Plasma Cutting System

39
CUTMASTER
PLASMA CUTTING SYSTEM
Operating Manual
Rev. AA Date: September 4, 2007 Manual # 0-4975
Operating Features:
30 120 208-
230
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-426-
1888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the

correct use and operation of your 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 Precautions. They will help you to avoid po-
tential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators
Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically ad-

vanced products to achieve a safer working environment within
the welding industry.
! WARNINGS
Read and understand this entire Manual and your employers 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 39
SL60 1Torch
Operating Manual Number 0-4975
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2007 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the

publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: September 4, 2007
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.................................................................................................1-3
1.04 Note, Attention et Avertissement.................................................................1-3
1.05 Precautions De Securite Importantes..........................................................1-4
1.06 Documents De Reference............................................................................1-5
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 Options and Accessories......................................................2-4
2.07 Torch Specifications.....................................................................................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: INSTALLATION ...................................................................................................3-1

3.01 Unpacking....................................................................................................3-1
3.02 Lifting Options..............................................................................................3-1
3.03 Primary Input Power Connections...............................................................3-2
3.04 Gas Connections.........................................................................................3-3
3.05 Torch Connections.......................................................................................3-5
SECTION 4 SYSTEM:OPERATION..........................................................................................4-1
4.01 Product Features.........................................................................................4-1
4.02 Preparations For Operating.........................................................................4-3
4.03 Sequence of Operation................................................................................4-7
SECTION 4 TORCH:OPERATION.......................................................................................... 4T-1

4T.01 Introduction................................................................................................ 4T-1
4T.02 Functional Overview.................................................................................. 4T-1
4T.03 Getting Started.......................................................................................... 4T-1
4T.04 Torch Parts Selection................................................................................. 4T-1
4T.05 Cut Quality................................................................................................. 4T-2
4T.06 General Cutting Information....................................................................... 4T-3
4T.07 Hand Torch Operation................................................................................ 4T-4
4T.08 Recommended Cutting Speeds................................................................. 4T-7
4T.09 Gouging..................................................................................................... 4T-7
TABLE OF CONTENTS
SECTION 5 SYSTEM: SERVICE..............................................................................................5-1
5.01 General Maintenance..................................................................................5-1
5.02 Common Faults............................................................................................5-6
5.03 Basic Troubleshooting Guide.......................................................................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 Replacement Assemblies............................................................................6-1
6.04 Power Supply Replacement Parts...............................................................6-1
6.05 Options and Accessories.............................................................................6-2
6.06 Torch Consumables.....................................................................................6-2
PATENT INFORMATION...........................................................................................................6-3
APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)......................................... A-1
APPENDIX 2: DATA TAG INFORMATION .............................................................................. A-2
APPENDIX 3: SYSTEM SCHEMATIC..................................................................................... A-4
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION.......................... Inside Rear Cover

cutmaster 39
SECTION 1:
GENERAL INFORMATION GASES AND FUMES
Gases and fumes produced during the plasma cut-
ting process can be dangerous and hazardous to
1.01 Notes, Cautions and Warnings your health.
Throughout this manual, notes, cautions, and Keep all fumes and gases from the breath-
warnings are used to highlight important informa- ing area. Keep your head out of the welding
tion. These highlights are categorized as follows: fume plume.
NOTE
Use an air-supplied respirator if ventilation is
An operation, procedure, or background infor- not adequate to remove all fumes and gases.
mation which requires additional emphasis or is
helpful in efficient operation of the system. The kinds of fumes and gases from the plas-
ma arc depend on the kind of metal being
used, coatings on the metal, and the different
CAUTION processes. You must be very careful when
cutting or welding any metals which may
A procedure which, if not properly followed, may
cause damage to the equipment. contain one or more of the following:
Antimony Chromium Mercury
! WARNING

Arsenic
Barium
Cobalt
Copper
Nickel
Selenium
Beryllium Lead Silver
A procedure which, if not properly followed,
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
1.02 Important Safety Precautions material you are using. These MSDSs will
give you the information regarding the kind
! WARNING
and amount of fumes and gases that may be
dangerous to your health.
OPERATION AND MAINTENANCE OF For information on how to test for fumes and
PLASMA ARC EQUIPMENT CAN BE DAN- gases in your workplace, refer to item 1 in
GEROUS AND HAZARDOUS TO YOUR Subsection 1.03, Publications in this manual.
HEALTH.
Use special equipment, such as water or
Plasma arc cutting produces intense electric and
down draft cutting tables, to capture fumes
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing and gases.
aids, or other electronic health equipment. Persons Do not use the plasma torch in an area where
who work near plasma arc cutting applications combustible or explosive gases or materials
should consult their medical health professional
and the manufacturer of the health equipment to
are located.
determine whether a hazard exists. Phosgene, a toxic gas, is generated from the
To prevent possible injury, read, understand vapors of chlorinated solvents and cleansers.
and follow all warnings, safety precautions Remove all sources of these vapors.
and instructions before using the equipment. This product, when used for welding or cut-
Call 1-603-298-5711 or your local distributor ting, produces fumes or gases which contain
if you have any questions. chemicals known to the State of California to
cause birth defects and, in some cases, can-
cer. (California Health & Safety Code Sec.
25249.5 et seq.)
Manual 0-4975 1-1 GENERAL INFORMATION

CutMaster 39
ELECTRIC SHOCK NOISE

Electric Shock can injure or kill. The plasma arc Noise can cause permanent hearing loss. Plasma
process uses and produces high voltage electrical arc processes can cause noise levels to exceed
energy. This electric energy can cause severe or safe limits. You must protect your ears from loud
fatal shock to the operator or others in the work- noise to prevent permanent loss of hearing.
place. To protect your hearing from loud noise,
Never touch any parts that are electrically wear protective ear plugs and/or ear muffs.
live or hot. Protect others in the workplace.
Wear dry gloves and clothing. Insulate your- Noise levels should be measured to be sure
self from the work piece or other parts of the the decibels (sound) do not exceed safe lev-
welding circuit. els.
Repair or replace all worn or damaged parts. For information on how to test for noise, see
Extra care must be taken when the workplace item 1 in Subsection 1.03, Publications, in
is moist or damp. this manual.
Install and maintain equipment according
to NEC code, refer to item 9 in Subsection PLASMA ARC RAYS
1.03, Publications. Plasma Arc Rays can injure your eyes and burn
your skin. The plasma arc process produces very
Disconnect power source before performing
bright ultra violet and infra red light. These arc
any service or repairs.
rays will damage your eyes and burn your skin if
Read and follow all the instructions in the you are not properly protected.
Operating Manual.
To protect your eyes, always wear a welding
helmet or shield. Also always wear safety
Fire AND EXPLOSION glasses with side shields, goggles or other
Fire and explosion can be caused by hot slag, protective eye wear.
sparks, or the plasma arc.
Wear welding gloves and suitable clothing
Be sure there is no combustible or flammable to protect your skin from the arc rays and
material in the workplace. Any material that sparks.
cannot be removed must be protected.
Keep helmet and safety glasses in good
Ventilate all flammable or explosive vapors condition. Replace lenses when cracked,
from the workplace. chipped or dirty.
Do not cut or weld on containers that may Protect others in the work area from the
have held combustibles. arc rays. Use protective booths, screens or
Provide a fire watch when working in an area shields.
where fire hazards may exist. Use the shade of lens as suggested in the fol-
Hydrogen gas may be formed and trapped lowing per ANSI/ASC Z49.1:
Minimum Protective Suggested
under aluminum workpieces when they are Arc Current Shade No. Shade No.
cut underwater or while using a water table. Less Than 300* 8 9
300 - 400* 9 12
DO NOT cut aluminum alloys underwater or 400 - 800* 10 14
on a water table unless the hydrogen gas can * These values apply where the actual arc is
be eliminated or dissipated. Trapped hydro- clearly seen. Experience has shown that lighter
gen gas that is ignited will cause an explo- filters may be used when the arc is hidden by the
sion. workpiece.
GENERAL INFORMATION 1-2 Manual 0-4975

cutmaster 39
1.03 Publications 14. American Welding Society Standard AWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPARA-
Refer to the following standards or their latest TION FOR WELDING AND CUTTING OF CONTAIN-
revisions for more information: ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
1910, obtainable from the Superintendent of Docu-
ments, U.S. Government Printing Office, Washington, 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
D.C. 20402 PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
10018
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
1.04 Note, Attention et
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable Avertissement
from the Superintendent of Documents, U.S. Govern- Dans ce manuel, les mots note, attention, et
ment Printing Office, Washington, D.C. 20402
avertissement sont utiliss pour mettre en relief
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC- des informations caractre important. Ces mises
CUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
en relief sont classifies comme suit :
Standards Institute, 1430 Broadway, New York, NY NOTE
10018
Toute opration, procdure ou renseignement
5. ANSI Standard Z41.1, STANDARD FOR MENS SAFE- gnral sur lequel il importe dinsister davantage
TY-TOE FOOTWEAR, obtainable from the American ou qui contribue lefficacit de fonctionnement
National Standards Institute, 1430 Broadway, New du systme.
York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain- ATTENTION
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
Toute procdure pouvant rsulter
lendommagement du matriel en cas de non-
7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procdure en question.
TAINERS WHICH HAVE HELD COMBUSTIBLES,
!
obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO- Toute procdure pouvant provoquer des bles-
CESSES, obtainable from the National Fire Protection sures de loprateur ou des autres personnes
Association, Batterymarch Park, Quincy, MA 02269 se trouvant dans la zone de travail en cas de
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, non-respect de la procdure en question.
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-
ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103

CutMaster 39
1.05 Precautions De Securite Lisez toujours les fiches de donnes sur la scu-
rit des matires (sigle amricain MSDS); celles-ci
Importantes devraient tre fournies avec le matriel que vous
utilisez. Les MSDS contiennent des renseignements
! AVERTISSEMENTS
quant la quantit et la nature de la fume et des gaz
pouvant poser des dangers de sant.
Pour des informations sur la manire de tester la
LOPRATION ET LA MAINTENANCE DU
fume et les gaz de votre lieu de travail, consultez
MATRIEL DE SOUDAGE LARC AU JET
larticle 1 et les documents cits la page 5.
DE PLASMA PEUVENT PRSENTER DES
RISQUES ET DES DANGERS DE SANT. Utilisez un quipement spcial tel que des tables de
coupe dbit deau ou courant descendant pour
Coupant larc au jet de plasma produit de
capter la fume et les gaz.
lnergie lectrique haute tension et des missions
magntique qui peuvent interfrer la fonction Nutilisez pas le chalumeau au jet de plasma dans
propre dun pacemaker cardiaque, les appareils une zone o se trouvent des matires ou des gaz
auditif, ou autre matriel de sant electronique. combustibles ou explosifs.
Ceux qui travail prs dune application larc
au jet de plasma devrait consulter leur membre Le phosgne, un gaz toxique, est gnr par la fume
professionel de mdication et le manufacturier de provenant des solvants et des produits de nettoyage
matriel de sant pour dterminer sil existe des chlors. Eliminez toute source de telle fume.
risques de sant. Ce produit, dans le procder de soudage et de coupe,
produit de la fume ou des gaz pouvant contenir des
Il faut communiquer aux oprateurs et au
lments reconnu dans Ltat de la Californie, qui
personnel TOUS les dangers possibles.
peuvent causer des dfauts de naissance et le cancer.
Afin dviter les blessures possibles, lisez, (La scurit de sant en Californie et la code scurit
comprenez et suivez tous les avertissements, Sec. 25249.5 et seq.)
toutes les prcautions de scurit et toutes les
consignes avant dutiliser le matriel. Compo-
sez le + 603-298-5711 ou votre distributeur CHOC ELECTRIQUE
local si vous avez des questions. Les chocs lectriques peuvent blesser ou mme
tuer. Le procd au jet de plasma requiert et
FUME et GAZ produit de lnergie lectrique haute tension.
La fume et les gaz produits par le procd de jet Cette nergie lectrique peut produire des chocs
de plasma peuvent prsenter des risques et des graves, voire mortels, pour loprateur et les au-
dangers de sant. tres personnes sur le lieu de travail.
Ne touchez jamais une pice sous tension ou
Eloignez toute fume et gaz de votre zone de respira-
vive; portez des gants et des vtements secs. Isolez-
tion. Gardez votre tte hors de la plume de fume
vous de la pice de travail ou des autres parties du
provenant du chalumeau.
circuit de soudage.
Utilisez un appareil respiratoire alimentation en
Rparez ou remplacez toute pice use ou endom-
air si laration fournie ne permet pas dliminer la
mage.
fume et les gaz.
Prenez des soins particuliers lorsque la zone de tra-
Les sortes de gaz et de fume provenant de larc de
vail est humide ou moite.
plasma dpendent du genre de mtal utilis, des
revtements se trouvant sur le mtal et des diffrents Montez et maintenez le matriel conformment au
procds. Vous devez prendre soin lorsque vous Code lectrique national des Etats-Unis. (Voir la page
coupez ou soudez tout mtal pouvant contenir un 5, article 9.)
ou plusieurs des lments suivants:
Dbranchez lalimentation lectrique avant tout
antimoine cadmium mercure travail dentretien ou de rparation.
argent chrome nickel
Lisez et respectez toutes les consignes du Manuel de
arsenic cobalt plomb consignes.
baryum cuivre slnium
bryllium manganse vanadium
INCENDIE ET EXPLOSION
cutmaster 39
Les incendies et les explosions peuvent rsulter Nuance Minimum Nuance Suggere
Courant Arc Protective Numro Numro
des scories chaudes, des tincelles ou de larc de Moins de 300* 8 9
plasma. Le procd larc de plasma produit du 300 - 400* 9 12
400 - 800* 10 14
mtal, des tincelles, des scories chaudes pouvant
* Ces valeurs sappliquent ou larc actuel est
mettre le feu aux matires combustibles ou provo- observ clairement. Lexperience a dmontrer que
quer lexplosion de fumes inflammables. les filtres moins foncs peuvent tre utiliss quand
Soyez certain quaucune matire combustible ou in- larc est cach par moiceau de travail.
flammable ne se trouve sur le lieu de travail. Protgez
toute telle matire quil est impossible de retirer de
la zone de travail. BRUIT
Procurez une bonne aration de toutes les fumes Le bruit peut provoquer une perte permanente de
inflammables ou explosives. loue. Les procds de soudage larc de plasma
Ne coupez pas et ne soudez pas les conteneurs ayant peuvent provoquer des niveaux sonores suprieurs
pu renfermer des matires combustibles. aux limites normalement acceptables. Vous d4ez
vous protger les oreilles contre les bruits forts
Prvoyez une veille dincendie lors de tout travail
dans une zone prsentant des dangers dincendie. afin dviter une perte permanente de loue.
Pour protger votre oue contre les bruits forts, portez
Le gas hydrogne peut se former ou saccumuler des tampons protecteurs et/ou des protections au-
sous les pices de travail en aluminium lorsquelles riculaires. Protgez galement les autres personnes
sont coupes sous leau ou sur une table deau. NE se trouvant sur le lieu de travail.
PAS couper les alliages en aluminium sous leau ou
sur une table deau moins que le gas hydrogne Il faut mesurer les niveaux sonores afin dassurer que
peut schapper ou se dissiper. Le gas hydrogne les dcibels (le bruit) ne dpassent pas les niveaux
accumul explosera si enflamm. srs.
Pour des renseignements sur la manire de tester le
bruit, consultez larticle 1, page 5.
RAYONS DARC DE PLASMA
Les rayons provenant de larc de plasma peuvent 1.06 Documents De Reference
blesser vos yeux et brler votre peau. Le procd
Consultez les normes suivantes ou les rvisions
larc de plasma produit une lumire infra-rouge
les plus rcentes ayant t faites celles-ci pour
et des rayons ultra-violets trs forts. Ces rayons
de plus amples renseignements :
darc nuiront vos yeux et brleront votre peau si
1. OSHA, NORMES DE SCURIT DU TRAVAIL ET
vous ne vous protgez pas correctement.
DE PROTECTION DE LA SANT, 29CFR 1910, dis-
Pour protger vos yeux, portez toujours un casque ponible auprs du Superintendent of Documents,
ou un cran de soudeur. Portez toujours des lunettes U.S. Government Printing Office, Washington, D.C.
de scurit munies de parois latrales ou des lunettes 20402
de protection ou une autre sorte de protection ocu-
laire. 2. Norme ANSI Z49.1, LA SCURIT DES OPRA-
TIONS DE COUPE ET DE SOUDAGE, disponible
Portez des gants de soudeur et un vtement pro- auprs de la Socit Amricaine de Soudage (Ameri-
tecteur appropri pour protger votre peau contre can Welding Society), 550 N.W. LeJeune Rd., Miami,
les tincelles et les rayons de larc. FL 33126
Maintenez votre casque et vos lunettes de protection 3. NIOSH, LA SCURIT ET LA SANT LORS DES
en bon tat. Remplacez toute lentille sale ou com- OPRATIONS DE COUPE ET DE SOUDAGE
portant fissure ou rognure. LARC ET AU GAZ, disponible auprs du Superin-
Protgez les autres personnes se trouvant sur la zone tendent of Documents, U.S. Government Printing
de travail contre les rayons de larc en fournissant des Office, Washington, D.C. 20402
cabines ou des crans de protection. 4. Norme ANSI Z87.1, PRATIQUES SURES POUR
Utilisez la nuance de lentille qui est suggre dans LA PROTECTION DES YEUX ET DU VISAGE AU
le recommendation qui suivent ANSI/ASC Z49.1:

CutMaster 39
TRAVAIL ET DANS LES ECOLES, disponible de SURES POUR LA PRPARATION LA COUPE ET
lInstitut Amricain des Normes Nationales (Ameri- AU SOUDAGE DE CONTENEURS ET TUYAUX AY-
can National Standards Institute), 1430 Broadway, ANT RENFERM DES PRODUITS DANGEREUX ,
New York, NY 10018 disponible auprs de la American Welding Society,
550 N.W. LeJeune Rd., Miami, FL 33126
5. N o r m e A N S I Z 4 1 . 1 , N O R M E S P O U R L E S
CHAUSSURES PROTECTRICES, disponible auprs 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
de lAmerican National Standards Institute, 1430 RESPIRATOIRE, disponible auprs de lAmerican
Broadway, New York, NY 10018 National Standards Institute, 1430 Broadway, New
York, NY 10018
6. Norme ANSI Z49.2, PRVENTION DES INCENDIES
LORS DE LEMPLOI DE PROCDS DE COUPE ET
DE SOUDAGE, disponible auprs de lAmerican
National Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de lAssociation Amricaine du Soud-
age (AWS), LE SOUDAGE ET LA COUPE DE CON-
TENEURS AYANT RENFERM DES PRODUITS
COMBUSTIBLES, disponible auprs de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de lAssociation Amricaine pour la Protec-
tion contre les Incendies (NFPA), LES SYSTEMES
GAZ AVEC ALIMENTATION EN OXYGENE POUR
LE SOUDAGE, LA COUPE ET LES PROCDS
ASSOCIS, disponible auprs de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, disponible auprs de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
10. Norme 51B de la NFPA, LES PROCDS DE COUPE
ET DE SOUDAGE, disponible auprs de la National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMS EN CYLINDRES,
disponible auprs de lAssociation des Gaz Compri-
ms (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SCURIT POUR
LE SOUDAGE ET LA COUPE, disponible auprs de
lAssociation des Normes Canadiennes, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SCURIT
DU SOUDAGE, disponible auprs de lAssociation
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
14. Norme AWSF4.1 de lAssociation Amricaine de
Soudage, RECOMMANDATIONS DE PRATIQUES

cutmaster 39
1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics Corporation warrants to the original
retail purchaser that new Thermal Dynamics CUTMASTER plasma cutting systems sold after the effective date of this warranty are
free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated
below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated
and maintained in accordance with 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.
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. Thermal Dynamics Corporation must be notified within 30 days of any failure, at
which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty
periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics
Distributor.
LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads
Product
(Parts and Labor) (Parts and Labor)
CUTMASTER 39 4 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 Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owners expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
Purchaser) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of 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 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
Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007

CutMaster 39

cutmaster 39
SECTION 2 SYSTEM: 2.02 Equipment Identification
INTRODUCTION The units identification number (specification or
part number), model, and serial number usually
appear on a data tag attached to the rear panel.
2.01 How To Use This Manual Equipment which does not have a data tag such
This Operating Manual applies to just as torch and cable assemblies are identified
specification or part numbers listed on page i. only by the specification or part number
To ensure safe operation, read the entire manual, printed on loosely attached card or the shipping
including the chapter on safety instructions and container. Record these numbers on the bottom of
warnings. page 1 for future reference.
Throughout this manual, the words WARNING,
2.03 Receipt Of Equipment
CAUTION, and NOTE may appear. Pay
particular attention to the information provided When you receive the equipment, check it against
under these headings. These special annotations the invoice to make sure it is complete and in-
are easily recognized as spect the equipment for possible damage due to
follows: shipping. If there is any damage, notify the car-
rier immediately to file a claim. Furnish complete
! WARNING
information concerning damage claims or ship-
ping errors to the location in your area listed in
A WARNING gives information regarding the inside back cover of this manual.
possible personal injury. Include all equipment identification numbers as
described above along with a full description of
the parts in error.
CAUTION Move the equipment to the installation site before
A CAUTION refers to possible equipment dam- un-crating the unit. Use care to avoid damaging
age. the equipment when using bars, hammers, etc., to
un-crate the unit.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be
purchased by contacting Thermal Dynamics at
the address and phone number in your area listed
in the inside back cover of this manual. Include
the Operating 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.thermal-dynamics.com
Manual 0-4975 2-1 INSTALLATION

CutMaster 39
2.04 Power Supply Specifications
CutMaster 39 Power Supply Specifications
Input Power (See Note 1) 120 VAC ( 10%), Single-Phase, 50/60 Hz
208 - 230 VAC ( 10%), Single-Phase, 50/60 Hz
Power Sensing Automatic Voltage Selection. See Note 1.
Input Power Cable Cable with plug, for 120VAC, 20-Amp Single-Phase input power.
Output Current 20-30 Amps, continuously variable
Power Supply Gas Filtering Ability Particulates to 20 Microns
CutMaster 39 Power Supply Duty Cycle (Note 2)
Ambient Temperature 104 F (40 C)
Duty Cycle 35% 60%
DC Voltage 78 vdc 89 vdc
Current 30 Amps 22 Amps
SL 60 Torch Gas Requirements
Gas Type Compressed Air
Gas specifications Clean, dry, oil-free (Note 3)
Maximum Input Gas Pressure 125 psi / 8.6 bar
Operating Gas Pressure 65 psi / 4.5 bar
Gas Flow Requirements 300 scfh / 141.5 lpm
Notes
1. Power supply accepts 120-230 VAC input power. No manual switching is required.
2. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is
reduced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.
3. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear. Optional filters provide increased filtering capabilities.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting with
a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables,
and actual cutting operation.
INSTALLATION 2-2 Manual 0-4975

cutmaster 39
Power Supply Dimensions & Weight Ventilation Clearance Requirements
Art # A-07924
Art # A-07925
15"
381 mm
6"
150 mm
24"
24" 0.6 m
0.61 m
12"
305 mm 6" 6"
45 lb / 20.4 kg 150 mm 150 mm
NOTE
Weight includes torch & leads, input power cord, and work cable with clamp.
CAUTION
Provide clearance for proper air flow through the power supply. Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
2.05 Input Wiring Specifications

CutMaster 39 Input Power Requirements
Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Freq. (kVA) (Amps) Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph 1-Ph
120 50 / 60 3.6 29 35 12 12
208 50 / 60 3.5 16 20 12 12
230 50 / 60 3.4 14 20 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
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.
The suggested sizes are based on flexible power cable with power plug installations.
Cable conductor temperature used is 167 F (75 C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should
be used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
Extension Cords
Extension cords must meet National Electric Code Guidelines (and OSHA Guidelines, where applicable). Exten-
sion cords must have the same rating as the service and must have a three-pronged plug.

CutMaster 39
2.06 Power Supply Options and Accessories
The following options and accessories are available for this Power Supply. Section 6 provides catalog
numbers and ordering information.
A. Single-Stage Air Filter Kit
A single-stage air filter for use on compressed air shop systems. Highly effective at removing moisture and
particulate matter from the air stream to at least 0.85 microns.
B. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobil-
ity for the power supply and can also serve as a display cart. Top shelf is 12 " (305 mm) x 20 (508 mm). Steel
handle is 30" (762 mm) high.
C. Cutting Guide Kit

Easy add-on attachments for straight line, circle, or bevel cutting.
2.07 Torch Specifications

A. Torch Configuration and Dimensions
The torch head is at 75 to the torch handle. The torch includes a torch handle and torch trigger assembly.
9.5" (241 mm)
3.75"
(95 mm)
1.17" (29 mm) Art # A-03322
Torch Configuration and Dimensions
B. Torch Leads Lengths

Leads are available in 20 ft (6.1 m) lengths.
C. Parts-In-Place (PIP)
Torch has built-in switch.
12 vdc circuit rating
D. Type of Cooling
Combination of ambient air and gas stream through torch
E. SL60 Torch Ratings (Refer to Note)
NOTE
Ratings shown apply to the SL60 Torch only. Refer to the Specifications chart on page 2T-1 for CutMaster 39
data.
F. Plasma Power Supply Used With

Thermal Dynamics CutMaster 39

cutmaster 39
SECTION 2 TORCH: 2T.03 Specifications
INTRODUCTION A. Torch Configurations
1. Hand Torch, Model SL60
2T.01 Scope of Manual The hand torch head is at 75 to the torch handle.
The hand torches include a torch handle and torch
This manual contains descriptions, operating trigger assembly.
instructions and maintenance procedures for 9.5" (241 mm)
the 1Torch Model SL60 Plasma Cutting Torch.
Service of this equipment is restricted to prop-
erly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or
adjustments not covered in this manual, at the risk 3.75"
of voiding the Warranty. (95 mm)
Read this manual thoroughly. A complete under-

1.17" (29 mm)
standing of the characteristics and capabilities of Art # A-03322
this equipment will assure the dependable opera- B. Torch Leads Lengths
tion for which it was designed. Hand Torches are available as follows:
2T.02 General Description 20 ft / 6.1 m.
Plasma torches are similar in design to the auto- C. Torch Parts
motive spark plug. They consist of negative and Starter Cartridge, Electrode, Tip, Shield Cup
positive sections separated by a center insulator.
D. Parts - In - Place (PIP)
Inside the torch, the pilot arc starts in the gap
between the negatively charged electrode and Torch Head has built - in switch
the positively charged tip. Once the pilot arc has 12 vdc circuit rating
ionized the plasma gas, the superheated column of
E. Type Cooling
gas flows through the small orifice in the torch tip,
which is focused on the metal to be cut. Combination of ambient air and gas stream through
A single torch lead provides gas from a single torch.
source to be used as both the plasma and second- F. Torch Ratings
ary gas. The air flow is divided inside the torch
SL60 Torch Ratings
head. Single - gas operation provides a smaller
sized torch and inexpensive operation. Ambient 104 F
Temperature 40 C
NOTE
Duty Cycle 100% @ 60 Amps @ 400 scfh
Refer to Section 2T.05, Introduction To Plasma, Maximum Current 60 Amps
for a more detailed description of plasma torch
operation. Voltage (Vpeak) 500V
Arc Striking Voltage 7kV
Refer to the Appendix Pages for additional specifi-
cations as related to the Power Supply used.
G. Current Ratings
SL60 Current Ratings
Up to 60 Amps, DC,
SL60 Torch & Leads
Straight Polarity
NOTE
Power Supply characteristics will determine mate-
rial thickness range.
Manual 0-4975 2T-1 INTRODUCTION

CutMaster 39
H. Gas Requirements 2T.05 Introduction to Plasma
SL60 Torch Gas Specifications A. Plasma Gas Flow
Gas (Plasma and Secondary) Compressed Air
Plasma is a gas which has been heated to an ex-
Operating Pressure 60 - 75 psi tremely high temperature and ionized so that it
Refer to NOTE 4.1 - 5.2 bar becomes electrically conductive. The plasma arc
cutting and gouging processes use this plasma to
Maximum Input Pressure 125 psi / 8.6 bar transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
300 - 500 scfh
Gas Flow (Cutting and Gouging) and then blown away.
142 - 235 lpm
While the goal of plasma arc cutting is separation of
! WARNING
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
This torch is not to be used with oxygen (O2). In a Plasma Cutting Torch a cool gas enters Zone B,
where a pilot arc between the electrode and the torch
NOTE
tip heats and ionizes the gas. The main cutting arc
Operating pressure varies with torch model, op- then transfers to the workpiece through the column
erating amperage, and torch leads length. Refer to of plasma gas in Zone C.
gas pressure settings charts for each model.
I. Direct Contact Hazard

For exposed tip the recommended standoff is 3/16
inches / 4.7 mm.
2T.04 Options And Accessories _

These items can adapt a standard system to a
Power
particular application or further enhance perfor- A
Supply
mance.
+
Deluxe Cutting Guide Kit - Easy add - on
attachments for precise straight line, circle B
cutting, and beveling. Includes carrying
case.
Workpiece
Trigger Guard Kits - These offer additional
protection from accidental activation of the C A-00002
torch switch.
Leads Extensions for torches with ATC con- Typical Torch Head Detail
nectors
By forcing the plasma gas and electric arc through a
Leather Leads Covers
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
Zone A channels a secondary gas that cools the torch.
This gas also assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for
a fast, slag - free cut.
INTRODUCTION 2T-2 Manual 0-4975

cutmaster 39
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
The plasma gas flows into the torch through the
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.
The secondary gas flows down around the outside
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot
arc creates a path for the main arc to transfer to the
work.
D. Main Cutting Arc

DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
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.
E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) circuit.
When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
is open.
Torch Switch Torch Trigger

To Control
Cable Wiring
PIP Switch Shield Cup
A-02997
Parts - In - Place Circuit Diagram for Hand Torch
Manual 0-4975 2T-3 INTRODUCTION

CutMaster 39
INTRODUCTION 2T-4 Manual 0-4975

cutmaster 39
SECTION 3:
INSTALLATION
3.01 Unpacking
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 ship-
ping company before proceeding with the installation.
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.
3.02 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely
and securely.
! WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
Only persons of adequate physical strength should lift the unit.

Lift unit by the handle, using two hands. Do not use straps for lifting.
Use optional cart or similar device of adequate capacity to move unit.
Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

CutMaster 39
3.03 Primary Input Power Connections
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power source,
fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection
and wiring requirements as specified in Section 2.
Power Cord and Plug

This power supply includes an input power cord and plug suitable for 120 VAC, 20 Amp, Single -
Phase input power.
A-03382 120 V, 20A, 1
For 208 / 230 VAC input power, replace the supplied power plug. Use only an approved replacement
input power plug with ground.
Replace the plug as follows:
1. Cut the original cord close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according to the plug manufacturer's instructions. All three conductors
must be connected to the plug.
Connect the input power cord as follows:

1. Check the power source for correct voltage before plugging in the unit.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

cutmaster 39
3.04 Gas Connections
A. Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure gas cylinders. Refer to subsection 3.4-C
if an optional air line filter is to be installed.
1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example.
NOTE
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 gas passages in
the torch.
Min. 1/4 inch

6.4 mm
A-07926
Gas Connection to Inlet Port
B. Check Air Quality

To test the quality of air, put the RUN / SET switch in the SET (down) position, place a welding filter
lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens.
Do not start an arc!
A
26
28
24
22
20 30
A-07927
C. Installing Optional Single - Stage Air Filter

An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and
debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port.
2. Attach the Filter Assembly to the filter hose.

CutMaster 39
3. Connect the gas line to the Filter. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the
torch. Connect as follows:
Filter Hose
Single-Stage
Filter Kit
No. 7-7507
Hose
Clamp
1/4 NPT
Hose Fitting
A-07928
Gas Supply Hose
Optional Single - Stage Filter Installation
D. Using High Pressure Gas Cylinders

When using high pressure gas cylinders as the gas supply:
1. Refer to the manufacturers specifications for installation and maintenance procedures for high pressure gas
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 gas supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure gas 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 gas passages in
the torch.

cutmaster 39
3.05 Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60
Torch to this power supply.
WARNING
Disconnect primary power at the source before connecting the torch.
1. Align the male connector (on the torch lead) with the female receptacle on the power supply.
Press the connector into the receptacle fully.
2. Turn the locking ring on the male connector fully clockwise until it clicks.
Art # A-07929
Connecting the Torch to the Power Supply
3. The system is ready for operation.

CutMaster 39

cutmaster 39
SECTION 4 SYSTEM:
OPERATION
4.01 Product Features
A. General Features
Handle and Leads Wrap
Gas Pressure Knob
Torch Leads
Connector
Art # A-07930
Control Panel
Work Cable
and Clamp
Manual 0-4975 4-1 OPERATION

CutMaster 39
B. Control Panel
4
2
5
1 A 6
26
28 7
24
3
22
20 30
A-07931
1. ON / OFF Switch
Controls input power to the power supply. Up is ON, down is OFF.
2. RUN / SET Switch
RUN (up) position is for general torch operation. SET (down) position is for setting gas pressure and purging
lines.
3. (A) Output Current Control
Sets the desired output current. If the overload protection (fuse or circuit breaker) on the input power circuit
opens frequently, either reduce cutting output, reduce the cutting time, or connect the unit to more adequate
input power. Refer to Section 2 for input power requirements.
4. AC Indicator
Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective in-
terlock mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to
Section 5 for details.
5. TEMP Indicator
Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Allow the unit
to run with the fan on until the Temp indicator turns off.
6. GAS Indicator
Indicator is ON when adequate input gas pressure is present to operate the power supply.
7. DC Indicator
Indicator is ON when DC output circuit is active.
OPERATION 4-2 Manual 0-4975

cutmaster 39
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts,
or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the
type of operation, and with the amperage output of this Power Supply (30 amps maximum). Use only genuine
Thermal Dynamics parts with this torch.
Art # A-03409
Large O-Ring,
Cat. No. 8-3487
Small O-Ring,
Cat. No. 8-3486
Electrode, Cat. No. 9-8215
Start Cartridge,
Cat. No. 9-8213
30Amp Cutting Tip, Cat. No. 9-8206
Shield Cup, Cat. No. 9-8218
Worn Electrode
Worn Tip
NOTE
When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield
cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components
may result.
B. Torch Connection
Check that the torch is properly connected.
C. Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the
power requirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the sys-
tem.

CutMaster 39
D. Gas Selection
Ensure gas source meets requirements (refer to Section 2). Check connections and turn gas supply on.
E. Connect Work Cable

Clamp the work cable to the workpiece or cutting 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.
Art # A-03387
F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on.
A
26
28
24
22
20 30
A-07932

cutmaster 39
G. Set Operating Pressure
Place the Power Supply RUN / SET switch to the SET (down) position. Gas will flow. Adjust gas pressure to
65 psi / 4.5 bar. Gas indicator turns on.

NOTE
If gas regulator leaks, reset gas pressure to 0 psi, then reset to 65 psi / 4.5 bar.
65 psi / 4.5 bar
A
26
28
24
22
20 30 A-07933
A-07927
H. Select Current Output Level

Place RUN / SET switch to RUN (up) position. Gas flow will stop. Set the desired current output level.
A
26
28
24
22
20 30
A-07934

CutMaster 39
I. Cutting Operation
Refer to Section 1, Important Safety Precautions. Wear heavy welding gloves and protective clothing. Protect
eyes with appropriate shielding. Aim the torch head away from yourself. Slide the trigger release to the rear.
Squeeze and hold the trigger. Gas flows for approximately 1 second, then shuts off briefly. The pilot arc then
starts. DC indicator turns on. Bring the torch within transfer distance to the workpiece. The pilot arc
stops and the main arc transfers to the workpiece.
NOTE
may result.
Trigger
1
2
Trigger Release
Art # A-03383
J. Cutting Technique
Hold the torch with one or two hands, with the torch tip close to the workpiece. Do not cut or handle the work-
piece without welding gloves and protective clothing. Always wear protective eye shielding when cutting or
gouging. Move the torch along the cut line so the arc penetrates the workpiece and sparks emerge from the
bottom of the cut. Good cutting speeds create a slight trailing arc.
K. Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 10 seconds. During post
- flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc
transfers to the workpiece if the torch tip is within transfer distance to the workpiece.
l. Shutdown
Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord
or disconnect input power. Power is removed from the system.

cutmaster 39
4.03 Sequence of Operation
The following is a typical sequence of operation for this power supply. Refer to Appendix 1 for block
diagram.
1. Plug the input power cord into an active circuit.
a. AC power is available at the Power Supply.
2. Place the ON / OFF switch on the Power Supply to ON (up) position.
a. AC indicator turns on; fan turns on.
NOTES
If there is adequate gas supply pressure to the power supply, gas comes on if Torch Trigger is pressed.
If torch trigger is held while user turns on main AC power, system goes into 'protective interlock' mode. AC
indicator flashes; torch will not pilot. Release torch trigger, turn AC switch OFF then ON.
3. Put RUN / SET switch to SET (down position).
a. Gas flows to set pressure. Turn gas pressure adjustment knob to set pressure to 65 psi / 4.5
bar; Gas indicator turns ON when there is sufficient gas pressure for power supply opera-
tion.
NOTE
Minimum pressure for power supply operation is lower than minimum pressure for torch operation.
4. Put RUN / SET switch to RUN (up position). Gas flow stops.
5. Wear protective clothing and welding gloves. Protect eyes. Slide the trigger release to the rear;
squeeze and hold the trigger. Gas flows briefly, then shuts off momentarily. Then gas flow will
resume. Pilot arc is established. DC indicator turns ON. Move Torch within transfer dis-
tance of workpiece.
a. Main arc transfers to workpiece.
6. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc
will automatically restart.
7. Release the torch trigger.
a. Main arc stops; gas flows for approximately 10 seconds.
8. Set the power supply ON / OFF switch to OFF (down position).
a. AC indicator turns OFF; fan turns OFF.
9. Set the main power disconnect to OFF, or unplug input power cord.
a. Input power is removed from the system.

CutMaster 39

cutmaster 39
SECTION 4 TORCH: NOTE
Refer to Appendix Pages for additional informa-
OPERATION tion as related to the Power Supply used.
Power On
4T.01 Introduction
Place the ON - OFF Switch on the Power Supply to
This section provides a description of the SL60 the ON position.
and SL100 Torch Assemblies followed by operat- Function Control Knob
ing procedures.
If the Function Control Knob is in SET position, gas
4T.02 Functional Overview will flow. If the control knob is in the RUN position
there will be no gas flow.
The Torch is designed to operate with vari-
ous Power Supplies to provide a plasma cutting Current Output Level
system which can cut most metals. With gouging At the Power Supply, set the desired current output
torch parts the torch can be used for plasma arc level. For drag cutting set the control at 40 amps or
gouging. less only.
NOTE Pressure Settings
Refer to Appendix Pages for additional informa- Place the Function Control Knob to the SET position.
tion as related to the Power Supply used. Adjust the gas pressure control on the Power Sup-
ply for the proper gas pressure. Refer to Appendix
4T.03 Getting Started Pages for gas pressure and other specifics.
Follow this procedure at the beginning of each Ready for Operation

shift: Return the Function Control Knob to RUN posi-
tion.
WARNING NOTES
Disconnect primary power at the source For general cutting, use the RUN position which
before assembling or disassembling power provides normal torch operation where the torch
switch must be held throughout the main arc
supply, torch parts, or torch and leads as-
transfer.
semblies.
For specific applications, use the LATCH position
Torch Parts where the torch switch can be released after the
Check the torch for proper assembly. Install proper main arc transfer. The torch remains activated
torch parts for the desired application (refer to next until the main arc breaks from the workpiece.
SubSection called "Torch Parts Selection"). Refer to Appendix 1 for a typical detailed block
Input Power diagram of Sequence of Operation.
Check the power source for proper input voltage.

The system is now ready for operation.
Close main disconnect switch or plug unit in to 4T.04 Torch Parts Selection
supply primary power to the system.
Depending on the type of operation to be done
Work Cable
determines the torch parts to be used.
Check for a solid cable connection to the work- Type of operation:
piece.
Drag cutting, standoff cutting or gouging
Gas Supply Torch parts:
Select desired single gas supply. Make sure gas Shield Cup, Cutting Tip, Electrode and Starter
sources meet requirements (see Note). Check con- Cartridge
nections and turn gas supply on.
Manual 0-4975 4T-1 OPERATION

CutMaster 39
NOTE 4T.05 Cut Quality
Refer to Section 6 and the Appendix Pages for
NOTES
additional information on torch parts.
Cut quality depends heavily on setup and pa-
Change the torch parts for a different operation as
rameters such as torch standoff, alignment with
follows: the workpiece, cutting speed, gas pressures, and
operator ability.
WARNING Refer to Appendix Pages for additional informa-

tion as related to the Power Supply used.
Disconnect primary power at the source be-
Cut quality requirements differ depending on
fore assembling or disassembling torch parts,
or torch and leads assemblies. application. For instance, nitride build - up and
bevel angle may be major factors when the sur-
face will be welded after cutting. Dross - free cut-
NOTE ting is important when finish cut quality is desired
The shield cup holds the tip and starter cartridge to avoid a secondary cleaning operation. The
in place. Position the torch with the shield cup following cut quality characteristics are illustrated
facing upward to keep these parts from falling out in the following figure:
when the cup is removed.
1. Unscrew and remove the shield cup assem- Kerf Width
bly from the torch head. Cut Surface
Bevel Angle
2. Remove the Electrode by pulling it straight
out of the Torch Head. Top
Spatter
Torch Head
Top Edge
Rounding
Electrode
Dross
Build-Up
Cut Surface A-00007
Start Cartridge Drag Lines
Cut Quality Characteristics
Tip
Cut Surface
Shield Cup The desired or specified condition (smooth or rough)
of the face of the cut.
A-03645
Nitride Build - Up
Torch Parts
Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
3. Install the replacement Electrode by push- These buildups may create difficulties if the material
ing it straight into the torch head until it is to be welded after the cutting process.
clicks.
Bevel Angle
4. Install the starter cartridge and desired tip
for the operation into the torch head. The angle between the surface of the cut edge and
5. Hand tighten the shield cup until it is seat- a plane perpendicular to the surface of the plate.
A perfectly perpendicular cut would result in a 0
ed on the torch head. If resistance is felt bevel angle.
when installing the cup, check the threads
before proceeding.
OPERATION 4T-2 Manual 0-4975

cutmaster 39
Top - Edge Rounding Torch Standoff
Rounding on the top edge of a cut due to wearing Improper standoff (the distance between the torch
from the initial contact of the plasma arc on the tip and workpiece) can adversely affect tip life as
workpiece. well as shield cup life. Standoff may also signifi-
cantly affect the bevel angle. Reducing standoff will
Bottom Dross Buildup generally result in a more square cut.
Molten material which is not blown out of the cut Edge Starting
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after For edge starts, hold the torch perpendicular to the
cutting. workpiece with the front of the tip near (not touch-
ing) the edge of the workpiece at the point where
Kerf Width the cut is to start. When starting at the edge of the
The width of the cut (or the width of material re- plate, do not pause at the edge and force the arc to
moved during the cut). "reach" for the edge of the metal. Establish the cut-
ting arc as quickly as possible.
Top Spatter (Dross)
Direction of Cut
Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting In the torches, the plasma gas stream swirls as it
tip whose orifice has become elongated. 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
4T.06 General Cutting Information direction of travel, the right side of the cut is more
square than the left.
! WARNINGS
Left Side
Cut Angle
Right Side
Cut Angle
Disconnect primary power at the source before
disassembling the power supply, torch, or torch
leads.
Frequently review the Important Safety Pre-

cautions at the front of this manual. Be sure
the operator is equipped with proper gloves, A-00512
clothing, eye and ear protection. Make sure
Side Characteristics Of Cut
no part of the operators body comes into
contact with the workpiece while the torch
is activated. To make a square - edged cut along an inside
diameter of a circle, the torch should move coun-
terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should
CAUTION travel in a clockwise direction.
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
NOTE
Handle torch leads with care and protect them
from damage.
Piloting
Piloting is harder on parts life than actual cutting
because the pilot arc is directed from the electrode
to the tip rather than to a workpiece. Whenever
possible, avoid excessive pilot arc time to improve
parts life.

CutMaster 39
Dross b. For standoff cutting, hold the torch 1/8
When dross is present on carbon steel, it is com-
- 3/8 in (3-9 mm) from the workpiece as
monly referred to as either high speed, slow speed, shown below.
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
Torch
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
edge, and can be easily scraped off. "High speed
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
Shield Cup Standoff
dross". Any resultant cleanup can be accomplished Distance 1/8" - 3/8"
by scraping, not grinding.
4T.07 Hand Torch Operation

Standoff Cutting With Hand Torch A-00024
NOTE Standoff Distance

For best performance and parts life, always use the
correct parts for the type of operation. 3. Hold the torch away from your body.
4. Slide the trigger release toward the back
1. The torch can be comfortably held in one
of the torch handle while simultaneously
hand or steadied with two hands. Position
squeezing the trigger. The pilot arc will
the hand to press the Trigger on the torch
start.
handle. With the hand torch, the hand may
be positioned close to the torch head for
maximum control or near the back end for
maximum heat protection. Choose the
holding technique that feels most comfort- Trigger
able and allows good control and move-
ment.
NOTE Trigger Release
Art # A-03962
The tip should never come in contact with the
workpiece except during drag cutting opera- 5. Bring the torch within transfer distance to
tions. the work. The main arc will transfer to the
2. Depending on the cutting operation, do one work, and the pilot arc will shut off.
of the following:
a. For edge starts, hold the torch perpen-
dicular to the workpiece with the front
of the tip on the edge of the workpiece
at the point where the cut is to start.

cutmaster 39
NOTE Drag Cutting With a Hand Torch
The gas preflow and postflow are a characteristic Drag cutting works best on metal 3/16" (4.7 mm)
of the power supply and not a function of the thick or less.
torch.
NOTE
Trigger
For best parts performance and life, always use the
correct parts for the type of operation.
1
1. Install the drag cutting tip and set the out-
2
put current to 30 amps or less.
Trigger Release 2. The torch can be comfortably held in one
the hand to press the Trigger on the torch
3
4 holding technique that feels most comfort-
able and allows good control and move-
Art # A-03383 ment.
4. Keep the torch in contact with the work-
6. Cut as usual. Simply release the trigger piece during the cutting cycle.
assembly to stop cutting. 5. Hold the torch away from your body.
7. Follow normal recommended cutting 6. Slide the trigger release toward the back
practices as provided in the power supply of the torch handle while simultaneously
operating manual. squeezing the trigger. The pilot arc will
NOTE
start.
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can Trigger
damage components.
8. For a consistent standoff height from the Trigger Release
workpiece, install the standoff guide by Art # A-03962
sliding it onto the torch shield cup. Install

the guide with the legs at the sides of the
shield cup body to maintain good visibility
of the cutting arc. During operation, posi-
tion the legs of the standoff guide against
the workpiece.
Shield Cup
Standoff Guide
Torch Tip
Workpiece Art # A-04034

CutMaster 39
7. Bring the torch within transfer distance to NOTE
the work. The main arc will transfer to the The tip should never come in contact with the
work, and the pilot arc will shut off. workpiece except during drag cutting opera-
NOTE tions.
The gas preflow and postflow are a characteristic 2. Angle the torch slightly to direct blowback
of the power supply and not a function of the particles away from the torch tip (and op-
torch. erator) rather than directly back into it until
Trigger the pierce is complete.
3. In a portion of the unwanted metal start the
pierce off the cutting line and then continue
1
the cut onto the line. Hold the torch per-
2
pendicular to the workpiece after the pierce
Trigger Release is complete.
4. Hold the torch away from your body.
5. Slide the trigger release toward the back
of the torch handle while simultaneously
3 squeezing the trigger. The pilot arc will
start.
Art # A-03383
Trigger
8. Cut as usual. Simply release the trigger
assembly to stop cutting.
9. Follow normal recommended cutting Trigger Release
practices as provided in the power supply Art # A-03962
operating manual. 6. Bring the torch within transfer distance to

NOTE the work. The main arc will transfer to the
When the shield cup is properly installed, there
work, and the pilot arc will shut off.
is a slight gap between the shield cup and the NOTE
torch handle. Gas vents through this gap as part The gas preflow and postflow are a characteristic
of normal operation. Do not attempt to force the of the power supply and not a function of the
shield cup to close this gap. Forcing the shield torch.
cup against the torch head or torch handle can
damage components. When the shield cup is properly installed, there
is a slight gap between the shield cup and the
Piercing With Hand Torch torch handle. Gas vents through this gap as part
1. The torch can be comfortably held in one of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
cup against the torch head or torch handle can
the hand to press the Trigger on the torch damage components.
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 amount of scale which
technique that feels most comfortable and
adheres to it.
allows good control and movement.
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 39
4T.08 Recommended Cutting Speeds
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds shown
are typical for this cutting system using air plasma to cut mild steel, with output current at 30 amps and torch
held at 0 - 1/16" (0 - 1.6 mm) standoff.
e
ch
ag
In
G
A-03381
12.7 0.5
0.4
9.5 0.375
MATERIAL THICKNESS
0.35
8 Typical Cutting Speeds
0.3 Air Plasma on Mild Steel
7
6 0.25
6 5 0.2
4 0.15
3 0.1
12
2
18 1 0.05
20 24
Inches 10 20 40 60 80 100 120 140 160 180 200 220 240 400
Meters 0.25 0.5 1.00 1.5 2.0 2.5 3.05 3.5 4.06 4.57 5.08 5.56 6.1 10.1
Inches/ Meters per Minute
CUTTING SPEED
Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, using
a template or cutting guide while still producing cuts of excellent quality.
4T.09 Gouging
! WARNINGS
Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions
at the front of this manual have been followed. Make sure no part of the operators body comes in contact with the
workpiece when the torch is activated.
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTIONS
Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and
metal.
Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 6 and the Appendix
Pages for additional information on torch parts.
Gouging Parameters
Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle
between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).
Torch Travel Speed

NOTE
Refer to Appendix Pages for additional information as related to the Power Supply used.

CutMaster 39
Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).
Current Setting
Current settings depend on torch travel speed,
mode of operation (hand or machine torch), and the
amount of material to be removed.
Lead Angle
The angle between the torch and workpiece depends
on the output current setting and torch travel speed.
At 80 amps, the recommended lead angle is 35. At
a lead angle greater than 45 the molten metal will
not be blown out of the gouge and may be blown
back onto the torch. If the lead angle is too small
(less than 35), less material may be removed, re-
quiring more passes. In some applications, such as
removing welds or working with light metal, this
may be desirable.

cutmaster 39
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 Replace as needed
tip, electrode 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
Manual 0-4975 5-1 SERVICE

CutMaster 39
A. Each Use
Check torch consumables for wear, replace if necessary.
WARNING
Shut off power before inspecting or removing torch parts.
NOTE
may result.
Art # A-03409
Large O-Ring,
Cat. No. 8-3487
Small O-Ring,
Cat. No. 8-3486
Electrode, Cat. No. 9-8215
Start Cartridge,
Cat. No. 9-8213
Worn Electrode
Worn Tip
SERVICE 5-2 Manual 0-4975

cutmaster 39
B. Every three months
A. Check internal air filter, replace if necessary.
1. Shut off input power; turn off the gas supply. Bleed down the gas supply.
2. Remove the upper cover screws.
3. Loosen the lower screws. Pull the cover up and away from the unit.
NOTE
Leave internal ground wire in place.
Upper screws
Upper screws
Ground
wire
Lower screws
Art #A-07935
Lower screws
Cover Removal

CutMaster 39
4. Pull the upper end of the drain tube off the fitting on the filter bowl
.
5. Unscrew the bowl. The filter element will be visible and still attached to the main body of the Regulator /
Filter.
6. Unscrew the filter element from the Regulator / Filter body. The filter element will come off with a spool and
some additional pieces.
7. Note the correct assembly of the filter / spool then remove the filter from the spool and either clean it or replace
it.
8. Screw the filter element and spool, with the baffle ring in place (teeth facing downward) back into the Regulator
body by compressing the spring on the spool. Tighten firmly by hand.
Ring
Replacement
Element
No. 9-0182
Spool
Bowl
Art # A-07936
Regulator / Filter Element Replacement
9. Clean the inside of the bowl if necessary. Check that the knurled valve on the bottom of the bowl is fully
open.
10. Reinstall the bowl. Reconnect the drain tube.
11. Reinstall the cover as follows:
a. Reconnect the ground wire, if necessary.
b. Set the cover onto the base so that it rests on the lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the upper screws.
12. Turn on the air supply.

cutmaster 39
C. O-Ring Lubrication D. Check Optional Single - Stage Filter
Element, replace if necessary.
An o-ring on the Torch ATC Male Connector requires
lubrication on a regular basis, depending on how 1. Shut off input power.
frequently the torch is disconnected and re-con-
nected. This will allow the o-ring to remain pliable 2. Shut off air supply, bleed down system.
and provide a proper seal. The o-ring will dry out, 3. Disconnect gas supply hose from filter.
becoming hard and cracked, if the o-ring lubricant is
not used on a regular basis. This can lead to potential 4. Turn the Cover counter - clockwise.
performance problems. 5. Remove the Filter Element from the Housing and set
It is recommended to apply a very light film of o- Element aside to dry.
ring lubricant (Catalog # 8-4025) to the o-ring on a 6. Wipe inside of housing clean, then insert the replace-
weekly basis. ment Filter Element open side first.
NOTE 7. Replace Housing on Cover.
DO NOT use other lubricants or grease, they may 8. Reattach gas supply hose. If unit leaks between
not be designed to operate within high tempera- housing and cover, inspect the "O" Ring for cuts or
tures or may contain unknown elements that other damage.
may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent per- Housing
formance or poor parts life.
ATC Male Connector

Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743) Assembled Filter
Cover
Barbed
Fitting Art # A-02476
Gas Fitting
Art #A-03791 O-Ring

CutMaster 39
5.02 Common Faults 5.03 Basic Troubleshooting Guide
Problem - Symptom Common Cause
Insufficient 1. Cutting speed too fast.
Penetration 2. Torch tilted too much. WARNING
3. Metal too thick. There are extremely dangerous voltage and
4. Worn torch parts power levels present inside this unit. Do not
5. Cutting current too low.
attempt to diagnose or repair unless you have
6. Non - Genuine Thermal Dynamics
parts used had training in power electronics measure-
7. Incorrect gas pressure ment and troubleshooting techniques.
Main Arc 1. Cutting speed too slow. A. Basic Troubleshooting: Overview
Extinguishes 2. Torch standoff too high from
This guide covers basic troubleshooting. It is
workpiece.
3. Cutting current too high. helpful for solving many of the common problems
4. Work cable disconnected. that can arise with this system. If major complex
5. Worn torch parts. subassemblies are faulty, the unit must be returned
6. Non - Genuine Thermal Dynamics to an authorized service center for repair.
parts used
Follow all instructions as listed and complete each
Excessive Dross 1. Cutting speed too slow. section in the order presented.
Formation 2. Torch standoff too high from For major troubleshooting and parts replacement pro-
workpiece. cedures refer to the Power Supply Service Manual for
3. Worn torch parts. this product.
4. Improper cutting current.
5. Non - Genuine Thermal Dynamics B. How to Use This Guide
parts used
6. Incorrect gas pressure
The following information will help the Cus-
tomer / Operator determine the most likely causes
Short Torch Parts Life1. Oil or moisture in air source.
for various symptoms. Follow all instructions
Exceeding system capability (material
too thick). as listed and complete each section in the order
3. Excessive pilot arc time presented.
4. Gas pressure too low. This guide is set up in the following manner:
5. Improperly assembled torch. X. Symptom (Bold Type)
6. Non - Genuine Thermal Dynamics
parts used Any Special Instructions
1. Cause
Difficult Starting 1. Worn torch parts.
2. Non - Genuine Thermal Dynamics a. Check / Remedy
parts used.
3. Incorrect gas pressure. Locate your symptom, check the causes (easiest
listed first), then remedies. Repair as needed be-
ing sure to verify that unit operates properly after
any repairs.
C. Common Symptoms
A. Gas regulator leaks
1. Regulator is open
a. Reset regulator to 0 psi, then adjust to 65 psi
( 4.5 bar ).

cutmaster 39
B. AC indicator OFF
1. Switch at customer's main power panel in OFF (open) E. AC indicator flashing; Temp indicator
position. ON
a. Close main power switch. 1. Fan disconnected or blocked.
2. Power Supply ON / OFF switch in OFF position. a. Clear fan if blocked; let power supply cool.
a. Turn switch to ON.

F. AC indicator ON; TEMP indicator ON
3. Customer's main power line fuse(s) or circuit
breaker(s) blown 1. Air flow blocked
a. Check main power panel fuse(s) and replace a. Check for blocked air flow around the unit
as required. and correct condition.
4. Actual input voltage does not correspond to voltage of 2. Fan blocked

unit a. Check and correct condition.
a. Verify that the input line voltage is correct. Re- 3. Unit is overheated
fer to Section 2, Input Wiring Requirements.
a. Let unit cool down for at least 5 minutes.
5. Faulty components in unit Make sure the unit has not been operated
a. Return for repair or have qualified technician beyond Duty Cycle limit. Refer to duty cycle
repair per Service Manual. data in Section 2.
C. AC indicator flashing; Torch cannot be 4. Input line voltage is below 100 Volts
activated a. Check and connect to proper input power
1. System is in protective interlock mode. (User held line.
torch trigger while turning on ON / OFF switch.) 5. Faulty components in unit
a. Release torch trigger, set ON / OFF switch to a. Return for repair or have qualified technician
OFF (down). Return ON / OFF switch to ON repair per Service Manual.
(up) position.
G. Torch will not pilot when torch switch is activat-
2. System is in protective interlock mode. (Torch parts ed
are missing or loose.)
1. System is in SET mode
a. Release torch trigger, and set ON / OFF
switch to OFF (down). Open main disconnect a. Change to RUN mode.
switch. Check torch parts, including O - rings
2. Upper O-ring on torch head is in wrong position.
on torch head. Refer to illustration on page 5
- 1. Replace parts as needed. Reinstall shield a. Remove shield cup from torch; check position
cup; hand - tighten it securely against the torch of upper O-ring. Correct if necessary.
head. Close main disconnect switch. Set ON
/ OFF switch to ON (up) position. Art # A-03640
3. System is in protective interlock mode. (User removed

shield cup from torch while power supply ON / OFF
switch was ON.)
a. Release torch trigger, and set ON / OFF switch Upper Groove
to OFF (down). Set ON / OFF switch to ON with Vent Holes
(up). Must Remain Open
D. Torch will not pilot; DC indicator and GAS
Upper O-Ring Threads
indicator flash alternately when torch trigger in Correct Groove Lower O-Ring
is activated
1. Gas pressure is too low. Adjust gas pressure to 65 psi
/ 4.5 bar.

CutMaster 39
3. Faulty torch parts 3. Faulty components in unit
a. Inspect torch parts and replace if necessary. a. Return for repair or have qualified technician
repair per Service Manual.
4. Gas pressure too high or too low
K. Erratic or improper cutting output
a. Adjust to proper pressure.
1. Poor input or output connections
5. Faulty components in unit
a. Check all input and output connections.
a. Return for repair or have qualified technician
repair per Service Manual. 2. Poor work cable connection
H. No cutting output; Torch activated; AC indicator a. Make sure that work cable has a proper con-
ON; Gas flows; Fan operates nection to a clean, dry area of the workpiece.
1. Torch not properly connected to power supply 3. Fluctuations in input power
a. Check that torch leads are properly connected a. Have electrician check input line voltage.
to power supply.
L. Difficult Starting
2. Work cable not connected to work piece, or connection
is poor 1. Worn torch parts (consumables)
a. Make sure that work cable has a proper con- a. Shut off input power. Remove and inspect
nection to a clean, dry area of the workpiece. torch shield cup, tip, starter cartridge, and
electrode. Replace electrode or tip if worn;
3. Shield cup not properly installed on torch replace starter cartridge if end piece does not
move freely; replace shield cup if excessive
a. Open main disconnect switch. Check that
spatter adheres to it.
shield cup is fully seated against torch head.
Set ON / OFF switch to OFF, check shield M. Arc shuts off during operation; arc will not re-
cup, close main disconnect switch, turn power start when torch switch is activated.
supply ON, and try cutting.
4. Faulty components in unit 1. Power Supply is overheated (TEMP indicator
a. Return for repair or have qualified technician ON)
repair per Service Manual. a. Let unit cool down for at least 5 minutes.
5. Faulty Torch Make sure the unit has not been operated
beyond Duty Cycle limit. Refer to Section 2
a. Return for repair or have qualified technician for duty cycle specifications.
repair.
2. Fan blades blocked (AC indicator flashing;
I. Low cutting output TEMP indicator ON)
1. Incorrect setting of CURRENT (A) control a. Check and clear blades.
a. Check and adjust to proper setting. 3. Air flow obstructed (AC indicator flashing;
TEMP indicator ON)
a. Check for obstructed air flow around the unit
and correct condition.
repair.
J. Limited output with no control
4. Gas pressure too low (GAS indicator OFF when
1. Poor input or output connections torch switch is activated)
a. Check all input and output connections. a. Check source for at least 65 psi / 4.5 bar; adjust
as needed.
2. Work cable connection to work piece is poor
a. Make sure that work cable has a proper con-
nection to a clean, dry area of the workpiece.

cutmaster 39
5. Torch consumables worn
a. Check torch shield cup, tip, starter element,
and electrode; replace as needed.
repair per Service Manual.
N. No gas flow; AC indicator ON; Fan oper-
ates
1. Gas not connected or pressure too low
a. Check gas connections. Adjust gas pressure
to proper setting.
2. Shield Cup not properly installed.
a. Check to see that Shield Cup is properly in-
stalled.
repair.
O. Torch cuts but not adequately
1. Current (A) control set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch). If there are
contaminants in the gas, additional filtering
may be needed.

CutMaster 39

cutmaster 39
SECTION 5 TORCH: O-Ring Lubrication
SERVICE An o-ring on the Torch ATC Male Connector requires

lubrication on a scheduled basis. This will allow the
o-ring to remain pliable and provide a proper seal.
The o-ring will dry out, becoming hard and cracked,
5T.01 General Maintenance if the o-ring lubricant is not used on a regular basis.
NOTE This can lead to potential performance problems.
Refer to Previous "Section 5 System" for common It is recommended to apply a very light film of o-
and fault indicator descriptions. ring lubricant (Catalog # 8-4025) to the o-ring on a
weekly basis.
Cleaning Torch
NOTE
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch be- DO NOT use other lubricants or grease, they may
comes coated with residue. This buildup can affect not be designed to operate within high tempera-
the pilot arc initiation and the overall cut quality of tures or may contain unknown elements that
the torch. may react with the atmosphere. This reaction
can leave contaminants inside the torch. Either
of these conditions can lead to inconsistent per-
formance or poor parts life.
WARNINGS
Disconnect primary power to the system before ATC Male Connector
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 electri-
cal contact cleaner using a cotton swab or soft wet
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 Gas Fitting
Dry the torch thoroughly before reinstalling.
Art #A-03791 O-Ring
Manual 0-4975 5T-1 SERVICE

CutMaster 39
5T.02 Inspection and Replacement 3. Remove the tip. Check for excessive wear (indi-
cated by an elongated or oversized orifice). Clean
of Consumable Torch Parts or replace the tip if necessary.
Good Tip Worn Tip
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
A-03406
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON. Tip Wear
Remove the consumable torch parts as follows: 4. Remove the starter cartridge. Check for excessive
wear, plugged gas holes, or discoloration. Check
NOTE
the lower end fitting for free motion. Replace if
The shield cup holds the tip and starter cartridge necessary.
shield cup in place. Position the torch with the Spring-Loaded Spring-Loaded
shield cup facing upward to prevent these parts Lower End Fitting Lower End Fitting at Rest /
from falling out when the cup is removed. Full Compression 1/8 Full Extension
1. Unscrew and remove the shield cup from the

torch.
NOTE
Slag built up on the shield cup that cannot be re-
moved may effect the performance of the system. Art # A-08064
2. Inspect the cup for damage. Wipe it clean or 5. Pull the Electrode straight out of the Torch Head.
replace if damaged. Check the face of the electrode for excessive wear.
Refer to the following figure.
Torch Head
New Electrode
Electrode
Start Cartridge Worn Electrode

Art # A-03284
Electrode Wear
Tip
6. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
Shield Cup
7. Reinstall the desired starter cartridge and tip into
the torch head.
A-03645
8. Hand tighten the shield cup until it is seated on
Consumable Parts the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
SERVICE 5T-2 Manual 0-4975

cutmaster 39
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable components.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper
authorization will not be accepted.
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 torch. Address all
inquiries to your authorized distributor.
6.03 Replacement Assemblies
The following items are included with the replacement power supply: input power cord and plug, work
cable & clamp, gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 39 Power Supply 3-3830
1 Surelok Model SL60 Torch 7-5204
6.04 Power Supply Replacement Parts

1 Regulator / Filter Assembly Filter Element 9-0182
1 Input Power Cord with 120 VAC, 20A plug 9-8660
Manual 0-4975 6-1 PARTS LISTS

CutMaster 39
6.05 Options and Accessories
1 120V, 15 - Amp Plug 9-8644
1 120V, 20 - Amp Receptacle 9-8645
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 Multi - Purpose Cart 7-8888
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
Single - Stage Air Filter O-ring
(Cat. No. 9-7743) Assembled Filter
Cover
Barbed
Fitting Art # A-02476
6.06 Torch Consumables
Art # A-03409
NOTE
Large O-Ring,
Cat. No. 8-3487 When operating the torch in
a normal condition, a small
Small O-Ring,
Cat. No. 8-3486 amount of gas vents through the
gap between the shield cup and
Electrode, Cat. No. 9-8215 torch handle. Do not attempt
to over tighten the shield cup as
Start Cartridge, irreparable damage to internal
Cat. No. 9-8213 components may result.
Worn Electrode
Worn Tip
PARTS LISTS 6-2 Manual 0-4975

cutmaster 39 & 15
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION ACTION ACTION ACTION ACTION
Close external ON / OFF switch RUN / SET switch to SET. RUN / SET switch Connect work cable
disconnect switch. to ON. to RUN. to workpiece.
RESULT Set output amperage
RESULT RESULT RESULT
Gas flows to set pressure. RESULT
Power to system. AC indicator ON. GAS indicator on when input Gas flow stops.
Fan on. pressure is adequate. System is ready
Power circuit ready. for operation.
ACTION ACTION
Protect eyes and Torch moved away

activate torch. from work (while
still activated).
RESULT
RESULT
Gas flows briefly,
then stops. PILOT ARC Main arc stops.
Gas restarts. Pilot arc automatically
restarts.
DC indicator on.
Pilot arc established.
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfers.

Pilot arc off.
ACTION
Release torch trigger.

RESULT
Main arc stops.

Gas flow stops after post - flow.
ACTION ACTION
ON / OFF switch Unplug input

to OFF power cord or
open external
RESULT disconnect.
All indicators off. RESULT

Power supply fan shuts off.
No power to system.
A-03299
Manual 0-4975 A-1 APPENDIX

CutMaster 39 & 15
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
Date of Mfr: and Production Code
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 3 I 1eff Maximum Effective
1
1 1
1 3
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. Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288
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.
NOTE
Sections of the data tag may be applied in
separate locations on the Power Supply.
APPENDIX A-2 Manual 0-4975

cutmaster 39 & 15
This Page Intentionally Blank.

CutMaster 39 & 15
APPENDIX 3: SYSTEM SCHEMATIC
1 2 3 4
PFC INDUCTOR
A INPUT 230V ONLY
T1
J7
TEST E11 E18
EMC 1 4
FILTER
E12A D47
CE ONLY
CHASSIS GND
+
(E12A)
K1
L1 SW1 E1 2
(E15A)
(E1) (E14A)
1 BR1 3 Q7 Q8
RING E14A 4
120/208/230V
-
FILTE
INPUT (E16A)
50/60HZ
B E2
(E2) E15A
SW1
STUD E13
E16A
P4 J4 E12B
M1 + RED BIAS
+
1 1 (E12B)
FAN1 CONVERTER
12VDC
BLACK (E14B) 2
2 2 (E15B)
1 BR2 3
E14B 4
P6 J6 LOGIC AND CONTROL CIRCUITRY
-
(5) 1 (E16B)
1
C CURRENT (6) E15B
2 2 TEST POINTS:
CONTROL
(7) 3 3
CURRENT ADJUST CW E16B TP1 LOGIC COMMON
20 - 30 TP2 SHORT TO TP23 TO DISABLE BIAS SUPPLY
P2 J2 TP6 SHORT TO TP24 TO DISABLE POWER
(8) 1 1 PANEL INDICATOR FACTOR CORRECTION
SET
SW2 2 2 TP8 SHORT TO TP26 TO DISABLE SHORTED
(9) 3 3 AC D7 TORCH PROTECTION
RUN
TEMP D13 CAUTION: SOME PORTIONS OF THE CONTROL/
LOGIC CIRCUITRY ARE CONNECTED TO THE
NORMALLY CLOSED GAS D16 INPUT LINE. CONNECTION TO A GROUNDED
OVER-TEMP P5 J5 INSTRUMENT COULD CAUSE A SHOCK
1 1 DC D19 HAZARD OR DESTROY THE POWER SUPPLY.
D 2 2
TS1 ACCESS BY AN AUTHORIZED TECHNICIAN ONLY.
P9J9 ZERO
1 1
(10) 2 2
(11) 3 3 MAIN PCB ASSEMBLY
PS1
PRESSURE SW
A-03405 1 2 3 4

cutmaster 39 & 15
5 6 7 8 9 10
MAIN
T3
o OUTPUT INDUCTOR
PRI SEC J8 P8 A
o E9 L1 E4 (E4)
E5 E6 E10 E20 TORCH
(-)
Q13
D56
D54
T
O
R
C70, 72, 81 C
Q11 H
C71, 73, 75 D53 E8 (E8)
Q12 B
PILOT
D55 J3 P3
WORK
1 1 (12) 4 4
TORCH
SWITCH
2 2 (13) 3 3
3 3 (14) 2 2
+14VA AGND
+12VB BGND 4 4 (15) 1 1 PIP
5
QUICK DISCONNECT
E19
TORCH SWITCH ON D22
C
WORK
PWM ON D99
J1 P1 SOL1
A B
1 1
2 2 GAS SOLENOID
COMPDESCRIPTION LOCATION
TS1 OVER-TEMP. SENSOR D2
M1FAN, 4.5" 12VDC C1
PS1PRESSURE SWITCH D1 E
SOL1GAS SOLENOID D9
T1 PFC INDUCTOR A4
T3 MAIN TRANSFORMER A7
L1OUTPUT INDUCTOR A8
SW1 SWITCH, ON/OFF B2
SW2 SWITCH, RUN/SET D1
Rev Revisions By Date PCB No:

THERMAL DYNAMICS
AA REL ECO 100213 GCW 7/29/02 Assy No:
INDUSTRIAL PARK
No. 2
AB REL ECO 100333 GCW 10/04/02 0 Scale
WEST LEBANON, NH3784 Supersedes
603-298-57
11
AC REL ECO 100535
AD REL ECO B505
DAT
RWH
2/27/03
Date: F
6/19/07 Information Proprietary to THERMAL DYNAMICS CORPORATION.
Tuesday, May 15, 2001
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn:References
NOTE: GCW
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk:App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Tuesday, June 19, 2007 15:05:29 CM38 120/208/230V SINGLE PH ASE 50/60 Hz C 42X1089
5 6 7 8 9 10 A-03405

CutMaster 39 & 15
This Page Intentionally Blank.

GLOBAL CUSTOMER SERVICE CONTACT
Thermadyne USA Thermadyne Asia Sdn Bhd

2800 Airport Road Lot 151, Jalan Industri 3/5A
Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang
Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan
800-426-1888 West Malaysia
Fax: 800-535-0557 Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Thermadyne Canada
2070 Wyecroft Road Cigweld, Australia
Oakville, Ontario 71 Gower Street
Canada, L6L5V6 Preston, Victoria
Telephone: (905)-827-1111 Australia, 3072
Fax: 905-827-3648 Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Europe
Europe Building Thermadyne Italy
Chorley North Industrial Park OCIM, S.r.L.
Chorley, Lancashire Via Benaco, 3
England, PR6 7Bx 20098 S. Giuliano
Telephone: 44-1257-261755 Milan, Italy
Fax: 44-1257-224800 Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A Thermadyne International
685 Ding Xi Rd 2070 Wyecroft Road
Chang Ning District Oakville, Ontario
Shanghai, PR, 200052 Canada, L6L5V6
Telephone: 86-21-69171135 Telephone: (905)-827-9777
Fax: 86-21-69171139 Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com

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39

PLASMA CUTTING SYSTEM

This Operating Manual has been designed to instruct you on the

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-

Above all, we are committed to developing technologically ad-

Plasma Cutting Power Supply

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the

Printed in the United States of America

Publication Date: September 4, 2007

Record the following information for Warranty purposes:

Where Purchased:________________________________ ________________

Purchase Date:___________________________________ ________________

Power Supply Serial #:____________________________ ________________

Torch Serial #:____________________________________________________

SECTION 2 SYSTEM:INTRODUCTION ..................................................................................2-1

SECTION 2 TORCH:INTRODUCTION .................................................................................. 2T-1

SECTION 3: INSTALLATION ...................................................................................................3-1

SECTION 4 TORCH:OPERATION.......................................................................................... 4T-1

SECTION 5 TORCH:SERVICE............................................................................................... 5T-1

SECTION 6:PARTS LISTS........................................................................................................6-1

APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)......................................... A-1

APPENDIX 2: DATA TAG INFORMATION .............................................................................. A-2

APPENDIX 3: SYSTEM SCHEMATIC..................................................................................... A-4

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION.......................... Inside Rear Cover

Manual 0-4975 1-1 GENERAL INFORMATION

ELECTRIC SHOCK NOISE

GENERAL INFORMATION 1-2 Manual 0-4975

Manual 0-4975 1-3 GENERAL INFORMATION

Manual 0-4975 1-5 GENERAL INFORMATION

GENERAL INFORMATION 1-6 Manual 0-4975

LIMITED WARRANTY PERIOD

This warranty does not apply to:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

Effective September 4, 2007

This Page Intentionally Blank

Manual 0-4975 1-7 GENERAL INFORMATION

GENERAL INFORMATION 1-8 Manual 0-4975

Manual 0-4975 2-1 INSTALLATION

INSTALLATION 2-2 Manual 0-4975

2.05 Input Wiring Specifications

Line Voltages with Suggested Circuit Protection and Wire Sizes

Manual 0-4975 2-3 INSTALLATION

C. Cutting Guide Kit

2.07 Torch Specifications

1.17" (29 mm) Art # A-03322

Torch Configuration and Dimensions

B. Torch Leads Lengths

E. SL60 Torch Ratings (Refer to Note)

F. Plasma Power Supply Used With

INSTALLATION 2-4 Manual 0-4975

Read this manual thoroughly. A complete under-

Manual 0-4975 2T-1 INTRODUCTION

I. Direct Contact Hazard

2T.04 Options And Accessories _

INTRODUCTION 2T-2 Manual 0-4975

D. Main Cutting Arc

E. Parts - In - Place (PIP)

Torch Switch Torch Trigger

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4975 2T-3 INTRODUCTION

Where Purchased:________________

Purchase Date:___________________

Power Supply Serial #:____________