Cutmaster 25 Service Manual

25mm
CUTMASTER ™
PLASMA CUTTING SYSTEM
Art # A-08803_AB
Service Manual
Rev. AB Date: May 29, 2009 Manual # 0-5081
Operating Features:
380V
400V
415V
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 employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply

CutMaster™ 25mm
SL60 1Torch™
Service Manual Number 0-5081
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2009 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
Original Publication Date: January 9, 2009

Revision Date: May 29, 2009
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
1.01 Notes, Cautions and Warnings....................................................................... 1
1.02 Important Safety Precautions......................................................................... 1
1.03 Publications.................................................................................................... 2
1.04 Note, Attention et Avertissement.................................................................... 3
1.05 Precautions De Securite Importantes............................................................. 3
1.06 Documents De Reference............................................................................... 5
1.07 Declaration of Conformity............................................................................... 6
1.08 Statement of Warranty.................................................................................... 7
SECTION 2 SYSTEM:INTRODUCTION ..................................................................................2-1

2.01 How To Use This Manual.............................................................................2-1
2.02 Equipment Identification..............................................................................2-1
2.03 Receipt Of Equipment..................................................................................2-1
2.04 Power Supply Specifications........................................................................2-2
2.05 Input Wiring Specifications...........................................................................2-3
2.06 Power Supply Features................................................................................2-4
SECTION 2 TORCH:INTRODUCTION .................................................................................. 2T-1

2T.01 Scope of Manual........................................................................................ 2T-1
2T.02 General Description................................................................................... 2T-1
2T.03 Specifications ........................................................................................... 2T-1
2T.04 Options And Accessories........................................................................... 2T-2
2T.05 Introduction to Plasma............................................................................... 2T-2
SECTION 3 SYSTEM: INSTALLATION ....................................................................................3-1

3.01 Unpacking....................................................................................................3-1
3.02 Lifting Options..............................................................................................3-1
3.03 Primary Input Power Connections...............................................................3-2
3.04 Gas Connections.........................................................................................3-4
SECTION 3 TORCH: INSTALLATION .................................................................................... 3T-1

3T.01 Torch Connections..................................................................................... 3T-1
3T.02 Setting Up Mechanical Torch..................................................................... 3T-1
SECTION 4 SYSTEM: OPERATION.........................................................................................4-1

4.01 Front Panel Controls / Features...................................................................4-1
4.02 Preparations for Operation...........................................................................4-2
SECTION 4 TORCH:OPERATION.......................................................................................... 4T-1

4T.01 Torch Parts Selection................................................................................. 4T-1
4T.02 Cut Quality................................................................................................. 4T-2
4T.03 General Cutting Information....................................................................... 4T-2
4T.04 Hand Torch Operation................................................................................ 4T-3
4T.05 Gouging..................................................................................................... 4T-7
4T.06 Mechanized Torch Operation..................................................................... 4T-8
4T.07 Parts Selection for Manual and Mechanized Torch Cutting....................... 4T-9
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed Tip 4T-10
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded Tip 4T-14
TABLE OF CONTENTS
PATENT INFORMATION....................................................................................................... 4T-18
SECTION 5 SYSTEM:SERVICE...............................................................................................5-1
5.01 General Maintenance..................................................................................5-1
5.02 Maintenance Schedule................................................................................5-2
5.03 Common Faults............................................................................................5-2
5.04 Fault Indicator..............................................................................................5-3
5.05 Basic Troubleshooting Guide.......................................................................5-4
5.06 Power Supply Basic Parts Replacement.....................................................5-6
5.07 Circuit Fault Isolation...................................................................................5-8
5.08 Main Input and Internal Power Problems...................................................5-12
5.09 Pilot Arc Problems.....................................................................................5-16
5.10 Main Arc and Controls Problems...............................................................5-17
5.11 CNC Interface Problems............................................................................5-18
5.12 Test Procedures.........................................................................................5-19
5.13 Capacitor PCB Layout & Signals...............................................................5-22
5.14 Logic PCB Layout & Signals......................................................................5-24
5.15 MAIN PCB Layout & Signals......................................................................5-28
5.16 Main PCB Wiring Diagram.........................................................................5-30
SECTION 5 TORCH:SERVICE............................................................................................... 5T-1

5T.01 General Maintenance................................................................................ 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts......................... 5T-2
SECTION 6:PARTS LISTS........................................................................................................6-1

6.01 Introduction..................................................................................................6-1
6.02 Ordering Information....................................................................................6-1
6.03 Power Supply Replacement.........................................................................6-1
6.04 Major External Replacement Parts..............................................................6-2
6.05 Front Panel Replacement Parts...................................................................6-3
6.06 Left Side Replacement Parts ......................................................................6-4
6.07 Right Side Replacement Parts . ..................................................................6-5
6.08 Options and Accessories.............................................................................6-6
6.09 Replacement Parts for Hand Torch .............................................................6-7
6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads........6-8
6.11 Torch Consumable Parts Manual and Mechanized Torches......................6-10
SECTION 7: REPLACEMENT PROCEDURES .......................................................................7-1

7.01 Scope...........................................................................................................7-1
7.02 Anti-Static Handling Procedures..................................................................7-1
7.03 Parts Replacement - General Information...................................................7-1
7.04 Major External Parts ...................................................................................7-2
7.05 Front Panel Parts Replacement...................................................................7-3
7.06 Left Side Internal Parts Replacement..........................................................7-4
7.07 Rear Panel Parts Replacement...................................................................7-5
7.08 Right Side Internal Parts Replacement........................................................7-7
TABLE OF CONTENTS
APPENDIX 1: SEQUENCE OF OPERATION(BLOCK DIAGRAM)......................................... A-1
APPENDIX 2: DATA TAG INFORMATION............................................................................... A-2
APPENDIX 3: TORCH PIN - OUT DIAGRAMS....................................................................... A-3
APPENDIX 4: TORCH CONNECTION DIAGRAMS................................................................ A-4
APPENDIX 5: SYSTEM SCHEMATIC, 380/400/415V UNITS................................................. A-6
APPENDIX 6: Publication History............................................................................................ A-8
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION.......................... Inside Rear Cover

TABLE OF CONTENTS
CUTMASTER 25mm
SECTION 1: • The kinds of fumes and gases from the plasma arc depend on
the kind of metal being used, coatings on the metal, and the
GENERAL INFORMATION different processes. You must be very careful when cutting
or welding any metals which may contain one or more of the
following:
1.01 Notes, Cautions and Warnings Antimony Chromium Mercury
Arsenic Cobalt Nickel
Throughout this manual, notes, cautions, and warnings are used to Barium Copper Selenium
highlight important information. These highlights are categorized as Beryllium Lead Silver
follows: Cadmium Manganese Vanadium
NOTE • Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
An operation, procedure, or background information will give you the information regarding the kind and amount of
which requires additional emphasis or is helpful in ef- fumes and gases that may be dangerous to your health.
ficient operation of the system.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.
CAUTION • Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
A procedure which, if not properly followed, may cause
damage to the equipment. • Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
!
• Phosgene, a toxic gas, is generated from the vapors of chlo-
rinated solvents and cleansers. Remove all sources of these
WARNING vapors.
A procedure which, if not properly followed, may cause • This product, when used for welding or cutting, produces
injury to the operator or others in the operating area. fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
1.02 Important Safety Precautions (California Health & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
WARNINGS
Electric Shock can injure or kill. The plasma arc process uses and
OPERATION AND MAINTENANCE OF PLASMA ARC produces high voltage electrical energy. This electric energy can cause
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS severe or fatal shock to the operator or others in the workplace.
TO YOUR HEALTH.
• Never touch any parts that are electrically “live” or “hot.”
Plasma arc cutting produces intense electric and
• Wear dry gloves and clothing. Insulate yourself from the work
magnetic emissions that may interfere with the proper
piece or other parts of the welding circuit.
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near • Repair or replace all worn or damaged parts.
plasma arc cutting applications should consult their • Extra care must be taken when the workplace is moist or
medical health professional and the manufacturer of damp.
the health equipment to determine whether a hazard
exists. • Install and maintain equipment according to NEC code, refer
to item 9 in Subsection 1.03, Publications.
To prevent possible injury, read, understand and follow • Disconnect power source before performing any service or
all warnings, safety precautions and instructions before repairs.
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions. • Read and follow all the instructions in the Operating Manual.
Fire AND EXPLOSION

GASES AND FUMES
Fire and explosion can be caused by hot slag, sparks, or the plasma
Gases and fumes produced during the plasma cutting process can be arc.
dangerous and hazardous to your health.
• Be sure there is no combustible or flammable material in the
• Keep all fumes and gases from the breathing area. Keep your workplace. Any material that cannot be removed must be
head out of the welding fume plume. protected.
• Use an air-supplied respirator if ventilation is not adequate to • Ventilate all flammable or explosive vapors from the work-
remove all fumes and gases. place.
Manual 0-5081 GENERAL INFORMATION

CUTMASTER 25mm
• Do not cut or weld on containers that may have held combus- 1.03 Publications
tibles.
• Provide a fire watch when working in an area where fire hazards Refer to the following standards or their latest revisions for more
may exist. information:
• Hydrogen gas may be formed and trapped under aluminum 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
workpieces when they are cut underwater or while using a water obtainable from the Superintendent of Documents, U.S.
table. DO NOT cut aluminum alloys underwater or on a water Government Printing Office, Washington, D.C. 20402
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion. 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
NOISE 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
Noise can cause permanent hearing loss. Plasma arc processes can WELDING AND CUTTING, obtainable from the Superintendent
cause noise levels to exceed safe limits. You must protect your ears of Documents, U.S. Government Printing Office, Washington,
from loud noise to prevent permanent loss of hearing. D.C. 20402
• To protect your hearing from loud noise, wear protective ear 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
plugs and/or ear muffs. Protect others in the workplace. AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
• Noise levels should be measured to be sure the decibels (sound) from American National Standards Institute, 1430 Broadway,
do not exceed safe levels. New York, NY 10018
• For information on how to test for noise, see item 1 in Subsec- 5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
tion 1.03, Publications, in this manual. FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
PLASMA ARC RAYS
TING AND WELDING PROCESSES, obtainable from American
Plasma Arc Rays can injure your eyes and burn your skin. The plasma National Standards Institute, 1430 Broadway, New York, NY
arc process produces very bright ultra violet and infra red light. These 10018
arc rays will damage your eyes and burn your skin if you are not
properly protected. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
• To protect your eyes, always wear a welding helmet or shield. American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
Also always wear safety glasses with side shields, goggles or 33126
other protective eye wear.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
• Keep helmet and safety glasses in good condition. Replace Park, Quincy, MA 02269
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
booths, screens or shields. from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1: 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
Minimum Protective Suggested obtainable from the National Fire Protection Association,
Arc Current Shade No. Shade No. Batterymarch Park, Quincy, MA 02269
Less Than 300* 8 9
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
300 - 400* 9 12 GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
400 - 800* 10 14
Arlington, VA 22202
* These values apply where the actual arc is clearly seen.
Experience has shown that lighter filters may be used 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
when the arc is hidden by the workpiece. AND CUTTING, obtainable from the Canadian Standards As-
sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
LEAD WARNING from the National Welding Supply Association, 1900 Arch
This product contains chemicals, including lead, or otherwise produces Street, Philadelphia, PA 19103
chemicals known to the State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)
GENERAL INFORMATION Manual 0-5081

CUTMASTER 25mm
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT FUMÉE et GAZ
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL La fumée et les gaz produits par le procédé de jet de plasma peuvent
33126 présenter des risques et des dangers de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO- • Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018 • Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
1.04 Note, Attention et Avertissement • Les sortes de gaz et de fumée provenant de l’arc de plasma dépen-
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont dent du genre de métal utilisé, des revêtements se trouvant sur le
utilisés pour mettre en relief des informations à caractère important. métal et des différents procédés. Vous devez prendre soin lorsque
Ces mises en relief sont classifiées comme suit : vous coupez ou soudez tout métal pouvant contenir un ou plusieurs
des éléments suivants:
NOTE
antimoine cadmium mercure
Toute opération, procédure ou renseignement général argent chrome nickel
sur lequel il importe d’insister davantage ou qui contribue arsenic cobalt plomb
à l’efficacité de fonctionnement du système. baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières
ATTENTION (sigle américain “MSDS”); celles-ci devraient être fournies avec le
matériel que vous utilisez. Les MSDS contiennent des renseigne-
Toute procédure pouvant résulter l’endommagement ments quant à la quantité et la nature de la fumée et des gaz pouvant
du matériel en cas de non-respect de la procédure en poser des dangers de santé.
question.
• Pour des informations sur la manière de tester la fumée et les gaz
de votre lieu de travail, consultez l’article 1 et les documents cités
! AVERTISSEMENT
•
à la page 5.
Utilisez un équipement spécial tel que des tables de coupe à débit
Toute procédure pouvant provoquer des blessures de d’eau ou à courant descendant pour capter la fumée et les gaz.
l’opérateur ou des autres personnes se trouvant dans
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
la zone de travail en cas de non-respect de la procédure
trouvent des matières ou des gaz combustibles ou explosifs.
en question.
• Le phosgène, un gaz toxique, est généré par la fumée provenant
1.05 Precautions De Securite Importantes des solvants et des produits de nettoyage chlorés. Eliminez toute
source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe, produit de
la fumée ou des gaz pouvant contenir des éléments reconnu dans
AVERTISSEMENTS L’état de la Californie, qui peuvent causer des défauts de naissance
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL et le cancer. (La sécurité de santé en Californie et la code sécurité
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT Sec. 25249.5 et seq.)
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie CHOC ELECTRIQUE
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker” Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
cardiaque, les appareils auditif, ou autre matériel de santé de plasma requiert et produit de l’énergie électrique haute tension. Cette
electronique. Ceux qui travail près d’une application à énergie électrique peut produire des chocs graves, voire mortels, pour
l’arc au jet de plasma devrait consulter leur membre pro- l’opérateur et les autres personnes sur le lieu de travail.
fessionel de médication et le manufacturier de matériel de • Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
santé pour déterminer s’il existe des risques de santé. gants et des vêtements secs. Isolez-vous de la pièce de travail ou
Il faut communiquer aux opérateurs et au personnel des autres parties du circuit de soudage.
TOUS les dangers possibles. Afin d’éviter les blessures • Réparez ou remplacez toute pièce usée ou endommagée.
possibles, lisez, comprenez et suivez tous les avertisse-
ments, toutes les précautions de sécurité et toutes les • Prenez des soins particuliers lorsque la zone de travail est humide
consignes avant d’utiliser le matériel. Composez le + ou moite.
603-298-5711 ou votre distributeur local si vous avez
des questions.

CUTMASTER 25mm
• Montez et maintenez le matériel conformément au Code électrique • Utilisez la nuance de lentille qui est suggèrée dans le recommenda-
national des Etats-Unis. (Voir la page 5, article 9.) tion qui suivent ANSI/ASC Z49.1:
• Débranchez l’alimentation électrique avant tout travail d’entretien Nuance Minimum Nuance Suggerée
ou de réparation. Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
• Lisez et respectez toutes les consignes du Manuel de consignes.
300 - 400* 9 12
400 - 800* 10 14
INCENDIE ET EXPLOSION
* Ces valeurs s’appliquent ou l’arc actuel est observé
Les incendies et les explosions peuvent résulter des scories chaudes, clairement. L’experience a démontrer que les filtres
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma moins foncés peuvent être utilisés quand l’arc est caché
produit du métal, des étincelles, des scories chaudes pouvant mettre par moiceau de travail.
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne BRUIT
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail. Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
• Procurez une bonne aération de toutes les fumées inflammables supérieurs aux limites normalement acceptables. Vous dú4ez vous
ou explosives. protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles. • Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
• Prévoyez une veille d’incendie lors de tout travail dans une zone les autres personnes se trouvant sur le lieu de travail.
présentant des dangers d’incendie.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
• Le gas hydrogène peut se former ou s’accumuler sous les pièces (le bruit) ne dépassent pas les niveaux sûrs.
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium sous • Pour des renseignements sur la manière de tester le bruit, consultez
l’eau ou sur une table d’eau à moins que le gas hydrogène peut l’article 1, page 5.
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera
si enflammé.
PLOMB AVERTISSEMENT
RAYONS D’ARC DE PLASMA Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
Californie comme pouvant être à l’origine de cancer, de mal-
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
formations fœtales ou d’autres problèmes de reproduction.
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
Il faut se laver les mains après toute manipulation.
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
pas correctement.
suivants)
• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.

CUTMASTER 25mm
1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM-
MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À
Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT
été faites à celles-ci pour de plus amples renseignements : RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
33126
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
20402 disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ameri-
can National Standards Institute), 1430 Broadway, New York, NY
10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO-
TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les
Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection As-
sociation, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUD-
AGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures de
Soudage (National Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103

CUTMASTER 25mm
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to
the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in conjunction with
hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to
ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous
testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Steve Ward

Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

CUTMASTER 25mm
1.08 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™ 1Series 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™ 10mm 3 Years 1 Year
CUTMASTER™12mm 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry
standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of 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 owner’s 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 25mm

CUTMASTER 25mm
SECTION 2 SYSTEM: 2.02 Equipment Identification
INTRODUCTION The unit’s identification number (specification or
part number), model, and serial number usually
appear on a data tag attached to the rear panel.
2.01 How To Use This Manual Equipment which does not have a data tag such
This Service Manual applies to just specification as torch and cable assemblies are identified
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 Thermadyne at the
address and phone number in your area listed
in the inside back cover of this manual. Include
the Service 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 0-5081 2-1 INTRODUCTION

CUTMASTER 25mm
2.04 Power Supply Specifications
CutMaster 25mm Power Supply Specifications
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power
400/415 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Power Supply includes input cable for 380/400/415V
Input Power Cable
3Phase..
Output Current 20 - 80 Amps, Continuously Adjustable
Power Supply Gas Particulates to 5 Microns
Filtering Ability
CutMaster 25mm Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
IEC Rating IEC Rating IEC Rating
Duty Cycle 40% 60% 100%
All Units Current 80 Amps 65 Amps 50 Amps
DC Voltage 112 106 102
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These 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.
Power Supply Dimensions & Weight Ventilation Clearance Requirements

10.75"
273 mm
Art # A-07941
Art # A-07925
16.375"
416 mm
6"
150 mm
24"
0.6 m
22.5"
0.57 m
6" 6"
43 lb / 19.5 kg 150 mm 150 mm
INTRODUCTION 2-2 Manual 0-5081

CUTMASTER 25mm
2.05 Input Wiring Specifications
CutMaster 25mm Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Fuse Flexible Cord
Volts Hz kVA I max I eff
(amps) (Min. AWG)
380 50/60 11.8 18 12 20 14
3 Phase
400/415 50/60 11.8 17 11 20 14
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.
Cable size is de-rated based on the Duty Cycle of the equipment.
Manual 0-5081 2-3 INTRODUCTION

CUTMASTER 25mm
2.06 Power Supply Features
Handle and Leads Wrap
Control Panel
Torch Leads Receptacle
Art # A-07942
Work Cable
and Clamp
Port for Optional Automation
Interface Cable
Filter Assembly
Gas Inlet Port
Art # A-08544
Input Power Cord
INTRODUCTION 2-4 Manual 0-5081

CUTMASTER 25mm
SECTION 2 TORCH: 2T.03 Specifications
INTRODUCTION A. Torch Configurations
1. Hand/Manual Torch, Models
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 the 10.125" (257 mm)
1Torch Models SL60/Manual and SL100/Mecha-
nized Plasma Cutting Torches. Service of this
equipment is restricted to properly trained person-
nel; unqualified personnel are strictly cautioned
3.75"
against attempting repairs or adjustments not
(95 mm)
covered in this manual, at the risk of voiding the Art # A-03322_AB
Warranty. 1.17" (29 mm)

Read this manual thoroughly. A complete under-
standing of the characteristics and capabilities of 2. Mechanized Torch, Model
this equipment will assure the dependable opera- The standard machine torch has a positioning
tion for which it was designed. tube with rack & pinch block assembly.
15.875" / 403 mm
2T.02 General Description 9.285" / 236 mm
Plasma torches are similar in design to the auto-

motive spark plug. They consist of negative and 1.175" / 30 mm
1.375" / 35 mm
positive sections separated by a center insulator. 4.95" / 126 mm
Inside the torch, the pilot arc starts in the gap 1.75" / 0.625" /
44.5 mm 16 mm Art # A-02998
between the negatively charged electrode and
the positively charged tip. Once the pilot arc has B. Torch Leads Lengths
ionized the plasma gas, the superheated column of Hand Torches are available as follows:
gas flows through the small orifice in the torch tip, • 20 ft / 6.1 m, with ATC connectors
which is focused on the metal to be cut.
A single torch lead provides gas from a single • 50 ft / 15.2 m, with ATC connectors
source to be used as both the plasma and second- Machine Torches are available as follows:
ary gas. The air flow is divided inside the torch • 5 foot / 1.5 m, with ATC connectors
head. Single - gas operation provides a smaller • 10 foot / 3.05 m, with ATC connectors
sized torch and inexpensive operation.
• 25 foot / 7.6 m, with ATC connectors
NOTE
• 50 foot / 15.2 m, with ATC connectors
Refer to Section 2T.05, Introduction To Plasma,
for a more detailed description of plasma torch C. Torch Parts
operation. Starter Cartridge, Electrode, Tip, Shield Cup
Refer to the Appendix Pages for additional specifi- D. Parts - In - Place (PIP)
cations as related to the Power Supply used.
Torch Head has built - in switch
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through
torch.
Manual 0-5081 2T-1 INTRODUCTION

CUTMASTER 25mm
F. Torch Ratings 2T.05 Introduction to Plasma
Manual Torch Ratings A. Plasma Gas Flow
Ambient 104° F
Temperature 40° C Plasma is a gas which has been heated to an ex-
tremely high temperature and ionized so that it
Duty Cycle 100% @ 60 Amps @ 400 scfh becomes electrically conductive. The plasma arc
Maximum Current 80 Amps cutting and gouging processes use this plasma to
Voltage (Vpeak) 500V transfer an electrical arc to the workpiece. The metal
to be cut or removed is melted by the heat of the arc
Arc Striking Voltage 7kV and then blown away.
While the goal of plasma arc cutting is separation of
Mechanized Torch Ratings
the material, plasma arc gouging is used to remove
Ambient 104° F metals to a controlled depth and width.
Temperature 40° C
In a Plasma Cutting Torch a cool gas enters Zone B,
Duty Cycle 100% @ 100 Amps @ 400 scfh
where a pilot arc between the electrode and the torch
Maximum Current 120 Amps tip heats and ionizes the gas. The main cutting arc
Voltage (Vpeak) 500V then transfers to the workpiece through the column
Arc Striking Voltage 7kV of plasma gas in Zone C.
G. Gas Requirements
Manual and Mechanized Torch Gas
Specifications
Gas (Plasma and Secondary) Compressed Air
Operating Pressure 60 - 95 psi _
Refer to NOTE 4.1 - 6.5 bar Power
Maximum Input Pressure 125 psi / 8.6 bar Supply A
300 - 500 scfh +
Gas Flow (Cutting and Gouging)
142 - 235 lpm
B
! WARNING
Workpiece
This torch is not to be used with oxygen (O2).
NOTE
C A-00002
Operating pressure varies with torch model, op-

Typical Torch Head Detail
erating amperage, and torch leads length. Refer to
gas pressure settings charts for each model.
By forcing the plasma gas and electric arc through a
H. Direct Contact Hazard small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
For standoff tip the recommended standoff is 3/16
arc is shown in Zone C. Direct current (DC) straight
inches / 4.7 mm.
polarity is used for plasma cutting, as shown in the
illustration.
2T.04 Options And Accessories
Zone A channels a secondary gas that cools the torch.
For options and accessories, see section 6. 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 0-5081

CUTMASTER 25mm
B. Gas Distribution E. Parts - In - Place (PIP)
The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) circuit.
and secondary gases. When the shield cup is properly installed, it closes
a switch. The torch will not operate if this switch
The plasma gas flows into the torch through the is open.
negative lead, through the starter cartridge, around
the electrode, and out through the tip orifice.
Torch Switch Torch Trigger
To Control
The secondary gas flows down around the outside
Cable Wiring
of the torch starter cartridge, and out between the
tip and shield cup around the plasma arc. PIP Switch Shield Cup
A-02997
C. Pilot Arc
Parts - In - Place Circuit Diagram for Hand Torch
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot Remote Pendant
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 To ATC PIP Switch Shield Cup
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.
CNC Start
To ATC PIP Switch Shield Cup
Art # A-08168
Automation Torch
To ATC PIP Switch Shield Cup
Parts - In - Place Circuit Diagram for Machine

Torch
Manual 0-5081 2T-3 INTRODUCTION

CUTMASTER 25mm
INTRODUCTION 2T-4 Manual 0-5081

CUTMASTER 25mm
SECTION 3 SYSTEM:
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 shipping 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 handles, 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.
Manual 0-5081 3-1 INSTALLATION

CUTMASTER 25mm
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.
Connections for Three Phase Input Power
WING
Disconnect input power from the power supply and input cable before attempting this procedure.
These instructions are for installing the input power cable to the power supply and connecting to
380/400/415VAC three phase Primary Input Power.
1. Remove the Power Supply cover per instructions found in section 5.
2. Loosen the strain relief on the back panel of the power supply.
3. Using a customer supplied four conductor input power cable for rated voltage, strip back the
insulation on the individual wires.
4. Pass the cable being used through the input cable opening / strain relief in the back panel of the
power supply. Refer to Section 2 for power cable specifications.
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2).
5. Connect the wires as follows.
For non CE units:
L1
L2
L3
L4
Main
Contactor
Art # A-08753
Ground
Terminal
• Three phase wires to L1, L2 and L3 on the W1 contactor. It does not matter what order these
wires are attached. See previous illustration and on label in the power supply.
• Green / Yellow wire to Ground Terminal.
INSTALLATION 3-2 Manual 0-5081

CUTMASTER 25mm
For CE units:
EMC Input
Power Filter
L1
L2
GND L3
Art # A-08752_AA
• Three phase wires to L1, L2 and L3 on the CE Input Power Filter. It does not matter what
order these wires are attached. See previous illustration and on label in the power supply.
• Green / Yellow wire to Ground.
6. With a little slack in the wires, tighten the strain relief to secure the power cable.
7. Reinstall the Power Supply cover.
8. Connect the opposite end of individual wires to a customer supplied plug and plug into an appro-
priate input power receptacle.( or connect directly to main disconnect)
9. Close the main disconnect switch to supply power to the unit..

CUTMASTER 25mm
3.04 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders. Refer to the following two
subsections if an optional air line filter is to be installed.
1. Connect the air 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 air passages in
the torch.
Regulator/Filter
Assembly
Inlet Port
Hose Clamp
1/4 NPT or ISO-R
to 1/4” (6mm) Fitting
Gas Supply
Hose
Art # A-07943
Air Connection to Inlet Port

CUTMASTER 25mm
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.
3. Connect the air 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 air passages in the
torch. Connect as follows:
Regulator/Filter
Assembly
Inlet Port
Art # A-07944
Hose Clamp
Gas Supply 1/4 NPT to 1/4"

Hose (6mm) Fitting
Optional Single - Stage Filter Installation

CUTMASTER 25mm
Installing Optional Two - Stage Air Filter Kit
This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes
moisture and contaminants to at least 5 microns.
Connect the air supply as follows:
1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied
with the filter assembly.
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 air passages in
the torch.
2. Connect the two stage filter outlet hose to the inlet port of the Regulator / Filter Assembly.
3. Use customer - supplied fittings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.
Regulator/Filter
Assembly
2-Stage Filter
Regulator Inlet Port (IN)
Input
Outlet Port
(OUT)
Two Stage
Filter
Assembly
Gas Supply
Hose
1/4 NPT to 1/4”

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

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

CUTMASTER 25mm
SECTION 3 TORCH: Check Air Quality
To test the quality of air:
INSTALLATION
1. Put the ON / OFF switch in the ON
3T.01 Torch Connections (up) position.
2. Put the Function Control switch in the SET
If necessary, connect the torch to the Power Sup-
ply. Connect only the Thermal Dynamics model position.
SL60 / Manual or SL100 / Mechanical Torch to 3. Place a welding filter lens in front of the
this power supply. Maximum torch leads length torch and turn on the air. Do not start an
is 100 feet / 30.5 m, including extensions. arc!
Any oil or moisture in the air will be visible
on the lens.
WARNING
Disconnect primary power at the source
3T.02 Setting Up Mechanical Torch
before connecting the torch. NOTE
1. Align the ATC male connector (on the An adapter is required to be installed in the power
torch lead) with the female receptacle. supply if converting a hand torch system to oper-
Push the male connector into the female ate a machine torch.
receptacle. The connectors should push
together with a small amount of pressure.
2. Secure the connection by turning the lock- WARNING
ing nut clockwise until it clicks. DO NOT Disconnect primary power at the source be-
use the locking nut to pull the connection fore disassembling the torch or torch leads.
together. Do not use tools to secure the The mechanical torch includes a positioning tube
connection. with rack and pinch block assembly.
1. Mount the torch assembly on the cutting
table.
2. To obtain a clean vertical cut, use a square
to align the torch perpendicular to the sur-
face of the workpiece.
1
Art # A-07885
Connecting the Torch to the Power Supply

3. The system is ready for operation.
Manual 0-5081 3T-1 INSTALLATION

CUTMASTER 25mm
Pinch Block
Assembly
Square
Workpiece
A-02585
Mechanical Torch Set - Up
3. The proper torch parts (shield cup, tip, start

cartridge, and electrode) must be installed
for the type of operation. Refer to Section
4T.07, Torch Parts Selection for details.
INSTALLATION 3T-2 Manual 0-5081

CUTMASTER 25mm
SECTION 4 SYSTEM: 1 2 3 4
OPERATION
4.01 Front Panel Controls / MIN
A
MAX
PSI BAR
Features MAX MAX
See Illustration for numbering Identification

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

torch tip contacting the workpiece) or higher for
standoff cutting.
2. Function Control
Art# A-07886
Function Control Knob, Used to select between the 5 6 7 8 9 10
different operating modes.
SET Used to purge the air through the unit

6. Temp Indicator
and torch and leads and to adjust gas pressure. Indicator is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Let the
RUN Used for general cutting operations unit cool before continuing operation.
RAPID AUTO RESTART Allows for faster
restarting of the Pilot Arc for uninterrupted cutting. 7. Gas Indicator
Indicator is ON when minimum input gas pressure
LATCH Used for longer hand held for power supply operation is present. Minimum
cuts. Once a cutting arc is established, the torch pressure for power supply operation is not sufficient
switch can be released. The cutting arc will remain for torch operation.
on until the torch is lifted away from the work
piece, the torch leaves the edge of the work piece 8. DC Indicator
the torch switch is activated again or if one of the
Indicator is ON when DC output circuit is active.
system interlocks is activated.
3. On Off Power Switch 9. ! Fault Error Indicator

Indicator is ON when Fault circuit is active. See sec-
ON / OFF Switch controls input power tion 5 for explanations of fault lights.
to the power supply. Up is ON, down is OFF.
10. Pressure Indicators
4. Air/Gas Pressure Control
PSI BAR
MAX MAX
The Pressure + Control is used in the "SET"
mode to adjust the air/gas pressure. Pull the knob 90 6.3
out to adjust and push in to lock. 85 5.9
80 5.5
5. AC Indicator 75 5.2
Art # A-08170
Steady light indicates power supply is ready for op- 70 4.8

eration. Blinking light indicates unit is in protective 65 4.5
interlock mode. Shut unit off, shut off or disconnect MIN MIN
input power, correct the fault, and restart the unit.
Refer to Section 5 for details.
The Indicators will illuminate according to the pres-
sure set by the Pressure Control Knob (number 4).
Manual 0-5081 4-1 OPERATION

CUTMASTER 25mm
4.02 Preparations for Operation Power On
At the start of each operating session: Place the Power Supply ON / OFF switch to the ON
(up) position. AC indicator turns on. Gas
WARNING indicator turns on if there is sufficient gas pres-

sure for power supply operation and the cooling
Disconnect primary power at the source fans turn on.
before assembling or disassembling power NOTE
supply, torch parts, or torch and leads as-
semblies. Minimum pressure for power supply operation is
lower than minimum for torch operation.
The cooling fans will turn on as soon as the unit
Torch Parts Selection is turned on. After the unit is idle for ten (10)
minutes the fans will turn off. The fans will come
Check the torch for proper assembly and appropri- back on as soon as the torch switch (Start Signal)
ate torch parts. The torch parts must correspond is activated or if the unit is turned off, then turned
with the type of operation, and with the amperage on again. If an over temperature condition occurs,
output of this Power Supply (80 amps maximum). the fans will continue to run while the condition
Refer to Section 4T.07 and following for torch parts exists and for a ten (10) minute period once the
selection. condition is cleared.
Torch Connection Set Operating Pressure
Check that the torch is properly connected. Only 1. Place the Power Supply Function Control
Thermal Dynamics model SL60 / Manual or SL100 /
Mechanical Torches may be connected to this Power knob to the SET position. Gas will
Supply. See Section 3T of this manual. flow.
Check Primary Input Power Source
2. For Standoff cutting, adjust gas pressure
1. Check the power source for proper input
from 70 - 85 psi / 4.8 - 5.9 bar (LED's
voltage. Make sure the input power source
in center of control panel). Refer to the
meets the power requirements for the unit
Standoff chart for pressure setting details.
per Section 2, Specifications.
2. Connect the input power cable (or close the 1 2
main disconnect switch) to supply power to
the system.
Air Source
Ensure source meets requirements (refer to Section MIN
A MAX
PSI BAR
2). Check connections and turn air supply on.

MAX MAX
Connect Work Cable

Clamp the work cable to the workpiece or cutting MIN MIN
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-07946
Art # A-04509
OPERATION 4-2 Manual 0-5081

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

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

.
2. Set the output current to desired amperage
with the Output Current Control Knob.
Cutting Operation
When the torch leaves the workpiece during cutting
operations with the Function Control Knob in the
RUN position, there is a brief delay in restarting
the pilot arc. With the knob in the RAPID AUTO
RESTART position, when the torch leaves the work-
piece the pilot arc restarts instantly, and the cutting
arc restarts instantly when the pilot arc contacts the
workpiece. (Use the 'Rapid Auto Restart' position
when cutting expanded metal or gratings, or in
gouging or trimming operations when an uninter-
rupted restart is desired). And with the knob in the
LATCH position the main cutting arc will be main-
tained after the torch switch is released.
Manual 0-5081 4-3 OPERATION

CUTMASTER 25mm
OPERATION 4-4 Manual 0-5081

CUTMASTER 25mm
SECTION 4 TORCH: 2. Remove the Electrode by pulling it straight
out of the Torch Head.
OPERATION
Torch Head
4T.01 Torch Parts Selection

Electrode
Depending on the type of operation to be done
determines the torch parts to be used.
Type of operation:
Start Cartridge
Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Starter Tip
Cartridge
NOTE Shield Cup
Refer to Section 4T.07 and following for additional A-03510_AB

information on torch parts.
Torch Parts (Drag Shield Cap & Shield Cup Body
Change the torch parts for a different operation as Shown)
follows:
3. Install the replacement Electrode by push-
ing it straight into the torch head until it
WARNING clicks.
Disconnect primary power at the source be- 4. Install the starter cartridge and desired tip
fore assembling or disassembling torch parts, for the operation into the torch head.
or torch and leads assemblies. 5. Hand tighten the shield cup assembly until
it is seated on the torch head. If resistance
NOTE is felt when installing the cup, check the
threads before proceeding.
The shield cup holds the tip and starter cartridge
in place. Position the torch with the shield cup
facing upward to keep these parts from falling out
when the cup is removed.
1. Unscrew and remove the shield cup assem-
bly from the torch head.
Manual 0-5081 4T-1 OPERATION

CUTMASTER 25mm
4T.02 Cut Quality Bottom Dross Buildup
NOTES Molten material which is not blown out of the cut

area and resolidifies on the plate. Excessive dross
Cut quality depends heavily on setup and may require secondary cleanup operations after
parameters such as torch standoff, alignment with cutting.
the workpiece, cutting speed, gas pressures, and
operator ability. Kerf Width
Cut quality requirements differ depending on The width of the cut (or the width of material re-
application. For instance, nitride build - up and moved during the cut).
bevel angle may be major factors when the sur- Top Spatter (Dross)
face will be welded after cutting. Dross - free cut-
Top spatter or dross on the top of the cut caused by
ting is important when finish cut quality is desired slow travel speed, excess cutting height, or cutting
to avoid a secondary cleaning operation. The tip whose orifice has become elongated.
following cut quality characteristics are illustrated
in the following figure: 4T.03 General Cutting Information
Kerf Width
Cut Surface
Bevel Angle
! WARNINGS
Top Disconnect primary power at the source before
Spatter disassembling the power supply, torch, or torch
leads.
Top Edge Frequently review the Important Safety Pre-

Rounding cautions at the front of this manual. Be sure
the operator is equipped with proper gloves,
Dross clothing, eye and ear protection. Make sure
Build-Up no part of the operator’s body comes into
Cut Surface A-00007
Drag Lines contact with the workpiece while the torch
is activated.
Cut Quality Characteristics
Cut Surface
CAUTION
The desired or specified condition (smooth or rough)
Sparks from the cutting process can cause damage
of the face of the cut.
to coated, painted, and other surfaces such as glass,
Nitride Build - Up plastic and metal.
Nitride deposits can be left on the surface of the cut NOTE

when nitrogen is present in the plasma gas stream. Handle torch leads with care and protect them
These buildups may create difficulties if the material from damage.
is to be welded after the cutting process.
Piloting
Bevel Angle
Piloting is harder on parts life than actual cutting
The angle between the surface of the cut edge and because the pilot arc is directed from the electrode
a plane perpendicular to the surface of the plate. to the tip rather than to a workpiece. Whenever
A perfectly perpendicular cut would result in a 0° possible, avoid excessive pilot arc time to improve
bevel angle. parts life.
Top - Edge Rounding
Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the
workpiece.
OPERATION 4T-2 Manual 0-5081

CUTMASTER 25mm
Torch Standoff Dross
Improper standoff (the distance between the torch When dross is present on carbon steel, it is com-
tip and workpiece) can adversely affect tip life as monly referred to as either “high speed, slow speed,
well as shield cup life. Standoff may also signifi- or top dross”. Dross present on top of the plate is
cantly affect the bevel angle. Reducing standoff will normally caused by too great a torch to plate dis-
generally result in a more square cut. tance. "Top dross" is normally very easy to remove
and can often be wiped off with a welding glove.
Edge Starting "Slow speed dross" is normally present on the bot-
For edge starts, hold the torch perpendicular to the tom edge of the plate. It can vary from a light to
workpiece with the front of the tip near (not touch- heavy bead, but does not adhere tightly to the cut
ing) the edge of the workpiece at the point where edge, and can be easily scraped off. "High speed
the cut is to start. When starting at the edge of the dross" usually forms a narrow bead along the bottom
plate, do not pause at the edge and force the arc to of the cut edge and is very difficult to remove. When
"reach" for the edge of the metal. Establish the cut- cutting a troublesome steel, it is sometimes useful
ting arc as quickly as possible. to reduce the cutting speed to produce "slow speed
dross". Any resultant cleanup can be accomplished
Direction of Cut by scraping, not grinding.
In the torches, the plasma gas stream swirls as it
leaves the torch to maintain a smooth column of 4T.04 Hand Torch Operation
gas. This swirl effect results in one side of a cut be-
Standoff Cutting With Hand Torch
ing more square than the other. Viewed along the
direction of travel, the right side of the cut is more NOTE
square than the left.
Left Side For best performance and parts life, always use the
Cut Angle correct parts for the type of operation.
Right Side
Cut Angle 1. The torch can be comfortably held in one
hand or steadied with two hands. Position
the hand to press the Trigger on the torch
handle. With the hand torch, the hand may
be positioned close to the torch head for
maximum control or near the back end for
A-00512 maximum heat protection. Choose the
Side Characteristics Of Cut holding technique that feels most comfort-
able and allows good control and move-
To make a square - edged cut along an inside ment.
diameter of a circle, the torch should move coun- NOTE
terclockwise around the circle. To keep the square
edge along an outside diameter cut, the torch should The tip should never come in contact with
travel in a clockwise direction. the workpiece except during drag cutting
operations.

CUTMASTER 25mm
2. Depending on the cutting operation, do one Trigger
of the following:
a. For edge starts, hold the torch perpen-
dicular to the workpiece with the front 1
2
of the tip on the edge of the workpiece
at the point where the cut is to start. Trigger Release
b. For standoff cutting, hold the torch 1/8
- 3/8 in (3-9 mm) from the workpiece as
shown below.
3
Torch
Art # A-03383
6. Cut as usual. Simply release the trigger

assembly to stop cutting.
Shield Cup Standoff Distance 7. Follow normal recommended cutting
1/8" - 3/8" (3 - 9mm) practices as provided in the power supply
operator's manual.
NOTE
When the shield cup is properly installed, there
A-00024_AB
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as part
Standoff Distance of normal operation. Do not attempt to force the
shield cup to close this gap. Forcing the shield
3. Hold the torch away from your body. cup against the torch head or torch handle can
damage components.
4. Slide the trigger release toward the back
of the torch handle while simultaneously 8. For a consistent standoff height from the
squeezing the trigger. The pilot arc will workpiece, install the standoff guide by
start. 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
Trigger the workpiece.
Trigger Release
A-02986
5. Bring the torch within transfer distance to

the work. The main arc will transfer to the Shield Cup
work, and the pilot arc will shut off. Standoff Guide
NOTE Torch Tip
The gas preflow and postflow are a characteristic Workpiece Art # A-04034
of the power supply and not a function of the
torch.

CUTMASTER 25mm
Shield Cup With Straight Edge 6. Slide the trigger release toward the back
The drag shield cup can be used with a non conduc-
of the torch handle while simultaneously
tive straight edge to make straight cuts by hand. squeezing the trigger. The pilot arc will
start.
WARNING
The straight edge must be non - conduc-
tive.
Trigger
Trigger Release
A-02986
Non-Conductive
Straight Edge 7. Bring the torch within transfer distance to
Cutting Guide the work. The main arc will transfer to the
work, and the pilot arc will shut off.
NOTE
A-03539
The gas preflow and postflow are a characteristic
Using Drag Shield Cup With Straight Edge of the power supply and not a function of the
torch.
Trigger
The crown shield cup functions best when cutting
3/16 inch (4.7 mm) solid metal with relatively
smooth surface.
1
Drag Cutting With a Hand Torch 2
Drag cutting works best on metal 1/4" (6 mm) thick Trigger Release
or less.
NOTE
For best parts performance and life, always use the
correct parts for the type of operation. 3
1. Install the drag cutting tip and set the out-
put current.
2. The torch can be comfortably held in one 4
hand or steadied with two hands. Position
the hand to press the Trigger on the torch Art # A-03383
handle. With the hand torch, the hand may 8. Cut as usual. Simply release the trigger
be positioned close to the torch head for assembly to stop cutting.
maximum control or near the back end for 9. Follow normal recommended cutting
maximum heat protection. Choose the practices as provided in the power supply
holding technique that feels most comfort- operator's manual.
able and allows good control and move- NOTE
ment.
When the shield cup is properly installed, there
4. Keep the torch in contact with the work-
is a slight gap between the shield cup and the
piece during the cutting cycle. torch handle. Gas vents through this gap as part
5. Hold the torch away from your body. of normal operation. Do not attempt to force the
cup against the torch head or torch handle can
damage components.

CUTMASTER 25mm
Piercing With Hand Torch 6. Bring the torch within transfer distance to
1. The torch can be comfortably held in one the work. The main arc will transfer to the
hand or steadied with two hands. Position work, and the pilot arc will shut off.
the hand to press the Trigger on the torch NOTES
handle. With the hand torch, the hand may The gas preflow and postflow are a characteristic
be positioned close to the torch head for of the power supply and not a function of the
maximum control or near the back end for torch.
maximum heat protection. Choose the When the shield cup is properly installed, there
technique that feels most comfortable and is a slight gap between the shield cup and the
allows good control and movement. torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
NOTE
The tip should never come in contact with cup against the torch head or torch handle can
the workpiece except during drag cutting damage components.
operations. 7. Clean spatter and scale from the shield cup
2. Angle the torch slightly to direct blowback and the tip as soon as possible. Spraying
particles away from the torch tip (and op- the shield cup in anti - spatter compound
erator) rather than directly back into it until will minimize the amount of scale which
the pierce is complete. adheres to it.
3. In a portion of the unwanted metal start the Cutting speed depends on material, thickness,
pierce off the cutting line and then continue and the operator’s ability to accurately follow the
the cut onto the line. Hold the torch per- desired cut line. The following factors may have
pendicular to the workpiece after the pierce an impact on system performance:
is complete. • Torch parts wear
4. Hold the torch away from your body.
5. Slide the trigger release toward the back • Air quality
of the torch handle while simultaneously • Line voltage fluctuations
squeezing the trigger. The pilot arc will • Torch standoff height
start.
• Proper work cable connection
Trigger
Trigger Release
A-02986

CUTMASTER 25mm
4T.05 Gouging Lead Angle
The angle between the torch and workpiece depends
! WARNINGS
on the output current setting and torch travel speed.
The recommended lead angle is 35°. At a lead angle
greater than 45° the molten metal will not be blown
Be sure the operator is equipped with proper out of the gouge and may be blown back onto the
gloves, clothing, eye and ear protection and that all torch. If the lead angle is too small (less than 35°),
safety precautions at the front of this manual have less material may be removed, requiring more pass-
been followed. Make sure no part of the operator’s es. In some applications, such as removing welds or
body comes in contact with the workpiece when working with light metal, this may be desirable.
the torch is activated.
Disconnect primary power to the system be- Torch Head

fore disassembling the torch, leads, or power
supply.
35°
CAUTION
Sparks from plasma gouging can cause damage Standoff Height
to coated, painted or other surfaces such as glass,
plastic, and metal.
Workpiece
Check torch parts. The torch parts must
A-00941_AB
correspond with the type of operation. Refer to
Section 4T.07, Torch Parts Selection. Gouging Angle and Standoff Distance
Gouging Parameters
Standoff Distance
Gouging performance depends on parameters
such as torch travel speed, current level, lead angle The tip to work distance affects gouge quality and
(the angle between the torch and workpiece), and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6
the distance between the torch tip and workpiece mm) allows for smooth, consistent metal removal.
(standoff). Smaller standoff distances may result in a severance
cut rather than a gouge. Standoff distances greater
than 1/4 inch (6 mm) may result in minimal metal
removal or loss of transferred main arc.
CAUTION
Slag Buildup
Touching the torch tip or shield cup to the work surface
will cause excessive parts wear. Slag generated by gouging on materials such as car-
bon and stainless steels, nickels, and alloyed steels,
Torch Travel Speed can be removed easily in most cases. Slag does not
NOTE obstruct the gouging process if it accumulates to the
side of the gouge path. However, slag build - up can
Refer to Appendix Pages for additional information cause inconsistencies and irregular metal removal if
as related to the Power Supply used. large amounts of material build up in front of the
arc. The build - up is most often a result of improper
Optimum torch travel speed is dependent on current
travel speed, lead angle, or standoff height.
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.

CUTMASTER 25mm
4T.06 Mechanized Torch Operation For optimum smooth surface quality, the travel
speed should be adjusted so that only the leading
Cutting With Mechanized Torch edge of the arc column produces the cut. If the travel
speed is too slow, a rough cut will be produced as
The mechanized torch can be activated by remote the arc moves from side to side in search of metal
control pendant or by a remote interface device for transfer.
such as CNC.
Travel speed also affects the bevel angle of a cut.
1. To start a cut at the plate edge, position the When cutting in a circle or around a corner, slowing
center of the torch along the edge of the down the travel speed will result in a squarer cut.
plate. The power source output should be reduced also.
Travel Speed Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
Proper travel speed is indicated by the trail of the may be required.
arc which is seen below the plate. The arc can be
one of the following: Piercing With Machine Torch
1. Straight Arc To pierce with a machine torch, the arc should be

started with the torch positioned as high as possible
A straight arc is perpendicular to the workpiece
above the plate while allowing the arc to transfer
surface. This arc is generally recommended
and pierce. This standoff helps avoid having molten
for the best cut using air plasma on stainless or
metal blow back onto the front end of the torch.
aluminum.
2. Leading Arc When operating with a cutting machine, a pierce or
dwell time is required. Torch travel should not be
The leading arc is directed in the same direction as enabled until the arc penetrates the bottom of the
torch travel. A five degree leading arc is generally plate. As motion begins, torch standoff should be
recommended for air plasma on mild steel. reduced to the recommended 1/8 - 1/4 inch (3-6
3. Trailing Arc mm) distance for optimum speed and cut quality.
Clean spatter and scale from the shield cup and the
The trailing arc is directed in the opposite direc-
tip as soon as possible. Spraying or dipping the
tion as torch travel.
shield cup in anti - spatter compound will minimize
the amount of scale which adheres to it.
Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el
Straight Arc
Trailing Arc
A-02586
Leading Arc
Mechanized Torch Operation

CUTMASTER 25mm
4T.07 Parts Selection for Manual and Mechanized Torch Cutting
Tips: Shield
DRAG TIP Cup Body, Shield Cap, Deflector
CUTTING 9-8237 9-8243
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
Shield Cap, Deflector
CUTTING Tip:
9-8237
9-8243
40A 9-8208 Standoff Guide

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

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps)
CutMaster 12mm uses 40A and less
Art # A-08951 CutMaster 20mm uses 60A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
Tip Gouging D 9-8228 (60 - 120 Amps) CutMaster 40mm uses 120A and less
Tip Gouging E 9-8254 (60 - 120 Amps)

CUTMASTER 25mm
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed
Tip
Type Torch: SL60 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
Thickness Tip Output Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (CFH) Pierce Pierce Height
Inches mm (Cat. No.) Volts(VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.036 0.9 9-8208 104 40 340 8.64 0.19 4.8 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 108 40 250 6.35 0.19 4.8 70 4.8 55 170 0.10 0.2 5.1
0.075 1.9 9-8208 108 40 190 4.83 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 110 40 105 2.67 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 113 40 60 1.52 0.19 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 111 40 40 1.02 0.19 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 124 40 21 0.53 0.19 4.8 70 4.8 55 170 NR NR NR
0.500 12.7 9-8208 123 40 11 0.28 0.19 4.8 70 4.8 55 170 NR NR NR
0.625 15.9 9-8208 137 40 7 0.18 0.19 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
0.036 0.9 9-8208 103 40 355 9.02 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.05 1.3 9-8208 98 40 310 7.87 0.125 3.2 70 4.8 55 170 0.00 0.2 5.1
0.06 1.5 9-8208 98 40 240 6.10 0.125 3.2 70 4.8 55 170 0.10 0.2 5.1
0.078 2.0 9-8208 100 40 125 3.18 0.125 3.2 70 4.8 55 170 0.30 0.2 5.1
0.135 3.4 9-8208 120 40 30 0.76 0.187 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 124 40 20 0.51 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.25 6.4 9-8208 122 40 15 0.38 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 126 40 10 0.25 0.187 4.8 70 4.8 55 170 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Aluminum

0.032 0.8 9-8208 110 40 440 11.18 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 109 40 350 8.89 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.064 1.6 9-8208 112 40 250 6.35 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 112 40 200 5.08 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 118 40 100 2.54 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 120 40 98 2.49 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 123 40 50 1.27 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 134 40 16 0.41 0.187 4.8 70 4.8 55 170 NR NR NR

CUTMASTER 25mm
0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8
0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 75 5.2 90 245 0.20 0.19 4.8
0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.19 4.8
0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 75 5.2 90 245 0.50 0.19 4.8
0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 75 5.2 90 245 0.75 0.19 4.8
0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 75 5.2 90 245 NR NR NR
0.06 1.5 9-8210 119 60 350 8.91 0.19 4.8 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 300 7.64 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 123 60 150 3.82 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 125 3.18 0.19 4.8 75 5.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 122 60 90 2.29 0.19 4.8 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 120 60 65 1.65 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 130 60 30 0.76 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 132 60 21 0.53 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 130 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 142 60 12 0.31 0.25 6.4 75 5.2 90 245 NR NR NR
Type Torch: SL60 With Exposed Tip Type Material: Aluminum

0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.00 0.25 6.4
0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 75 5.2 90 245 0.20 0.25 6.4
0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 75 5.2 90 245 0.30 0.25 6.4
0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 75 5.2 90 245 0.50 0.25 6.4
0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 75 5.2 90 245 0.80 0.25 6.4
0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 75 5.2 90 245 NR NR NR

CUTMASTER 25mm
0.060 1.5 9-8211 113 80 320 8.13 0.19 4.8 70 4.8 115 340 0.00 0.19 4.8
0.120 3.0 9-8211 113 80 230 5.84 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8
0.135 3.4 9-8211 115 80 180 4.57 0.19 4.8 70 4.8 115 340 0.10 0.19 4.8
0.188 4.8 9-8211 114 80 140 3.56 0.19 4.8 70 4.8 115 340 0.20 0.19 4.8
0.250 6.4 9-8211 114 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.19 4.8
0.375 9.5 9-8211 117 80 42 1.07 0.19 4.8 70 4.8 115 340 0.40 0.19 4.8
0.500 12.7 9-8211 120 80 33 0.84 0.19 4.8 70 4.8 115 340 0.60 0.19 4.8
0.625 15.9 9-8211 133 80 22 0.56 0.19 4.8 70 4.8 115 340 0.75 0.19 4.8
0.750 19.1 9-8211 128 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 133 80 10 0.25 0.19 4.8 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 132 80 9 0.23 0.19 4.8 70 4.8 115 340 NR NR NR
0.060 1.5 9-8211 120 80 340 8.64 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4
0.120 3.0 9-8211 120 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4
0.135 3.4 9-8211 120 80 280 7.11 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 120 80 140 3.56 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 120 80 100 2.54 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 126 80 50 1.27 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 129 80 28 0.71 0.25 6.4 70 4.8 115 340 0.80 0.25 6.4
0.625 15.9 9-8211 135 80 20 0.51 0.25 6.4 70 4.8 115 340 1.00 0.25 6.4
0.750 19.1 9-8211 143 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 143 80 9 0.23 0.25 6.4 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 146 80 8 0.20 0.25 6.4 70 4.8 115 340 NR NR NR

CUTMASTER 25mm
Type Torch: SL60 with Exposed Tip Type Material: Aluminum
0.06 1.5 9-8211 120 80 350 8.89 0.25 6.4 70 4.8 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 124 80 300 7.62 0.25 6.4 70 4.8 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 124 80 180 4.57 0.25 6.4 70 4.8 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 128 80 110 2.79 0.25 6.4 70 4.8 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 136 80 55 1.40 0.25 6.4 70 4.8 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 139 80 38 0.97 0.25 6.4 70 4.8 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.25 6.4 70 4.8 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 145 80 24 0.61 0.25 6.4 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 153 80 10 0.25 0.25 6.4 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 162 80 6 0.15 0.25 6.4 70 4.8 115 340 NR NR NR
NOTES
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

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

0.032 0.8 9-8208 116 40 220 5.59 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.051 1.3 9-8208 116 40 210 5.33 0.187 4.8 70 4.8 55 170 0.00 0.2 5.1
0.064 1.6 9-8208 118 40 180 4.57 0.187 4.8 70 4.8 55 170 0.10 0.2 5.1
0.079 2.0 9-8208 116 40 150 3.81 0.19 4.8 70 4.8 55 170 0.30 0.2 5.1
0.125 3.2 9-8208 130 40 75 1.91 0.19 4.8 70 4.8 55 170 0.40 0.2 5.1
0.188 4.8 9-8208 132 40 60 1.52 0.187 4.8 70 4.8 55 170 0.60 0.2 5.1
0.250 6.4 9-8208 134 40 28 0.71 0.187 4.8 70 4.8 55 170 1.00 0.2 5.1
0.375 9.5 9-8208 143 40 11 0.28 0.187 4.8 70 4.8 55 170 NR NR NR

CUTMASTER 25mm
Inches mm (Cat. No.) Volts (VDC) (Amps) Inches Meters Inches mm psi* bar Plasma Total** Delay (Sec) Inches mm
0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 75 5.2 90 245 0.00 0.2 5.1
0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 75 5.2 90 245 0.20 0.2 5.1
0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.2 5.1
0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 75 5.2 90 245 0.50 0.2 5.1
0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 75 5.2 90 245 0.75 0.2 5.1
0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 75 5.2 90 245 NR NR NR
0.06 1.5 9-8210 110 60 165 4.19 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 116 60 155 3.94 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 115 60 125 3.18 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.135 3.4 9-8210 118 60 80 2.03 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.188 4.8 9-8210 120 60 75 1.91 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 121 60 60 1.52 0.13 3.2 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 129 60 28 0.71 0.13 3.2 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 135 60 17 0.43 0.19 4.8 75 5.2 90 245 0.75 0.20 5.1
0.625 15.9 9-8210 135 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 142 60 10 0.25 0.19 4.8 75 5.2 90 245 NR NR NR

0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 75 5.2 90 245 0.80 0.20 5.1
0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR

CUTMASTER 25mm
0.060 1.5 9-8211 128 80 280 7.11 0.19 4.8 70 4.8 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 126 80 203 5.16 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 128 80 182 4.62 0.19 4.8 70 4.8 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 128 80 137 3.48 0.19 4.8 70 4.8 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 131 80 100 2.54 0.19 4.8 70 4.8 115 340 0.30 0.2 5.1
0.375 9.5 9-8211 134 80 40 1.02 0.19 4.8 70 4.8 115 340 0.50 0.2 5.1
0.500 12.7 9-8211 136 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.2 5.1
0.625 15.9 9-8211 145 80 21 0.53 0.19 4.8 70 4.8 115 340 0.75 0.2 5.1
0.750 19.1 9-8211 144 80 14 0.36 0.19 4.8 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 149 80 11 0.28 0.19 4.8 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 162 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR
0.060 1.5 9-8211 110 80 340 8.50 0.125 3.2 70 4.8 115 340 0.00 0.2 5.1
0.120 3.0 9-8211 115 80 260 6.50 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1
0.135 3.4 9-8211 113 80 250 6.25 0.125 3.2 70 4.8 115 340 0.10 0.2 5.1
0.188 4.8 9-8211 114 80 170 4.25 0.125 3.2 70 4.8 115 340 0.20 0.2 5.1
0.250 6.4 9-8211 116 80 85 2.13 0.125 3.2 70 4.8 115 340 0.30 0.2 5.1
0.375 9.5 9-8211 123 80 45 1.13 0.125 3.2 70 4.8 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 133 80 18 0.45 0.125 3.2 70 4.8 115 340 0.75 0.25 6.4
0.625 15.9 9-8211 135 80 16 0.40 0.125 3.2 70 4.8 115 340 1.00 0.25 6.4
0.750 19.1 9-8211 144 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 137 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 140 80 8 0.20 0.125 3.2 70 4.8 115 340 NR NR NR

CUTMASTER 25mm
0.06 1.5 9-8211 115 80 320 8.13 0.13 3.2 70 4.8 115 340 0.00 0.25 6.4
0.12 3.0 9-8211 120 80 240 6.10 0.13 3.2 70 4.8 115 340 0.10 0.25 6.4
0.188 4.8 9-8211 120 80 165 4.19 0.13 3.2 70 4.8 115 340 0.20 0.25 6.4
0.250 6.4 9-8211 124 80 100 2.54 0.13 3.2 70 4.8 115 340 0.30 0.25 6.4
0.375 9.5 9-8211 138 80 60 1.52 0.19 4.8 70 4.8 115 340 0.40 0.25 6.4
0.500 12.7 9-8211 141 80 36 0.91 0.19 4.8 70 4.8 115 340 0.60 0.25 6.4
0.625 15.9 9-8211 142 80 26 0.66 0.19 4.8 70 4.8 115 340 0.75 0.25 6.4
0.750 19.1 9-8211 150 80 18 0.46 0.19 4.8 70 4.8 115 340 NR NR NR
0.875 22.2 9-8211 156 80 8 0.20 0.19 4.8 70 4.8 115 340 NR NR NR
1.000 25.4 9-8211 164 80 6 0.15 0.19 4.8 70 4.8 115 340 NR NR NR
NOTES
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, set gas pressure to 70 psi / 4.8 bar.
** Total flow rate includes plasma and secondary gas flow.

CUTMASTER 25mm
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709; D499620;
D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
9-8241 Shield Cap US Pat No(s) 6914211; D505309
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633

CUTMASTER 25mm
Catalog # Description Patent(s)
The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:
Catalog # Description
9-8235 Shield Cap
9-8236 Shield Cap
9-8237 Shield Cup
9-8238 Shield Cap
9-8239 Shield Cap
9-8244 Shield Cap
9-8245 Shield Cap

CUTMASTER 25mm

CUTMASTER 25mm
SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Manual 0-5081 5-1 SERVICE

CUTMASTER 25mm
5.02 Maintenance Schedule 5.03 Common Faults
NOTE Problem - Symptom Common Cause
The actual frequency of maintenance may need Insufficient 1. Cutting speed too fast.
to be adjusted according to the operating envi- Penetration 2. Torch tilted too much.
ronment. 3. Metal too thick.
4. Worn torch parts
Daily Operational Checks or Every Six Cutting 5. Cutting current too low.
Hours: 6. Non - Genuine Thermal Dynamics
parts used
1. Check torch consumable parts, replace if dam- 7. Incorrect gas pressure
aged, worn or when cut performance has demi-
nished. Main Arc 1. Cutting speed too slow.
Extinguishes 2. Torch standoff too high from
2. Check plasma and secondary supply and pres- workpiece.
sure. 3. Cutting current too high.
3. Purge plasma gas line to remove any moisture 4. Work cable disconnected.
build-up. 5. Worn torch parts.
6. Non - Genuine Thermal Dynamics
Weekly or Every 30 Cutting Hours: parts used
1. Check fan for proper operation and adequate air Excessive Dross 1. Cutting speed too slow.
flow. Formation 2. Torch standoff too high from
workpiece.
2. Inspect torch for any cracks or exposed wires,
3. Worn torch parts.
replace if necessary.
4. Improper cutting current.
3. Inspect input power cable for damage or exposed 5. Non - Genuine Thermal Dynamics
wires, replace if necessary. parts used
6. Incorrect gas pressure
Six Months or Every 720 Cutting Hours:
Short Torch Parts Life1. Oil or moisture in air source.
1. Check the in-line air filter(s), clean or replace as 2. Exceeding system capability
required (material too thick).
3. Excessive pilot arc time
2. Check cables and hoses for leaks or cracks, replace
4. Gas pressure too low.
if necessary.
5. Improperly assembled torch.
3. Check all contactor points for severe arcing or 6. Non - Genuine Thermal Dynamics
pits, replace if necessary. parts used
4. Vacuum dust and dirt out of the entire machine. Difficult Starting 1. Worn torch parts.
2. Non - Genuine Thermal Dynamics
parts used.
3. Incorrect gas pressure.
CAUTION
Do not blow air into the power supply during
cleaning. Blowing air into the unit can cause
metal particles to interfere with sensitive electrical
components and cause damage to the unit.
SERVICE 5-2 Manual 0-5081

CUTMASTER 25mm
5.04 Fault Indicator Explanation of Faults
At initial power up, two lights will temporarily illu- UNDER PRESSURE: Indicates that operating pres-
minate for 2-3 seconds to show the version of software sure is set too low and power supply output
used. power will be disabled.
To determine the first digit, count the function indicators INPUT POWER: Indicates primary line voltage is out-
left to right, 1 through 5. To determine the second digit side the operating limits of the power supply.
count the pressure indicators, reading from bottom to PART IN PLACE: Indicates that the shield cup is not
top, 0 through 7. In the example below the Temp indica- properly installed or tightened.
tor and 75 psi indicators are on indicating the version
would be 2.3. START ERROR: Indicates that the START SIGNAL
was active (ie. Torch Trigger depressed, hand
held pendant switch on or CNC signal for torch
on) during one of three conditions:
7
6 1) During initial power up when ON/OFF
5 MIN
A
MAX
PSI
MAX
BAR
MAX
switch is turned to ON position
+
4
2) When fault which had been disabling the
3
system is cleared.
2
1 MIN MIN
3) When the FUNCTION CONTROL SWITCH
0 Mode is moved from SET position to any of
! the other three (3) modes of operation.
CONSUMABLES MISSING: Indicates that the elec-
trode, start cartridge or tip is missing or exces-
sively worn.
Art# A-07988
SHORTED TORCH: Indicates the torch or lead has
1 2 3 4 5 a shorted condition between positive and nega-
tive leads.
When the ! "Fault" indicator is on or blinking it INTERNAL ERROR: Indicates a microprocessor er-
will be accompanied by one of the pressure indica- ror.
tor lights depending on what the Fault is. Only one
of these faults will be displayed at one time. If more OVER PRESSURE: Indicates that operating pressure
than one fault exists, when the first fault is corrected is set too high. The Error Indicator will not flash
and cleared, the next fault will then be displayed. It when the pressure is above 95 PSI. This LED will
is possible to have a fault indicated in the function remain on and the system will operate but pilot
indicators and another fault indictated in the pres- starting and cut performance may be affected.
sure indicators. The following table shows each of
NOTE
the Faults possible.
The cooling fans will turn on as soon as the unit
Pressure Fault is turned on. After the unit is idle for ten (10)
Indicator minutes the fans will turn off. The fans will come
back on as soon as the torch switch (Start Signal)
Max Over Pressure
is activated or if the unit is turned off, then turned
90 Internal Error on again. If an over temperature condition occurs,
85 Shorted Torch the fans will continue to run while the condition
exists and for a ten (10) minute period once the
80 Consumables Missing condition is cleared.
75 Start Error
70 Parts in Place
65 Input Power
Min Under Pressure
NOTE
Fault explantions are covered in the following
tables.
CUTMASTER 25mm
5.05 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or
repair unless you have had training in power electronics measurement and troubleshooting techniques.
Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch is on 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
but the A/C Indicator OFF position.
does not light 2. Primary fuses / breakers are 2. a) Have qualified person check primary fuses / breakers.
blown or tripped. b) Connect unit to known good primary power receptacle
3. Faulty components in unit. 3. Return to authorized service center for repair or replacement.
FAULT indicator 1. Incorrect Primary line Voltage. 1. Check that appropriate line voltage is connected to unit.
flashing, 65 PSI 2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
indicator flashing meets unit requirements see section 2.04.
3. Faulty components in unit. 3. Return to authorized service center for repair or replacement.
TEMPERATURE 1. Air flow through or around the 1. Refer to clearance information – section 2.04
indicator on. unit is obstructed.
FAULT indicator 2. Duty cycle of the unit has been 2. Allow unit to cool.
flashing. exceeded
3. Failed components in unit 3. Return to authorized service center for repair or replacement.
GAS indicator off, 1. Gas supply not connected to 1. Connect gas supply to unit.
FAULT and MIN unit.
pressure indicators 2. Gas supply not turned on. 2. Turn gas supply on.
flashing. 3. Gas supply pressure too low. 3. Set air supply inlet pressure to unit to 120 psi.
4. AIR PRESSURE CONTROL 4. Adjust regulator to set air pressure - see section 4.02.
regulator set too low.
5. Failed components in unit. 5. Return to authorized service center for repair or replacement.
FAULT and 70 PSI 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
indicators flashing. 2. Torch not properly connected to 2. Insure torch ATC is securely fastened to unit.
power supply.
3. Problem in torch and leads PIP 3. Replace torch and leads or return to authorized service center
circuit. for repair or replacement.
FAULT and 75 PSI 1. Start signal is active when 1. Start can be active for one of the following:
indicators flashing. ON/OFF SWITCH is turned to ON • Hand torch switch held closed
position. • Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service center
switch circuit. for repair or replacement.

CUTMASTER 25mm
Problem - Symptom Possible Cause Recommended Action
FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten.
indicators flashing. 2. Torch tip, electrode or starter 2. Turn off power supply. Remove shield cup. Install missing
Gas flow is cycling on cartridge missing. parts.
and off. 3. Torch start cartridge is stuck. 3. Turn off power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Open conductor in torch leads. 4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6.Return to authorized service center for repair or
replacement.
Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed ( Or CNC 2. CNC Contoller device not 2. Contact Controller manufacturer.
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit. 3. Return to authorized service center for repair or
DC LED OFF. replacement.
FAULT indicator 1. Upper O-Ring on torch 1. Remove shield cup from torch; check
flashing and 85 PSI head is in wrong position. upper O-Ring position; correct if necessary.
indicators flashing. at 2. Torch start cartridge is stuck. 2. Turn off power supply. Bleed down system pressure.
1 cycle per second. Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Worn or faulty torch parts. 3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch. 4. Replace torch and leads or return to an authorized service
center for repair.
FAULT indicator 1. Low output voltage during pilot. 1. Low output voltage during pilot. 2.
flashing and 85 PSI 2. Low output voltage during cut. Low output voltage during cut.
indicators flashing. at 3.For Automation Torch only: Tip 3.For Automation Torch only: Tip contacted work piece during
5 cycles per second contacted work piece during cut cut with output currect set above 45 amps.
with output currect set above 45
amps.
No Fault lights on, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 90 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service center
for repair.
Pilot arc is on but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.
Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.

CUTMASTER 25mm
5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement
Replacement The Filter Element Assembly is in the rear panel. For
better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection 5.02),
and either cleaned or replaced.
WARNING
1. Remove power from the power supply; turn off
Disconnect primary power to the system before the gas supply and bleed down the system.
disassembling the torch, leads, or power supply.
2. Remove the system cover. See "A Cover Re-
This section describes procedures for basic parts replace- moval" in this section.
ment. For more detailed parts replacement procedures,
refer to the Power Supply Service Manual. 3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
A. Cover Removal illustration.
1. Remove the upper and lower screws which 4. Hold a wrench or similar tool against the lock-
secure the cover to the main assembly. Do not ing ring on the filter assembly fitting, then pull
loosen the lower screws inside the cut out slots on the hose to release it. (Numbers 2 and 3 in the
in the bottom of the cover. following illustration).
Upper
Screws
Lower
Screws 1
Slots
Lower
Screws
Art # A-07989
Art # A-07947
2. Carefully pull the Cover up and away from the

unit.
3 4
B. Cover Installation 5
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that 6mm
slots in the bottom edges of the cover engage the
lower screws.
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.

CUTMASTER 25mm
5. Remove the fitting from the filter element as- 4. Turn the Filter Housing Cover counter-clockwise
sembly by inserting a 6 mm hex wrench into and remove it. The Filter Element is located inside
the internal hex fitting and turning it counter the Housing.
clock-wise (left). Numbers 4 and 5 in the previous
illustration.
Housing
6. Disconnect the input line from the filter element
assembly.
7. Remove the filter element assembly through the
rear opening. Filter
Element
NOTE (Cat. No. 9-7741)
If replacing or cleaning just the filter element refer Spring

to the following illustration for disassembly.
O-ring
(Cat. No. 9-7743) Assembled Filter
Cover
Barbed
Fitting Art # A-02476
Filter Element
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and

set Element aside to dry.
6. Wipe inside of housing clean, then insert the
replacement Filter Element open side first.
7. Replace Housing on Cover.
Art # A-07990 8. Reattach gas supply.
8. Install the new or cleaned assembly by reversing NOTE
these procedures.
If unit leaks between housing and cover, inspect
9. Turn on the air supply and check for leaks before the "O" Ring for cuts or other damage.
reinstalling the cover.
Optional Single-Stage Filter Element

Replacement
These instructions apply to power supplies where the
optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when
the Filter Element becomes completely saturated. The
Filter Element can be removed from its housing, dried,
and reused. Allow 24 hours for Element to dry. Refer
to Section 6, Parts List, for replacement filter element
catalog number.
1. Remove power from power supply.
2. Shut off air supply and bleed down system before
disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.

CUTMASTER 25mm
Optional Two-Stage Filter Element 5.07 Circuit Fault Isolation
Replacement
The Two-Stage Air Filter has two Filter Elements. When
the Filter Elements become dirty the Power Supply will WARNING
continue to operate but cut quality may become unac-
ceptable. Refer to Section 6, Parts List, for replacement The following procedures should not be attempted
filter element catalog number. by anyone who has not had proper training or
authorized to do so.
1. Shut off primary input power.
A. Cover Removal
2. Shut off air supply and bleed down system.
1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not
loosen the lower screws inside the cut out slots
WARNING in the bottom of the cover.
Always turn off the air supply and bleed the sys- Note
tem before disassembling the Filter Assembly as
injury could result. The upper screws and lower screws are not the
same. Do not mix them. The upper screws are
3. Loosen the two bolts on the top of the Filter As- for threading into the plastic of the front and rear
sembly enough to allow the Filter Elements to panels. DO NOT use the finer threaded lower
move freely. screws for this.
4. Note the location and orientation of the old Filter
Elements. Upper
Screws
5. Slide out the old Filter Elements.
Lower
Screws
Slots
Lower
Screws
First & Second

Stage
Cartridges
(as marked)
Art # A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Art # A-07947

Filter Assembly, with the same orientation as
noted in Step 4 above.
7. Hand tighten the two bolts evenly, then torque 2. Carefully pull the Cover up and away from the
each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper unit.
torque may damage the gasket.
8. Slowly apply air pressure to the assembly, check-
ing for leaks.
NOTE
A small amount of air leakage from the bottom
fitting is normal.
This completes the parts replacement procedures.

CUTMASTER 25mm
B. Cover Installation 3. Set the Power Supply controls as follows:
1. Reverse previous procedures for cover installa- • ON/OFF SWITCH to OFF position
tion.
• Turn FUNCTION CONTROL SWITCH to SET
NOTE position
When installing the upper screws, attempt to • CURRENT CONTROL POTENTIOMETER to
reuse the original threads. The easaiest way to MAXIMUM position, fully clockwise.
do this is by turning the screw counter-clockwise
until you feel the threads lign up, then begin to E. Main Input and Internal Power Test
turn the screw clockwise to tighten to 15-18 in. 1. Connect Primary Line power to the unit.
lbs.. Do not over tighten.
2. Turn the ON/OFF SWITCH ( SW1) to ON position
C. Pre Power Up Tests and observe the following:
Prior to applying primary line power to the unit, • Software version is displayed (See section 5.04
perform the following checks to prevent component Fault Indicators)
failure or blowing primary fuses. The troubleshoot-
ing guide will assume these tests were done and no After approx. three (3) seconds
failure was found or that any failures found were • Inrush relay on PCB1 energizes, starting pre-
corrected. charging of working capacitors.
1. Main Contactor (W1) Check – Section 5.12 A • W1 energizes
2 Input Diode Module Test – Section 5.12 B • AC and GAS Indicators come on
3 Input Capacitor Pcb Test –Section 5.12 C • Gas flows
4 IGBT Modules Test – Section 5.12 D 3. Adjust the pressure regulator to set the gas pres-
5 Output Diode Module Test – Section 5.12 E sure as specified in charts.
6 Pilot IGBT Test – Section 5.12 F STANDOFF

CutMaster 25mm Gas Pressure Settings
If all of the Pre Power-Up Tests are ok, proceed with
the trouble shooting guide. Leads SL60 SL100
Length (Hand Torch) (Mechanized Torch)
Up to 25' 75 psi 75 psi
CAUTION (7.6 m) 5.2 bar 5.2 bar
Each
Due to the close proximity of the Main Pcb to the
additional Add 5 psi Add 5 psi
Capacitor Pcb, It is recommended to use an insu-
25' 0.4 bar 0.4 bar
lated meter probe when making measurements on
(7.6 m)
the J2 connector on the Main Pcb. Do not short
between the pins. Do not short to the Capacitor
Pcb connections. DRAG
CutMaster 25mm Gas Pressure
D. Initial Set up Conditions Settings
This section is to help isolate the defective circuit
Leads SL60
before troubleshooting, identify symptoms, and test
Length (Hand Torch)
the unit for proper operation. Follow the instructions
as given to identify the possible symptom(s) and the Up to 25' 80 psi
defective circuit. After repairs are complete, run the (7.6 m) 5.5 bar
following tests again to verify that the unit is fully
operational. Each
Add 5 psi 0.4
additional 25'
1. Connect gas supply to rear of Power Supply. bar
(7.6 m)
2. Turn on gas supply and set operating pressure
per pressure setting label on power supply.

CUTMASTER 25mm
4. Turn FUNCTION CONTROL SWITCH to RUN G. Main Arc and Controls Test
position
Connect work Cable to the work piece, Close torch
• Solenoid turns off, gas stops flowing (pressure switch (Pendant switch or activate CNC Start) to es-
display may increase slightly when gas is not tablish a pilot arc. Bring torch to within 1/8” – 3/8”
flowing) of the work piece to establish main cutting arc.
This completes the Main Input and Internal Power Test. • Main Cutting Arc Establishes
If the above are all correct then proceed to the next section
"F. Pilot Arc Test". If the unit does not function as stated • On Main Pcb D59 turns off and D78 turns
above, then note the symptom and proceed to Section on
"5.07, Main Input and Internal Power Problems". 1. Clamp DC ammeter around the work cable. Out-
F. Pilot Arc Test put will be 80 amps.
1. Activate or depress the torch switch (Activate 2. While cutting, adjust the CURRENT CONTROL
START signal) to establish a pilot arc and note POTENTIOMETER from maximum setting to
the following minimum setting.
• Gas solenoid opens • Current adjusts from 80amps down to 20

amps
• Gas flows
3. Set the CURRENT CONTROL POTENTIOM-
• After two seconds the gas solenoid closes ETER to maximum position.
and gas stops flowing momentarily, then gas
solenoid re-opens and gas resumes flowing • Current adjusts from 20 amps up to 80 amps
• DC LED comes on 4. While cutting, touch the tip of the torch to the
work piece, This is called Drag Mode.
• Pilot arc is established
• Tip Saver circuit will activate, current drops
2. Open the torch switch (Remote Pendant switch to 60 amps.
or remove CNC start signal)
5. Lift tip off the plate approx 1/4”
• Gas continues to flow
• Tip Saver circuit deactivates, current goes back
• DC LED goes off to 80 amps
After 20 second post flow time 6. While cutting keep the torch switch closed, bring
the torch off the edge of the material.
• Gas solenoid closes
• Cutting arc extinguishes
• Gas flow stops
This completes the Pilot Arc Test. If the above are all
correct then proceed to the next section "G, Main Arc • Gas flow stops momentarily then restarts
and Controls Test". If the unit does not function as stated when solenoid opens
above, then note the symptom and proceed to Section
"5.08, Pilot Arc Problems". • Pilot arc ignites
7. Open the torch switch
• DC LED turns off
After 20 second post flow time
• Gas flow stops
8. Set the FUNCTION CONTROL SWITCH to
RAPID AUTO RESTART mode.

CUTMASTER 25mm
9. Close torch switch (Pendant switch or activate 3. Remove jumper from J6.
CNC Start) to establish a pilot arc. Bring torch to
• OK-TO-MOVE signal off (Meter shows no
within 1/8” – 3/8” of the work piece to establish
continuity)
main cutting arc.
• Gas continues to flow
10. While cutting keep the torch switch closed and
bring the torch off the edge of the material. • DC LED goes off
• Pilot Arc re-ignites immediately After 20 second Post flow time
11. Open the torch switch • Gas solenoid closes
• DC LED turns off • Gas flow stops
After 20 second post flow time If the unit has the Basic CNC Interface harness the
• Gas solenoid closes test is complete. If the unit does not function as
stated above, then note the symptom and proceed
• Gas flow stops to Section "5.10 CNC Interface Problems".If the unit
has the Automation Interface PCB installed, continue
12. Set the FUNCTION CONTROL SWITCH to
with this section.
LATCH mode
4. There are three (3) ARC VOLTs signals available
13. Start a cut, and release the torch switch
from the J6 connector.
• Main cutting arc will remain on until the torch
a) J2-9 (+) to J2-7 (-)
is lifted away from the plate approx ¾” or until
the torch is brought off the edge of the metal b) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-
nector with jumper installed between pins 1
Once the arc has extinguished
and 2) = ARC VOLTS divided by 50
• DC LED turns off
c) J2-5 (+) to J2-6 (-) (Auto Interface pcb J3 con-
After 20 second post flow time nector with jumper installed between pins 2
and 3) = ARC VOLTS divided by 16
Measure the voltage between these points while pi-
• Gas flow stops loting (Open Circuit Voltage) and while cutting. The
This completes the Main Arc and Controls Test. If the voltages should approx as listed below
above are all correct then proceed to the next section Open Circuit Voltage Cutting Voltage
"H CNC Interface Test." If the unit does not function as
stated above, then note the symptom and proceed to a) 300 VDC 100 VDC
Section "5.09, Main Arc and Controls Problems".
b) 6 VDC 2 VDC
H. CNC INTERFACE TEST c) 19 DVC 6 VDC
If the unit has one of the two factory supplied options This completes the CNC Interface Test. If the above are all
for CNC interface installed, proceed with this section, correct then the unit is functioning correctly. If the unit
otherwise the tests are complete. does not function as stated, then note the symptom and
1. Connect an ohmmeter between J2-12 to J2-14 proceed to Section "5.10, CNC Interface Problems".
(START signal). Position the torch to pilot. Check
the OK-TO-MOVE signal by connecting a jumper
between J2-3 and J2-4 (START signal).
• Pilot arc is established
2. Bring the torch to the work piece and transfer to
cutting arc.
• OK-TO-MOVE signal is present. (Meter shows
continuity)

CUTMASTER 25mm
5.08 Main Input and Internal Power C. Gas flows with ON/OFF SWITCH in OFF
position
Problems
1. Foreign debris has lodged in gas solenoid.
A. Primary input line fuse blows as soon as
primary disconnect is closed. a) Replace gas solenoid. This is a problem caused
by improperly filtered air supply. Customer
1. Primary input cable installed incorrectly. needs to add filtration to air supply prior to
unit inlet.
a) For Non EMC units - Check wiring of primary
power cable to the W1 contactor D. All front panel indicators are off, fans
Input Power Cable Connections do not run. Main Contactor W1 does not
380-415 VAC Three-Phase (3ø) close.
1. Primary power not connected.
L1
L2 a) Check that cable is connected to primary
power.
L3
Art # A-08795
2. Primary line fuse/breaker is blown/tripped.

L4
GND a) Replace fuse or reset breaker.
3. Defective ON/OFF SWITCH
b) For EMC units - Check wiring of primary pow-
er cable to the EMC Filter terminal block. a) Check continuity
EMC Input 4. Defective Main Pcb
Power Filter
a) Measure Main Pcb power supply voltages at
L1 the following test points
L2
GND L3 GND1 to +12V = 12VDC
GND1 to +48V = 48 VDC
Replace Main Pcb if not correct
5. Defective Ribbon Cable
Three Phase Input Power Wiring a) Check continuity
Art # A-08752_AA
2 W1 contactor points are stuck closed 6. Defective Logic
a) Check per section 5.11A a) Replace Logic Pcb
3. Primary plug not wired correctly.
E. AC LED on, W1 contactor does not
a) Check manufacturer's plug installation instruc- energize. (In earlier revision units, the
tions. fan MOT1 will come on after approx 20
4. Primary input cable is defective.
seconds)
1. Defective contactor.
a) Check cable for shorts.
a) Measure for 24vac between wires 5 & 6. If
voltage is present, replace W1.
B. Primary line fuses blow immediately after
2. Defective Logic PCB 3.
ON/OFF SWITCH (SW1) is turned to ON
position. a) Measure /W1_ON signal on Logic PCB 3 be-
tween J1-9 to TP1. Voltage should be 12VDC
1. Shorted Input Diode Module then drop to less than 1vdc, 2 seconds after
a) Check per section 5.11B turning SW1 to ON.
2. Shorted Input Capacitor Pcb

a) Check per section 5.11C

CUTMASTER 25mm
3. Open or improperly connected ribbon cable to J2
H. PARTS-IN-PLACE (PIP) FAULT. The FAULT
connector on Main PCB 1 Indicator and 70 PSI LED is flashing. After
20 seconds fan MOT1 turns on.
a) Inspect connaction and check continuity. Re-
place if open. 1. Shield Cup loose
4) Defective Main PCB 1. a) Hand tighten the shield cup to close the PIP
switch
a) Replace Main PCB 1.
2. Torch not properly connected to power supply
F. UNDER PRESSURE FAULT. AC LED on,
a) Insure torch ATC is securely fastened to unit.
FAULT Indicator and 60 PSI LED flashing.
3. Problem with torch and leads PIP circuit
1. Air pressure source to unit is too low.
a) Check continuity of torch PIP circuit at ATC
a) Set input pressure source to 90-100PSI.
pins 1 & 2.
2. Regulator set too low. Negative / Plasma Lead
a) Adjust unit regulator to increase pressure.
3. Defective Logic PCB 3
a) Measure for 5VDC on the Logic PCB 3 between 4 Torch Switch
J3-3 to J3-1. Replace Logic PCB 3 if voltage is 3 Torch Switch
not present or low. 2 PIP
b) Measure for voltage on the Logic PCB 3 be- 1 PIP
tween J3-2 to J3-1. If the voltage is between
3-4.5VDC, replace the Logic PCB 3.
4. Defective Pressure Transducer Pilot Lead Art # A-08124
a) Replace Pressure Transducer 4. Defective Logic Pcb

G. INPUT POWER FAULT. AC LED on, FAULT a) Measure the voltage on Main Pcb between J2-17
Indicator and 65 PSI LED flashing. to test point GND1 for 12VDC. If the voltage
is less than 2VDC, Replace Logic Pcb
1. Primary line voltage out of tolerance range.
5. Defective Main Pcb
a) Connect unit to voltage with unit specifica-
tions. See section "2.04 Power supply speci- a) Replace Main Pcb
fications". If using a generator, connect unit
to a wall receptacle to see if problem is cor-
rected.
2 Defective Main PCB 1
a) Measure voltage on Main PCB 1 between test
point GND1 to J2-22.
400 VAC input = approx 2.6 VDC
If voltage is less than 2vdc, replace Main PCB 1.
3. Defective Ribbon cable.
a) Check continuity of the ribbon cable connect-
ing between the Main PCB 1 and the Logic
PCB 3.
4. Defective Logic PCB 3.
a) Replace Logic PCB 3.

CUTMASTER 25mm
I. START ERROR FAULT. The FAULT 4. Open conductor in torch leads
Indicator and 75 PSI LED flashing. a) Check continuity
1. Start signal is active when SW1 is turned to ON 5. Defective Main PCB
position.
b) Measure voltage at Main Pcb between J2-2
a) START can be active for one of the following: to test point GND1 for 12VDC. If voltage is
• Hand torch switch held closed present, replace Main PCB
• Hand pendant switch held closed 6. Defective Logic PCB
• CNC START signal is active low a) Replace Logic PCB
Release the START signal source. K. AC LED on, yellow TEMP LED is on, red
FAULT Indicator is flashing.
2. Problem in the torch and leads switch circuit
1. Air flow through unit is restricted
a) Check continuity of torch switch circuit at ATC
pins 3 & 4. See previous illustration. a) Provide adequate airflow. See Ventillation
Clearance Requirements section 2.04.
3. Short in CNC cable
2. Exceeded duty cycle of the power supply.
a) Check continuity
a) Allow unit to remain on, but at idle, with fan
4. Defective Logic PCB 3
running to cool power supply. See Power Sup-
a) Measure voltage at Main PCB 1 between J2-16 ply Specifications section 2.04 for duty cylcle
to test point GND1 for 12VDC. If voltage is information.
present, replace Logic PCB 3.
NOTE
5. Defective Main PCB 1.
When the unit is turned on the cooling fans
a) Replace Main PCB 1.` MOT1 &2 will remain off. (In earlier units MOT1
will turn on for .one (1) second and then turns
J. TIP MISSING FAULT. The FAULT Indicator off) The fans will turn on when a START signal
and 80 PSI LED is flashing. Gas solenoid ( Torch Switch, Remote Pendant switch, or CNC
cycles on and off. START) is active and will remain on for ten (10)
minutes after the START signal is removed. If an
1. Torch Shield Cup is loose. over temperature condition occurs, the fans will
a) Tighten shield cup by hand. Do not over continue to run while the condition exists and
tighten. for a ten (10) minute period after the condition
is cleared.
2. Torch tip, electrode, or starter cartridge missing.
a) Turn off power supply. Replace missing
part(s). 3. Fan(s) not turning
3. Starter Cartridge is stuck. a) Measure voltage at plug between J7-1 to J7-

2 and between J8-1 to J8-2 on Main Pcb for
a) Turn off power supply. Bleed down the system. 12VDC If voltage is present replace fan.
Remove the shield cup, tip,start cartridge and
electrode. Check the lower end unit of the 4. Defective Main PCB
start cartridge for free movement. Replace a) Measure voltage at plug between J7-1 to J7-
the cartridge if the lower end unit does not 2 and between J8-1 to J8-2 on Main Pcb for
move freely. 12VDC. If voltage is missing at either recep-
tacle, replace Main PCB.
5. Defective Logic PCB
a) Replace Logic PCB

CUTMASTER 25mm
L. AC LED on, TEMP, GAS, DC LED's are off, P. AC LED on, TEMP LED off, GAS LED on,
FAULT Indicator is flashing. MIN PRESSURE Gas does not flow in SET mode using a
LED is flashing. Gas is not flowing machine torch with remote solenoid.
1. Gas supply not connected to unit Disconnect the gas solenoid SOL1 from the back of
the ATC connector.
a) Connect gas supply to unit
If Gas DOES NOT flow out of SOL1 when the unit is
2. Gas supply not turned on
in SET mode :
a) Turn gas supply on
1. Defective gas solenoid (SOL1)
3. Gas supply pressure too low.
a) Measure voltage on Main PCB between J5-1 to
a) Set gas supply pressure to 95-120psi J5-3 for 12 VDC. If voltage is present, change
SOL 1
4. Air Pressure Control Regulator set too low.
a) Adjust AIR PRESSURE CONTROL to set
pressure as specified in section 4.02 Setting a) Measure on Main PCB between J2-12 to test
Operational Pressure. point GND1 for 12VDC. If voltage is present,
replace Main PCB.
M. INTERNAL ERROrR. FAULT and 90PSI
indicators flashing. 3. Defective Main PCB
1. There has been a microprocessor problem. a) Replace Main PCB
a) Turn ON/OFF SWITCH to OFF position and If gas DOES flow out of SOL1 when the unit is in SET
then turn to ON position to clear the error mode, reconnect SOL1 to the ATC connector.
N. MAX PRESSURE ERROR 4. Defective torch solenoid.
MAX Pressure LED is lit. a) Measure the coil terminals of the torch mounted
gas solenoid SOL2 for 24vac. If present, re-
1. Gas pressure set too high place SOL2.
a) Reduce gas pressure 5. Defective Main PCB
2. Defective Logic PCB a) Measure on Main PCB between J2-20 to GND1
for less than 2VDC.
If voltage is 12VDC replace Main PCB
O. AC LED on, TEMP LED off, GAS LED on,
Gas does not flow in SET mode using a b) Measure on Main PCB between J2-11 to GND1
hand torch or a machine torch without for less than 2VDC. If voltage is less than
remote solenoid. 2VDC replace Main PCB
1. Defective gas solenoid (SOL1) 6. Defective Logic PCB
a) Measure voltage on Main Pcb between J5-1 to a) Measure on Main PCB between J2-11 to GND1
J5-3 for 12 VDC. If voltage is present, change for less than 2VDC. If voltage is 12vdc, replace
SOL 1 Logic PCB.
2. Defective Logic Pcb Q. Cannot adjust gas pressure in the SET

mode
a) Measure on Main PCB between J2-12 to test
point GND1 for 12VDC. If voltage is present, 1. Inlet gas pressure is too low
replace Main PCB.
a) Increase inlet gas pressure to 95-120 psi
3. Defective Main PCB
2. Faulty regulator
a) Replace Main PCB
a) Replace Regulator

CUTMASTER 25mm
5.09 Pilot Arc Problems B. SHORTED TORCH FAULT
A. AC LED on, TEMP LED off, GAS LED on. After torch switch is closed, gas flows for two (2)
seconds then momentarily shuts off then back
Nothing happens when torch switch or
on, FAULT INDICATOR flashes, and 85 PSI LED
remote switch is closed ( Or CNC START flashes.
signal is active) No gas flow, DC LED OFF.
1. Upper O-Ring on torch head is in the wrong posi-
1. Problem in the torch and leads switch circuit (or tion.
remote pendant or CNC signal missing
a) Remove shield cup from torch; check position
a) For hand torches, Check continuity of torch of the upper o-ring and correct if needed.
switch circuit at ATC pins 3 & 4.
Negative / Plasma Lead
Upper Groove
4 Torch Switch with Vent Holes
Must Remain Open
3 Torch Switch
2 PIP Upper O-Ring
1 PIP in Correct Groove
Threads
Lower O-Ring Art # A-03725
Art # A-08124
Pilot Lead
2. Torch start cartridge is stuck.
b) For machine torches using a remote pendant,
Check continuity of Pendant switch circuit a) Turn off power supply. Bleed down the system.
Remove the shield cup, tip,start cartridge and
c) For CNC input see section "5.07 H CNC IN- electrode. Check the lower end unit of the
TERFACE TEST start cartridge for free movement. Replace
the cartridge if the lower end unit does not
move freely.
a) Jumper on Main PCB between J2-16 and test
point GND1. If gas does not flow, replace
Logic PCB
b) With Torch Switch closed, measure voltage
on Main PCB between test points GND1 to
I_DMD1 for 1.4VDC. Replace Logic PCB if
voltage is not present.
a) With Torch Switch closed, measure voltage
on Main PCB between test points GND1 to 3. Worn or faulty torch parts
I_DMD1 for 1.4 VDC. Replace Main PCB if a) Inspect torch consumables parts. Replace if
voltage is present. necessary.

CUTMASTER 25mm
4. Shorted Torch E. AC LED on, TEMP LED off, GAS LED on,
a) Disconnect torch from unit. With consumables gas flowing, DC LED on, Fault Indicators
removed from the torch, Check continuity of off, Pilot Arc is intermittent.
torch at ATC, between negative/plasma lead 1. Defective Logic PCB
connection to pilot lead connection.
Negative / Plasma Lead a) Measure for 12VDC on Main PCB between
test Point GND1 to J2-8. If 12VDC is present,
replace Logic PCB
4 Torch Switch a) Replace Main PCB
3 Torch Switch
F. INTERNAL ERROR FAULT INDICATOR AND
2 PIP
90 PSI INDICATOR FLASHING
1 PIP
1. There has been a microprocessor problem.
a) Turn ON/OFF SWITCH to OFF position and
Pilot Lead Art # A-08124 then turn to ON position to clear the error
5.10 Main Arc and Controls

C. AC LED on, TEMP LED off, GAS LED on, Problems
gas flowing, DC LED off, Fault Indicators
off, No arc in torch A. Main arc will not establish, LED D59 on
Main PCB remains on while pilot arc is
striking the work piece.
a) Measure voltage at Main PCB between test
1. Work Cable not connected.
point GND1 to J2-10.
a) Connect cable to work piece
Voltage is normally 12VDC and should drop to less
than 2VDC two (2) seconds after torch switch is 2. Work cable open / broken.
depressed. If voltage does not drop replace Logic
a) Check continuity of work cable. Insure connec-
PCB
tion of cable to clamp is secure.
b) While pilot arc is established, measure voltage
on Main PCB between test points GND1 to B. Main arc transfers but current cannot be
I_DMD1 for 1.4 VDC. If voltage is low or not adjusted
present, replace Logic PCB. 1. Defective Logic PCB
2. Defective Main PCB a) While main arc is transferred,measure voltage
a) a) Measure voltage at Main PCB between test on Main PCB between test points GND1 to
point GND1 to J2-10. I_DMD1.
Voltage is normally 12VDC and should drop to less b) Adjust CURRENT CONTROL POTENTIOM-
than 2VDC two (2) seconds after torch switch is de- ETER from maximum to minimum. Voltage
pressed. If voltage does not drop to less than 2VDC should vary from 4VDC at max to 1 VDC at
for approx one (1) second then replace Main PCB min
D. AC LED on, TEMP LED off, GAS LED on, If voltage does not vary with CURRENT CONTROL
POTENTIOMETER, Replace Logic PCB
gas flowing, DC LED on, Fault Indicators
off, No arc in torch. 2. Defective Main PCB
1. Defective Main PCB a) Replace Main PCB
a) Install jumper on Main PCB between test point C. In LATCH mode, when the torch switch is
GND1 to terminal TIP1. released the arc shuts off immediately.
b) Close torch switch. If Pilot starts, replace Main 1. Defective Logic PCB
PCB

CUTMASTER 25mm
D. With CURRENT CONTROL 5.11 CNC Interface Problems
POTENTIOMETER set at maximum, output
current is only 60 amps. A. Nothing happens when jumper is installed
between J2-3 to J2-4.
1. Tip is touching the work piece, Drag mode.
1. Defective Automation Interface PCB (PCB4)
a) Lift tip off work piece
a) Measure voltage on PCB4 between J1-6 to J1-8
2. Defective Pilot IGBT on Main PCB for 12VDC.
a) Check per section 4.10. If 12VDC is present replace PCB4
E. In RAPID AUTO RESTART mode, with 2. Defective Main PCB
torch switch closed, the pilot does not
start immediately when the cutting arc a) Measure voltage on Main PCB between J1-6 to
J1-8 for less than 2VDC.
extinguishes
If voltage is less than 2VDC, replace PCB1
a) Replace Logic PCB B. No OK-TO-MOVE signal while cutting.
1. Defective Main Pcb (PCB1)
F. INTERNAL ERROR FAULT INDICATOR AND
90 PSI INDICATOR FLASHING a) Measure voltage on PCB4 between J1-1 to J1-3
for 12VDC while cutting.
1. There has been a microprocessor problem.
If 12VDC is present, replace PCB1
a) Turn ON/OFF SWITCH to OFF position and
then turn to ON position to clear the error 2. Defective Automation Interface PCB (PCB4)
a) Measure voltage on PCB4 between J1-1 to J1-3
for less than 2VDC while cutting.
If voltage is less than 2VDC, replace PCB4.
C. ARC VOLTS signals are low or not present

1. Defective Automation Interface PCB (PCB4)
a) Replace PCB4

CUTMASTER 25mm
5.12 Test Procedures B. Input Diode Module Test
1. Using an ohmmeter perform the tests in the
A. Main Contactor (W1) Test
chart
1. Check continuity between:
Input Diode Module
L1 to T1 Meter (+) Meter (-) Indication
L2 to T2 AC1 MTH 2 Forward Bias
AC2 MTH 2 Forward Bias
L3 to T3
AC3 MTH 2 Forward Bias
L4 to T4 MTH 2 AC1 Reverse Bias
The contacts should be open – no continuity. MTH 2 AC2 Reverse Bias
MTH 2 AC3 Reverse Bias
Cover Screws
MTH 5 AC1 Forward Bias
Actuator Button MTH 5 AC2 Forward Bias
T1
T2 L1
MTH 5 AC3 Forward Bias
Actuator Arm T3 L2
T4 AC1 MTH 5 Reverse Bias
L3
L4 AC2 MTH 5 Reverse Bias
AC3 MTH 5 Reverse Bias
2. If the test reveals a failed component, replace
Main PCB and perform main contactor test – Sec-
tion 5.12A
Main Contactor
Input
Side Art # A-08794 C. Input Capacitor PCB Test
1. Using an ohmmeter check continuity between the
2. Retest continuity between terminals while engag-
following points:
ing the contacts manually. This can be done by
pushing down on the recessed actuator button on Input Capacitors
the top of W1 or pushing down on the actuator Meter + Meter - Indication
arm on the side of W1.
MTH 2 MTH 4 Charging
L1 to T1 MTH 4 MTH 5 Open
L2 to T2 MTH 6 MTH 5 Charging
L3 to T3 Most meters will show a charging action. Initially a
low resistance will be shown and then the resistance
L4 to T4 will start to increase. If the meter probes are reversed
The contacts should be closed – Continuity the reading will decrease to zero, then start charging
in the opposite polarity.
3. Visually check W1 contact points. To take the
cover off, remove the two cover screws shown in 2. If a short is found replace Capacitor PCB assem-
the previous illustration. Replace if contacts are bly.
stuck together or show excessive arcing 3. Check continuity between the following points
Input relays Indication
MTH 2 MTH 6 Open
MTH 4 MTH 6 Open
MTH 4 MTH 5 Open
4. If a short is found, replace Capacitor PCB assem-
bly

CUTMASTER 25mm
D. IGBT Modules Test F. Pilot IGBT Test
1. Disconnect transformer wires from Main PCB 1. Disconnect wire from Main PCB terminal TIP1
terminals PRI 1 (A) and PRI 4 (D).
2. Measure continuity on Main PCB between test
2. Using an ohmmeter perform the following point GND1 to terminal TIP1
checks
IGBT A Main PCB. If no problem is found, reconnect wire
Meter (+) Meter (-) Indication to Main PCB.
PRI 1 (A) MTH 2 Forward Bias
PRI 1 (A) MTH 4 Reverse Bias
MTH 2 PRI 1 (A) Reverse Bias
MTH 4 PRI 1 (A) Forward Bias
PRI 2 (B) MTH 2 Forward Bias
PRI 2 (B) MTH 4 Reverse Bias
MTH 2 PRI 2 (B) Reverse Bias
MTH 4 PRI 2 (B) Forward Bias
IGBT B
Meter (+) Meter (-) Indication
PRI 3 (C) MTH 6 Forward Bias
PRI 3 (C) MTH 5 Reverse Bias
MTH 6 PRI 3 (C) Reverse Bias
MTH 5 PRI 3 (C) Forward Bias
PRI 4 (D) MTH 6 Forward Bias
PRI 4 (D) MTH 5 Reverse Bias
MTH 6 PRI 4 (D) Reverse Bias
MTH 5 PRI 4 (D) Forward Bias
Main Pcb and perform main contactor test – Sec-
tion 5.12A. If no problem is found, reconnect the
transformer wires to Main PCB.
E. Output Diode Module Test

1. Disconnect transformer wires from Main PCB
terminal SEC 1.
2. Using an ohmmeter perform the tests in the
chart
Output Diode Module
Meter (+) Meter (-) Indication
SEC 1 WORK 1 Forward Bias
SEC 1 CHOKE 1 Reverse Bias
WORK 1 SEC 1 Reverse Bias
CHOKE 1 SEC 1 Forward Bias
SEC 2 WORK 1 Forward Bias
SEC2 CHOKE 1 Reverse Bias
WORK 1 SEC2 Reverse Bias
CHOKE 1 SEC 2 Forward Bias
Main Pcb. If no problem is found, reconnect the
transformer wires to Main PCB.

CUTMASTER 25mm
Signal Information
Many of the signal listed will be low voltage signals
that will be in one of two states: +12VDC (High) or
0VDC (Low) with respect to pcb common.. When a
signal name is preceded by the “/” mark, it denotes
that the signal is an active low. For example:
/OVERTEMP – This signal is normally High but
when an over temperature fault exists, this line will
change state to a Low.

CUTMASTER 25mm
5.13 Capacitor PCB Layout & Signals
J3*
MTH8 MTH7 MTH5 MTH6 MTH1 MTH3 MTH4 MTH2
Art # A-08841
*J3 CONNECTOR PINOUT
1 2 3
CAPACITOR PCB LAYOUT
A. CAPACITOR PCB SIGNALS

J1-1 Capacitor bank A+
J1-5 Capacitor bank A-
J2-1 Capacitor Bank B+

J2-5 Capacitor Bank B-
Signal Source/Destination
J3-1 +12 VDC M-C

J3-2 /400 Active low for 400VAC input M-C
J3-2 N/A

CUTMASTER 25mm
B. CAPACITOR PCB TEST POINTS
MTH1,2 Capacitor bank A+
MTH3,4 Capacitor bank A-
MTH6,8 Capacitor Bank B+
MTH 5,7 Capacitor Bank B-

CUTMASTER 25mm
5.14 Logic PCB Layout & Signals
D1 TP3
TP4
TP1
TP7
J1*
TP2
D2
D3
TP6
D4
D5
D6
D7
D8
TP5 D9
J3
D10 D12 D14

D11 D13
*J1 Pinout
1 37
Art # A-08504_AB
4 40
LOGIC PCB LAYOUT
A. LOGIC PCB SIGNALS

(Same for MAIN PCB J2) Signal Source/Destination
J1-1 -VOUT (-) OUTPUT VOLTAGE M-L

J1-2 /TIP VOLTS Active high when tip is installed M-L
J1-3 TIP_SEN Approx. 100VDC while cutting with tip not in M-L
contact w/work piece, Active low when tip
contact work during cut (Drag Mode)
J1-4 /400V_IN Active low with 400vac primary input voltage L-M
J1-5 N/A

CUTMASTER 25mm
Signal Source/Destination
J1-6 CUR_SET Current demand signal. Variable 1-4VDC L-M

J1-7 /RAR Active low when in Rapid Auto Restart mode L-M
J1-8 /INRUSH Active low after inrush time expires L-M
J1-9 /W1_ON Active low to enable W1 contactor L-M
J1-10 SHDN Active low enables PWM circuit
J1-11 /TRCH_SOL Active low to enable Torch Solenoid L-M
J1-12 /SOL_ON Active low to enable Power Supply solenoid L-M
J1-13 /OK_TO_MOVE Active low to enable OK_TO_MOVE (CNC) L-M
J1-14 /FAN_ON Active low to enable fans L-M
J1-15 /LATCH_ACTIVE Active low when Latch mode is active during cut L-M
J1-16 /TRCH_SW Active low = START is active -Torch switch, CNC M-L
J1-17 /PIP Active low = PARTS IN PLACE satisfied M-L
J1-18 AC_ON Pulse signal M-L
J1-19 CSR Active high during main transfer M-L
J1-20 /TORCH_SOL_DETECTED Active low for torch with remote solenoid M-L
J1-21 /OVERTEMP Active low when over temperature M-L
J1-22 V_IN Input Voltage signal M-L
2.6VDC = 400 VAC
J1-23 +12VDC M-L
J1-24 +12VDC M-L
J1-25 GND M-L
J1-26 GND M-L
J1-27 Not Used
J1-28 Not Used
J1-29 MAIN_BD_ID Voltage level to identify Main PCBs M-L
J1-30 Not Used
J1-31 Not Used
J1-32 Not Used
J1-33 Not Used
J1-34 For Factory Use M-L
J1-38 GND M-L
J1-40 Not Used

CUTMASTER 25mm
B. LOGIC PCB LED INDICATORS
NORMAL INDICATION FIRMWARE VERSION ERROR MESSAGE
D1 +12VDC
D2 MAX PRESSURE X.7 Over Pressure
D3 90 PSI X.6 Internal Error
D4 85 PSI X.5 Shorted torch
D5 80 PSI X.4 Tip Missing
D6 75 PSI X.3 Start Signal active during power up
D7 70 PSI X.2 Parts-In-Place Fault (PIP)
D8 65 PSI X.1 Input Power Fault
D9 MIN PRESSURE X.0 Low Pressure
D10 AC 1.X
D11 OVERTEMP 2.X
D12 GAS 3.X
D13 DC 4.X
D14 ERROR 5.X
C. LOGIC PCB TEST POINTS

TP1 Common
TP2 +12VDC
TP3 +5VDC
TP4 +3.3DCV
TP5 0.5 to 5 VDC / 0 - 100 psi
TP6 +1.8VDC
TP7 Potentiometer Current Demand (0-3.3VDC)

CUTMASTER 25mm

CUTMASTER 25mm
5.15 MAIN PCB Layout & Signals
*J2 PINOUT
40 2
39 1
PRI_4 TP7 TP3 TP2 TP1

J4 J3 *J2 J13 J12 J1
I_DMD1
PRI_1
TP4
GND1
AC1
J14
AC2
TP8 AC3
TP5
PRI_3
PRI_2
D59
TP6
TIP1
ELECTRODE1 SEC1
+48V2
+12V2
-V_OUT1
+48V1
D78
J11 J10 J9 J8 J7 J6 J5
Art # A-08518_AB CHOKE1 SEC2 +12V1 WORK_1 GND2
MAIN PCB LAYOUT
A. MAIN PCB SIGNALS

J1-1 L1 Primary AC Line
J1-2 Not used
J1-3 Not used
J1-4 Not used
J1-5 L2 Primary AC Line
J2 Signal info is the same as Logic PCB - J1 connector

CUTMASTER 25mm
J3-1 N/A J12-1 +12VDC
J3-2 Common J12-2 /400VAC
J12-3 N/A
J4-1 3.3VDc
J4-2 TXD B. MAIN PCB LED INDICATORS
J4-3 RXD D59 PCR I ndicates Pilot IGBT gate signal is on
D78 CSR I ndicates cutting arc has been established
J4-4 Common
J4-5 D C. MAIN PCB TEST POINTS
GND1 Common
J5-1 +12VDC GND2 Common
J5-2 Not used GND3 Common
+12V1 +12VDC
J5-3 /SOLENOID +48V1 +48VDC
I_DMD1 0-4VDC Cur. Demand Signal
J6-1 24VAC Supply for W1
J6-2 24VAC Return
J7-1 +12VDC
J7-2 /FAN
J8-1 +12VDC
J8-2 /FAN
J9-1 /PIP
J9-2 Common
J9-3 /TORCH SWITCH (Start)

J9-4 Common
J9-5 Torch solenoid 24VAC supply
J9-6 Not Used
J9-7 Torch solenoid 24VAC return
J10-1 /OK-TO-MOVE
J10-2 Not used
J10-3 /OK-TO-MOVE
J10-4 Not used
J10-5 Common
J10-6 Common
J10-7 Not used
J10-8 /START (Torch Switch)
J11-1 Jumper installed

J11-2 Jumper installed

CUTMASTER 25mm
5.16 Main PCB Wiring Diagram
J4 J3 J2 J12 J1
N/A To SW2 To Logic Pcb To PCB2 To SW1
7
D 7A
9
B
C SEC1 SEC1
E35
CHOKE1
E64
SEC2
SEC2
ELEC-1
Work Art # A-08902

Cable
To ATC
J11 J10 J9 J8 J7 J6 J5
CM52 - Jumper To Automation To ATC connector To Fan To Fan To W1 To SOL1
CM82 - TS2 Interface Pcb
MAIN PCB WIRING DIAGRAM

CUTMASTER 25mm
SECTION 5 TORCH: It is recommended to apply a very light film of o-
ring lubricant (Catalog # 8-4025) to the o-rings on a
SERVICE weekly basis.
5T.01 General Maintenance

NOTE Upper Groove
Refer to Previous "Section 5 System" for common with Vent Holes
and fault indicator descriptions. Must Remain Open
Cleaning Torch Upper O-Ring

in Correct Groove
Even if precautions are taken to use only clean air
with a torch, eventually the inside of the torch be- Threads
comes coated with residue. This buildup can affect Lower O-Ring Art # A-03725
the pilot arc initiation and the overall cut quality of Torch Head O-Ring
the torch.
ATC Male Connector
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power 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. Gas Fitting
CAUTION
Dry the torch thoroughly before reinstalling.
O-Ring Lubrication
An o-ring on the Torch Head and ATC Male Connec- Art #A-03791 O-Ring
tor requires lubrication on a scheduled basis. This
will allow the o-rings to remain pliable and provide ATC O-Ring
a proper seal. The o-rings will dry out, becoming NOTE
hard and cracked if the lubricant is not used on a
regular basis. This can lead to potential performance DO NOT use other lubricants or grease, they may
problems. not be designed to operate within high tempera-
tures or may contain “unknown elements” that
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.
Manual 0-5081 5T-1 SERVICE

CUTMASTER 25mm
5T.02 Inspection and Replacement 4. 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. Example of Tip Wear
Remove the consumable torch parts as follows: 5. 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.
in place. Position the torch with the shield cup
facing upward to prevent these parts from falling
out when the cup is removed.
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.
2. Inspect the cup for damage. Wipe it clean or 6. 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.
New Electrode
Art # A-08067
Shield Cups
3. On torches with a shield cup body and a shield
cap or deflector, ensure that the cap or deflector is Worn Electrode
Art # A-03284
threaded snugly against the shield cup body. In
shielded drag cutting operations (only), there may Electrode Wear
be an O-ring between the shield cup body and
drag shield cap. Do not lubricate the O-ring.
7. Reinstall the Electrode by pushing it straight into
the torch head until it clicks.
Drag Shield Cap
8. Reinstall the desired starter cartridge and tip into
Shield the torch head.
Cup Body
9. Hand tighten the shield cup until it is seated on
the torch head. If resistance is felt when installing
the cup, check the threads before proceeding.
O-Ring No. 8-3488 This completes the parts replacement procedures.
Art # A-03878
SERVICE 5T-2 Manual 0-5081

CUTMASTER 25mm
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement

Section 6.04 Major External Replacement Parts
Section 6.05 Front Panel Replacement parts
Section 6.06 Left Side Replacement Parts
Section 6.07 Right Side Replacement Parts
Section 6.08 Options and Accessories
Section 6.09 Replacement Parts for Hand Torch
Section 6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads
Section 6.11 Torch Consumable Parts Manual and Mechanized Torches
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authoriza-
tion will not be accepted.
6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial number of the power supply. Address all inquiries to
your authorized distributor.
6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 25mm Non CE Power Supply
with 380/400/415VAC, 3 Phase, 50/60 Hz, with input power cable 3-1330-3
1 CutMaster 25mm CE Power Supply

with 380/400/415VAC, 3 Phase, 50/60 Hz, with input power cable 3-1330-4
Manual 0-5081 6-1 PARTS LIST

CUTMASTER 25mm
6.04 Major External Replacement Parts
Item # Qty Description Catalog #
1 1 Cover with labels 9-0222
2 1 Base Enclosure Assembly 9-0118
3 1 Tube, roll handle 9-0121
4 1 Front Panel 9-0228
5 1 Rear Panel 9-0101
4
3
Art # A-08120
NOTE
Illustration may vary slightly from unit.
PARTS LIST 6-2 Manual 0-5081

CUTMASTER 25mm
6.05 Front Panel Replacement Parts
Item# Qty Description Ref. Catalog #
1 1 Output Current Control and Function Control Knobs 9-8527
2 1 Toggle - On/Off Switch SW1 9-0109
3 1 Work Cable with Clamp, 20 Ft / 6.1 m 9-0184
Not Shown:
1 Wire harness (from SW1) w/EMI Choke (CE Power Supplies Only) 9-0247
Art # A-08123
NOTE

CUTMASTER 25mm
6.06 Left Side Replacement Parts
Item # Qty Description Ref Catalog #
1 1 Main PCB Assembly PCB1 9-0125
2 1 Logic PCB PCB3 9-0107*
3 1 Center Chassis Molded Plastic 9-0102
4 2 Fan, MOT1,2 9-0104
5 1 Transformer, Main T1 9-0199
6 1 Inductor, Output L1 9-0105
Not Shown:
1 Power Cable Strain Relief, for all units 9-0111
1 Input Power Cable 380/400/415 V 3 phase 9-0218
NOTE:
*9-0107 Logic PCB, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will
be needed to replace not only the Logic PCB (9-0107) but the regulator (9-0115) as well. Another way to tell if
the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting. If there is a
transducer and wire harness instead of the tube, the kit is not needed.
1
2
Art # A-08122
6 5
NOTE

CUTMASTER 25mm
6.07 Right Side Replacement Parts
Item # Qty Description Ref Catalog #
1 1 Contactor, 4 Pole W1 9-8587
2 1 Solenoid, 12V SOL1 9-0114
3 1 Spare Parts Box 7-3267
4 1 Spare Parts Box Cover 7-3266
5 1 Console Quick Disconnect 9-0161
6 1 Regulator, with knob and mounting nut 9-0115*
7 1 Assembly, PCB, Input Capacitors PCB2 9-0126
8 1 Filter, Auto Drain 9-0116
9 1 3 Phase Input Line EMI Filter (CE Power Supplies Only)) 9-0252
NOTE:
*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be
needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed
is to see if the regulator has a small diameter tube coming out of the bottom fitting. If there is a transducer and
wire harness instead of the tube, the kit is not needed.
5
4
6
9
1
Art # A-08828
NOTE

CUTMASTER 25mm
6.08 Options and Accessories
Qty Description Catalog #
1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two - Stage Filter Kit (includes Hose & Mounting Screws
Bracket, Filter Mounting (not shown) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable ( 50 ft / 15.2 m ) with Clamp 9-8529
1 Multi - Purpose Cart 7-8888
1 Automation Interface Kit 9-8310
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313
1 Nylon Dust Cover 9-7071

Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942
Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

CUTMASTER 25mm
6.09 Replacement Parts for Hand Torch
Item # Qty Description Catalog #
1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O - Ring 8-3487
6 1 Small O - Ring 8-3486
7 Leads Assemblies with ATC connectors (includes switch assemblies)
1 SL60, 20 - foot Leads Assembly with ATC connector 4-7834
1 SL100 , 50 - foot Leads Assembly with ATC connector 4-7837
8 1 Switch Kit 9-7031
10 1 Torch Control Cable Adapter (includes item # 11) 7-3447
11 1 Through - Hole Protector 9-8103
1
5
6
3
Art # A-07993_AB

CUTMASTER 25mm
6.10 Replacement Parts - for Mechanized Torches with Unshielded Leads
Item No. Qty Description Catalog No.
1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220
2 1 Large O - Ring 8-3487
3 1 Small O - Ring 8-3486
4 1 PIP Switch Kit 9-7036
5 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
6 1 11” / 279 mm Rack 9-7041
7 1 11” / 279 mm Mounting Tube 9-7043
8 1 End Cap Assembly 9-7044
9 2 Body, Mounting, Pinch Block 9-4513
10 1 Pin, Mounting, Pinch Block 9-4521
11 1 Torch Holder Sleeve 7-2896
12 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042
NOTE
* Does not include Control Cable Adapter or Through - Hole Protector.

CUTMASTER 25mm
8
10
1
2 10
3
4 11
12
A-07994

CUTMASTER 25mm
6.11 Torch Consumable Parts Manual and Mechanized Torches
Tips: Shield
DRAG TIP Cup Body, Shield Cap, Deflector
CUTTING 9-8237 9-8243
20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
CUTTING Tip:
9-8237
9-8243
40A 9-8208 Standoff Guide

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

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243
70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING
40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AC CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
CutMaster 152 uses 120A and less
Tip Gouging D 9-8228 (60 - 120 Amps)
Tip Gouging E 9-8254 (60 - 120 Amps)

CUTMASTER 25mm
SECTION 7: REPLACEMENT B. Procedure
PROCEDURES 1. Open the wrist strap and unwrap the first two
folds of the band. Wrap the adhesive side firmly
around your wrist.
7.01 Scope 2. Unroll the rest of the band and peel the liner from
the copper foil at the opposite end.
This section describes parts replacement procedures
which may be performed on the CutMaster 25mm 3. Attach the copper foil to a convenient and ex-
Power Supply. posed electrical ground.
Under no circumstances are field repairs to be attempted 4. Connect the equipment primary cable ground to
on Printed Circuits or other subassemblies of this unit. the same electrical ground as the wrist strap.
Evidence of unauthorized repairs may void the factory
5. Open the equipment enclosure and remove the
warranty.
failed PC board.
7.02 Anti-Static Handling 6. Carefully open the ESD protective bag and re-
move the replacement PC Board.
Procedures
7. Install the replacement PC Board in the equip-
A. General ment and make all necessary connections.
8. Place the failed PC Board in the ESD protective
bag and seal for return shipping.
Caution
9. Replace the power supply cover.
PC Boards can be irreparably damaged by im-
proper handling due to electrostatic discharge 10. Remove the grounding wrist strap from your
(ESD). wrist and from the electrical ground connection
before reconnecting primary power to the equip-
Replacement PC Boards are shipped in a protective en- ment.
closure to prevent damage from electrostatic discharge
(ESD) during shipping. A ground strap is included with
each replacement board to prevent static damage during
7.03 Parts Replacement - General
installation. Information
The parts replacement procedures described in this
! WARNINGS
manual, except for filter replacement, require that the
Power Supply be disassembled. The part to be replaced
will determine to what extent the Power Supply must
Read and understand these instructions and be disassembled.
the instructions on the grounding wrist strap
package before opening the equipment enclo- Before removing any connection mark each wire with
sure or removing the replacement PC board the connection designation. When reassembling make
sure the wires go to the proper terminals.
from its protective enclosure.
Note the routing of wires and make sure the wires are put
Disconnect primary power to the system back in the same place when re-assembling the unit.
before disassembling the torch, torch leads,
or power supply enclosure. Each subsection is referenced to Section 6 for parts lists
and overall detailed drawings.
Where these instructions include specific
torquing instructions, failure to torque prop-
erly will cause component damage. WARNING
Do not operate the equipment or test equip- Disconnect primary power from the source
ment under power while wearing the ground- before opening or disassembling the power
ing wrist strap. supply.
Manual 0-5081 7-1 PARTS REPLACEMENT

CUTMASTER 25mm
7.04 Major External Parts C. Tube Handle Replacement
Tools required: T20 Torx Driver
A. Cover Removal
1. Disconnect the Torch and Leads from the unit.
2. Remove the cover per subsection 7.04 A.
1. Remove the upper and lower screws which
secure the cover to the main assembly. Do not 3. Remove the screws securing the tube handles to
loosen the lower screws inside the cut out slots the base of the unit.
in the bottom of the cover.
NOTE
Note
Some of the earliest manufactured units have Tube
The upper screws and lower screws are not the Handles tha are joined together under the base of
same. Do not mix them. The upper screws are the unit. Later versions are not joined together.
for threading into the plastic of the front and rear
panels. DO NOT use the finer threaded lower 4. Remove the power supply from the Tube Han-
screws for this. dles.
5. Replace the Tube Handles by reversing the above
Upper steps.
Screws
6. Reinstall the power supply cover.
Lower D. Disconnecting Front and Rear Panels from
Screws the base
In many of the replacement procedures, it may be help-
Slots ful to disconnect the front or rear panel from the base in
order to allow more room to access the parts.
Lower
Screws Tools required: T20 Torx Driver
1. Remove the cover per subsection 7.04 A.
2. For earlier models remove the Tube Handles
per subsection 7.04 C. The earlier model Tube
Handles join together under the base. Later mod-
els do not and there is enough room to perform
this procedure without removing them.
3. While grasping the panel close to the base, pull
the panel directly from the base to release the
locking tabs..
Art # A-07947
4. To re-engage the panel, position the panel so that
the locking tabs are above the base, then push the
2. Carefully pull the Cover up and away from the panel back onto the base until the locking tabs
unit. engage the mating holes in the base.
B. Cover Installation 5. For complete removal of panel, disconnect any

other item still attached to the panel and another
1. Reverse previous procedures for cover installa- component of the power supply.
tion.
NOTE
When installing the upper screws, attempt to
reuse the original threads. The easaiest way to
do this is by turning the screw counter-clockwise
until you feel the threads lign up, then begin to
turn the screw clockwise to tighten. Do not over
tighten.
PARTS REPLACEMENT 7-2 Manual 0-5081

CUTMASTER 25mm
7.05 Front Panel Parts Replacement D. Air Regulator Replacement
Refer to section 6.05 for Front Panel Replacement Parts Tools required: T20 Torx Driver
and overall detailed drawing. 1. Remove the cover per subsection 7.04A
A. Current Control Potentiometer (A) Knob 2. Remove the three (3) air hoses from the regulator
Replacement per subsection 7.05-C
Tools required: Flat Screw Driver 3. Pull the Air Regulator adjusting knob from the
shaft.
1. Turn the potentiometer fully clockwise and note
the location of the pointer mark on the knob. 4. Loosen and remove the locking nut securing the
Air Regulator to the front Panel, then remove the
2. Loosen the screw securing the Current Control regulator.
Knob to the potentiometer shaft and remove the
knob. 5. Install replacement Air Regulator by reversing
the above steps.
3. Replace the knob on the potentiometer shaft with
the pointer in the same position as noted in step 6. Reinstall the power supply cover
1.
E. Gas Solenoid Replacement
B. Function Control Switch Knob
Tools required: T20 Torx Driver, Flat Screw Driver
Replacement
1. Remove the cover per subsection 7:04A
Tools required: Flat Screw Driver
2. Disconnect J5 connector from the Main PCB.
1. Turn the Function Control Switch until the
pointer on the knob is in the LATCH position. 3. Remove the air hose from Gas Solenoid per sub-
section 7.05-C
2. Loosen the screw securing the knob to the switch
shaft and remove the knob. 4. The Solenoid utilizes the same type locking fit-
ting as the gas hoses. Using a flat blade screw
3. Replace the knob on the switch shaft with the
driver, push the locking ring towards the Sole-
pointer in the position noted in step 1.
noid while pulling the Solenoid away from the
C. Replacing Gas Hoses ATC.
Tools required: T20 Torx Driver 5. Install the replacement Gas Solenoid by reversing
the above steps
1. Remove the cover per subsection 7.04A
6. Reinstall the power supply cover
2. Push the gas fitting locking ring back. A small
open end wrench works well for this. F. Logic PCB (PCB3) Replacement
1 Tools required: T20 Torx Driver Flat Screw Driver, ½”
2 wrench
2. Remove the two large and one small gas hoses
from the pressure regulator per subsection
7.05C.
3
3. Unplug the connector J2 from the Main PCB.
Art # A-08150
4. Remove the Current Control Potentiometer Knob
and nut securing the potentiometer shaft to the
front panel per subsection 7.05A
3. Pull the hose from the fitting.
5. Remove the Function Control Switch Knob and
4. Replace the hose by pushing the hose back into
the nut securing the switch shaft to the front
the fitting until it fully seats. Check it by pull-
panel per subsection 7.05B.
ing on the hose. If done correctly it will not pull
out. 6. Pull the top of the front panel forward slightly
and carefully remove the Logic PCB from the
unit.

CUTMASTER 25mm
7. Install the replacement Logic PCB by reversing 7.06 Left Side Internal Parts
the above steps.
Replacement
A. Fan Replacement
G. ON/OFF Switch (SW1) Replacement
1. Remove the Cover per subsection 7.04A
2. Unplug J7 and J8 connectors from Main PCB.
2. Disconnect the wires on the rear of the switch,
noting the location and orientation of each wire 3. Carefully feed the fan wires through the center
as shown below. chassis wire slot.
Switch
4. Remove the fan by pushing the fan retaining
clips apart and pulling the fan out of the center
chassis.
5. On the replacement fan(s) note the direction of
Art # A-08169
4 3 air flow as labeled on the fan housing and orient

so fan will blow air into the unit.
6. Install replacement fan by reversing the above
steps.
2 1
3. Squeeze together the clips on the back of the
switch, then remove the switch through the front B. Main Transformer (T1) Replacement
panel. Tools required: T20 Torx Driver, ½” Nut Driver
4. Install the replacement switch by reversing the 1. Remove the Cover per subsection 7.04A
above steps.
2. Remove the Tube Handle per subsection 7.04C
3. Remove the two large and one small gas hoses
H. Work Cable Replacement per subsection 7.05C
Tools required: T20 Torx Driver 4. Remove the Gas Solenoid per subsection 7.05E
1. Remove the Cover per subsection 7.04A. 5. Disconnect the transformer wires from terminals
PRI 1 (A), PRI 2 (B), PRI 3 (C), PRI 4 (D), SEC1,
2. Disconnect the work cable from the WORK1
SEC2 on the Main PCB.
terminal on the Main PCB.
6. Disconnect J2 & J3 connectors from Main PCB.
3. Squeeze the top and bottom of the Work Cable
Strain Relief and remove from the front panel. 7. Remove the two screws securing the Center
Chassis to the base.
4. Install the replacement Work Cable by reversing
the above steps. 8. Loosen the two screws on the Input Power Cable
strain relief.
9. Disengage the Rear panel from the base per sec-
tion 7.04D.
10. Guide the rear panel back six (6) inches away
from the base.
11. Guide the Center Chassis towards the center of
the base to disengage the bottom locking tabs
securing the Chassis to the base.
12. Carefully guide the Center Chassis up far enough
to lay the Chassis down to the right side of the
unit.

CUTMASTER 25mm
13. Remove the two screws securing the Main Trans- 7.07 Rear Panel Parts Replacement
former to the base.
A. Filter Element Assembly Replacement
14. Remove the Main Transformer, carefully guiding
all its wires through from the right side of the The Filter Element Assembly is in the rear panel. For
unit. better system performance, the filter element should be
checked per the Maintenance Schedule (Subsection 5.02),
15. Install replacement Transformer by reversing the
and either cleaned or replaced.
above steps.
1. Remove power from the power supply; turn off
the gas supply and bleed down the system.
C. Output Inductor (L1) 2. Remove the system cover. See "A Cover Re-
Tools required: T20 Torx Driver, ½” Nut Driver moval" in this section.
1. Remove the Cover per subsection 7.04A 3. Locate the internal air line and the fitting from
the filter assembly. Number 1 in the following
2. Remove the Tube Handle per subsection 7.04C illustration.
3. Remove the two large and one small gas hoses 4. Hold a wrench or similar tool against the locking
per subsection 7.05-C ring on the filter assembly fitting, then pull on
4. Remove the Gas Solenoid per subsection 7.05-E the hose to release it. (Numbers 2 and 3 in the
following illustration).
5. Disconnect J2 & J3 connectors from Main PCB.
6. Disconnect Output Inductor wire from terminal
Choke1 on the Main PCB.
7. Disconnect Output inductor wire from ATC con-
nector. 1
8. Remove the two screws securing the Center

Chassis to the base.
9. Loosen the two screws on the Input Power Cable
strain relief.
10. Disengage the Rear panel from the base per sec-
tion 7.04D.
11. Guide the rear panel back six (6) inches away Art # A-07989
from the base.
12. Guide the Center Chassis towards the center of
the base to disengage the bottom locking tabs
securing the Chassis to the base.
2
13. Carefully guide the Center Chassis up far enough
to lay the Chassis down towards the right side
of the unit.
14. Remove the two screws securing the Output
Inductor to the base.
15. Remove the Output Inductor, carefully guid-
3 4
ing its wires through from the right side of the 5
unit.
16. Install replacement Output Inductor by reversing
the above steps. 6mm
5. Remove the fitting from the filter element as-
sembly by inserting a 6 mm hex wrench into

CUTMASTER 25mm
the internal hex fitting and turning it counter C. Optional Single-Stage Filter Element
clock-wise (left). Numbers 4 and 5 in the previous Replacement
illustration.
These instructions apply to power supplies where the
6. Disconnect the input line from the filter element optional Single-Stage Filter has been installed.
assembly.
The Power Supply shuts down automatically when
7. Remove the filter element assembly through the the Filter Element becomes completely saturated. The
rear opening. Filter Element can be removed from its housing, dried,
NOTE and reused. Allow 24 hours for Element to dry. Refer
to Section 6, Parts List, for replacement filter element
If replacing or cleaning just the filter element refer catalog number.
to the following illustration for disassembly.
1. Remove power from power supply.
2. Shut off air supply and bleed down system before
disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Filter Housing Cover counter-clockwise
Filter Element
and remove it. The Filter Element is located
inside the Housing.
Housing
Filter
Art # A-07990 Element
(Cat. No. 9-7741)
8. Install the new or cleaned assembly by reversing
these procedures. Spring
9. Turn on the air supply and check for leaks before O-ring
reinstalling the cover. (Cat. No. 9-7743) Assembled Filter
10.. Reinstall the power supply cover Cover
Barbed
Fitting Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and

set Element aside to dry.
6. Wipe inside of housing clean, then insert the
replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.

CUTMASTER 25mm
7.08 Right Side Internal Parts
Replacement
A. Capacitor PCB (PCB2) Replacement
2. Remove the eight screws securing PCB2 to the
Main PCB.
3. Install the replacement PCB by reversing the
above steps.
B. Main PCB (PCB1) Replacement

2. Remove the two large gas hoses per subsection
7.05-C
3. Remove the Gas Solenoid per subsection 5.05E
4. Remove Capacitor PCB per subsection 7.08 A.
5. Disconnect the wires and connectors from the
PCB, noting the location and orientation of each
wire and connector.
6. Remove the four (4) mounting screws securing
the PCB to the center chassis.
7. Carefully guide the PCB assembly up and out of
the unit.
8. Install the replacement PCB by reversing the
above steps.
C. Main Contactor (W1) Replacement

2. Remove all wires from W1, noting the location
and orientation of each wire
3. Loosen the two (2) Torx head screws securing the
Main Contactor to the base.
4. Slide the contactor towards the rear of the unit
slightly to allow the contactor to clear the mount-
ing screws.
5. Lift Main Contactor up and out of the unit.
6. Install the replacement Contactor by reversing
the above steps.
7 Reinstall the power supply cover.

CUTMASTER 25mm

CUTMASTER 25MM
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION: ACTION: ACTION: ACTION:
ON / OFF switch to ON RUN / Rapid Auto Restart /
Close external RUN / SET / LATCH
disconnect switch. Rapid Auto Restart /
RESULT: switch to RUN
RESULT: SET / LATCH switch
AC indicator ON. to SET (for most applications)
Power to system. or to
GAS indicator ON Rapid Auto Restart
when input RESULT:
pressure is adequate (for gouging, trimming,
for power supply operation. Gas flows to set or expanded metal
pressure. applications)
Power circuit ready.
or to
LATCH
is used for specific applications

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

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

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

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

Pilot arc off.
ACTION:
Release Torch switch.
RESULT: ACTION:
ACTION:
Main arc stops. Unplug input
Gas flow stops after post - flow. ON / OFF switch power cord or
to OFF open external
(Fans will continue to run for disconnect.
10 minutes after the Torch switch RESULT:
[START] is removed) RESULT:
All indicators off. No power to system.
Power supply fans shut off.
Art #A-08793
Manual 0-5081 A-1 APPENDIX

CUTMASTER 25MM
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 3Ø I 1eff Maximum Effective
1
1Ø 1Ø
1 3Ø
Supply Current
Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)
NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288
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.
APPENDIX A-2 Manual 0-5081

CUTMASTER 25MM
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
ATC Male Connector ATC Female Receptacle
Negative / Front View Front View Negative /
Plasma Plasma
4 - Green / 8 - Open 8 - Ground

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

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701
B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector MACHINE TORCH ATC Female Receptacle
Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP
5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot
Art # A-08576
C. Automation (Machine) Torch Pin - Out Diagram

ATC Male Connector - ATC Female Receptacle -
Front View Front View
Negative / Plasma Negative / Plasma
4 - Not Used
8 - Open
4- Open 8 - Open
7 - Green / 7 - Torch 3 - Not Used

8 4
3 - Open 4 8 - Torch Solenoid
Solenoid 7 3
3 7 6 2
2 6 2 - PIP Circuit
6 - Open 6 - Open 5 1
2 - Orange / 1 5
PIP
5 - White / 5 - Torch 1 - PIP Circuit
1 - Black / - Torch Solenoid
PIP Solenoid Pilot
Pilot
Art # A-07114

CUTMASTER 25MM
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
Torch: SL60 / SL100 Hand Torch

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

Torch: Mechanized SL100 Machine Torch
Leads: Leads with ATC Connector and
Remote Pendant Connector To Remote Control
Power Supply: with ATC Female Receptacle
Remote
Male ATC Female
Pendant
ATC Leads Receptacle
Connector
Connector
Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
White 5 5
6 6
Not Black 4 4 To Power Supply
Used
White 3 3 Circuitry
Green 8 8
Green 7 7
Negative / Plasma Lead Negative / Plasma
Pilot Lead
Pilot
Art # A-08577

CUTMASTER 25MM
C. Automation Torch Connection Diagram
Automated CutMaster Power Supply with ATC Torch Receptacle,
Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector
ATC Male ATC Female
Torch Leads Connector Torch Receptacle
Torch Head Torch Leads Power Supply

Socket
Pin No.s No.s
PIP Black 1 1 Main PC Board
Switch Orange 2 2 Main PC Board
White 5 5 Main PC Board
4 4
Not Connected
3 3
Green 7 7 Main PC Board
6 6 Not Connected
Solenoid 8 8
Negative / Plasma Lead
Pilot Lead
Art # A-07115

CUTMASTER 25MM
APPENDIX 5: SYSTEM SCHEMATIC, 380/400/415V UNITS

CUTMASTER 25MM

CUTMASTER 25MM
APPENDIX 6: Publication History
Cover Date Rev. Change(s)
Jan 9, 2009 AA Manual released.

May 29, 2009 AB Updated 400V/600V schematic in appendix per ECOB1399

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Fax: 86-21-69171139 Fax: 905-827-9797
Corporate Headquarters
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Suite 300
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Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com

Cutmaster 25 Service Manual

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25mm

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

Original Publication Date: January 9, 2009

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 SYSTEM: INSTALLATION ....................................................................................3-1

SECTION 3 TORCH: INSTALLATION .................................................................................... 3T-1

SECTION 4 SYSTEM: OPERATION.........................................................................................4-1

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

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

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

SECTION 7: REPLACEMENT PROCEDURES .......................................................................7-1

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

APPENDIX 3: TORCH PIN - OUT DIAGRAMS....................................................................... A-3

APPENDIX 4: TORCH CONNECTION DIAGRAMS................................................................ A-4

APPENDIX 5: SYSTEM SCHEMATIC, 380/400/415V UNITS................................................. A-6

APPENDIX 6: Publication History............................................................................................ A-8

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

Fire AND EXPLOSION

Manual 0-5081  GENERAL INFORMATION

GENERAL INFORMATION  Manual 0-5081

Manual 0-5081  GENERAL INFORMATION

GENERAL INFORMATION  Manual 0-5081

Manual 0-5081  GENERAL INFORMATION

National Standard and Technical Specifications

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

Manufacturers responsible representative: Steve Ward

GENERAL INFORMATION  Manual 0-5081

LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads

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

Manual 0-5081  GENERAL INFORMATION

This Page Intentionally Blank

GENERAL INFORMATION  Manual 0-5081

Manual 0-5081 2-1 INTRODUCTION

Power Supply Dimensions & Weight Ventilation Clearance Requirements

INTRODUCTION 2-2 Manual 0-5081

Manual 0-5081 2-3 INTRODUCTION

Torch Leads Receptacle

Gas Inlet Port

INTRODUCTION 2-4 Manual 0-5081

Warranty. 1.17" (29 mm)

Where Purchased:________________

Purchase Date:___________________

Power Supply Serial #:____________

Manual 0-5081 GENERAL INFORMATION

GENERAL INFORMATION Manual 0-5081

Manual 0-5081 GENERAL INFORMATION

GENERAL INFORMATION Manual 0-5081

Manual 0-5081 GENERAL INFORMATION

GENERAL INFORMATION Manual 0-5081

Manual 0-5081 GENERAL INFORMATION

GENERAL INFORMATION Manual 0-5081