMENT: Ce produit contient des produits
• Portez des gants de soudeur et un vêtement protec-
chimiques, notamment du plomb, reconnu par l'État de
teur approprié pour protéger votre peau contre les
la Californie pour causer des malformations congénitales
étincelles et les rayons de l’arc.
et d'autres dommages touchant le système reproductif.
• Maintenez votre casque et vos lunettes de protection Se laver les mains après manipulation.
en bon état. Remplacez toute lentille sale ou compor-
tant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance MinimumNuance 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 démon-
trer que les filtres moins foncés peuvent être
utilisés quand l’arc est caché par moiceau de
travail.
Manuel 0-4961 INFORMATIONS GÉNÉRALES 1-5

CUTMASTER 52
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible
auprès du Superintendent of Documents, U.S. Government Printing Office, 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 Office, Washington,
D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET
DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards
Institute), 1430 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, disponible 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 Association), 1235 Jefferson Davis Highway, Suite
501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Asso-
ciation 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 Association), 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 CONTENEURS ET TUYAUX AYANT REN-
FERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National
Standards Institute, 1430 Broadway, New York, NY 10018

CUTMASTER 52
1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Technologies, Inc. warrants to
the original retail purchaser that new Victor Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the
effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this
warranty appear within the applicable period stated below, Victor Technologies, Inc. shall, upon notification thereof and
substantiation that the product has been stored operated and maintained in accordance with Victor Thermal Dynamics’
specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair
or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Victor Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects
in material or workmanship within the time periods set out below. Victor Technologies, Inc. must be notified within 30
days of any failure, at which time Victor Technologies, Inc. will provide instructions on the warranty procedures to be
implemented.
Victor Technologies, Inc. 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
Power Supply Components Torch and Leads

Product
(Parts and Labor) (Parts and Labor)
U.S. Non U.S.
CUTMASTER™ 39 4 Years 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o-rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Victor Technologies, Inc. :
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 Technologies, Inc. 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
Manual 0-4961 GENERAL INFORMATION 1-7

CUTMASTER 52

CUTMASTER 52
SECTION 2 SYSTEM: 2.02 Equipment Identification
INTRODUCTION 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
2.01 How To Use This Manual does not have a data tag such as torch and cable as-
semblies are identified only by the specification or part
This Owner’s Manual applies to just specification or part
number printed on loosely attached card or the shipping
numbers listed on page i.
container. Record these numbers on the bottom of page
To ensure safe operation, read the entire manual, includ- i for future reference.
ing the chapter on safety instructions and warnings.
Throughout this manual, the words WARNING, CAU-
2.03 Receipt Of Equipment
TION, and NOTE may appear. Pay particular attention When you receive the equipment, check it against the
to the information provided under these headings. These invoice to make sure it is complete and inspect the
special annotations are easily recognized as follows: equipment for possible damage due to shipping. If there
is any damage, notify the carrier immediately to file a
NOTE claim. Furnish complete information concerning dam-
An operation, procedure, or background age claims or shipping errors to the location in your area
information which requires additional em- listed in the inside back cover of this manual.
phasis or is helpful in efficient operation of Include all equipment identification numbers as de-
the system. scribed above along with a full description of the parts
in error.
Move the equipment to the installation site before
CAUTION
un-crating the unit. Use care to avoid damaging the
A procedure which, if not properly followed, equipment when using bars, hammers, etc., to un-crate
may cause damage to the equipment. the unit.
! WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
WARNING
Gives information regarding possible electri-
cal shock injury. Warnings will be enclosed in
a box such as this.
Additional copies of this manual may be purchased

by contacting Victor Technologies International at the
address and phone number in your area listed on back
cover of this manual. Include the Owner’s Manual
number and equipment identification numbers.
Electronic copies of this manual can also be downloaded
at no charge in Acrobat PDF format by going to the
Thermal Dynamics web site listed below and clicking
on Thermal Dynamics and then on the Literature link:
http://www.victorthermaldynamics.com
Manual 0-4961 INTRODUCTION 2-1

CUTMASTER 52
2.04 Power Supply Specifications
CutMaster 52 Power Supply Specifications
208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz
Power Supply includes input cable.
Input Power Cable
Cable for 208/230V input power includes molded plug.
Output Current 20 - 60 Amps, Continuously Adjustable
Power Supply Gas
Particulates to 5 Microns
Filtering Ability
CutMaster 52 Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
IEC Rating
Duty Cycle 40% 60% 100%
All Units Current 60 Amps 50 Amps 30 Amps
DC Voltage 104 100 92
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low or the
output voltage (DC) is higher than shown in this chart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These speci-
fications include calculating an output voltage based upon power supply rated current. To facilitate
comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.
Power Supply Dimensions & Weight Ventilation Clearance Requirements
10.75"
273 mm
Art # A-07941
Art # A-07925_AB
16.375"
416 mm
6"
150 mm
24"
610 mm
22.5"
0.57 m
6" 6"
43 lb / 19.5 kg 150 mm 150 mm
2-2 INTRODUCTION Manual 0-4961

CUTMASTER 52
2.05 Input Wiring Specifications
CutMaster 52 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes
Flexible Cord
Volts Hz kVA I max I1eff Fuse (amps) (Min. AWG)
208 60 10.4 47 30 50 10
1 Phase 230 60 10.8 45 29 50 10
460 60 15.2 31 20 35 12
208 60 5.4 26 17 30 12
230 50/60 5.8 24 16 30 12
380 50/60 6.1 16 11 20 14
3 Phase
400 50/60 6.4 16 11 20 14
460 60 7.4 16 10 20 12
600 60 7.8 13 11 15 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
Manual 0-4961 INTRODUCTION 2-3

CUTMASTER 52
2.06 Power Supply Features
Handle and Leads Wrap
Control Panel
Torch Leads Receptacle
Art # A-07942
Work Cable
and Clamp
Port for Optional Automation

Interface Cable
Input Power Selection
Filter Assembly
Gas Inlet Port
Art # A-07981
Input Power Cord
2-4 INTRODUCTION Manual 0-4961

CUTMASTER 52
SECTION 2 TORCH: 10.125" (257 mm)
INTRODUCTION
2T.01 Scope of Manual
3.75"
This manual contains descriptions, operating instruc- (95 mm)
Art # A-03322_AB
tions and maintenance procedures for the 1Torch Models
SL60/Manual and SL100/Mechanized Plasma Cut- 1.17" (29 mm)
ting Torches. Service of this equipment is restricted to 2. Mechanized Torch, Model
properly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or adjust- The standard machine torch has a positioning
ments not covered in this manual, at the risk of voiding tube with rack & pinch block assembly.
the Warranty. 15.875" / 403 mm
9.285" / 236 mm
Read this manual thoroughly. A complete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed. 1.375" / 35 mm 1.175" / 30 mm
4.95" / 126 mm
1.75" /
2T.02 General Description 44.5 mm
0.625" /
16 mm Art # A-02998
Plasma torches are similar in design to the automotive B. Torch Leads Lengths
spark plug. They consist of negative and positive sec-
tions separated by a center insulator. Inside the torch, Hand Torches are available as follows:
the pilot arc starts in the gap between the negatively
• 20 ft / 6.1 m, with ATC connectors
charged electrode and the positively charged tip. Once
the pilot arc has ionized the plasma gas, the superheated • 50 ft / 15.2 m, with ATC connectors
column of gas flows through the small orifice in the torch Machine Torches are available as follows:
tip, which is focused on the metal to be cut.
• 5 foot / 1.5 m, with ATC connectors
A single torch lead provides gas from a single source
to be used as both the plasma and secondary gas. The • 10 foot / 3.05 m, with ATC connectors
air flow is divided inside the torch head. Single - gas • 25 foot / 7.6 m, with ATC connectors
operation provides a smaller sized torch and inexpensive
• 50 foot / 15.2 m, with ATC connectors
operation.
C. Torch Parts
NOTE Starter Cartridge, Electrode, Tip, Shield Cup
Refer to Section "2T.05 Introduction to
Plasma", for a more detailed description of D. Parts - In - Place (PIP)
plasma torch operation. Torch Head has built - in switch
Refer to the Appendix Pages for additional
specifications as related to the Power Sup- 12 VDC circuit rating
ply used. E. Type Cooling
2T.03 Specifications Combination of ambient air and gas stream through

torch.
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.
Manual 0-4961 INTRODUCTION 2T-1

CUTMASTER 52
F. Torch Ratings 2T.05 Introduction to Plasma
Manual Torch Ratings
A. Plasma Gas Flow
Ambient 104° F
Temperature 40° C Plasma is a gas which has been heated to an ex-
tremely high temperature and ionized so that it
Duty Cycle 100% @ 60 Amps @ 400 scfh
becomes electrically conductive. The plasma arc
Maximum Current 60 Amps cutting and gouging processes use this plasma to
Voltage (Vpeak) 500V transfer an electrical arc to the workpiece. The metal
Arc Striking Voltage 7kV to be cut or removed is melted by the heat of the arc
and then blown away.
Mechanized Torch Ratings While the goal of plasma arc cutting is separation of
Ambient 104° F the material, plasma arc gouging is used to remove
Temperature 40° C metals to a controlled depth and width.
Duty Cycle 100% @ 100 Amps @ 400 scfh In a Plasma Cutting Torch a cool gas enters Zone B,
Maximum Current 120 Amps where a pilot arc between the electrode and the torch
Voltage (Vpeak) 500V tip heats and ionizes the gas. The main cutting arc
then transfers to the workpiece through the column
Arc Striking Voltage 7kV of plasma gas in Zone C.
G. Gas Requirements
Manual and Mechanized Torch Gas Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure 60 - 95 psi
Refer to NOTE 4.1 - 6.5 bar _
Maximum Input Pressure 125 psi / 8.6 bar Power
300 - 500 scfh Supply A
Gas Flow (Cutting and Gouging)
142 - 235 lpm +
! WARNING
B
This torch is not to be used with oxygen (O2). Workpiece

C A-00002
NOTE
Typical Torch Head Detail
Operating pressure varies with torch model,
operating amperage, and torch leads length.
Refer to gas pressure settings charts for each By forcing the plasma gas and electric arc through a
model. small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
H. Direct Contact Hazard arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
For standoff tip the recommended standoff is 3/16 illustration.
inches / 4.7 mm.
Zone A channels a secondary gas that cools the torch.
2T.04 Options And Accessories This gas also assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for
For options and accessories, see Section 6. a fast, slag - free cut.
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
2T-2 INTRODUCTION Manual 0-4961

CUTMASTER 52
The plasma gas flows into the torch through the Remote Pendant
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
To ATC PIP Switch Shield Cup
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 CNC Start
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
negative output is connected to the torch electrode To ATC PIP Switch Shield Cup
through the torch lead. The positive output is con-
nected to the workpiece via the work cable and to
the torch through a pilot wire.
Art # A-08168
E. Parts - In - Place (PIP)
The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes Automation Torch
a switch. The torch will not operate if this switch
is open.
To ATC PIP Switch Shield Cup
Torch Switch Torch Trigger
To Control
Cable Wiring
PIP Switch Shield Cup Parts - In - Place Circuit Diagram for Machine Torch
A-02997
Parts - In - Place Circuit Diagram for Hand Torch
Manual 0-4961 INTRODUCTION 2T-3

CUTMASTER 52
2T-4 INTRODUCTION Manual 0-4961

CUTMASTER 52
SECTION 3 SYSTEM:
INSTALLATION
1
3.01 Unpacking
2
1
2
1. Use the packing lists to identify and account for
each item.
2. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor and
/ or shipping company before proceeding with
the installation. Art# A-11478
Contactor cover
3. Record Power Supply and Torch model and serial
numbers, purchase date and vendor name, in the
information block at the front of this manual. 3.04 Primary Input Power Connections
3.02 Lifting Options

The Power Supply includes a handle for hand lifting CAUTION
only. Be sure unit is lifted and transported safely and Check your power source for correct voltage
securely. before plugging in or connecting the unit.
Check the Voltage Selector at the rear of the
! WARNING
unit for correct setting before plugging in
or connecting the unit. The primary power
source, fuse, and any extension cords used
Do not touch live electrical parts. must conform to local electrical code and the
recommended circuit protection and wiring
Disconnect input power cord before moving
requirements as specified in Section 2.
unit.
FALLING EQUIPMENT can cause serious Most units are shipped from the factory with a 230Volt
personal injury and can damage equipment. input power cable wired to the input contactor in the
single - phase configuration. The following illustrations
HANDLE is not for mechanical lifting. and directions are for changing that configuration to a
different voltage and or to three - phase operation or
back again if a change had already been made.
• Only persons of adequate physical strength should
Single-Phase (1ø) and Jumper Settings
lift the unit.
• Lift unit by the handles, using two hands. Do not
Jumper L1 -L4
use straps for lifting. L1 L1
• Use optional cart or similar device of adequate L2 L2 Jumper

Art # A-07984_AB
capacity to move unit. L3 L2-L3

L3
L4
• Place unit on a proper skid and secure in place L4
before transporting with a fork lift or other vehicle. GND
3.03 Opening the Contactor Cover Single Phase Input Power Wiring
The input power cord is connected to the main contactor, Three-Phase (3ø) and Jumper Settings
the contactor is located inside a box with a snap on cover.
Store copper jumper in spare parts box
The cover is held in place with two or more snap lock
tabs. To remove the cover release the front latch and tilt L1 L1 Jumper L1 -L4
the cover up about ½ inch. Then squeeze both sides of L2 L2
the cover and lift it straight up. See the Primary Input
Art # A-07983_AB
L3
Power Connections section for the necessary changes to L3
L4
the Contactor. Remember to replace the Contactor Cover L4
GND
when the changes are complete.
Three Phase Input Power Wiring

Manual 0-4961 INSTALLATION 3-1
CUTMASTER 52
NOTE 7. With a little slack in the wires, tighten the through
There is only one jumper setting that changes - hole protector to secure the power cable.
between the single and three phase settings. 8. Reinstall the Power Supply cover per instructions
To change from single phase to three phase, found in Section 5.
the jumper connected to L2 needs to be
removed and placed on the other L3 connec- 9. Connect the opposite end of individual wires to
tion so both ends of the jumper are attached a customer supplied plug or main disconnect.
to the same electrical point. See previous
10. Connect the input power cable (or close the main
illustrations.
disconnect switch) to supply power.
A. Connections to Single Phase Input Power
B. Connections to Three Phase Input Power
WARNING
WARNING
Disconnect input power from the power
Disconnect input power from the power
supply and input cable before attempting
supply and input cable before attempting
this procedure.
this procedure.
These instructions are for changing the input power and These instructions are for changing the input power and
or cable on the 208/230, 400, 460 VAC Power Supply to or cable on the 208/230, 400, 460 VAC Power Supply to
Single - Phase input power. Three - Phase input power.
1. Remove the Power Supply cover per instructions 1. Remove the Power Supply cover per instructions
found in Section 5. found in Section 5.
2. Disconnect the original input power cable from 2. Disconnect the original input power cable from
the main input contactor and the chassis ground the main input contactor and the chassis ground
connection. connection.
3. Loosen the through - hole protector on the back 3. Loosen the through - hole protector on the back
panel of the power supply. Pull the original panel of the power supply. Pull the original
power cable out of power supply. power cable out of the power supply.
4. If the power cable being used is not the factory 4. Using a customer supplied four - conductor input
- supplied cable, use a three - conductor input power cable for the voltage desired, strip back
power cable for the voltage desired and strip the insulation on the individual wires.
back the insulation on the individual wires.
5. Pass the cable being used through the access
5. Pass the cable being used through the access opening in the back panel of the power supply.
opening in the back panel of the power supply. Refer to Section 2 for power cable specifications.
Refer to Section 2 for power cable specifications.
CAUTION
CAUTION
The primary power source and power cable
The primary power source and power cable must conform to local electrical code and the
must conform to local electrical code and the recommended circuit protection and wiring
recommended circuit protection and wiring requirements (refer to table in Section 2).
requirements (refer to table in Section 2).
6. Connect the wires as follows.
6. Connect the wires as follows.
• Set Jumper wires on the contactor. See previ-
• Set Jumper wires on the contactor. See previous illustrations..
ous illustrations.
• Green / Yellow wire to Ground.
• Green / Yellow wire to Ground.
• Remaining wires to L1, L2 and L3 input. It
• Remaining wires to L1 and L2 input. It does does not matter what order these wires are
not matter what order these wires are at- attached.
tached.
3-2 INSTALLATION Manual 0-4961

CUTMASTER 52
7. With a little slack in the wires, tighten the through NOTE
- hole protector to secure the power cable. For a secure seal, apply thread sealant to the
8. Reinstall the Power Supply cover per instructions fitting threads, according to the maker's in-
found in Section 5. structions. Do Not use Teflon tape as a thread
sealer, as small particles of the tape may break
9. Connect the opposite end of individual wires to off and block the small air passages in the
a customer supplied plug or main disconnect. torch. Connect as follows:
Regulator/Filter
10. Connect the input power cable (or close the main
Assembly
disconnect switch) to supply power.
3.05 Gas Connections

Inlet Port
Connecting Gas Supply to Unit
The connection is the same for compressed air or high
pressure cylinders. Refer to the following two subsec-
tions if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The illustra-
tion shows typical fittings as an example. Art # A-07944
NOTE
For a secure seal, apply thread sealant to the Hose Clamp
fitting threads, according to manufacturer's
Gas Supply 1/4 NPT to 1/4"
instructions. Do not use Teflon tape as a
Hose (6mm) Fitting
thread sealer, as small particles of the tape
may break off and block the small air pas- Optional Single - Stage Filter Installation
sages in the torch.
Installing Optional Two - Stage Air Filter Kit
Regulator/Filter
Assembly This optional two - stage air line filter is also for use on
compressed air shop systems. Filter removes moisture
and contaminants to at least 5 microns.
Inlet Port
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back
Hose Clamp of the power supply per instructions supplied
1/4 NPT or ISO-R with the filter assembly.
to 1/4” (6mm) Fitting
Gas Supply
Hose NOTE
For a secure seal, apply thread sealant to the
fitting threads according to manufacturer's
instructions. Do Not use Teflon tape as a
Art # A-07943
thread sealer as small particles of the tape
Air Connection to Inlet Port may break off and block the small air pas-
sages in the torch.
Installing Optional Single - Stage Air Filter 2. Connect the two stage filter outlet hose to the
An optional filter kit is recommended for improved fil- inlet port of the Regulator / Filter Assembly.
tering with compressed air, to keep moisture and debris 3. Use customer - supplied fittings to connect the air
out of the torch. line to the Filter. A 1/4 NPT to 1/4" hose barbed
1. Attach the Single - Stage Filter Hose to the Inlet fitting is shown as an example.
Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the air line to the Filter. The illustration
shows typical fittings as an example.
Manual 0-4961 INSTALLATION 3-3
CUTMASTER 52
Regulator/Filter
Assembly
2-Stage Filter
Regulator Inlet Port (IN)
Input
Outlet Port
(OUT)
Two Stage
Filter
Hose Clamp Assembly
Gas Supply
Hose
1/4 NPT to 1/4”

(6mm) Fitting
Art # A-07945_AC
Optional Two - Stage Filter Installation
Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure
regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly
open each cylinder valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up
to 100 psi (6.9 bar) maximum and flows of at least 300 scfh (141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small
air passages in the torch.
3-4 INSTALLATION Manual 0-4961

CUTMASTER 52
SECTION 3 TORCH: 3. Place a welding filter lens in front of the torch and turn
ON the air. Do not start an arc!
INSTALLATION Any oil or moisture in the air will be visible on the lens.
3T.01 Torch Connections 3T.02 Setting Up Mechanical Torch
If necessary, connect the torch to the Power Supply. NOTE

Connect only the Thermal Dynamics model SL60 /
When converting a hand torch or a machine
Manual or SL100 / Mechanical Torch to this power sup-
torch system to operate an Automation
ply. Maximum torch leads length is 100 feet / 30.5 m,
100SLV torch, one of the CNC interface
including extensions.
options will be required if not previously
installed.
WARNING
Disconnect primary power at the source be- WARNING
fore connecting the torch.
Disconnect primary power at the source be-
fore disassembling the torch or torch leads.
1. Align the ATC male connector (on the torch lead)
with the female receptacle. Push the male con-
The mechanical torch includes a positioning tube with
nector into the female receptacle. The connectors
rack and pinch block assembly.
should push together with a small amount of
pressure. 1. Mount the torch assembly on the cutting table.
2. Secure the connection by turning the locking nut 2. To obtain a clean vertical cut, use a square to
clockwise until it clicks. DO NOT use the locking align the torch perpendicular to the surface of
nut to pull the connection together. Do not use the workpiece.
tools to secure the connection.
Pinch Block
Assembly
2 Square
1
Art # A-07885
Workpiece
A-02585
Connecting the Torch to the Power Supply

3. The system is ready for operation.
Check Air Quality
To test the quality of air:
Mechanical Torch Set - Up
1. Put the ON / OFF switch in the ON (up) posi-
tion. 3. The proper torch parts (shield cup, tip, start car-
tridge, and electrode) must be installed for the
type of operation. Refer to Section "4T.01 Torch
2. Put the Function Control switch in the SET posi- Parts Selection" on page 4T-1 for details.
tion.
Manual 0-4961 INSTALLATION 3T-1

CUTMASTER 52
3T-2 INSTALLATION Manual 0-4961

CUTMASTER 52
SECTION 4 SYSTEM: 1 2 3 4
OPERATION
4.01 Front Panel Controls / Features
A
MIN MAX
PSI BAR
See Illustration for numbering Identification

MAX MAX
1. Output Current Control

Sets the desired output current. Output settings up MIN MIN
to 60 Amps may be used for drag cutting (with the

torch tip contacting the workpiece) or for standoff !
cutting.
2. Function Control
Function Control Knob; Used to select between the
different operating modes. Art# A-07886
5 6 7 8 9 10
SET Used to purge the air through the unit
and torch and leads and to adjust gas pressure.
6. Temp Indicator
RUN Used for general cutting operations
Indicator is normally OFF. Indicator is ON when
RAPID AUTO RESTART Allows for faster internal temperature exceeds normal limits. Let the
restarting of the Pilot Arc for uninterrupted cutting. unit cool before continuing operation.
LATCH Used for longer hand held cuts. 7. Gas Indicator

Once a cutting arc is established, the torch switch can
Indicator is ON when minimum input gas pressure
be released. The cutting arc will remain ON until the
for power supply operation is present. Minimum
torch is lifted away from the work piece, the torch
pressure for power supply operation is not sufficient
leaves the edge of the work piece the torch switch
for torch operation.
is activated again or if one of the system interlocks
is activated. 8. DC Indicator
3. ON OFF Power Switch Indicator is ON when DC output circuit is active.
ON / OFF Switch controls input power to the 9. ! Fault Error Indicator

power supply. Up is ON, down is OFF.
Indicator is ON when Fault circuit is active. See Sec-
4. Air/Gas Pressure Control tion 5 for explanations of fault lights.
10. Pressure Indicators
The Pressure + Control is used in the "SET"
mode to adjust the air/gas pressure. Pull the knob PSI BAR
MAX MAX
OUT to adjust and push IN to lock.
90 6.3
5. AC Indicator 85 5.9
80 5.5
Steady light indicates power supply is ready for
operation. Blinking light indicates unit is in pro- 75 5.2
Art # A-08170
tective interlock mode. Shut unit OFF, shut OFF or 70 4.8

disconnect input power, correct the fault, and restart 65 4.5
the unit. Refer to Section 5 for details.
MIN MIN
The Indicators will illuminate according to the pres-

sure set by the Pressure Control Knob (number 4).
Manual 0-4961 OPERATION 4-1

CUTMASTER 52
4.02 Preparations for Operation Power ON
At the start of each operating session: Place the Power Supply ON / OFF switch to the ON
(up) position. AC indicator turns ON. Gas
indicator turns ON if there is sufficient gas pres-

WARNING
sure for power supply operation and the cooling
Disconnect primary power at the source be- fans turn ON.
fore assembling or disassembling power sup-
ply, torch parts, or torch and leads assemblies. NOTE
Minimum pressure for power supply op-
eration is lower than minimum for torch
Torch Parts Selection operation.
Check the torch for proper assembly and appropriate The cooling fans will turn ON as soon as the
torch parts. The torch parts must correspond with unit is turned ON. After the unit is idle for
the type of operation, and with the amperage output ten (10) minutes the fans will turn OFF. The
of this Power Supply (60 amps maximum). Refer to fans will come back ON as soon as the torch
Section 4T.07 and following for torch parts selection. switch (Start Signal) is activated or if the unit
is turned OFF, then turned ON again. If an
Torch Connection over temperature condition occurs, the fans
Check that the torch is properly connected. Only will continue to run while the condition ex-
Thermal Dynamics model SL60 / Manual or SL100 / ists and for a ten (10) minute period once the
Mechanical Torches may be connected to this Power condition is cleared.
Supply. See Section 3T of this manual. Set Operating Pressure
Check Primary Input Power Source 1. Place the Power Supply Function Control knob
1. Check the power source for proper input volt-
to the SET position. Gas will flow.
age. Make sure the input power source meets
the power requirements for the unit per Section
2, Specifications. 2. For Standoff cutting, adjust gas pressure from 70
- 85 psi / 4.8 - 5.9 bar (LED's in center of control
2. Connect the input power cable (or close the
panel). Refer to the Standoff chart for pressure
main disconnect switch) to supply power to the
setting details.
system.
Air Source 1 2
Ensure source meets requirements (refer to Section
2). Check connections and turn air supply ON.
Connect Work Cable
A
Clamp the work cable to the workpiece or cutting
MIN MAX
PSI BAR
MAX MAX
+
table. The area must be free from oil, paint and rust.
Connect only to the main part of the workpiece; do
not connect to the part to be cut off.
MIN MIN
Art# A-07946
Art # A-04509
4-2 OPERATION Manual 0-4961

CUTMASTER 52
STANDOFF Typical Cutting Speeds
CutMaster 52 Gas Pressure Settings Cutting speeds vary according to torch output am-
Leads SL60 SL100 perage, the type of material being cut, and operator
Length (Hand Torch) (Mechanized Torch) skill. Refer to Section "4T.08 Recommended Cutting
Speeds for Mechanized Torch With Exposed Tip" and
Up to 25' 75 psi 75 psi
following for greater details.
(7.6 m) 5.2 bar 5.2 bar
Each Output current setting or cutting speeds may be
additional Add 5 psi Add 5 psi reduced to allow slower cutting when following a
25' 0.4 bar 0.4 bar line, or using a template or cutting guide while still
(7.6 m) producing cuts of excellent quality.
Postflow
3. For Drag cutting, adjust gas pressure from 75 -
95 psi / 5.2 - 6.5 bar (LED's in center of control Release the trigger to stop the cutting arc. Gas con-
panel). Refer to the Drag Cutting chart for pres- tinues to flow for approximately 20 seconds. During
sure setting details. post - flow, if the user moves the trigger release to
the rear and presses the trigger, the pilot arc starts.
DRAG The main arc transfers to the workpiece if the torch
CutMaster 52 Gas Pressure Settings tip is within transfer distance to the workpiece.
SL60 Shutdown
Leads Length
(Hand Torch)
Up to 25' 80 psi Turn the ON / OFF switch to OFF
(7.6 m) 5.5 bar (down). All Power Supply indicators shut OFF.
Unplug the input power cord or disconnect input
Each additional 25' Add 5 psi power. Power is removed from the system.
(7.6 m) 0.4 bar
Select Current Output Level

1. Place the Function Control Knob in one of the
three operating positions available:
RUN ,
RAPID AUTO RESTART
or LATCH . Gas flow stops.

2. Set the output current to desired amperage with
the Output Current Control Knob.
Cutting Operation
When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the
RUN position, there is a brief delay in restarting
the pilot arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the work-
piece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the
workpiece. (Use the 'Rapid Auto Restart' position
when cutting expanded metal or gratings, or in
gouging or trimming operations when an uninter-
rupted restart is desired). And with the knob in the
LATCH position the main cutting arc will be main-
tained after the torch switch is released.
Manual 0-4961 OPERATION 4-3

CUTMASTER 52
4-4 OPERATION Manual 0-4961

CUTMASTER 52
SECTION 4 TORCH:
OPERATION Torch Head
Electrode
4T.01 Torch Parts Selection
Depending on the type of operation to be done deter-
mines the torch parts to be used. Start Cartridge
Type of operation:
Drag cutting, standoff cutting or gouging Tip
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter Shield Cup
Cartridge
A-03510_AB
NOTE Torch Parts (Drag Shield Cap & Shield Cup Body Shown)
Refer to Section 4T.07 and following for ad-
ditional information on torch parts. 3. Install the replacement Electrode by pushing it
straight into the torch head until it clicks.
Change the torch parts for a different operation as fol-
4. Install the starter cartridge and desired tip for
lows:
the operation into the torch head.
5. Hand tighten the shield cup assembly until it
WARNING is seated on the torch head. If resistance is felt
when installing the cup, check the threads before
Disconnect primary power at the source be- proceeding.
fore assembling or disassembling torch parts,
or torch and leads assemblies.
4T.02 Cut Quality
NOTE
NOTE
Cut quality depends heavily on setup and
The shield cup holds the tip and starter car- parameters such as torch standoff, alignment
tridge in place. Position the torch with the with the workpiece, cutting speed, gas pres-
shield cup facing upward to keep these parts sures, and operator ability.
from falling out when the cup is removed.
Cut quality requirements differ depending on applica-
1. Unscrew and remove the shield cup assembly tion. For instance, nitride build - up and bevel angle
from the torch head. may be major factors when the surface will be welded
2. Remove the Electrode by pulling it straight out after cutting. Dross - free cutting is important when fin-
of the Torch Head. ish cut quality is desired to avoid a secondary cleaning
operation. The following cut quality characteristics are
illustrated in the following figure:
Manual 0-4961 OPERATION 4T-1

CUTMASTER 52
Kerf Width 4T.03 General Cutting Information
Cut Surface
Bevel Angle
Top
Spatter
! WARNING
Disconnect primary power at the source be-
fore disassembling the power supply, torch,
Top Edge or torch leads.
Rounding
Frequently review the Important Safety Pre-
Dross
cautions at the front of this manual. Be sure
Build-Up the operator is equipped with proper gloves,
Cut Surface A-00007
clothing, eye and ear protection. Make sure
Drag Lines no part of the operator’s body comes into
Cut Quality Characteristics contact with the workpiece while the torch
is activated.
Cut Surface
The desired or specified condition (smooth or rough)
of the face of the cut. CAUTION
Nitride Build - Up Sparks from the cutting process can cause
damage to coated, painted, and other surfaces
Nitride deposits can be left on the surface of the cut such as glass, plastic and metal.
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material NOTE
is to be welded after the cutting process. Handle torch leads with care and protect
them from damage.
Bevel Angle
Piloting
The angle between the surface of the cut edge and
a plane perpendicular to the surface of the plate. Piloting is harder on parts life than actual cutting
A perfectly perpendicular cut would result in a 0° because the pilot arc is directed from the electrode
bevel angle. to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
Top - Edge Rounding
parts life.
Rounding on the top edge of a cut due to wearing
Torch Standoff
from the initial contact of the plasma arc on the
workpiece. Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
Bottom Dross Buildup
shield cup life. Standoff may also significantly affect
Molten material which is not blown out of the cut the bevel angle. Reducing standoff will generally
area and resolidifies on the plate. Excessive dross result in a more square cut.
may require secondary cleanup operations after
Edge Starting
cutting.
For edge starts, hold the torch perpendicular to the
Kerf Width
workpiece with the front of the tip near (not touch-
The width of the cut (or the width of material re- ing) the edge of the workpiece at the point where the
moved during the cut). cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to "reach"
Top Spatter (Dross) for the edge of the metal. Establish the cutting arc
Top spatter or dross on the top of the cut caused by as quickly as possible.
slow travel speed, excess cutting height, or cutting Direction of Cut
tip whose orifice has become elongated.
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 be-
ing more square than the other. Viewed along the
direction of travel, the right side of the cut is more
square than the left.
4T-2 OPERATION Manual 0-4961
CUTMASTER 52
Left Side NOTE
Cut Angle The tip should never come in contact with
Right Side
Cut Angle the workpiece except during drag cutting
operations.
2. Depending on the cutting operation, do one of

the following:
a. For edge starts, hold the torch perpendicular
to the workpiece with the front of the tip on
A-00512
the edge of the workpiece at the point where
Side Characteristics Of Cut the cut is to start.
b. For standoff cutting, hold the torch 1/8 - 3/8
To make a square - edged cut along an inside
in (3-9 mm) from the workpiece as shown
diameter of a circle, the torch should move coun-
below.
terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
travel in a clockwise direction.
Dross Torch
When dross is present on carbon steel, it is com-

monly referred to as either “high speed, slow speed,
or top dross”. Dross present on top of the plate is
normally caused by too great a torch to plate dis-
tance. "Top dross" is normally very easy to remove
and can often be wiped off with a welding glove.
"Slow speed dross" is normally present on the bot-
tom edge of the plate. It can vary from a light to
heavy bead, but does not adhere tightly to the cut Shield Cup Standoff Distance
edge, and can be easily scraped off. "High speed 1/8" - 3/8" (3 - 9mm)
dross" usually forms a narrow bead along the bottom
of the cut edge and is very difficult to remove. When
cutting a troublesome steel, it is sometimes useful
to reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished A-00024_AB
Standoff Distance
by scraping, not grinding.
3. Hold the torch away from your body.
4T.04 Hand Torch Operation
4. Slide the trigger release toward the back of the
Standoff Cutting With Hand Torch torch handle while simultaneously squeezing the
trigger. The pilot arc will start.
NOTE
For best performance and parts life, always
use the correct parts for the type of operation.
1. The torch can be comfortably held in one hand

or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the Trigger
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
Trigger Release
back end for maximum heat protection. Choose
A-02986
the holding technique that feels most comfortable
and allows good control and movement.
5. Bring the torch within transfer distance to the
work. The main arc will transfer to the work,
and the pilot arc will shut OFF.

CUTMASTER 52
NOTE Shield Cup With Straight Edge
The gas preflow and postflow are a character- The drag shield cup can be used with a non conductive
istic of the power supply and not a function straight edge to make straight cuts by hand.
of the torch.
Trigger
WARNING
The straight edge must be non - conductive.
1
2
Trigger Release
Non-Conductive
Straight Edge
Cutting Guide
3
4 A-03539
Using Drag Shield Cup With Straight Edge

Art # A-03383
The crown shield cup functions best when cutting

6. Cut as usual. Simply release the trigger assembly 3/16 inch (4.7 mm) solid metal with relatively
to stop cutting. smooth surface.
7. Follow normal recommended cutting practices as Drag Cutting With a Hand Torch
provided in the power supply operator's manual.
Drag cutting works best on metal 1/4" (6 mm) thick
NOTE or less.
When the shield cup is properly installed,
there is a slight gap between the shield cup NOTE
and the torch handle. Gas vents through this For best parts performance and life, always
gap as part of normal operation. Do not at- use the correct parts for the type of operation.
tempt to force the shield cup to close this gap.
1. Install the drag cutting tip and set the output
Forcing the shield cup against the torch head
current.
or torch handle can damage components.
8. For a consistent standoff height from the work- or steadied with two hands. Position the hand to
piece, install the standoff guide by sliding it onto press the Trigger on the torch handle. With the
the torch shield cup. Install the guide with the hand torch, the hand may be positioned close to
legs at the sides of the shield cup body to main- the torch head for maximum control or near the
tain good visibility of the cutting arc. During back end for maximum heat protection. Choose
operation, position the legs of the standoff guide the holding technique that feels most comfortable
against the workpiece. and allows good control and movement.
4. Keep the torch in contact with the workpiece
during the cutting cycle.
Shield Cup torch handle while simultaneously squeezing the
Standoff Guide
Torch Tip
Workpiece Art # A-04034

CUTMASTER 52
Piercing With Hand Torch
or steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
Trigger
the torch head for maximum control or near the
back end for maximum heat protection. Choose
Trigger Release the technique that feels most comfortable and
A-02986
allows good control and movement.
7. Bring the torch within transfer distance to the NOTE

work. The main arc will transfer to the work,
The tip should never come in contact with
the workpiece except during drag cutting
operations.
NOTE
The gas preflow and postflow are a character- 2. Angle the torch slightly to direct blowback
istic of the power supply and not a function particles away from the torch tip (and operator)
of the torch. rather than directly back into it until the pierce
is complete.
Trigger
3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue the
cut onto the line. Hold the torch perpendicular
1
to the workpiece after the pierce is complete.
2
Trigger Release
torch handle while simultaneously squeezing the
4
Trigger
Art # A-03383
8. Cut as usual. Simply release the trigger assembly Trigger Release

A-02986
to stop cutting.
9. Follow normal recommended cutting practices as 6. Bring the torch within transfer distance to the
provided in the power supply operator's manual. work. The main arc will transfer to the work,
NOTE
NOTE
When the shield cup is properly installed,
there is a slight gap between the shield cup The gas preflow and postflow are a character-
and the torch handle. Gas vents through this istic of the power supply and not a function
gap as part of normal operation. Do not at- of the torch.
tempt to force the shield cup to close this gap. When the shield cup is properly installed,
Forcing the shield cup against the torch head there is a slight gap between the shield cup
or torch handle can damage components. and the torch handle. Gas vents through this
gap as part of normal operation. Do not at-
tempt to force the shield cup to close this gap.
Forcing the shield cup against the torch head
or torch handle can damage components.

CUTMASTER 52
7. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying the shield
cup in anti - spatter compound will minimize the CAUTION
amount of scale which adheres to it. Touching the torch tip or shield cup to the
Cutting speed depends on material, thickness, and the work surface will cause excessive parts wear.
operator’s ability to accurately follow the desired cut Torch Travel Speed
line. The following factors may have an impact on sys-
tem performance:
NOTE
• Torch parts wear Refer to Appendix Pages for additional infor-
• Air quality mation as related to the Power Supply used.
• Line voltage fluctuations Optimum torch travel speed is dependent on current
• Torch standoff height setting, lead angle, and mode of operation (hand or
machine torch).
• Proper work cable connection
Current Setting
Current settings depend on torch travel speed,
4T.05 Gouging mode of operation (hand or machine torch), and the
amount of material to be removed.
! WARNING
Lead Angle
The angle between the torch and workpiece depends
Be sure the operator is equipped with proper on the output current setting and torch travel speed.
gloves, clothing, eye and ear protection and The recommended lead angle is 35°. At a lead angle
that all safety precautions at the front of this greater than 45° the molten metal will not be blown
manual have been followed. Make sure no out of the gouge and may be blown back onto the
part of the operator’s body comes in contact torch. If the lead angle is too small (less than 35°),
with the workpiece when the torch is acti- less material may be removed, requiring more pass-
vated. es. In some applications, such as removing welds
Disconnect primary power to the system or working with light metal, this may be desirable.
before disassembling the torch, leads, or
power supply.
Torch Head
CAUTION
35°
Sparks from plasma gouging can cause dam-
age to coated, painted or other surfaces such
as glass, plastic, and metal.
Standoff Height
Check torch parts. The torch parts must cor-
respond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection. Workpiece
A-00941_AB
Gouging Parameters
Gouging Angle and Standoff Distance
Gouging performance depends on parameters
such as torch travel speed, current level, lead angle Standoff Distance
(the angle between the torch and workpiece), and
the distance between the torch tip and workpiece The tip to work distance affects gouge quality and
(standoff). depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
mm) allows for smooth, consistent metal removal.
Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater
than 1/4 inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.

CUTMASTER 52
Slag Buildup
Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be
removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the
gouge path. However, slag build - up can cause inconsistencies and irregular metal removal if large amounts of
material build up in front of the arc. The build - up is most often a result of improper travel speed, lead angle,
or standoff height.
4T.06 Mechanized Torch Operation

Cutting With Mechanized Torch
The mechanized torch can be activated by remote control pendant or by a remote interface device such as CNC.
1. To start a cut at the plate edge, position the center of the torch along the edge of the plate.
Travel Speed
Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the
following:
1. Straight Arc
A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut
using air plasma on stainless or aluminum.
2. Leading Arc
The leading arc is directed in the same direction as torch travel. A five degree leading arc is generally recom-
mended for air plasma on mild steel.
3. Trailing Arc
The trailing arc is directed in the opposite direction as torch travel.
Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el
Straight Arc
Trailing Arc
A-02586
Leading Arc
Mechanized Torch Operation

CUTMASTER 52
For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the
arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves
from side to side in search of metal for transfer.
Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down
the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the
appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.
Piercing With Machine Torch
To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above
the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow
back onto the front end of the torch.
When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled
until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the rec-
ommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from
the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound
will minimize the amount of scale which adheres to it.

CUTMASTER 52
4T.07 Parts Selection for Manual and Mechanized Torch Cutting
Tips: Shield
DRAG TIP Cup Body, Shield Cap, Deflector
CUTTING 9-8237 9-8243
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
Shield Cap, Deflector
CUTTING Tip:
9-8237
9-8243
40A 9-8208 Standoff Guide

Shield Cup 9-8251
STANDOFF
9-8218
CUTTING
DRAG SHIELD
CUTTING Shield 50-60A 9-8235
50-60A Tips:
Cup Body,
CUTTING 9-8237
9-8243
Start
Cartridge 50-55A 9-8209
Shield Cup Standoff Guide
9-8213 60A 9-8210 9-8281
9-8218
STANDOFF
CUTTING
DRAG SHIELD O-Ring No. 8-3488

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
Tip Gouging D 9-8228 (60 - 120 Amps)
Tip Gouging E 9-8254 (60 - 120 Amps)

CUTMASTER 52
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip
Type Torch: SL60 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Speed (Per Plasma Gas Pierce
Thickness Tip Output Amperage Standoff Flow (CFH) Pierce
Minute) Press Height
(Cat. Volts Delay
Inches (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm No.) (VDC) (Sec)
0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 70 4.8 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 70 4.8 55 170 NR NR NR
0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 70 4.8 55 170 NR NR NR
0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Aluminum

(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 70 4.8 55 170 NR NR NR

CUTMASTER 52
Type Torch: SL60 With Exposed Tip Type Material: Mild Steel
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8
0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 75 5.2 90 245 0.20 0.19 4.8
0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.19 4.8
0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 75 5.2 90 245 0.50 0.19 4.8
0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 75 5.2 90 245 0.75 0.19 4.8
0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 75 5.2 90 245 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 75 5.2 90 245 NR NR NR

CUTMASTER 52
Type Torch: SL60 With Exposed Tip Type Material: Aluminum
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.00 0.25 6.4
0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 75 5.2 90 245 0.20 0.25 6.4
0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 75 5.2 90 245 0.30 0.25 6.4
0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 75 5.2 90 245 0.50 0.25 6.4
0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 75 5.2 90 245 0.80 0.25 6.4
0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 75 5.2 90 245 NR NR NR
NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
Section "Set Operating Pressure" on page 4-2.
** Total flow rate includes plasma and secondary gas flow.

CUTMASTER 52
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip
Type Torch: SL60 With Shielded Tip Type Material: Mild Steel
Volts Delay
Inches (Cat. No.) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm (VDC) (Sec)
0.036 0.9 9-8208 114 40 170 4.32 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 120 40 90 2.29 0.19 4.8 70 4.8 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 121 40 80 2.03 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 122 40 75 1.91 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 123 40 30 0.76 0.19 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 125 40 25 0.64 0.19 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 138 40 11 0.28 0.19 4.8 70 4.8 55 170 NR NR NR
0.500 12.7 9-8208 142 40 7 0.18 0.19 4.8 70 4.8 55 170 NR NR NR
0.625 15.9 9-8208 152 40 3 0.08 0.19 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.036 0.9 9-8208 109 40 180 4.57 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 105 40 165 4.19 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 115 40 120 3.05 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 120 40 65 1.65 0.187 4.8 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 125 40 25 0.64 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 130 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 130 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Shielded Tip Type Material: Aluminum

(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 70 4.8 55 170 NR NR NR

CUTMASTER 52
Type Torch: SL60 With Shielded Tip Type Material: Mild Steel
Volts Delay
Inches (Cat. No.) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Inches mm
mm (VDC) (Sec)
0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 75 5.2 90 245 0.00 0.2 5.1
0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 75 5.2 90 245 0.20 0.2 5.1
0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.2 5.1
0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 75 5.2 90 245 0.50 0.2 5.1
0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 75 5.2 90 245 0.75 0.2 5.1
0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 75 5.2 90 245 NR NR NR
Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel
(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 75 5.2 90 245 NR NR NR

CUTMASTER 52
Type Torch: SL60 With Shielded Tip Type Material: Aluminum

(Cat. Volts Delay
mm No.) (VDC) (Sec)
0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 75 5.2 90 245 0.80 0.20 5.1
0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR
NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
Section "Set Operating Pressure" on page 4-2.
** Total flow rate includes plasma and secondary gas flow.

CUTMASTER 52
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709; D499620;
D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8241 Shield Cap US Pat No(s) 6914211; D505309
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633

CUTMASTER 52
Catalog # Description Patent(s)
The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:
Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap

CUTMASTER 52

CUTMASTER 52
SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Maintain more often
Warning! if used under severe
Disconnect input power before maintaining. conditions
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the

cables and leads.
Visually inspect the torch body tip, Replace as needed
electrode, start cartridge and shield cup
3 Months
Replace all
Clean
broken parts
exterior
of power supply
6 Months
Visually check and

Carefully clean the
interior
Art # A-07938_AB
Manual 0-4961 SERVICE 5-1

CUTMASTER 52
5.02 Maintenance Schedule 5.03 Common Faults
NOTE Problem - Symptom Common Cause
The actual frequency of maintenance may Insufficient 1. Cutting speed too fast.
need to be adjusted according to the operat- Penetration 2. Torch tilted too much.
ing environment. 3. Metal too thick.
4. Worn torch parts
Daily Operational Checks or Every Six Cutting Hours: 5. Cutting current too low.
1. Check torch consumable parts, replace if dam- 6. Non - Genuine Thermal Dynamics
aged or worn. parts used
7. Incorrect gas pressure
2. Check plasma and secondary supply and pres-
sure/flow. Main Arc 1. Cutting speed too slow.
Extinguishes 2. Torch standoff too high from
3. Purge plasma gas line to remove any moisture workpiece.
build-up. 3. Cutting current too high.
4. Work cable disconnected.
Weekly or Every 30 Cutting Hours:
5. Worn torch parts.
1. Check fan for proper operation and adequate air 6. Non - Genuine Thermal Dynamics
flow. parts used
2. Inspect torch for any cracks or exposed wires, Excessive Dross 1. Cutting speed too slow.
replace if necessary. Formation 2. Torch standoff too high from
workpiece.
3. Inspect input power cable for damage or exposed 3. Worn torch parts.
wires, replace if necessary. 4. Improper cutting current.
Six Months or Every 720 Cutting Hours: 5. Non - Genuine Thermal Dynamics
parts used
1. Check the in-line air filter(s), clean or replace as 6. Incorrect gas pressure
required.
Short Torch Parts Life 1. Oil or moisture in air source.
2. Check cables and hoses for leaks or cracks, re- 2. Exceeding system capability
place if necessary. (material too thick).
3. Excessive pilot arc time
3. Check all contactor points for severe arcing or
4. Gas pressure too low.
pits, replace if necessary.
5. Improperly assembled torch.
4. Vacuum dust and dirt out of the entire machine. 6. Non - Genuine Thermal Dynamics
parts used
Difficult Starting 1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
CAUTION parts used.
Do not blow air into the power supply during 3. Incorrect gas pressure.
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive
electrical components and cause damage to
the unit.
5-2 SERVICE Manual 0-4961

CUTMASTER 52
5.04 Fault Indicator
At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.
To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit
count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator
and 75 psi indicators are ON indicating the version would be 2.3.
7
6
5 MIN
A
MAX
PSI
MAX
BAR
MAX
+
4
3
2
1 MIN MIN
0
!
Art# A-07988
1 2 3 4 5
When the ! "Fault" indicator is ON or blinking it will be accompanied by one of the pressure indicator lights
depending on what the fault is. The following table explains each of those Faults.
Pressure Fault
Indicator
Max Over Pressure
90 Internal Error
85 Shorted Torch
80 Consumables Missing
75 Start Error
70 Parts in Place
65 Input Power
Min Under Pressure
NOTE
Fault explanations are covered in the following tables.

CUTMASTER 52
5.05 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and troubleshooting
techniques.
Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
is ON but the A/C OFF position.
Indicator does not 2. Primary fuses / breakers are 2. a) Have qualified person check primary fuses / breakers.
light blown or tripped. b) Connect unit to known good primary power receptacle
3. Units internal fuse blown. 3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Faulty components in unit. 4. Return to authorized service center for repair or replacement.
Fault indicator 1. INPUT VOLTAGE SELECTION 1. Set INPUT VOLTAGE SELECTION SWITCH to match primary
flashing, 65 PSI SWITCH set for incorrect voltage. input voltage.
indicator flashing 2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.05 Input Wiring
3. Faulty components in unit. Specifications" on page 2-3.
3. Return to authorized service center for repair or replacement.
TEMPERATURE 1. Air flow through or around the 1. Refer to clearance information – see Section "2.04 Power
indicator ON. unit is obstructed. Supply Specifications" on page 2-2
FAULT indicator 2. Duty cycle of the unit has been 2. Allow unit to cool.
flashing. exceeded.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.
GAS LED OFF, 1. Gas supply not connected to 1. Connect gas supply to unit.
FAULT and MIN unit.
pressure indicators 2. Gas supply not turned ON. 2. Turn gas supply ON.
flashing. 3. Gas supply pressure too low. 3. Set air supply inlet pressure to unit to 120 psi.
4. AIR PRESSURE CONTROL 4. Adjust regulator to set air pressure - see Section "4. Air/Gas
regulator set too low. Pressure Control" on page 4-1
FAULT and 70 PSI 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
indicators flashing. 2. Torch not properly connected to 2. Insure torch ATC is securely fastened to unit.
power supply.
3. Problem in torch and leads PIP 3. Replace torch and leads or return to authorized service center
circuit. for repair or replacement.
FAULT and 75 PSI 1. Start signal is active when ON/ 1. Start can be active for one of the following:
indicators flashing. OFF SWITCH is turned to ON • Hand torch switch held closed
position. • Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service center
switch circuit. for repair or replacement.

CUTMASTER 52
Problem - Symptom Possible Cause Recommended Action
FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten.
indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install
Gas flow is cycling cartridge missing. missing parts.
ON and OFF. 3. Torch start cartridge is stuck. 3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Open conductor in torch leads. 4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6. Return to authorized service center for repair or
replacement.
Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC Controller device not 2. Contact Controller manufacturer.
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit. 3. Return to authorized service center for repair or
DC LED OFF. replacement.
FAULT and 85 PSI 1. Upper O-ring on torch head is in 1. Remove shield cup from torch; check upper O-ring position;
indicators flashing. wrong position. correct if necessary.
2. Torch starter cartridge is stuck. 2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Worn or faulty torch parts. 3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch. 4. Replace torch and leads or return to an authorized service
center for repair.
5. Temporary Short indicated by 5 5. Release torch switch and reactivate.
blinks per second.
6. Power Supply Failure (Standard 6. Return to authorized service center for repair or
rate of blinking) replacement.
No Fault lights ON, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 85 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service center
for repair.
Pilot arc is ON but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.
Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in Section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.

CUTMASTER 52
5.06 Power Supply Basic Parts Replacement C. Filter Element Assembly Replacement
The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
WARNING checked per the Maintenance Schedule (Section 5.02),
and either cleaned or replaced.
Disconnect primary power to the system
before disassembling the torch, leads, or 1. Remove power from the power supply; turn OFF
power supply. the gas supply and bleed down the system.
2. Remove the system cover. See "A Cover Re-
This section describes procedures for basic parts replace- moval" in this section.
ment. For more detailed parts replacement procedures,
refer to the Power Supply Service Manual. 3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
A. Cover Removal illustration.
1. Remove the upper and lower screws which 4. Hold a wrench or similar tool against the locking
secure the cover to the main assembly. Do not ring on the filter assembly fitting, then pull on
loosen the lower screws inside the cut out slots the hose to release it. (Numbers 2 and 3 in the
in the bottom of the cover. following illustration).
Upper
Screws
Lower 1
Screws
Slots
Lower
Screws
Art # A-07989
Art # A-07947
2. Carefully pull the Cover up and away from the

unit.
B. Cover Installation 4
3 5
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that
slots in the bottom edges of the cover engage the 6mm
lower screws.
3. Tighten lower screws.
5. Remove the fitting from the filter element as-
4. Reinstall and tighten the upper screws. sembly by inserting a 6 mm hex wrench into
the internal hex fitting and turning it counter
clock-wise (left). Numbers 4 and 5 in the previous
illustration.

CUTMASTER 52
6. Disconnect the input line from the filter element
assembly.
Housing
7. Remove the filter element assembly through the
rear opening.
NOTE Filter
Element
If replacing or cleaning just the filter element (Cat. No. 9-7741)
refer to the following illustration for disas-
sembly. Spring
O-ring
(Cat. No. 9-7743) Assembled Filter
Cover
Barbed
Filter Element Fitting Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and

set Element aside to dry.
6. Wipe inside of housing clean, then insert the
replacement Filter Element open side first.
7. Replace Housing on Cover.
Art # A-07990
8. Reattach gas supply.
8. Install the new or cleaned assembly by reversing these
procedures. NOTE
9. Turn ON the air supply and check for leaks before If unit leaks between housing and cover,
reinstalling the cover. inspect the O-ring for cuts or other damage.
Optional Single-Stage Filter Element Replacement Optional Two-Stage Filter Element Replacement
These instructions apply to power supplies where the The Two-Stage Air Filter has two Filter Elements. When
optional Single-Stage Filter has been installed. the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unac-
The Power Supply shuts down automatically when
ceptable. Refer to Section 6, Parts List, for replacement
the Filter Element becomes completely saturated. The
filter element catalog number.
Filter Element can be removed from its housing, dried,
and reused. Allow 24 hours for Element to dry. Refer 1. Shut OFF primary input power.
to Section 6, Parts List, for replacement filter element
catalog number. 2. Shut OFF air supply and bleed down system.
1. Remove power from power supply.

2. Shut OFF air supply and bleed down system WARNING
before disassembling Filter to change Filter Ele-
Always turn OFF the air supply and bleed
ment.
the system before disassembling the Filter
3. Disconnect gas supply hose. Assembly as injury could result.
4. Turn the Filter Housing Cover counter-clockwise
and remove it. The Filter Element is located 3. Loosen the two bolts on the top of the Filter As-
inside the Housing. sembly enough to allow the Filter Elements to
move freely.
4. Note the location and orientation of the old Filter
Elements.
5. Slide out the old Filter Elements.

CUTMASTER 52
First & Second

Stage
Cartridges
(as marked)
Art # A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4
above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque
may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom fitting is normal.
This completes the parts replacement procedures.

CUTMASTER 52
SECTION 5 TORCH:
SERVICE
Upper Groove
5T.01 General Maintenance with Vent Holes
Must Remain Open
NOTE
Upper O-Ring
Refer to Previous "Section 5: System" for com- in Correct Groove
mon and fault indicator descriptions.
Threads
Cleaning Torch
Lower O-Ring Art # A-03725
Even if precautions are taken to use only clean air Torch Head O-Ring
with a torch, eventually the inside of the torch be-
comes coated with residue. This buildup can affect
the pilot arc initiation and the overall cut quality of ATC Male Connector
the torch.
WARNING
before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while
the AC indicator light of the Power Supply
is ON.
The inside of the torch should be cleaned with elec-

trical contact cleaner using a cotton swab or soft wet Gas Fitting
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
CAUTION
Art #A-03791 O-Ring
Dry the torch thoroughly before reinstalling.
ATC O-Ring
O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male Con- NOTE
nector requires lubrication on a scheduled basis.
DO NOT use other lubricants or grease, they
This will allow the O-Rings to remain pliable and
may not be designed to operate within high
provide a proper seal. The O-Rings will dry out,
temperatures or may contain “unknown ele-
becoming hard and cracked if the lubricant is not
ments” that may react with the atmosphere.
used on a regular basis. This can lead to potential
This reaction can leave contaminants inside
performance problems.
the torch. Either of these conditions can lead
It is recommended to apply a very light film of O- to inconsistent performance or poor parts life.
Ring lubricant (Catalog # 8-4025) to the O-Rings on
a weekly basis.
Manual 0-4961 SERVICE 5T-1

CUTMASTER 52
5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive wear (indi-
Consumable Torch Parts cated by an elongated or oversized orifice). Clean
or replace the tip if necessary.
Good Tip Worn Tip
WARNING
before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while
A-03406
the AC indicator light of the Power Supply
is ON. Example of Tip Wear
5. Remove the starter cartridge. Check for excessive

Remove the consumable torch parts as follows:
wear, plugged gas holes, or discoloration. Check
NOTE the lower end fitting for free motion. Replace if
necessary.
The shield cup holds the tip and starter
cartridge in place. Position the torch with Spring-Loaded Spring-Loaded
the shield cup facing upward to prevent Lower End Fitting Lower End Fitting at Reset /
these parts from falling out when the cup is Full Compression Full Extension
removed.
1. Unscrew and remove the shield cup from the

torch.
NOTE
Slag built up on the shield cup that cannot Art # A-08064_AC
be removed may effect the performance of
the system. 6. Pull the Electrode straight out of the Torch Head.
Check the face of the electrode for excessive wear.
2. Inspect the cup for damage. Wipe it clean or Refer to the following figure.
replace if damaged.
New Electrode
Art # A-08067
Shield Cups
Worn Electrode
3. On torches with a shield cup body and a shield Art # A-03284
cap or deflector, ensure that the cap or deflector Electrode Wear

is threaded snugly against the shield cup body.
In shielded drag cutting operations (only), there 7. Reinstall the Electrode by pushing it straight into
may be an O-Ring between the shield cup body the torch head until it clicks.
and drag shield cap. Do not lubricate the O-Ring.
8. Reinstall the desired starter cartridge and tip into
Drag Shield Cap
the torch head.
Shield 9. Hand tighten the shield cup until it is seated on
Cup Body the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
O-Ring No. 8-3488 This completes the parts replacement procedures.
Art # A-03878
5T-2 SERVICE Manual 0-4961

CUTMASTER 52
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
6.03 Power Supply Replacement

6.04 Replacement Power Supply Parts
6.05 Options and Accessories
6.06 Replacement Parts for Hand Torch
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
6.08 Replacement Shielded Machine Torch Leads Assemblies
6.09 Torch Consumable Parts (SL60)
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.
6.02 Ordering Information

Order replacement parts by catalog 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 power supply. Address all inquiries to
your authorized distributor.
6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 52 Power Supply
208/230 - 460VAC, Single or 3 Phase, 60Hz,
with input power cable and plug 3-5130-1
460VAC, Single or 3 Phase, 60Hz,
with input power cable 3-5130-2
600VAC, 3 Phase, 60Hz,
with input power cable 3-5130-5
6.04 Replacement Power Supply Parts

1 Regulator 9-0115*
1 Filter Assembly Replacement Element 9-0116
1 Input Power Cord for 208/230 V Power Supply 8-4384
1 Input Power Cord for 460/600 V Power Supply 9-8593
Manual 0-4961 PARTS LIST 6-1

CUTMASTER 52
NOTE
*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201
will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if
the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting. If
there is a transducer and wire harness instead of the tube, the kit is not needed.
6.05 Options and Accessories

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529
1 Multi - Purpose Cart 7-8888
1 Automation Interface Kit 9-8311
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011
1 Nylon Dust Cover 9-7071
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit
6-2 PARTS LIST Manual 0-4961

CUTMASTER 52
6.06 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60, 20 - foot Leads Assembly with ATC connector 4-7834
8 1 Switch Kit 9-7031
5
6
3
Art # A-07993_AB

CUTMASTER 52
6.07 Replacement Parts - for Machine Torches with Unshielded Leads
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O-Ring 8-3487
3 1 Small O-Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Le-ads Assembly with ATC connector 4-7842
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

CUTMASTER 52
10
10
1
2 11
3
12
4
13
5&6
A-07994_AB

CUTMASTER 52
6.08 Replacement Shielded Machine Torch Leads Assemblies
Item No. Qty Description Catalog No.
1 Mechanized Shielded Leads Assemblies with ATC Connectors
1 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846
Remote Pendant Adapter is Torch Continuity

present on Mechanized leads only. ('PIP') Switch
A-03684

CUTMASTER 52
Tips: Shield
DRAG TIP Cup Body, Shield Cap, Deflector
CUTTING 9-8237 9-8243
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
CUTTING Tip:
9-8237
9-8243
40A 9-8208 Standoff Guide

Shield Cup 9-8251
STANDOFF
9-8218
CUTTING
DRAG SHIELD
CUTTING Shield 50-60A 9-8235
50-60A Tips:
Cup Body,
CUTTING 9-8237
9-8243
Start
Cartridge 50-55A 9-8209
Shield Cup Standoff Guide
9-8213 60A 9-8210 9-8281
9-8218
STANDOFF
CUTTING
DRAG SHIELD O-Ring No. 8-3488

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
Tip Gouging D 9-8228 (60 - 120 Amps)
Tip Gouging E 9-8254 (60 - 120 Amps)

CUTMASTER 52
Ohmic Clip
Automation Torch
Ohmic Clip 9-8224
Manual Torch
9-8259
20-40A Tip:
Shield
Cup Body, Shield Cap, Machine
STANDOFF 40A 9-8245
9-8237
CUTTING
20A 9-8205 Shield Cup Shield Cap, Deflector

30A 9-8206 9-8218 9-8243
40A 9-8208
Drag Shield Cup

9-8235
50-60A Tips:
Shield
Cup Body,
STANDOFF Shield Cap, Machine
CUTTING 9-8237
50-60A 9-8238
50-55A 9-8209 Shield Cup

60A 9-8210 9-8218 Shield Cap, Deflector
9-8243
Drag Shield Cup

70-100A 9-8236
Electrode Starter Heavy Duty
Auto 9-8232 Cartridge Starter Cartridge Tips: Shield Drag Shield Cup
Manual 9-8215 9-8213 Non HF Only 9-8277 Cup Body, 120A 9-8258
9-8237
Shield Cap, Machine
70-100A 9-8239
70-120A 70A 9-8231
STANDOFF 80A 9-8211 Shield Cup Shield Cap, Machine
CUTTING 90/100A 9-8212 9-8218 120A 9-8256
120A Auto 9-8233
120A Manual 9-8253
9-8243
40-120A
GOUGING Shield
Cup Body,
9-8237
Tips:
Tip A 9-8225 (40 Amps Max.) Shield Cup, Gouging

9-8241
Tip B 9-8226 (50 - 120 Amps)
Tip C 9-8227 (60 - 120 Amps)
Tip D 9-8228 (60 - 120 Amps)

Art # A-08066_AG Tip E 9-8254 (60 - 120 Amps)

CUTMASTER 52
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION: ACTION: ACTION: ACTION:
ON / OFF switch to ON RUN / Rapid Auto Restart /
Close external RUN / SET / LATCH
disconnect switch. Rapid Auto Restart /
RESULT: switch to RUN
RESULT: SET / LATCH switch
AC indicator ON. to SET (for most applications)
Power to system. or to
GAS indicator ON Rapid Auto Restart
when input RESULT:
pressure is adequate (for gouging, trimming,
for power supply operation. Gas flows to set or expanded metal
pressure. applications)
Power circuit ready.
or to
LATCH
is used for specific applications

(torch switch can be released
after main arc transfer).
ACTION: RESULT: Gas flow stops.
Connect work cable to workpiece.

Set output amperage. ACTION:
RESULT:
Torch moved away from work (while
System is ready still activated).
for operation.
RESULT:
Main arc stops.

Pilot arc automatically
ACTION:
restarts.
Protect eyes and activate
Torch switch (START) PILOT ARC
RESULT:
Fans turn on. Gas flows briefly, ACTION:

then stops.Gas restarts.
Torch moved within
DC indicator ON transfer distance of workpiece.
Pilot arc established.
RESULT:
Main arc transfers.

Pilot arc off.
ACTION:
Release Torch switch.
RESULT: ACTION:
ACTION:
Main arc stops. Unplug input
Gas flow stops after post - flow. ON / OFF switch power cord or
to OFF open external
(Fans will continue to run for disconnect.
10 minutes after the Torch switch RESULT:
[START] is removed) RESULT:
All indicators off. No power to system.
Power supply fans shut off.
Art #A-07979_AB
Manual 0-4961 APPENDIX A-1

CUTMASTER 52
APPENDIX 2: DATA TAG INFORMATION
West Lebanon, NH USA 03784 Manufacturer's Name and/or

Logo, Location, Model and
Model : Revision Level, Serial Number
S/N
and Production Code
Dat e of Mf r : Made in USA
Type of Power Regulatory Standard Covering
Supply (Note 1) 1/ 3 f1
f2 This Type of Power Supply
Output Current Type Duty Cycle Factor

Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol X
I Duty Cycle Data (Note 3)
U0 =
U2
Rated No- Conventional
Load Voltage Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1 I 1max 3Ø I 1eff Maximum Effective
1
1Ø 1
1Ø 3Ø
Supply Current
Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288_AB
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.
A-2 APPENDIX Manual 0-4961

CUTMASTER 52
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
ATC Male Connector ATC Female Receptacle

Negative / Front View Front View Negative /
Plasma Plasma
4 - Green / 8 - Open 8 - Ground

Switch 4 - Switch
7 - Open 7 - Open 3 - Switch

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701
B. Mechanized (Machine) Torch Pin - Out Diagram
ATC Male Connector UNSHIELDED MACHINE TORCH ATC Female Receptacle

Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP
5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot
Art # A-03799

CUTMASTER 52
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
5 5
6 6
Torch Green 4 4 To Power Supply
Switch White 3 3 Circuitry
8 8
7 7
Negative / Plasma Negative / Plasma
Pilot
Pilot
Art # A-03797
B. Mechanized Torch Connection Diagram
Torch: Unshielded Mechanized SL100 Machine Torch

Leads: Leads with ATC Connector and
Remote Pendant Connector To Remote Control
Power Supply: with ATC Female Receptacle
Remote
Male ATC Female
Pendant
ATC Leads Receptacle
Connector
Connector
Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
White 5 5
6 6
Not Black 4 4 To Power Supply
Used
White 3 3 Circuitry
Green 8 8
Green 7 7
Negative / Plasma Lead Negative / Plasma
Pilot Lead
Pilot
Art # A-03798

CUTMASTER 52

CUTMASTER 52
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
5 4 3 2
J3
1
2
3
T1
K5, K6 K1-K4
J12
1
2
3
PRI 2 PRI 1 PRI 4 PRI 3
+12VDC
D
B A D C
/460
/230
BIAS
SUPPLY
J1 MTH1 MTH2
SW1
1 3 1
2
3 Q1
4
2 4 5
K1
RESISTORS
INRUSH
C1-C4* +
/INRUSH
D1
MTH3 MTH4
W1
AC1
* PRIMARY L1 7
AC INPUT L1 T1
AC2
L2 8
K1 K2 K5 K6 K3 K4
L2 T2
JUMPER AC3
L3 9
L3 T3
GND 7A
L4 T4 MTH6 MTH8
Q2
C
*PRIMARY POWER CONNECTIONS:

3PH USE L1,L2,L3 & GND + C5-C8*
REMOVE JUMPER BETWEEN L2 TO L3
1PH USE L1, L2 & GND -

INSTALL JUMPER BETWEEN L2 TO L3
SW2
J3 MTH5 MTH7
1 460_IN
2
INPUT VOLTAGE SELECTOR * CM52 & A40
(Closed for 230VAC input) C3 & C5 not installed
24VAC
PCB2 INPUT CAPACITOR PCB
5
J6
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D
PCB1 MAIN PCB ASSY

/SOLENOID
J5
1
2
3
J2
40 CIRCUIT
RIBBON CABLE
J1
40 PIN RIBBON CABLE SIGNALS

SOL1
1 -V_OUT_SIGNAL M-L
2 /TIP_VOLTS M-L ERROR IND FAULT MAX
3 /TIP_SENSE M-L AC
4 /460V_IN L-M MAX OVER PRESSURE
5 /230V_IN L-M 90 INTERNAL ERROR
6 CUR_SET L-M 85 SHORTED TORCH 90
7 /RAR (RAPID AUTO RESTART) L-M OVERTEMP 80 CONSUMABLES MISSING
8 /INRUSH L-M 75 START ERROR
9 /W1_ON L-M 70 PARTS IN PLACE
10 /SHDN L-M 65 INPUT POWER 85
11 /TORCH_SOLENOID L-M GAS MIN UNDER PRESSURE
12 /SOLENOID_ON L-M
13 /OK_TO_MOVE L-M
14 /FAN_ON L-M TEST POINTS 80
DC
15 /LATCH_ACTIVE L-M
TP1 GND
16 /TORCH_SWITCH M-L
TP2 +12 VDC
17 /PIP M-L
TP3 +5 VDC 75 GAS CONTROL
18 AC_ON M-L ERROR TP4 3.3 VDC
19 CSR M-L
TP5 0.v - 5.0 VDC / 0-100PSI
20 /TORCH_SOLENOID_DETECT M-L REGULATOR
TP6 1.8 VDC SOLENOID
21 /OVERTEMP M-L 70 ATC
TP7 POT. DEMAND VALVE
A
22 V_IN M-L
23 +12VDC M-L
24 +12VDC M-L
25 COMMON M-L Current Control 65 FILTER
26 COMMON M-L +12VDC AIR
29 MAIN_PCB_ID M-L INLET
34 460_IN M-L
35 +3.3VDC L-M D1 MIN
LATCH PRESSURE
36 TXD M-L
TRANSDUCER
37 RXD M-L SET
A-09131_AC
38 COMMON L-M J3
1
2
3
39 D M-L RUN +5VDC

1
RAR 0-100PSI / 0-4.5VDC 2
3
PCB3 LOGIC PCB
5 4 3 2

CUTMASTER 52
CM82 / A60 ONLY

TS1
1TORCH
L1
PIP SWITCH
J11
1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH
TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1
-
E64
ELECTRODE1
D3
+
TIP1 E35
Q5
PILOT IGBT
WORK1
WORK
J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7
CNC INTERFACE STANDARD ON A40 & A60 UNITS

CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS
J2
J10 P10 14
1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1
B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
1
2
3
J7 To -V OUT 1
1
2
1
2
J8 J3
on PCB1
E1 J2
1
2
P10 J1 3
+12VDC
4 } /START / STOP
1 1 5 (-)
+ FAN - + FAN - 2 2 6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
}(+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14
AUTOMATION
PCB4 INTERFACE PCB
A-09131_AC A
Rev Revisions By Date PCB No:

VICTOR TECHNOLOGIES
AA INTRO ECO B534 RWH 07/23/07 16052 Swingley Ridge Road Assy No:
AB ECO B890 MNC 04/23/08 Suite 300 Scale Supersedes
St Louis, MO 63017 USA
AC ECO B855 MNC 05/09/08
Date:
AD ECO B1159 MNC 10/03/08 Information Proprietary to THERMAL DYNAMICS CORPORATION.
Thursday, March 27, 2008
AE ECO B1357 RWH 03/31/09 Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
NOTE: UNLESS OTHERWISE SPECIFIED - RWH
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Monday, March 30, 2009 13:16:29
CUTMASTER 52/82/A40/A60 230/460V C 42X1298
1

CUTMASTER 52
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS
5 4
PRI 2 PRI 1 PRI 4 PRI 3

D
BIAS B A D C
SUPPLY
J1 MTH1 MTH2
SW1
1 3 +12VDC
1
2
3 Q1
4
2 4 5
K1
*CHOKE RESISTORS
INRUSH
EMI + C1-C4*
/INRUSH
* CEONLY
UNITS D1
MTH3
*FILTER
EMI
W1
MTH4
AC1
7
L1 1 1
L1 T1
AC2
8
L2 2 2
L2 T2
AC3
9
L3 3 3
L3 T3
7A
GND 4 4 L4 T4 MTH6 MTH8
Q2
C
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS: + C5-C8*
USE L1, L2, L3 & GND
MTH7 MTH5
PCB2
INPUT CAPACITOR PCB
24VAC
5 *CM52/12mm/20mm/A40
J6
C3 & C5 may not be installed
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D
PCB1 MAIN PCB ASSY

/SOLENOID
J5
1
2
3
J2
40 CIRCUIT
RIBBON CABLE
J1
40 PIN RIBBON CABLE SIGNALS

SOL1
1 -V_OUT_SIGNAL M-L
2 /TIP_VOLTS M-L ERROR IND FAULT MAX
3 /TIP_SENSE M-L AC
4 /460V_IN L-M MAX OVER PRESSURE
5 /230V_IN L-M 90 INTERNAL ERROR
6 CUR_SET L-M 85 SHORTED TORCH 90
7 /RAR (RAPID AUTO RESTART) L-M OVERTEMP 80 CONSUMABLES MISSING
8 /INRUSH L-M 75 START ERROR
9 /W1_ON L-M 70 PARTS IN PLACE
10 /SHDN L-M 65 INPUT POWER 85
11 /TORCH_SOLENOID L-M GAS MIN UNDER PRESSURE
12 /SOLENOID_ON L-M
13 /OK_TO_MOVE L-M
14 /FAN_ON L-M TEST POINTS 80
DC
15 /LATCH_ACTIVE L-M
TP1 GND
16 /TORCH_SWITCH M-L
TP2 +12 VDC
17 /PIP M-L
TP3 +5 VDC 75 GAS CONTROL
18 AC_ON M-L ERROR TP4 3.3 VDC
19 CSR M-L
TP5 0.v - 5.0 VDC / 0-100PSI
20 /TORCH_SOLENOID_DETECT M-L REGULATOR
TP6 1.8 VDC SOLENOID
21 /OVERTEMP M-L 70 ATC
TP7 POT. DEMAND VALVE
A
22 V_IN M-L
23 +12VDC M-L
24 +12VDC M-L
25 COMMON M-L Current Control 65 FILTER
26 COMMON M-L +12VDC AIR
29 MAIN_PCB_ID M-L INLET
34 460_IN M-L
35 +3.3VDC L-M D1 MIN
LATCH PRESSURE
36 TXD M-L
TRANSDUCER
37 RXD M-L SET
A-09133_AD
38 COMMON L-M J3
1
2
3
39 D M-L RUN +5VDC

1
RAR 0-100PSI / 0-4.5VDC 2
3
PCB3 LOGIC PCB
5 4

CUTMASTER 52
3 2 1
TS1
T1
1TORCH
L1
PIP SWITCH
J11
1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH
TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1
-
E64
ELECTRODE1
+
D3
TIP1 E35
Q5
PILOT IGBT
WORK1
WORK
J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7
CNC INTERFACE STANDARD ON A40 & A60 UNITS

CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS
J2
J10 P10 14
1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1
B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
1
2
3
J7 To -V OUT 1
1
2
1
2
J8 J3
on PCB1
E1 J2
1
2
P10 J1 3
+12VDC
4
} /START / STOP
(-)
+ FAN - + FAN -
1
2
1
2
5
6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
} (+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14
AUTOMATION
PCB4 INTERFACE PCB
A-09133_AD A
Rev Revisions By Date PCB No:

VICTOR TECHNOLOGIES
AA INTRO ECO B1357 RWH 03/31/09 16052 Swingley Ridre Road, Assy No:
AB ECO B1399 RWH 05/05/09 Suite 300 Scale Supersedes
St Louis, MO 63017 USA
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Thursday, March 27, 2008
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
NOTE: UNLESS OTHERWISE SPECIFIED - RWH
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Wednesday, May 06, 2009 13:16:29
CM52/82/12mm/20mm/25mm/A40/A60 380/400/415/600V C 42X1329
3 2 1

CUTMASTER 52
APPENDIX 7: Publication History
Cover Date Rev. Change(s)
Sept 17, 2007 AA Manual released.

Oct. 2, 2007 AB Upgraded information in Section 4Torch to make easier to understand
Apr. 15, 2008 AC Per ECOB752 updated firmware changes to pgs. 4-1 and 5-5. Per ECOB845 corrected drag
cutting statement to ¼” pg. 4T-5. Per ECOB803 releasing 400 – 460V systems.
May 7, 2008 AD Per ECOB890 Updated system schematic to Rev. AB. Updated Section 2 spec chart and input
wiring chart per ECOB880 for CSA approval.
May 16, 2008 AE Added information to Section 6 about regulator - logic PCB kit upgrade for older systems per
ECOB908.
July 17, 2008 AF Updated input power and cable charts in Section 2. Updated 208/460V System schematic.
Jan 27, 2009 AG Corrected pressure "NOTE" at the end of each cut chart section in Section 4T. updated two
stage air filter part numbers and updated pg 6-4 by removing number. 5 automation items and
renumbering. Fixed two stage air filter art Section 3 per ECOB1248.
Apr. 14, 2009 AH Updated system specs and input writing specs in Section 2. Added 600V system information
ECOB1346
May 29, 2009 AI Updated 400V/600V schematic in appendix per ECOB1399. Updated 230/460v schematic per
ECOB1357
Feb. 25, 2010 AJ Updated CNC cable part numbers in Section 6 per ECOB1637
Sept. 14, 2010 AK Fixed SL100 consumable art in Section 6 per ECOB1819
Feb. 8, 2011 AL Per ECOB1859 corrected Schematics with art number A-09131 and A-09133 to show proper
ARC Volts for Automation Interface PCB.
Mar. 20, 2012 AM Changed Country of Origin from USA to Mexico per ECO B2149, updated art A-08066
April 25, 2012 AN Updated ART A-07994 per ECOB2136.
Aug. 20, 2012 AO Added Opening the Contactor Cover text per ECOB2122. Inserted Victor Technologies branding text.
Nov. 26, 2012 AP Changed logo on Front Cover and Inside Front Cover from "Thermal Dynamics" to "Victor
Thermal Dynamics", modified Prop 65 text Section 1, changed wording for "NOTE" below
Subsection 3T.02 pg. 3T-1; changed Catalog Number for Automation Interface Kit from
9-8310 to 9-8311 pg. 6-2; deleted Item 10 &11 pg. 6-3; Delete "NOTE" pg. 6-4 per ECOB 2342
Oct. 3. 2013 AQ Updated Declaration of Conformity. Made the following changes per ECO B2527: updated
cover to show new Victor Thermal Dynamics trade dress, updated thank you text, changed
headers and footers, changed logo on art on pages A-2, A-7, A-9, updated rear cover.
Feb. 11, 2014 AR Revised and implemented per ECO-B2422. Removed DoC as manual is CSA.

THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph 1-940-381-1212
Fax: 1-940-483-8178
Miami, FL USA
Sales Office, Latin America
Ph 1-954-727-8371
Fax: 1-954-727-8376
Oakville, Ontario, Canada

Canada Customer Care
Ph 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)
EUROPE
Chorley, United Kingdom
Customer Care
Ph +44 1257-261755
Fax: +44 1257-224800
Milan, Italy
Customer Care
Ph +39 0236546801
Fax: +39 0236546840
ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph 6221-8990-6095
Fax: 6221-8990-6096
Rawang, Malaysia
Customer Care
Ph +603 6092-2988
Fax: +603 6092-1085
Melbourne, Australia
Australia Customer Care
Ph 1300-654-674 (tollfree)
Ph 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph 61-3-9474-7508
Fax: 61-3-9474-7488
Shanghai, China
Sales Office
Ph +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph +65 6832-8066
Fax: +65 6763-5812
INNOVATION TO SHAPE THE WORLD™
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
© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in Mexico

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60 208-

Revision: AR Issue Date: February 11, 2014 Manual No.: 0-4961

YOU ARE IN GOOD COMPANY!

Plasma Cutting Power Supply

Copyright 2007, 2008, 2009, 2010, 2011, 2012, 2013 by

All rights reserved.

Original Publication Date: September 4, 2007

Record the following information for Warranty purposes:

Power Supply Serial #:_______________________________________________

Torch Serial #:_____________________________________________________

Manuel 0-4961 INFORMATIONS GÉNÉRALES 1-3

1-4 INFORMATIONS GÉNÉRALES Manuel 0-4961

Manuel 0-4961 INFORMATIONS GÉNÉRALES 1-5

1-6 GENERAL INFORMATION Manual 0-4961

LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads

Manual 0-4961 GENERAL INFORMATION 1-7

This Page Intentionally Blank

1-8 GENERAL INFORMATION Manual 0-4961

Additional copies of this manual may be purchased

Manual 0-4961 INTRODUCTION 2-1

Power Supply Dimensions & Weight Ventilation Clearance Requirements

2-2 INTRODUCTION Manual 0-4961

CutMaster 52 Power Supply Input Cable Wiring Requirements

Manual 0-4961 INTRODUCTION 2-3

Torch Leads Receptacle

Port for Optional Automation

Input Power Selection

Gas Inlet Port

2-4 INTRODUCTION Manual 0-4961

2T.03 Specifications Combination of ambient air and gas stream through

Manual 0-4961 INTRODUCTION 2T-1

This torch is not to be used with oxygen (O2). Workpiece

2T-2 INTRODUCTION Manual 0-4961

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4961 INTRODUCTION 2T-3

This Page Intentionally Blank

2T-4 INTRODUCTION Manual 0-4961

3.02 Lifting Options

• Use optional cart or similar device of adequate L2 L2 Jumper

capacity to move unit. L3 L2-L3

Three Phase Input Power Wiring

3-2 INSTALLATION Manual 0-4961

3.05 Gas Connections

1/4 NPT to 1/4”

Optional Two - Stage Filter Installation

Using High Pressure Air Cylinders

3-4 INSTALLATION Manual 0-4961

3T.01 Torch Connections 3T.02 Setting Up Mechanical Torch

If necessary, connect the torch to the Power Supply. NOTE

Connecting the Torch to the Power Supply

Manual 0-4961 INSTALLATION 3T-1

This Page Intentionally Blank

3T-2 INSTALLATION Manual 0-4961

See Illustration for numbering Identification

1. Output Current Control

to 60 Amps may be used for drag cutting (with the

LATCH Used for longer hand held cuts. 7. Gas Indicator

ON / OFF Switch controls input power to the 9. ! Fault Error Indicator