52

CUTMASTER ™

PLASMA CUTTING SYSTEM

Art # A-08623_AC

Service Manual
Rev. AO Date: November 27, 2012 Manual # 0-4962
Operating Features:

460 600
v v
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 Service Manual has been designed to instruct you on the cor-
rect 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
potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators World-
wide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Victor Technologies International, 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 sup-
port, 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.
 ! WARNING
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

CutMaster™ 52
SL60 1Torch™
Service Manual Number 0-4962

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711

www.thermal-dynamics.com

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

Victor Technologies International, Inc.

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the publisher is
prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or
damage caused by any error or omission in this Manual, whether such error results from negli-
gence, accident, or any other cause.

Original Publication Date: October 7, 2007

Revision Date: November 27, 2012

Record the following information for Warranty purposes:

Where Purchased:__________________________________________________

Purchase Date:_____________________________________________________

Power Supply Serial #:_______________________________________________

Torch Serial #:_____________________________________________________

i
 TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION............................................................................ 1-1
1.01 Notes, Cautions and Warnings......................................................................... 1-1
1.02 Important Safety Precautions.......................................................................... 1-1
1.03 Publications..................................................................................................... 1-2
1.04 Note, Attention et Avertissement...................................................................... 1-3
1.05 Precautions De Securite Importantes.............................................................. 1-3
1.06 Documents De Reference................................................................................ 1-5
1.07 Declaration of Conformity................................................................................ 1-6
1.08 Statement of Warranty..................................................................................... 1-7
SECTION 2 SYSTEM:
INTRODUCTION ...................................................................................... 2-1
2.01 How To Use This Manual................................................................................. 2-1
2.02 Equipment Identification.................................................................................. 2-1
2.03 Receipt Of Equipment...................................................................................... 2-1
2.04 Power Supply Specifications........................................................................... 2-2
2.05 Input Wiring Specifications.............................................................................. 2-3
2.06 Power Supply Features.................................................................................... 2-4
SECTION 2 TORCH:
INTRODUCTION ..................................................................................... 2T-1
2T.01 Scope of Manual.............................................................................................2T-1
2T.02 General Description........................................................................................2T-1
2T.03 Specifications ................................................................................................2T-1
2T.04 Options And Accessories................................................................................2T-2
2T.05 Introduction to Plasma...................................................................................2T-2
SECTION 3 SYSTEM:
INSTALLATION ........................................................................................ 3-1
3.01 Unpacking........................................................................................................ 3-1
3.02 Lifting Options................................................................................................. 3-1
3.03 Primary Input Power Conn.............................................................................. 3-1
3.04 Gas Connections.............................................................................................. 3-3
SECTION 3 TORCH:
INSTALLATION....................................................................................... 3T-1
3T.01 Torch Connections..........................................................................................3T-1
3T.02 Setting Up Mechanical Torch..........................................................................3T-1
SECTION 4 SYSTEM:
OPERATION........................................................................................... 4-1
4.01 Front Panel Controls / Features........................................................................ 4-1
4.02 Preparations for Operation............................................................................... 4-2
 TABLE OF CONTENTS
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-13
PATENT INFORMATION.................................................................................. 4T-16

SECTION 5 SYSTEM:
SERVICE................................................................................................ 5-1
5.01 General Maintenance....................................................................................... 5-1
5.02 Maintenance Schedule..................................................................................... 5-2
5.03 Common Faults................................................................................................ 5-2
5.04 Fault Indicator.................................................................................................. 5-3
5.05 Basic Troubleshooting Guide........................................................................... 5-3
5.06 Power Supply Basic Parts Replacement.......................................................... 5-6
5.07 Circuit Fault Isolation....................................................................................... 5-8
5.08 Main Input and Internal Power Problems...................................................... 5-11
5.09 Pilot Arc Problems......................................................................................... 5-15
5.10 Main Arc and Controls Problems................................................................... 5-16
5.11 CNC Interface Problems................................................................................ 5-16
5.12 Test Procedures............................................................................................. 5-17
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
 TABLE OF CONTENTS
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
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)................................................................................... A-1

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

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

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

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS................................................ A-6

APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS...................................................... A-8

APPENDIX 7: Publication History..................................................................A-10

 cutmaster 52
SECTION 1:
GENERAL INFORMATION GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.
1.01 Notes, Cautions and Warnings
• Keep all fumes and gases from the breathing area. Keep your
Throughout this manual, notes, cautions, and warnings are used to
head out of the welding fume plume.
highlight important information. These highlights are categorized as
follows: • Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
NOTE
• The kinds of fumes and gases from the plasma arc depend on
An operation, procedure, or background informa- the kind of metal being used, coatings on the metal, and the
tion which requires additional emphasis or is help- different processes. You must be very careful when cutting
ful in efficient operation of the system. or welding any metals which may contain one or more of the
following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
CAUTION Barium Copper Selenium
Beryllium Lead Silver
A procedure which, if not properly followed, may Cadmium Manganese Vanadium
cause damage to the equipment. • Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs

! WARNING
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your
A procedure which, if not properly followed, may workplace, refer to item 1 in Subsection 1.03, Publications in
cause injury to the operator or others in the op- this manual.
erating area. • Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
WARNING
• Phosgene, a toxic gas, is generated from the vapors of chlo-
Gives information regarding possible electrical rinated solvents and cleansers. Remove all sources of these
shock injury. Warnings will be enclosed in a box vapors.
such as this. • This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
1.02 Important Safety Precautions of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)

! WARNING ELECTRIC SHOCK

OPERATION AND MAINTENANCE OF PLASMA ARC Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
EQUIPMENT CAN BE DANGEROUS AND HAZARD-
severe or fatal shock to the operator or others in the workplace.
OUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and • Never touch any parts that are electrically “live” or “hot.”
magnetic emissions that may interfere with the • Wear dry gloves and clothing. Insulate yourself from the work
proper function of cardiac pacemakers, hearing piece or other parts of the welding circuit.
aids, or other electronic health equipment. Persons • Repair or replace all worn or damaged parts.
who work near plasma arc cutting applications
• Extra care must be taken when the workplace is moist or
should consult their medical health professional
damp.
and the manufacturer of 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 all warnings, safety precautions and • Disconnect power source before performing any service or
repairs.
instructions before using the equipment. Call
1-603-298-5711 or your local distributor if you • Read and follow all the instructions in the Operating Manual.
have any questions.

Manual 0-4962 1-1 GENERAL INFORMATION

cutmaster 52

Fire AND EXPLOSION

LEAD WARNING
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
This product contains chemicals, including lead, or otherwise pro-
• Be sure there is no combustible or flammable material in the duces chemicals known to the State of California to cause birth defects
workplace. Any material that cannot be removed must be and other reproductive harm. Wash hands after handling.
protected.
• Ventilate all flammable or explosive vapors from the workplace. 1.03 Publications
• Do not cut or weld on containers that may have held combus- Refer to the following standards or their latest revisions for more
tibles. information:
• Provide a fire watch when working in an area where fire hazards 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
may exist. obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
• Hydrogen gas may be formed and trapped under aluminum
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
workpieces when they are cut underwater or while using a water obtainable from the American Welding Society, 550 N.W.
table. DO NOT cut aluminum alloys underwater or on a water LeJeune Rd, Miami, FL 33126
table unless the hydrogen gas can be eliminated or dissipated. 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
Trapped hydrogen gas that is ignited will cause an explosion. WELDING AND CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
NOISE 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
Noise can cause permanent hearing loss. Plasma arc processes can from American National Standards Institute, 1430 Broadway,
cause noise levels to exceed safe limits. You must protect your ears New York, NY 10018
from loud noise to prevent permanent loss of hearing. 5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
• To protect your hearing from loud noise, wear protective ear Institute, 1430 Broadway, New York, NY 10018
plugs and/or ear muffs. Protect others in the workplace. 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
• Noise levels should be measured to be sure the decibels (sound) TING AND WELDING PROCESSES, obtainable from American
do not exceed safe levels. National Standards Institute, 1430 Broadway, New York, NY
10018
• For information on how to test for noise, see item 1 in Subsec- 7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
tion 1.03, Publications, in this manual. ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
PLASMA ARC RAYS 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
Plasma Arc Rays can injure your eyes and burn your skin. The plasma from the National Fire Protection Association, Batterymarch
arc process produces very bright ultra violet and infra red light. These Park, Quincy, MA 02269
arc rays will damage your eyes and burn your skin if you are not 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
properly protected. from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
• To protect your eyes, always wear a welding helmet or shield. 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
Also always wear safety glasses with side shields, goggles or obtainable from the National Fire Protection Association,
other protective eye wear. Batterymarch Park, Quincy, MA 02269
• Wear welding gloves and suitable clothing to protect your skin 11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
from the arc rays and sparks.
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
• Keep helmet and safety glasses in good condition. Replace Arlington, VA 22202
lenses when cracked, chipped or dirty. 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
• Protect others in the work area from the arc rays. Use protective AND CUTTING, obtainable from the Canadian Standards As-
sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale,
booths, screens or shields.
Ontario, Canada M9W 1R3
• Use the shade of lens as suggested in the following per ANSI/ 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
ASC Z49.1: from the National Welding Supply Association, 1900 Arch
Minimum Protective Suggested Street, Philadelphia, PA 19103
Arc Current Shade No. Shade No. 14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
Less Than 300* 8 9
300 - 400* 9 12
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT
400 - 800* 10 14
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
* These values apply where the actual arc is clearly 33126
seen. Experience has shown that lighter filters may 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-
be used when the arc is hidden by the workpiece. TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-4962

 cutmaster 52
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont FUMÉE et GAZ
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit : La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.

NOTE • Eloignez toute fumée et gaz de votre zone de respiration. Gardez

votre tête hors de la plume de fumée provenant du chalumeau.
Toute opération, procédure ou renseignement général sur
lequel il importe d’insister davantage ou qui contribue à • Utilisez un appareil respiratoire à alimentation en air si l’aération
l’efficacité de fonctionnement du système. fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépen-
dent du genre de métal utilisé, des revêtements se trouvant sur le
métal et des différents procédés. Vous devez prendre soin lorsque
ATTENTION vous coupez ou soudez tout métal pouvant contenir un ou plusieurs
Toute procédure pouvant résulter l’endommagement des éléments suivants:
du matériel en cas de non-respect de la procédure en
antimoine cadmium mercure
question.
argent chrome nickel
arsenic cobalt plomb

! AVERTISSEMENT
baryum cuivre sélénium
béryllium manganèse vanadium

Toute procédure pouvant provoquer des blessures de • Lisez toujours les fiches de données sur la sécurité des matières
l’opérateur ou des autres personnes se trouvant dans (sigle américain “MSDS”); celles-ci devraient être fournies avec
la zone de travail en cas de non-respect de la procédure le matériel que vous utilisez. Les MSDS contiennent des rensei-
en question. gnements quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• 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.
Fournit l'information concernant des dommages • Utilisez un équipement spécial tel que des tables de coupe à débit
possibles de choc électrique. Des avertissements d’eau ou à courant descendant pour capter la fumée et les gaz.
seront enfermés dans une boîte de ce type.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
1.05 Precautions De Securite Importantes
• Le phosgène, un gaz toxique, est généré par la fumée provenant
des solvants et des produits de nettoyage chlorés. Eliminez toute
! AVERTISSEMENTS
source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe, produit de
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE la fumée ou des gaz pouvant contenir des éléments reconnu dans
SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉ- L’état de la Californie, qui peuvent causer des défauts de naissance
SENTER DES RISQUES ET DES DANGERS DE SANTÉ. et le cancer. (La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé CHOC ELECTRIQUE
electronique. Ceux qui travail près d’une application à Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
l’arc au jet de plasma devrait consulter leur membre pro- de plasma requiert et produit de l’énergie électrique haute tension. Cette
fessionel de médication et le manufacturier de matériel énergie électrique peut produire des chocs graves, voire mortels, pour
de santé pour déterminer s’il existe des risques de santé. l’opérateur et les autres personnes sur le lieu de travail.
Il faut communiquer aux opérateurs et au personnel • Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
TOUS les dangers possibles. Afin d’éviter les blessures gants et des vêtements secs. Isolez-vous de la pièce de travail ou
possibles, lisez, comprenez et suivez tous les avertis- des autres parties du circuit de soudage.
sements, toutes les précautions de sécurité et toutes
les consignes avant d’utiliser le matériel. Composez le
+ 603-298-5711 ou votre distributeur local si vous avez
des questions.

Manual 0-4962 1-3 INFORMATIONS GÉNÉRALES

cutmaster 52
• Réparez ou remplacez toute pièce usée ou endommagée. Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
• Prenez des soins particuliers lorsque la zone de travail est humide Moins de 300* 8 9
ou moite. 300 - 400* 9 12
400 - 800* 10 14
• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page 5, article 9.) * Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
• Débranchez l’alimentation électrique avant tout travail d’entretien moins foncés peuvent être utilisés quand l’arc est caché
ou de réparation. par moiceau de travail.
• Lisez et respectez toutes les consignes du Manuel de consignes.

BRUIT
INCENDIE ET EXPLOSION Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
Les incendies et les explosions peuvent résulter des scories chaudes,
supérieurs aux limites normalement acceptables. Vous dú4ez vous
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma
protéger les oreilles contre les bruits forts afin d’éviter une perte
produit du métal, des étincelles, des scories chaudes pouvant mettre
permanente de l’ouïe.
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables. • Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
• Soyez certain qu’aucune matière combustible ou inflammable ne
les autres personnes se trouvant sur le lieu de travail.
se trouve sur le lieu de travail. Protégez toute telle matière qu’il
est impossible de retirer de la zone de travail. • Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
• Procurez une bonne aération de toutes les fumées inflammables
ou explosives. • Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie. PLOMB AVERTISSEMENT

• Le gas hydrogène peut se former ou s’accumuler sous les pièces Ce produit contient des produits chimiques, comme le
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou plomb, ou engendre des produits chimiques, reconnus par
sur une table d’eau. NE PAS couper les alliages en aluminium sous l’état de Californie comme pouvant être à l’origine de mal-
l’eau ou sur une table d’eau à moins que le gas hydrogène peut formations fœtales ou d’autres problèmes de reproduction.
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera Il faut se laver les mains après toute manipulation.
si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• 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.
• Utilisez la nuance de lentille qui est suggèrée dans le recommen-
dation qui suivent ANSI/ASC Z49.1:

INFORMATIONS GÉNÉRALES 1-4 Manual 0-4962

 cutmaster 52
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 (American
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 Asso-
ciation, 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 SOU-
DAGE, 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

Manual 0-4962 1-5 INFORMATIONS GÉNÉRALES

cutmaster 52
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’ (European Council Directive
73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

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 in=dividual 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:

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* 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

Victor Technologies Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire ,

England PR6 7BX

GENERAL INFORMATION 1-6 Manual 0-4962

 cutmaster 52
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™ 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)
U.S. Non U.S.
CUTMASTER™ 39 4 Years 3 Years 1 Year
CUTMASTER™ 52 4 Years 3 Years 1 Year
CUTMASTER™ 82 4 Years 3 Years 1 Year
CUTMASTER™ 102 4 Years 3 Years 1 Year
CUTMASTER™ 152 4 Years 3 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o-rings, starter cartridges, gas distributors, fuses, filters.

2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon
industry standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of 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

Manual 0-4962 1-7 GENERAL INFORMATION

cutmaster 52

This Page Intentionally Blank

GENERAL INFORMATION 1-8 Manual 0-4962

 cutmaster 52
SECTION 2 SYSTEM: Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
INTRODUCTION by going to the Thermal Dynamics web site listed
below and clicking on Thermal Dynamics and then
2.01 How To Use This Manual on the Literature link:
http://www.thermal-dynamics.com
This Owner’s Manual applies to just specification
or part numbers listed on page i. 2.02 Equipment Identification
To ensure safe operation, read the entire manual, The unit’s identification number (specification
including the chapter on safety instructions and or part number), model, and serial number
warnings. usually appear on a data tag attached to the
Throughout this manual, the words WARNING, rear panel. Equipment which does not have a
CAUTION, and NOTE may appear. Pay particular data tag such as torch and cable assemblies are
attention to the information provided under these identified only by the specification or part number
headings. These special annotations are easily printed on loosely attached card or the shipping
recognized as container. Record these numbers on the bottom of
follows: page i for future reference.
NOTE
2.03 Receipt Of Equipment
An operation, procedure, or background infor-
mation which requires additional emphasis or
When you receive the equipment, check it against
is helpful in efficient operation of the system. the invoice to make sure it is complete and in-
spect the equipment for possible damage due to
shipping. If there is any damage, notify the car-
rier immediately to file a claim. Furnish complete
CAUTION
information concerning damage claims or ship-
A procedure which, if not properly followed, ping errors to the location in your area listed in the
may cause damage to the equipment. inside back cover of this manual.
Include all equipment identification numbers as
! WARNING
described above along with a full description of
the parts in error.
Move the equipment to the installation site before
A procedure which, if not properly followed,
may cause injury to the operator or others in un-crating the unit. Use care to avoid damaging
the operating area. the equipment when using bars, hammers, etc., to
un-crate the unit.

WARNING
Gives information regarding possible electrical
shock injury. Warnings will be enclosed in a
box such as this.

Additional copies of this manual may be purchased

by contacting Victor Technologies at the address
and phone number in your area listed in the inside
back cover of this manual. Include the Owner’s
Manual number and equipment identification
numbers.

Manual 0-4962 2-1 INTRODUCTION

CutMaster 52
2.04 Power Supply Specifications
CutMaster 52 Power Supply Specifications
208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz
380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (540 - 630), Three Phase, 60 Hz
Power Supply includes input cable.
Input Power Cable
Cable for 208/230V input power includes molded plug.
Output Current 20 - 60 Amps, Continuously Adjustable
Power Supply Gas
Particulates to 5 Microns
Filtering Ability
CutMaster 52 Power Supply Duty Cycle *
Duty Cycle Ratings @ 40° C (104° F)
Ambient Temperature
Operating Range 0° - 50° C
IEC IEC IEC
Rating Rating Rating
Duty Cycle 40% 60% 100%
All Units Current 60 Amps 50 Amps 30 Amps
DC Voltage 104 100 92
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.

NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifica-
tions include calculating an output voltage based upon power supply rated current. To facilitate comparison
between power supplies, all manufacturers use this output voltage to determine duty cycle.

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10.75"
273 mm

Art # A-07941

Art # A-07925_AB
16.375"
416 mm

6"
150 mm

24"
610 mm
22.5"
0.57 m
6" 6"
43 lb / 19.5 kg 150 mm 150 mm

INTRODUCTION 2-2 Manual 0-4962

 cutmaster 52
2.05 Input Wiring Specifications
CutMaster 52 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Flexible Cord
Volts Hz kVA I max I1eff Fuse (amps) (Min. AWG)
208 60 10.4 47 30 50 10
1 Phase 230 60 10.8 45 29 50 10
460 60 15.2 31 20 35 12
208 60 5.4 26 17 30 12
230 50/60 5.8 24 16 30 12
380 50/60 6.1 16 11 20 14
3 Phase
400 50/60 6.4 16 11 20 14
460 60 7.4 16 10 20 12
600 60 7.8 13 11 15 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

NOTE
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.

Manual 0-4962 2-3 INTRODUCTION

CutMaster 52
2.06 Power Supply Features
Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Art # A-07942

Work Cable
and Clamp

Port for Optional Automation

Interface Cable

Input Power Selection

Filter Assembly

Gas Inlet Port

Art # A-07981
Input Power Cord

INTRODUCTION 2-4 Manual 0-4962

 cutmaster 52
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 trigger
This manual contains descriptions, operating 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- 2. Mechanized Torch, Model
standing of the characteristics and capabilities of The standard machine torch has a positioning tube with
this equipment will assure the dependable opera- rack & pinch block assembly.
tion for which it was designed. 15.875" / 403 mm
9.285" / 236 mm
2T.02 General Description
Plasma torches are similar in design to the auto-
motive spark plug. They consist of negative and 1.375" / 35 mm 1.175" / 30 mm
positive sections separated by a center insulator. 4.95" / 126 mm
1.75" / 0.625" /
Inside the torch, the pilot arc starts in the gap 44.5 mm 16 mm Art # A-02998

between the negatively charged electrode and the

B. Torch Leads Lengths
positively charged tip. Once the pilot arc has ion-
Hand Torches are available as follows:
ized the plasma gas, the superheated column of
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. • 50 ft / 15.2 m, with ATC connectors
A single torch lead provides gas from a single Machine Torches are available as follows:
source to be used as both the plasma and second- • 5 foot / 1.5 m, with ATC connectors
ary gas. The air flow is divided inside the torch
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 C. Torch Parts
Plasma" on page 2T-2, for a more detailed Starter Cartridge, Electrode, Tip, Shield Cup
description of plasma torch operation.
D. Parts - In - Place (PIP)
Refer to the Appendix Pages for additional
specifications as related to the Power Supply Torch Head has built - in switch
used. 12 VDC circuit rating

E. Type Cooling
Combination of ambient air and gas stream through torch.

Manual 0-4962 2T-1 INTRODUCTION

CutMaster 52
F. Torch Ratings 2T.05 Introduction to Plasma
Manual Torch Ratings
Ambient 104° F A. Plasma Gas Flow
Temperature 40° C Plasma is a gas which has been heated to an extremely
Duty Cycle 100% @ 60 Amps @ 400 scfh high temperature and ionized so that it becomes electri-
cally conductive. The plasma arc cutting and gouging
Maximum Current 60 Amps processes use this plasma to transfer an electrical arc to
Voltage (Vpeak) 500V the workpiece. The metal to be cut or removed is melted
Arc Striking Voltage 7kV by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of the
Mechanized Torch Ratings
material, plasma arc gouging is used to remove metals to
Ambient 104° F a controlled depth and width.
Temperature 40° C
In a Plasma Cutting Torch a cool gas enters Zone B, where
Duty Cycle 100% @ 100 Amps @ 400 scfh
a pilot arc between the electrode and the torch tip heats and
Maximum Current 120 Amps ionizes the gas. The main cutting arc then transfers to the
Voltage (Vpeak) 500V workpiece through the column of plasma gas in Zone C.
Arc Striking Voltage 7kV

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
Supply A
Maximum Input Pressure 125 psi / 8.6 bar
+
Gas Flow (Cutting and 300 - 500 scfh
Gouging) 142 - 235 lpm
B

! WARNING Workpiece
This torch is not to be used with oxygen (O2). C A-00002

NOTE Typical Torch Head Detail

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

INTRODUCTION 2T-2 Manual 0-4962

 cutmaster 52
The plasma gas flows into the torch through the negative
lead, through the starter cartridge, around the electrode, Torch Switch Torch Trigger
and out through the tip orifice. To Control
Cable Wiring
The secondary gas flows down around the outside of the PIP Switch Shield Cup
torch starter cartridge, and out between the tip and shield A-02997
cup around the plasma arc.
Parts - In - Place Circuit Diagram for Hand Torch
C. Pilot Arc
Remote Pendant
When the torch is started a pilot arc is established between
the electrode and cutting tip. This pilot arc creates a path
for the main arc to transfer to the work.

D. Main Cutting Arc

To ATC PIP Switch Shield Cup
DC power is also used for the main cutting arc. The nega-
tive output is connected to the torch electrode through
the torch lead. The positive output is connected to the
workpiece via the work cable and to the torch through a
pilot wire. CNC Start

E. Parts - In - Place (PIP)

The torch includes a 'Parts - In - Place' (PIP) circuit. When
the shield cup is properly installed, it closes a switch. The
torch will not operate if this switch is open. 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 0-4962 2T-3 INTRODUCTION

CutMaster 52

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4962

 cutmaster 52
SECTION 3 SYSTEM: 3.03 Primary Input Power Conn.
INSTALLATION
CAUTION
3.01 Unpacking Check your power source for correct voltage
before plugging in or connecting the unit.
1. Use the packing lists to identify and account Check the Voltage Selector at the rear of the
for each item. unit for correct setting before plugging in
2. Inspect each item for possible shipping or connecting the unit. The primary power
damage. If damage is evident, contact your source, fuse, and any extension cords used
distributor and / or shipping company before must conform to local electrical code and the
proceeding with the installation. recommended circuit protection and wiring
3. Record Power Supply and Torch model and requirements as specified in Section 2.
serial numbers, purchase date and vendor Most units are shipped from the factory with a
name, in the information block at the front of 230Volt input power cable wired to the input con-
this manual. tactor in the single - phase configuration. The fol-
lowing illustrations and directions are for changing
3.02 Lifting Options
that configuration to a different voltage and or to
The Power Supply includes a handle for hand three - phase operation or back again if a change
lifting only. Be sure unit is lifted and transported had already been made.
safely and securely. Single-Phase (1ø) and Jumper Settings

! WARNING L1 L1 Jumper L1 -L4

L2 L2
Do not touch live electrical parts. Jumper

Art # A-07984_AB
L3 L2-L3
L3
Disconnect input power cord before moving L4
L4
unit. GND
FALLING EQUIPMENT can cause serious per-
sonal injury and can damage equipment. Single Phase Input Power Wiring
HANDLE is not for mechanical lifting.
Three-Phase (3ø) and Jumper Settings
Store copper jumper in spare parts box

• Only persons of adequate physical strength L1 L1 Jumper L1 -L4

should lift the unit. L2 L2

Art # A-07983_AB
• Lift unit by the handles, using two hands. Do L3
L3
L4
not use straps for lifting. L4
GND
• Use optional cart or similar device of ad-
equate capacity to move unit.
Three Phase Input Power Wiring
• Place unit on a proper skid and secure in
place before transporting with a fork lift or NOTE
other vehicle.
There is only one jumper setting that changes
between the single and three phase settings.
To change from single phase to three phase,
the jumper connected to L2 needs to be
removed and placed on the other L3 connec-
tion so both ends of the jumper are attached
to the same electrical point. See previous
illustrations.
Manual 0-4962 3-1 INSTALLATION
CutMaster 52
A. Connections to Single Phase Input B. Connections to Three Phase Input
Power Power

WARNING WARNING
Disconnect input power from the power sup- Disconnect input power from the power sup-
ply and input cable before attempting this ply and input cable before attempting this
procedure. procedure.

These instructions are for changing the input These instructions are for changing the input
power and or cable on the 208/230, 400, 460 VAC power and or cable on the 208/230, 400, 460 VAC
Power Supply to Single - Phase input power. Power Supply to Three - Phase input power.
1. Remove the Power Supply cover per instruc- 1. Remove the Power Supply cover per instruc-
tions found in Section 5. tions found in Section 5.
2. Disconnect the original input power cable 2. Disconnect the original input power cable
from the main input contactor and the chas- from the main input contactor and the chas-
sis ground connection. sis ground connection.
3. Loosen the through - hole protector on the 3. Loosen the through - hole protector on the
back panel of the power supply. Pull the origi- back panel of the power supply. Pull the origi-
nal power cable out of the power supply. nal power cable out of the power supply.
4. If the power cable being used is not the fac- 4. Using a customer supplied four - conductor
tory - supplied cable, use a three - conductor input power cable for the voltage desired,
input power cable for the voltage desired and strip back the insulation on the individual
strip back the insulation on the individual wires.
wires. 5. Pass the cable being used through the ac-
5. Pass the cable being used through the ac- cess opening in the back panel of the power
cess opening in the back panel of the power supply. Refer to Section 2 for power cable
supply. Refer to Section 2 for power cable specifications.
specifications.

CAUTION
CAUTION
The primary power source and power cable
The primary power source and power cable must conform to local electrical code and the
must conform to local electrical code and the recommended circuit protection and wiring
recommended circuit protection and wiring requirements (refer to table in Section 2).
requirements (refer to table in Section 2). 6. Connect the wires as follows.
6. Connect the wires as follows. • Set Jumper wires on the contactor. See
• Set Jumper wires on the contactor. See illustration.
previous illustrations. • Green / Yellow wire to Ground.
• Green / Yellow wire to Ground. • Remaining wires to L1, L2 and L3 input.
• Remaining wires to L1 and L2 input. It It does not matter what order these
does not matter what order these wires wires are attached. See the previous il-
are attached. lustrations.
7. With a little slack in the wires, tighten the
7. With a little slack in the wires, tighten the
through - hole protector to secure the power
through - hole protector to secure the power
cable.
cable.
8. Reinstall the Power Supply cover per instruc-
8. Reinstall the Power Supply cover per instruc-
tions found in Section 5.
tions found in Section 5.
9. Connect the opposite end of individual wires to a
9. Connect the opposite end of individual wires to a
customer supplied plug or main disconnect.
customer supplied plug or main disconnect.
10. Connect the input power cable (or close the
10. Connect the input power cable (or close the
main disconnect switch) to supply power.
main disconnect switch) to supply power.

INSTALLATION 3-2 Manual 0-4962

 cutmaster 52
3.04 Gas Connections Regulator/Filter
Assembly
Connecting Gas Supply to Unit
The connection is the same for compressed air
or high pressure cylinders. Refer to the following Inlet Port
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 ex-
ample.
NOTE Art # A-07944

For a secure seal, apply thread sealant to the

fitting threads, according to manufacturer's
instructions. Do not use Teflon tape as a Hose Clamp
thread sealer, as small particles of the tape 1/4 NPT to 1/4"
Gas Supply
may break off and block the small air passages Hose (6mm) Fitting
in the torch.
Regulator/Filter Optional Single - Stage Filter Installation
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

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 illustra-
tion shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the
fitting threads, according to the maker's in-
structions. 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:

Manual 0-4962 3-3 INSTALLATION

 CutMaster 52
Installing Optional Two - Stage Air Filter Using High Pressure Air Cylinders
Kit When using high pressure air cylinders as the air
This optional two - stage air line filter is also supply:
for use on compressed air shop systems. Filter 1. Refer to the manufacturer’s specifications for
removes moisture and contaminants to at least 5 installation and maintenance procedures for
microns. high pressure regulators.
Connect the air supply as follows: 2. Examine the cylinder valves to be sure
1. Attach the Two Stage Filter bracket to the they are clean and free of oil, grease or any
back of the power supply per instructions foreign material. Briefly open each cylinder
supplied with the filter assembly. valve to blow out any dust which may be
present.
NOTE 3. The cylinder must be equipped with an
For a secure seal, apply thread sealant to the adjustable high - pressure regulator capable
fitting threads according to manufacturer's of outlet pressures up to 100 psi (6.9 bar)
instructions. Do Not use Teflon tape as a maximum and flows of at least 300 scfh
thread sealer as small particles of the tape may (141.5 lpm).
break off and block the small air passages in 4. Connect supply hose to the cylinder.
the torch.
NOTE
2. Connect the two stage filter outlet hose to the
inlet port of the Regulator / Filter Assembly. Pressure should be set at 100 psi (6.9 bar) at
3. Use customer - supplied fittings to connect the high pressure cylinder regulator.
the air line to the Filter. A 1/4 NPT to 1/4" Supply hose must be at least 1/4 inch (6 mm)
hose barbed fitting is shown as an example. I.D.
Regulator/Filter For a secure seal, apply thread sealant to the
Assembly fitting threads, according to manufacturer's
2-Stage Filter
Inlet Port (IN) instructions. Do Not use Teflon tape as a
Regulator
Input thread sealer, as small particles of the tape
Outlet Port
may break off and block the small air passages
(OUT)
in the torch.
Two Stage
Filter
Hose Clamp Assembly
Gas Supply
Hose

1/4 NPT to 1/4”

(6mm) Fitting

Art # A-07945_AC

Optional Two - Stage Filter Installation

INSTALLATION 3-4 Manual 0-4962

 cutmaster 52
SECTION 3 TORCH: Check Air Quality
To test the quality of air:
INSTALLATION 1. Put the ON / OFF switch in the ON
(up) position.
3T.01 Torch Connections 2. Put the Function Control switch in the SET
If necessary, connect the torch to the Power Sup- position.
ply. Connect only the Thermal Dynamics model 3. Place a welding filter lens in front of the
SL60 / Manual or SL100 / Mechanical Torch to this torch and turn ON the air. Do not start an
power supply. Maximum torch leads length is 100 arc!
feet / 30.5 m, including extensions. Any oil or moisture in the air will be visible on
the lens.
WARNING 3T.02 Setting Up Mechanical Torch
Disconnect primary power at the source before
connecting the torch. NOTE
When converting a hand torch or a machine
1. Align the ATC male connector (on the torch
torch system to operate an Automation 100SLV
lead) with the female receptacle. Push the torch, one of the CNC interface options will be
male connector into the female receptacle. required.
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 before
use the locking nut to pull the connection 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 0-4962 3T-1 INSTALLATION

CutMaster 52

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 Parts Selection for Manual and
Mechanized Torch Cutting" on page 4T-9 for
details.

INSTALLATION 3T-2 Manual 0-4962

 cutmaster 52
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 MIN MIN

1. Output Current Control !

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 standoff cutting.

2. Function Control Art# A-07886

Function Control Knob; Used to select between the differ- 5 6 7 8 9 10
ent 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 unit cool before
RUN Used for general cutting operations continuing operation.

RAPID AUTO RESTART Allows for faster re-

starting of the Pilot Arc for uninterrupted cutting. 7. Gas Indicator
Indicator is ON when minimum input gas pressure for
LATCH Used for longer hand held cuts. power supply operation is present. Minimum pressure for
Once a cutting arc is established, the torch switch can be power supply operation is not sufficient for torch operation.
released. The cutting arc will remain ON until the torch
is lifted away from the work piece, the torch leaves the 8. DC Indicator
edge of the work piece the torch switch is activated again Indicator is ON when DC output circuit is active.
or if one of the system interlocks is activated.
9. ! Fault Error Indicator
3. ON/OFF Power Switch
Indicator is ON when Fault circuit is active. See Section 5
ON / OFF Switch controls input power to the power for explanations of fault lights.
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"

90 6.3
mode to adjust the air/gas pressure. Pull the knob 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 operation. 70 4.8

Blinking light indicates unit is in protective interlock mode.
65 4.5
Shut unit OFF, shut OFF or disconnect input power, correct
the fault, and restart the unit. Refer to Section 5 for details. MIN MIN

The Indicators will illuminate ac-

cording to the pressure set by the Pressure Control Knob
(number 4).

Manual 0-4962 4-1 OPERATION

CutMaster 52
4.02 Preparations for Operation Power ON
Place the Power Supply ON/OFF switch to the ON (up)
At the start of each operating session:
position. AC indicator turns ON. Gas indicator
turns ON if there is sufficient gas pressure for power supply
WARNING operation and the cooling fans turn ON.
Disconnect primary power at the source before
assembling or disassembling power supply, NOTE
torch parts, or torch and leads assemblies. Minimum pressure for power supply operation
is lower than minimum for torch operation.
The cooling fans will turn ON as soon as the
Torch Parts Selection unit is turned ON. After the unit is idle for ten
Check the torch for proper assembly and appropriate torch (10) minutes the fans will turn OFF. The fans
parts. The torch parts must correspond with the type of will come back ON as soon as the torch switch
operation, and with the amperage output of this Power (Start Signal) is activated or if the unit is turned
Supply (60 amps maximum). Refer to subsection "4T.07 OFF, then turned ON again. If an over tempera-
Parts Selection for Manual and Mechanized Torch Cutting" ture condition occurs, the fans will continue to
and following for torch parts selection.
run while the condition exists and for a ten (10)
minute period once the condition is cleared.
Torch Connection
Check that the torch is properly connected. Only Thermal Set Operating Pressure
Dynamics model SL60 / Manual or SL100 / Mechanical 1. Place the Power Supply Function Control
Torches may be connected to this Power Supply. See Sec-
tion 3T of this manual. knob to the SET position. Gas will flow.
2. For Standoff cutting, adjust gas pressure
Check Primary Input Power Source
from 70 - 85 psi / 4.8 - 5.9 bar (LED's in
1. Check the power source for proper input
center of control panel). Refer to the Stand-
voltage. Make sure the input power source
off chart for pressure setting details.
meets the power requirements for the unit
per Section 2, Specifications. 1 2
2. Connect the input power cable (or close the
main disconnect switch) to supply power to
the system.
Air Source MIN
A MAX
PSI BAR
MAX MAX

Ensure source meets requirements (refer to Section 2). +

Check connections and turn air supply ON.

Connect Work Cable MIN MIN

Clamp the work cable to the workpiece or cutting table.

The area must be free from oil, paint and rust. Connect !

only to the main part of the workpiece; do not connect to

the part to be cut off.

Art# A-07946

Art # A-04509

OPERATION 4-2 Manual 0-4962

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

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 opera-
tions 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 workpiece 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 trim-
ming operations when an uninterrupted restart is desired).
And with the knob in the LATCH position the main cutting
arc will be maintained after the torch switch is released.

Manual 0-4962 4-3 OPERATION

CutMaster 52

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4962

 cutmaster 52
SECTION 4 TORCH: 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.
Start Cartridge
Type of operation:
Drag cutting, standoff cutting or gouging
Torch parts: Tip

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

Shield Cup
NOTE
A-03510_AB
Refer to subsection "4T.07 Parts Selection for
Manual and Mechanized Torch Cutting" and Torch Parts (Drag Shield Cap & Shield Cup Body Shown)
following for additional information on torch
parts. 3. Install the replacement Electrode by push-
Change the torch parts for a different operation as ing it straight into the torch head until it
follows: clicks.
4. Install the starter cartridge and desired tip
for the operation into the torch head.
WARNING 5. Hand tighten the shield cup assembly until
Disconnect primary power at the source before it is seated on the torch head. If resistance
assembling or disassembling torch parts, or is felt when installing the cup, check the
torch and leads assemblies. threads before proceeding.

NOTE
The shield cup holds the tip and starter car-
tridge 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.
2. Remove the Electrode by pulling it straight

Manual 0-4962 4T-1 OPERATION

CutMaster 52
4T.02 Cut Quality Bottom Dross Buildup
Molten material which is not blown out of the cut area
NOTE and resolidifies on the plate. Excessive dross may require
secondary cleanup operations after cutting.
Cut quality depends heavily on setup and
parameters such as torch standoff, alignment Kerf Width
with the workpiece, cutting speed, gas pres-
The width of the cut (or the width of material removed
sures, and operator ability. during the cut).
Cut quality requirements differ depending on ap-
plication. For instance, nitride build - up and bevel Top Spatter (Dross)
angle may be major factors when the surface will Top spatter or dross on the top of the cut caused by slow
be welded after cutting. Dross - free cutting is im- travel speed, excess cutting height, or cutting tip whose
orifice has become elongated.
portant when finish cut quality is desired to avoid
a secondary cleaning operation. The following cut
4T.03 General Cutting Information
quality characteristics are illustrated in the follow-
ing figure:

Kerf Width
! WARNING
Cut Surface Disconnect primary power at the source before
Bevel Angle
disassembling the power supply, torch, or
Top torch leads.
Spatter
Frequently review the Important Safety Pre-
cautions at the front of this manual. Be sure
Top Edge the operator is equipped with proper gloves,
Rounding
clothing, eye and ear protection. Make sure no
part of the operator’s body comes into contact
Dross with the workpiece while the torch is activated.
Build-Up
Cut Surface A-00007
Drag Lines
Cut Quality Characteristics CAUTION
Sparks from the cutting process can cause
Cut Surface damage to coated, painted, and other surfaces
The desired or specified condition (smooth or rough) of such as glass, plastic and metal.
the face of the cut.
NOTE
Nitride Build - Up Handle torch leads with care and protect them
Nitride deposits can be left on the surface of the cut when from damage.
nitrogen is present in the plasma gas stream. These build-
ups may create difficulties if the material is to be welded Piloting
after the cutting process. Piloting is harder on parts life than actual cutting because
the pilot arc is directed from the electrode to the tip rather
Bevel Angle than to a workpiece. Whenever possible, avoid excessive
The angle between the surface of the cut edge and a plane pilot arc time to improve parts life.
perpendicular to the surface of the plate. A perfectly per-
pendicular cut would result in a 0° bevel angle. Torch Standoff
Improper standoff (the distance between the torch tip and
Top - Edge Rounding workpiece) can adversely affect tip life as well as shield cup
Rounding on the top edge of a cut due to wearing from the life. Standoff may also significantly affect the bevel angle.
initial contact of the plasma arc on the workpiece. Reducing standoff will generally result in a more square cut.

OPERATION 4T-2 Manual 0-4962

 cutmaster 52
Edge Starting 4T.04 Hand Torch Operation
For edge starts, hold the torch perpendicular to the work-
piece with the front of the tip near (not touching) the edge Standoff Cutting With Hand Torch
of the workpiece at the point where the cut is to start.
When starting at the edge of the plate, do not pause at the NOTE
edge and force the arc to "reach" for the edge of the metal. For best performance and parts life, always
Establish the cutting arc as quickly as possible. use the correct parts for the type of operation.
Direction of Cut 1. The torch can be comfortably held in one
In the torches, the plasma gas stream swirls as it leaves hand or steadied with two hands. Position
the torch to maintain a smooth column of gas. This swirl the hand to press the Trigger on the torch
effect results in one side of a cut being more square than handle. With the hand torch, the hand
the other. Viewed along the direction of travel, the right may be positioned close to the torch head
side of the cut is more square than the left.
for maximum control or near the back end
Left Side
Cut Angle for maximum heat protection. Choose the
Right Side
Cut Angle holding technique that feels most comfort-
able and allows good control and move-
ment.
NOTE
The tip should never come in contact with the
workpiece except during drag cutting opera-
A-00512
tions.
Side Characteristics Of Cut
2. Depending on the cutting operation, do one
of the following:
To make a square - edged cut along an inside diameter of a
circle, the torch should move counterclockwise around the a. For edge starts, hold the torch perpen-
circle. To keep the square edge along an outside diameter dicular to the workpiece with the front of
cut, the torch should travel in a clockwise direction. the tip on the edge of the workpiece at
the point where the cut is to start.
Dross b. For standoff cutting, hold the torch 1/8
When dross is present on carbon steel, it is commonly - 3/8 in (3-9 mm) from the workpiece as
referred to as either “high speed, slow speed, or top dross”.
Dross present on top of the plate is normally caused by
shown below.
too great a torch to plate distance. "Top dross" is normally
very easy to remove and can often be wiped off with a
welding glove. "Slow speed dross" is normally present on
the bottom edge of the plate. It can vary from a light to
heavy bead, but does not adhere tightly to the cut edge,
and can be easily scraped off. "High speed dross" usually
forms a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a troublesome
steel, it is sometimes useful to reduce the cutting speed
to produce "slow speed dross". Any resultant cleanup can
be accomplished by scraping, not grinding.

Manual 0-4962 4T-3 OPERATION

CutMaster 52
Torch Trigger

1
2

Trigger Release

Shield Cup Standoff Distance

1/8" - 3/8" (3 - 9mm)
3

4
A-00024_AB

Art # A-03383
Standoff Distance
6. Cut as usual. Simply release the trigger as-
3. Hold the torch away from your body. sembly to stop cutting.
4. Slide the trigger release toward the back 7. Follow normal recommended cutting
of the torch handle while simultaneously practices as provided in the power supply
squeezing the trigger. The pilot arc will operator's manual.
start. NOTE
When the shield cup is properly installed, there
is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as
part of normal operation. Do not attempt to
Trigger
force the shield cup to close this gap. Forcing
the shield cup against the torch head or torch
Trigger Release handle can damage components.
A-02986 8. For a consistent standoff height from the
5. Bring the torch within transfer distance to workpiece, install the standoff guide by slid-
the work. The main arc will transfer to the ing it onto the torch shield cup. Install the
work, and the pilot arc will shut OFF. guide with the legs at the sides of the shield
cup body to maintain good visibility of the
NOTE
cutting arc. During operation, position the
The gas preflow and postflow are a character- legs of the standoff guide against the work-
istic of the power supply and not a function piece.
of the torch.

Shield Cup
Standoff Guide
Torch Tip
Workpiece Art # A-04034

OPERATION 4T-4 Manual 0-4962

 cutmaster 52
Shield Cup With Straight Edge squeezing the trigger. The pilot arc will
The drag shield cup can be used with a non conductive start.
straight edge to make straight cuts by hand.

WARNING
Trigger
The straight edge must be non - conductive.

Trigger Release
A-02986

7. Bring the torch within transfer distance to

Non-Conductive the work. The main arc will transfer to the
Straight Edge
Cutting Guide
work, and the pilot arc will shut OFF.
NOTE
The gas preflow and postflow are a character-
A-03539 istic of the power supply and not a function
of the torch.
Using Drag Shield Cup With Straight Edge
Trigger

The crown shield cup functions best when cutting 3/16

inch (4.7 mm) solid metal with relatively smooth surface.
1
2
Drag Cutting With a Hand Torch
Drag cutting works best on metal 1/4" (6 mm) thick or less. Trigger Release

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

8. Cut as usual. Simply release the trigger as-
may be positioned close to the torch head
sembly to stop cutting.
for maximum control or near the back end
9. Follow normal recommended cutting
for 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-
ment. NOTE
4. Keep the torch in contact with the workpiece When the shield cup is properly installed, there
during the cutting cycle. is a slight gap between the shield cup and the
5. Hold the torch away from your body. torch handle. Gas vents through this gap as
6. Slide the trigger release toward the back part of normal operation. Do not attempt to
of the torch handle while simultaneously force the shield cup to close this gap. Forcing
the shield cup against the torch head or torch
handle can damage components.

Manual 0-4962 4T-5 OPERATION

CutMaster 52
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 NOTE
handle. With the hand torch, the hand
may be positioned close to the torch head The gas preflow and postflow are a character-
istic of the power supply and not a function
for maximum control or near the back end
of the torch.
for maximum heat protection. Choose the
technique that feels most comfortable and When the shield cup is properly installed, there
allows good control and movement. is a slight gap between the shield cup and the
torch handle. Gas vents through this gap as
NOTE part of normal operation. Do not attempt to
The tip should never come in contact with the force the shield cup to close this gap. Forcing
workpiece except during drag cutting opera- the shield cup against the torch head or torch
tions. handle can damage components.
2. Angle the torch slightly to direct blowback 7. Clean spatter and scale from the shield cup
particles away from the torch tip (and op- and the tip as soon as possible. Spraying
erator) rather than directly back into it until the shield cup in anti - spatter compound
the pierce is complete. will minimize the amount of scale which
3. In a portion of the unwanted metal start the adheres to it.
pierce off the cutting line and then continue Cutting speed depends on material, thickness,
the cut onto the line. Hold the torch perpen- and the operator’s ability to accurately follow the
dicular to the workpiece after the pierce is desired cut line. The following factors may have
complete. an impact on system performance:
4. Hold the torch away from your body. • Torch parts wear
5. Slide the trigger release toward the back • Air quality
of the torch handle while simultaneously
squeezing the trigger. The pilot arc will • Line voltage fluctuations
start. • Torch standoff height
• Proper work cable connection

Trigger

Trigger Release
A-02986

OPERATION 4T-6 Manual 0-4962

 cutmaster 52
4T.05 Gouging Lead Angle
The angle between the torch and workpiece depends on

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

CAUTION
Standoff Height
Sparks from plasma gouging can cause dam-
age to coated, painted or other surfaces such
Workpiece
as glass, plastic, and metal.
A-00941_AB
Check torch parts. The torch parts must cor-
Gouging Angle and Standoff Distance
respond with the type of operation. Refer to
subsection "4T.07 Parts Selection for Manual
and Mechanized Torch Cutting". Standoff Distance
The tip to work distance affects gouge quality and depth.
Gouging Parameters Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for
Gouging performance depends on parameters such as smooth, consistent metal removal. Smaller standoff dis-
torch travel speed, current level, lead angle (the angle be- tances may result in a severance cut rather than a gouge.
tween the torch and workpiece), and the distance between Standoff distances greater than 1/4 inch (6 mm) may result
the torch tip and workpiece (standoff). in minimal metal removal or loss of transferred main arc.

Slag Buildup
Slag generated by gouging on materials such as carbon and
CAUTION stainless steels, nickels, and alloyed steels, can be removed
Touching the torch tip or shield cup to the easily in most cases. Slag does not obstruct the gouging
work surface will cause excessive parts wear. process if it accumulates to the side of the gouge path.
However, slag build - up can cause inconsistencies and
Torch Travel Speed irregular metal removal if large amounts of material build
up in front of the arc. The build - up is most often a result
NOTE of improper travel speed, lead angle, or standoff height.
Refer to Appendix Pages for additional infor-
mation as related to the Power Supply used.
Optimum torch travel speed is dependent on current set-
ting, 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.

Manual 0-4962 4T-7 OPERATION

CutMaster 52
4T.06 Mechanized Torch Operation a rough cut will be produced as the arc moves from side
to side in search of metal for transfer.
Cutting With Mechanized Torch Travel speed also affects the bevel angle of a cut. When
The mechanized torch can be activated by remote control cutting in a circle or around a corner, slowing down the
pendant or by a remote interface device such as CNC. travel speed will result in a squarer cut. The power source
output should be reduced also. Refer to the appropriate
1. To start a cut at the plate edge, position the Control Module Operating Manual for any Corner Slow-
center of the torch along the edge of the down adjustments that may be required.
plate.
Piercing With Machine Torch
Travel Speed
To pierce with a machine torch, the arc should be started
Proper travel speed is indicated by the trail of the arc which with the torch positioned as high as possible above the
is seen below the plate. The arc can be one of the following: plate while allowing the arc to transfer and pierce. This
1. Straight Arc standoff helps avoid having molten metal blow back onto
the front end of the torch.
A straight arc is perpendicular to the workpiece surface.
This arc is generally recommended for the best cut us- When operating with a cutting machine, a pierce or dwell
ing air plasma on stainless or aluminum. time is required. Torch travel should not be enabled until
the arc penetrates the bottom of the plate. As motion be-
2. Leading Arc
gins, torch standoff should be reduced to the recommended
The leading arc is directed in the same direction as 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and
torch travel. A five degree leading arc is generally cut quality. Clean spatter and scale from the shield cup
recommended for air plasma on mild steel. and the tip as soon as possible. Spraying or dipping the
3. Trailing Arc shield cup in anti - spatter compound will minimize the
amount of scale which adheres to it.
The trailing arc is directed in the opposite direction as
torch travel.

Dir
ect
ion
of T
orc
hT
rav Standoff Distance
el

Straight Arc

Trailing Arc

A-02586

Leading Arc

Mechanized Torch Operation

For optimum smooth surface quality, the travel speed

should be adjusted so that only the leading edge of the arc
column produces the cut. If the travel speed is too slow,

OPERATION 4T-8 Manual 0-4962

 cutmaster 52
4T.07 Parts Selection for Manual and Mechanized Torch Cutting
Tips: Shield
DRAG TIP Cup Body, Shield Cap, Deflector
CUTTING 9-8237 9-8243

20A 9-8205
30A 9-8206 Shield Cup
40A 9-8207 9-8218
60A 9-8252
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
40A 9-8244
CUTTING Shield
40A Cup Body,
Shield Cap, Deflector
CUTTING Tip:
9-8237
9-8243

40A 9-8208 Standoff Guide

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

DRAG SHIELD O-Ring No. 8-3488

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243

70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING

40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
CutMaster 152 uses 120A and less
Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

Manual 0-4962 4T-9 OPERATION

CutMaster 52
4T.08 Recommended Cutting Speeds for Mechanized Torch With Exposed
Tip
Type Torch: SL60 With Exposed Tip Type Material: Mild Steel
Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch
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
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 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

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
0.032 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

OPERATION 4T-10 Manual 0-4962

 cutmaster 52
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
0.060 1.5 9-8210 110 60 290 7.37 0.19 4.8 75 5.2 90 245 0.00 0.19 4.8
0.075 1.9 9-8210 120 60 285 7.24 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.120 3.0 9-8210 120 60 180 4.57 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.135 3.4 9-8210 119 60 170 4.32 0.19 4.8 75 5.2 90 245 0.10 0.19 4.8
0.188 4.8 9-8210 121 60 100 2.54 0.19 4.8 75 5.2 90 245 0.20 0.19 4.8
0.250 6.4 9-8210 119 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.19 4.8
0.375 9.5 9-8210 124 60 50 1.27 0.19 4.8 75 5.2 90 245 0.50 0.19 4.8
0.500 12.7 9-8210 126 60 26 0.66 0.19 4.8 75 5.2 90 245 0.75 0.19 4.8
0.625 15.9 9-8210 127 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 134 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 140 60 6 0.15 0.19 4.8 75 5.2 90 245 NR NR NR

Type Torch: SL60 With Exposed Tip Type Material: Stainless Steel
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
0.06 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

Manual 0-4962 4T-11 OPERATION

CutMaster 52
Type Torch: SL60 With Exposed Tip Type Material: Aluminum
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
0.060 1.5 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.00 0.25 6.4
0.075 1.9 9-8210 110 60 440 11.18 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.120 3.0 9-8210 116 60 250 6.35 0.25 6.4 75 5.2 90 245 0.10 0.25 6.4
0.188 3.4 9-8210 116 60 170 4.32 0.25 6.4 75 5.2 90 245 0.20 0.25 6.4
0.250 6.4 9-8210 132 60 85 2.16 0.25 6.4 75 5.2 90 245 0.30 0.25 6.4
0.375 9.5 9-8210 140 60 45 1.14 0.25 6.4 75 5.2 90 245 0.50 0.25 6.4
0.500 12.7 9-8210 143 60 30 0.76 0.25 6.4 75 5.2 90 245 0.80 0.25 6.4
0.625 15.9 9-8210 145 60 20 0.51 0.25 6.4 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 18 0.46 0.25 6.4 75 5.2 90 245 NR NR NR

NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
subsection "4.02 Preparations for Operation".
** Total flow rate includes plasma and secondary gas flow.

OPERATION 4T-12 Manual 0-4962

 cutmaster 52
4T.09 Recommended Cutting Speeds for Mechanized Torch With Shielded
Tip
Type Torch: SL60 With Shielded 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 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
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 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

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
0.032 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

Manual 0-4962 4T-13 OPERATION

CutMaster 52
Type Torch: SL60 With Shielded 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
0.060 1.5 9-8210 124 60 250 6.35 0.19 4.8 75 5.2 90 245 0.00 0.2 5.1
0.075 1.9 9-8210 126 60 237 6.02 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.120 3.0 9-8210 126 60 230 5.84 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.135 3.4 9-8210 128 60 142 3.61 0.19 4.8 75 5.2 90 245 0.10 0.2 5.1
0.188 4.8 9-8210 128 60 125 3.18 0.19 4.8 75 5.2 90 245 0.20 0.2 5.1
0.250 6.4 9-8210 123 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.2 5.1
0.375 9.5 9-8210 132 60 34 0.86 0.19 4.8 75 5.2 90 245 0.50 0.2 5.1
0.500 12.7 9-8210 137 60 23 0.58 0.19 4.8 75 5.2 90 245 0.75 0.2 5.1
0.625 15.9 9-8210 139 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 145 60 14 0.36 0.19 4.8 75 5.2 90 245 NR NR NR
1.000 25.4 9-8210 156 60 4 0.10 0.19 4.8 75 5.2 90 245 NR NR NR

Type Torch: SL60 With Shielded Tip Type Material: Stainless Steel
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
0.06 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

OPERATION 4T-14 Manual 0-4962

 cutmaster 52
Type Torch: SL60 With Shielded Tip Type Material: Aluminum
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
0.060 1.5 9-8210 105 60 350 8.89 0.13 3.2 75 5.2 90 245 0.00 0.20 5.1
0.075 1.9 9-8210 110 60 350 8.89 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.120 3.0 9-8210 110 60 275 6.99 0.13 3.2 75 5.2 90 245 0.10 0.20 5.1
0.188 3.4 9-8210 122 60 140 3.56 0.13 3.2 75 5.2 90 245 0.20 0.20 5.1
0.250 6.4 9-8210 134 60 80 2.03 0.19 4.8 75 5.2 90 245 0.30 0.20 5.1
0.375 9.5 9-8210 140 60 45 1.14 0.19 4.8 75 5.2 90 245 0.50 0.20 5.1
0.500 12.7 9-8210 144 60 26 0.66 0.19 4.8 75 5.2 90 245 0.80 0.20 5.1
0.625 15.9 9-8210 145 60 19 0.48 0.19 4.8 75 5.2 90 245 NR NR NR
0.750 19.1 9-8210 150 60 15 0.38 0.19 4.8 75 5.2 90 245 NR NR NR

NOTE
* Gas pressure shown is for torches with leads up to 25’ / 7.6 m long. For 50’ / 15.2 m leads, refer to
subsection 4.02 "Operating Pressure".
** Total flow rate includes plasma and secondary gas flow.

Manual 0-4962 4T-15 OPERATION

CutMaster 52
PATENT INFORMATION
Plasma Cutting Torch Patents
The following parts are covered under U.S. and Foreign Patents as follows:
Catalog # Description Patent(s)
9-8215 Electrode US Pat No(s) 6163008; 6987238
Other Pat(s) Pending
9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;
6703581; D496842; D511280; D492709; D499620;
D504142 Other Pat(s) Pending
9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461
Other Pat(s) Pending
9-8241 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8243 Shield Cap US Pat No(s) 6914211; D493183
Other Pat(s) Pending
9-8235 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8236 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending
9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633
Other Pat(s) Pending
9-8238 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8239 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending
9-8244 Shield Cap US Pat No(s) 6914211; D505309
Other Pat(s) Pending

OPERATION 4T-16 Manual 0-4962

 cutmaster 52
Catalog # Description Patent(s)
9-8245 Shield Cap US Pat No(s) 6914211; D496951
Other Pat(s) Pending

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

Manual 0-4962 4T-17 OPERATION

CutMaster 52

This Page Intentionally Blank

OPERATION 4T-18 Manual 0-4962

 cutmaster 52
SECTION 5 SYSTEM:
SERVICE
5.01 General Maintenance
Maintain more often
Warning! if used under severe
Disconnect input power before maintaining. conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the

cables and leads.
Visually inspect the torch body tip, Replace as needed
electrode, start cartridge and shield cup

3 Months

Replace all
Clean
broken parts
exterior
of power supply

6 Months

Visually check and

Carefully clean the
interior

Art # A-07938_AB

Manual 0-4962 5-1 SERVICE

CutMaster 52
5.02 Maintenance Schedule 5.03 Common Faults
NOTE Problem - Symptom Common Cause
Insufficient 1. Cutting speed too fast.
The actual frequency of maintenance may
Penetration 2. Torch tilted too much.
need to be adjusted according to the operating 3. Metal too thick.
environment. 4. Worn torch parts
Daily Operational Checks or Every Six Cutting Hours: 5. Cutting current too low.
6. Non - Genuine Thermal Dynamics
1. Check torch consumable parts, replace if damaged, parts used
worn or when cut performance has diminished. 7. Incorrect gas pressure
2. Check plasma and secondary supply and pressure. Main Arc 1. Cutting speed too slow.
Extinguishes 2. Torch standoff too high from
3. Purge plasma gas line to remove any moisture build-up. workpiece.
3. Cutting current too high.
Weekly or Every 30 Cutting Hours:
4. Work cable disconnected.
1. Check fan for proper operation and adequate air flow. 5. Worn torch parts.
6. Non - Genuine Thermal Dynamics
2. Inspect torch for any cracks or exposed wires, replace parts used
if necessary.
Excessive Dross 1. Cutting speed too slow.
3. Inspect input power cable for damage or exposed wires,
Formation 2. Torch standoff too high from
replace if necessary.
workpiece.
Six Months or Every 720 Cutting Hours: 3. Worn torch parts.
4. Improper cutting current.
1. Check the in-line air filter(s), clean or replace as re- 5. Non - Genuine Thermal Dynamics
quired. parts used
6. Incorrect gas pressure
2. Check cables and hoses for leaks or cracks, replace if
necessary. Short Torch Parts Life1. Oil or moisture in air source.
2. Exceeding system capability
3. Check all contactor points for severe arcing or pits, (material too thick).
replace if necessary. 3. Excessive pilot arc time
4. Vacuum dust and dirt out of the entire machine. 4. Gas pressure too low.
5. Improperly assembled torch.
6. Non - Genuine Thermal Dynamics
parts used
CAUTION
Difficult Starting 1. Worn torch parts.
Do not blow air into the power supply during 2. Non - Genuine Thermal Dynamics
cleaning. Blowing air into the unit can cause parts used.
metal particles to interfere with sensitive 3. Incorrect gas pressure.
electrical components and cause damage to
the unit.

SERVICE 5-2 Manual 0-4962

 cutmaster 52
5.04 Fault Indicator INPUT POWER: Indicates primary line voltage is outside
the operating limits of the power supply as selected by
At initial power up, two lights will temporarily illuminate for 2-3 the setting of INPUT VOLTAGE SELECTION SWITCH at
seconds to show the version of software used. the rear of the unit. Low is 208/230 VAC and high is
460 VAC.
To determine the first digit, count the function indicators left
to right, 1 through 5. To determine the second digit count the LO
pressure indicators, reading from bottom to top, 0 through 7.

HI
In the example below the Temp indicator and 75 psi indicators S
are ON indicating the version would be 2.3.
Art # A-08316

PART IN PLACE: Indicates that the shield cup is not properly

7 installed or tightened.
6
5 MIN
A
MAX
PSI BAR START ERROR: Indicates that the START SIGNAL was ac-
tive (ie. Torch Trigger depressed, hand held pendant
MAX MAX

+
4
3 switch ON or CNC signal for torch ON) during one of
2 three conditions:
1 MIN MIN

1) During initial power up when ON/OFF switch is

0
! turned to ON position
2) When fault which had been disabling the system is
cleared.
3) When the FUNCTION CONTROL SWITCH Mode is
Art# A-07988 moved from SET position to any of the other three
1 2 3 4 5
(3) modes of operation.
When the ! "Fault" indicator is ON or blinking it will CONSUMABLES MISSING: Indicates that the electrode, start
be accompanied by one of the pressure indicator lights cartridge or tip is missing or excessively worn.
depending on what the Fault is. Only one of these faults
SHORTED TORCH: Indicates the torch or lead has a shorted
will be displayed at one time. If more than one fault exists,
condition between positive and negative leads.
when the first fault is corrected and cleared, the next fault
will then be displayed. It is possible to have a fault indicated INTERNAL ERROR: Indicates a microprocessor error.
in the function indicators and another fault indicated in the
pressure indicators. The following table shows each of the OVER PRESSURE: Indicates that operating pressure is set
Faults possible. too high. The Error Indicator will not flash when the
pressure is above 95 PSI. This LED will remain ON
Pressure Fault and the system will operate but pilot starting and cut
Indicator performance may be affected.
Max Over Pressure NOTE
90 Internal Error The cooling fans will turn ON as soon as the
85 Shorted Torch unit is turned ON. After the unit is idle for ten
80 Consumables Missing (10) minutes the fans will turn OFF. The fans
will come back ON as soon as the torch switch
75 Start Error
(Start Signal) is activated or if the unit is turned
70 Parts in Place OFF, then turned ON again. If an over tempera-
65 Input Power ture condition occurs, the fans will continue to
Min Under Pressure run while the condition exists and for a ten (10)
minute period once the condition is cleared.
NOTE
Fault explanations are covered in the follow- 5.05 Basic Troubleshooting Guide
ing tables.
Explanation of Faults
" UNDER PRESSURE: Indicates that operating pressure is set
! WARNING
too low and power supply output power will be disabled. There are extremely dangerous voltage and
power levels present inside this unit. Do not
Manual 0-4962 5-3 SERVICE
CutMaster 52
attempt to diagnose or repair unless you have had training in power electronics measurement and trouble-
shooting techniques.

Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position.
is ON but the A/C OFF position.
Indicator does not 2. Primary fuses / breakers are 2. a) Have qualified person check primary fuses / breakers.
light blown or tripped. b) Connect unit to known good primary power receptacle.
3. Faulty components in unit. 3. Return to authorized service center for repair or replacement.

FAULT indicator 1. INPUT VOLTAGE SELECTION 1. Turn OFF power to unit then set INPUT VOLTAGE SELECTION
flashing, 65 PSI SWITCH set for incorrect voltage. SWITCH to match primary input voltage.
indicator flashing 2. Primary input voltage problem. 2. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.04 Power Supply
Specifications" on page 2-2.
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 Power
indicator ON. unit is obstructed. Supply Specifications" on page 2-2
FAULT indicator 2. Duty cycle of the unit has been 2. Allow unit to cool.
flashing. exceeded
3. Failed components in unit 3. Return to authorized service center for repair or replacement.
GAS 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. Preparations for Operation" on page 4-2.
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.
4. Failed components in unit. 4. Return to authorized service center for repair or replacement.
FAULT and 75 PSI 1. Start signal is active when ON/ 1. Start can be active for one of the following:
indicators flashing. OFF SWITCH is turned to ON • Hand torch switch held closed
position. • Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Problem in the torch and leads 2. Replace torch and leads or return to authorized service center
switch circuit. for repair or replacement.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.

SERVICE 5-4 Manual 0-4962

 cutmaster 52
Problem - Symptom Possible Cause Recommended Action
FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten.
indicators flashing. 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install
Gas flow is cycling cartridge missing. missing parts.
ON and OFF. 3. Torch start cartridge is stuck. 3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Open conductor in torch leads. 4. Replace torch and leads or return to authorized service
center for repair or replacement.

5. Problem in the torch and leads 5. Replace torch and leads or return to authorized service
switch circuit. center for repair or replacement.
6. Failed components in unit. 6. Return to authorized service center for repair or
replacement.

Nothing happens 1. Problem in the torch and leads 1. Take Torch and Leads (Remote Pendant) to Authorized
when torch switch switch circuit (Remote pendant Repair Facility.
or remote switch switch circuit).
is closed (Or CNC 2. CNC 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 and 85 PSI 1. Upper O-Ring on torch head is in 1. Remove shield cup from torch; check upper O-Ring
indicators flashing. wrong position. position; correct if necessary.
2. Torch starter cartridge is stuck. 2. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
3. Worn or faulty torch parts. 3. Inspect torch consumable parts. Replace if necessary.
4. Shorted Torch. 4. Replace torch and leads or return to an authorized service
center for repair.
5. Temporary Short indicated by 5 5. Release torch switch and reactivate.
blinks per second.
6. Power Supply Failure (Standard 6. Return to authorized service center for repair or
rate of blinking) replacement.

No Fault lights ON, no 1. Failed components in unit. 1. Return to an authorized service center for repair.
arc in torch.
FAULT and 85 PSI 1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that
indicators flashing does not clear the fault, return to an authorized service center
for repair.
Pilot arc is ON but 1. Work cable not connected to 1. Connect work cable.
cutting arc will not work piece.
establish 2. Work cable/connector broken. 2. Replace work cable.
3. Failed components in unit. 3. Return to an authorized service center for repair.

Torch cutting is 1. Incorrect current setting. 1. Check and adjust to proper setting.
diminished 2. Worn torch consumables. 2. Check torch consumables and replace as needed.
3. Poor work cable connection to 3. Check the connection of the Work Lead to the work piece.
work piece.
4. Torch being moved too fast. 4. Reduce cutting speed.
5. Excessive oil or water in torch. 5. Refer to "Check air quality" in Section 3 Torch.
6. Failed components in unit. 6. Return to an authorized service center for repair.

Manual 0-4962 5-5 SERVICE

CutMaster 52
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 the
Disconnect primary power to the system be- gas supply and bleed down the system.
fore disassembling the torch, leads, or power
2. Remove the system cover. See "A. Cover Removal" in
supply.
this section.
This section describes procedures for basic parts replacement. 3. Locate the internal air line and the fitting from the filter
For more detailed parts replacement procedures, refer to the assembly. Number 1 in the following illustration.
Power Supply Service Manual.
4. Hold a wrench or similar tool against the locking ring
A. Cover Removal on the filter assembly fitting, then pull on the hose to
release it. (Numbers 2 and 3 in the following illustra-
1. Remove the upper and lower screws which secure the
tion).
cover to the main assembly. Do not loosen the lower
screws inside the cut out slots in the bottom of the
cover.

Upper
Screws 1

Lower
Screws

Slots

Lower
Screws
Art # A-07989

Art # A-07947

3 4
2. Carefully pull the Cover up and away from the unit. 5

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

SERVICE 5-6 Manual 0-4962

 cutmaster 52
7. Remove the filter element assembly through the rear
opening.
Housing
NOTE
If replacing or cleaning just the filter element
refer to the following illustration for disas-
Filter
sembly. Element
(Cat. No. 9-7741)

Spring

O-ring
(Cat. No. 9-7743) Assembled Filter
Filter Element 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.

Art # A-07990
6. Wipe inside of housing clean, then insert the replace-
ment Filter Element open side first.
8. Install the new or cleaned assembly by reversing these
procedures. 7. Replace Housing on Cover.

9. Turn ON the air supply and check for leaks before rein- 8. Reattach gas supply.
stalling the cover.
NOTE
Optional Single-Stage Filter Element Replacement
If unit leaks between housing and cover,
These instructions apply to power supplies where the optional inspect the O-Ring for cuts or other damage.
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.
4. Turn the Filter Housing Cover counter-clockwise and
remove it. The Filter Element is located inside the
Housing.

Manual 0-4962 5-7 SERVICE

CutMaster 52
Optional Two-Stage Filter Element Replacement 5.07 Circuit Fault Isolation
The Two-Stage Air Filter has two Filter Elements. When the Filter
Elements become dirty the Power Supply will continue to oper-
ate but cut quality may become unacceptable. Refer to Section WARNING
6, Parts List, for replacement filter element catalog number.
The following procedures should not be at-
1. Shut OFF primary input power.
tempted by anyone who has not had proper
2. Shut OFF air supply and bleed down system. training or authorized to do so.

A. Cover Removal
WARNING 1. Remove the upper and lower screws which secure the
Always turn OFF the air supply and bleed the cover to the main assembly. Do not loosen the lower
screws inside the cut out slots in the bottom of the
system before disassembling the Filter As-
cover.
sembly as injury could result.
NOTE
3. Loosen the two bolts on the top of the Filter Assembly
The upper screws and lower screws are not the
enough to allow the Filter Elements to move freely.
same. Do not mix them. The upper screws are
4. Note the location and orientation of the old Filter Ele- for threading into the plastic of the front and
ments. rear panels. DO NOT use the finer threaded
5. Slide out the old Filter Elements. lower screws for this.

Upper
Screws

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 Filter

Assembly, with the same orientation as noted in Step Art # A-07947

4 above.
2. Carefully pull the Cover up and away from the unit.
7. Hand tighten the two bolts evenly, then torque each bolt
to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may B. Cover Installation
damage the gasket.
1. Reverse previous procedures for cover installation.
8. Slowly apply air pressure to the assembly, checking for NOTE
leaks.
When installing the upper screws, attempt to
NOTE reuse the original threads. The easiest way
A small amount of air leakage from the bottom to do this is by turning the screw counter-
fitting is normal. clockwise until you feel the threads line up,
then begin to turn the screw clockwise to
This completes the parts replacement procedures.
tighten to 15-18 in. lbs. Do not over tighten.

SERVICE 5-8 Manual 0-4962

 cutmaster 52
C. Pre Power Up Tests 2. Turn the ON/OFF SWITCH (SW1) to ON position and
observe the following:
Prior to applying primary line power to the unit, perform
the following checks to prevent component failure or blow- • Software version is displayed. (See Section "5.04
ing primary fuses. The troubleshooting guide will assume Fault Indicator" on page 5-3)
these tests were done and no failure was found or that any
After approximately three (3) seconds
failures found were corrected.
• Inrush relay on PCB 1 energizes, starting pre-
1. Main Contactor (W1) Check – Section 5.11-A.
charging of working capacitors.
2. Input Diode Module Test – Section 5.11-B.
• W1 energizes
3. Input Capacitor PCB Test –Section 5.11-C.
• AC and GAS Indicators come ON
4. IGBT Modules Test – Section 5.11-D.
• Gas flows
5. Output Diode Module Test – Section 5.11-E.
• Fans turn ON
6. Pilot IGBT Test – Section 5.11-F.
3. Adjust the pressure regulator to set the gas pressure
If all of the Pre Power-Up Tests are OK, proceed with the as specified in charts.
trouble shooting guide.
STANDOFF
CutMaster 52 Gas Pressure Settings
Leads SL60 SL100
CAUTION Length (Hand Torch) (Mechanized Torch)
Due to the close proximity of the Main PCB Up to 25' 75 psi 70 psi
to the Capacitor PCB, It is recommended to (7.6 m) 5.2 bar 4.8 bar
use an insulated meter probe when making
Each additional Add 5 psi Add 5 psi
measurements on the J2 connector on the 25' (7.6 m) 0.4 bar 0.4 bar
Main PCB. Do not short between the pins. Do
not short to the Capacitor PCB connections.
DRAG
D. Initial Set up Conditions CutMaster 52 Gas Pressure Settings
This section is to help isolate the defective circuit before Leads SL60 SL100
troubleshooting, identify symptoms, and test the unit for Length (Hand Torch) (Mechanized Torch)
proper operation. Follow the instructions as given to identify
Up to 25' 80 psi 75 psi
the possible symptom(s) and the defective circuit. After
(7.6 m) 5.5 bar 5.2 bar
repairs are complete, run the following tests again to verify
that the unit is fully operational. Each additional Add 5 psi Add 5 psi
25'(7.6 m) 0.4 bar 0.4 bar
1. Connect gas supply to rear of Power Supply.
2. Turn ON gas supply and set operating pressure per
4. Turn FUNCTION CONTROL SWITCH to RUN position
pressure setting label on power supply.
• Solenoid turns OFF, gas stops flowing (pressure
3. Set the Power Supply controls as follows:
display may increase slightly when gas is not flow-
• ON/OFF SWITCH to OFF position ing)
• Turn FUNCTION CONTROL SWITCH to SET position This completes the Main Input and Internal Power Test. If the
above are all correct then proceed to the next section "F. Pilot
• CURRENT CONTROL POTENTIOMETER to MAXI- Arc Test". If the unit does not function as stated above, then
MUM position, fully clockwise. note the symptom and proceed to Section "5.07, Main Input
E. Main Input and Internal Power Test and Internal Power Problems".

1. Connect Primary Line power to the unit. F. Pilot Arc Test

1. Activate or depress the torch switch (Activate START
signal) to establish a pilot arc and note the following
• Gas solenoid opens
• Gas flows

Manual 0-4962 5-9 SERVICE

CutMaster 52
• After two seconds the gas solenoid closes and gas • Gas solenoid closes
stops flowing momentarily, then gas solenoid re-
opens and gas resumes flowing • Gas flow stops

• DC LED comes ON 6. Set the FUNCTION CONTROL SWITCH to RAPID AUTO

RESTART mode.
• Pilot arc is established
7. Close torch switch (Pendant switch or activate CNC
2. Open the torch switch (Remote Pendant switch or Start) to establish a pilot arc. Bring torch to within 1/8”
remove CNC start signal) – 3/8” (3 - 9.5 mm) of the work piece to establish main
cutting arc.
• Gas continues to flow
8. While cutting keep the torch switch closed and bring
• DC LED goes OFF
the torch OFF the edge of the material.
After 20 second post flow time
• Pilot Arc re-ignites immediately
• Gas solenoid closes
9. Open the torch switch
• Gas flow stops
• DC LED turns OFF
This completes the Pilot Arc Test. If the above are all correct
After 20 second post flow time
then proceed to the next Section "G, Main Arc and Controls
Test". If the unit does not function as stated above, then note • Gas solenoid closes
the symptom and proceed to Section "5.08, Pilot Arc Problems".
• Gas flow stops
G. Main Arc and Controls Test 10. Set the FUNCTION CONTROL SWITCH to LATCH mode
Connect work Cable to the work piece, Close torch switch 11. Start a cut, and release the torch switch
(Pendant switch or activate CNC Start) to establish a pilot
arc. Bring torch to within 1/8” – 3/8” (3 - 9.5 mm) of the • Main cutting arc will remain ON until the torch is
work piece to establish main cutting arc. lifted away from the plate approximately ¾” (19
mm) or until the torch is brought OFF the edge of
• Main Cutting Arc Establishes the metal.
• On Main PCB D59 turns OFF and D78 turns ON Once the arc has extinguished
1. Clamp DC ammeter around the work cable. Output will • DC LED turns OFF
be 60 amps.
After 20 second post flow time
2. While cutting, adjust the CURRENT CONTROL POTEN-
TIOMETER from maximum setting to minimum setting. • Gas solenoid closes

• Current adjusts from 60 amps down to 20 amps • Gas flow stops

3. Set the CURRENT CONTROL POTENTIOMETER to This completes the Main Arc and Controls Test. If the above
maximum position. are all correct then proceed to the next Section "H CNC Inter-
face Test." If the unit does not function as stated above, then
• Current adjusts from 20 amps up to 60 amps note the symptom and proceed to Section "5.09, Main Arc and
4. While cutting keep the torch switch closed, bring the Controls Problems".
torch OFF the edge of the material.
H. CNC INTERFACE TEST
• Cutting arc extinguishes
If the unit has one of the two factory supplied options for
• Gas solenoid closes CNC interface installed, proceed with this section, otherwise
the tests are complete.
• Gas flow stops momentarily then restarts when
solenoid opens 1. Connect an ohmmeter between J2-12 to J2-14 (START
signal). Position the torch to pilot. Check the OK-TO-
• Pilot arc ignites
MOVE signal by connecting a jumper between J2-3 and
5. Open the torch switch J2-4 (START signal).

• DC LED turns OFF • Pilot arc is established

2. Bring the torch to the work piece and transfer to cutting
After 20 second post flow time
arc.

SERVICE 5-10 Manual 0-4962

 cutmaster 52
• OK-TO-MOVE signal is present. (Meter shows Single-Phase (1ø) and Jumper Settings
continuity)
3. Remove jumper from J2.
L1 L1 Jumper L1 -L4
• Arc shuts OFF
L2 L2
• OK-TO-MOVE signal OFF (Meter shows no continu- Jumper

Art # A-07984_AB
ity) L3 L2-L3
L3
L4
• Gas continues to flow L4
• DC LED goes OFF GND
After 20 second Post flow time
Single Phase Input Power Wiring
• Gas solenoid closes
• Gas flow stops Three-Phase (3ø) and Jumper Settings
If the unit has the Basic CNC Interface harness the test is Store copper jumper in spare parts box
complete. If the unit does not function as stated above,
then note the symptom and proceed to Section "5.10 CNC L1 L1 Jumper L1 -L4
Interface Problems". If the unit has the Automation Interface L2 L2
PCB installed, continue with this section.

Art # A-07983_AB
L3
L3
4. There are three (3) ARC VOLTs signals available from L4
the J2 connector. L4
GND
a) J2-9 (+) to J2-7 (-)
b) J2-5 (+) to J2-6 (-) (Auto Interface PCB J3 con- Three Phase Input Power Wiring
nector with jumper installed between pins 1 and 2) 3. W1 contactor points are stuck closed
= ARC VOLTS divided by 50
c) J2-5 (+) to J2-6 (-) (Auto Interface PCB J3 con- a) Check per Section 5.11-A.
nector with jumper installed between pins 2 and 3) 4. Primary plug not wired correctly.
= ARC VOLTS divided by 16
a) Check manufacturer's plug installation instructions.
Measure the voltage between these points while piloting
(Open Circuit Voltage) and while cutting. The voltages 5. Primary input cable is defective.
should approximately as listed below
a) Check cable for shorts.
Open Circuit Voltage Cutting Voltage
B. Primary line fuses blow immediately after ON/
a) 300 VDC 100 VDC OFF SWITCH (SW1) is turned to ON position.
b) 6 VDC 2 VDC
1. Shorted Input Diode Module
c) 19 VDC 6 VDC
This completes the CNC Interface Test. If the above are all a) Check per Section 5.11-B.
correct then the unit is functioning correctly. If the unit does 2. Shorted Input Capacitor PCB
not function as stated, then note the symptom and proceed to
Section "5.10, CNC Interface Problems". a) Check per Section 5.11-C.

C. Gas flows with ON/OFF SWITCH in OFF position

5.08 Main Input and Internal Power
Problems 1. Foreign debris has lodged in gas solenoid.
a) Replace gas solenoid. This is a problem caused by
A. Primary input line fuse blows as soon as primary improperly filtered air supply. Customer needs to
disconnect is closed. add filtration to air supply prior to unit inlet.
1. Primary input cable installed incorrectly.
a) Check wiring of primary power cable to the contac-
tor. See illustration below.
2. W1 jumpers installed incorrectly
a) Check jumper installation for correct phase being
used.

Manual 0-4962 5-11 SERVICE

CutMaster 52
D. All front panel indicators are OFF, fans do not 4. Defective Main PCB
run. Main Contactor W1 does not close.
a) Measure voltage on Main PCB between test point
1. Primary power not connected. GND1 to J2-22. 460 VAC input = approx 3 VDC 230
VAC input = approx 1.5 VDC
a) Check that cable is connected to primary power.
b) With all power removed from the unit, disconnect
2. Primary line fuse/breaker is blown/tripped. the ribbon cable from J2 connector on Main PCB.
a) Replace fuse or reset breaker. Check continuity between J2-34 to test point GND
1. With SW2 in LOW position continuity should be
3. Defective ON/OFF SWITCH present, with SW2 in the HIGH position. It should
a) Check continuity read open.

4. Defective Main PCB If not correct, replace Main PCB assembly

a) Measure Main PCB power supply voltages at the 5. Defective Logic assembly
following test points a) Replace Logic PCB
GND1 to +12V = 12VDC
F. PARTS-IN-PLACE (PIP) FAULT. The FAULT
GND1 to +48V = 48 VDC Indicator and 70 PSI LED is flashing.

Replace Main PCB if not correct 1. Shield Cup loose

5. Defective Ribbon Cable a) Hand tighten the shield cup to close the PIP switch

a) Check continuity 2. Torch not properly connected to power supply

6. Defective Logic a) Insure torch ATC is securely fastened to unit.

a) Replace Logic PCB 3. Problem with torch and leads PIP circuit

E. INPUT POWER FAULT. a) Check continuity of torch PIP circuit at ATC pins 1
& 2.
AC LED ON, FAULT Indicator and 65 PSI LED is flashing.
1. INPUT VOLTAGE SELECTOR SWITCH (SW2) set for
incorrect voltage
a) Set SW2 to correspond to the primary line voltage.
Turn SW1 to OFF position then back to ON position
to clear the error.
2. Defective SW2
a) Check continuity
3. Primary line voltage out of tolerance range.
a) Connect unit to voltage with unit specifications. See
Section "2.04 Power Supply Specifications" on
page 2-2. If using a generator, connect unit to a
wall receptacle to see if problem is corrected.

SERVICE 5-12 Manual 0-4962

 cutmaster 52
Negative / Plasma Lead electrode. Check the lower end unit of the start
cartridge for free movement. Replace the cartridge
if the lower end unit does not move freely.
Spring-Loaded Spring-Loaded
4 Torch Switch
Lower End Fitting Lower End Fitting at Reset /
3 Torch Switch Full Compression Full Extension
2 PIP
1 PIP

Art # A-08124
Pilot Lead

4. Defective Logic PCB Art # A-08064_AC

a) Measure the voltage on Main PCB between J2-17 4. Open conductor in torch leads
to test point GND1 for 12VDC. If the voltage is less
a) Check continuity
than 2VDC, replace Logic PCB
5. Defective Main PCB
5. Defective Main PCB
b) Measure voltage at Main PCB between J2-2 to test
a) Replace Main PCB
point GND1 for 12VDC. If voltage is present, replace
G. TRIGGER LOCKED DURING POWER UP FAULT. Main PCB
The FAULT Indicator and 75 PSI LED is flashing. 6. Defective Logic PCB
1. Start signal is active when SW1 is turned to ON position. a) Replace Logic PCB
a) Start can be active for one of the following:
I. AC LED ON, yellow TEMP LED is ON, red FAULT
• Hand torch switch held closed Indicator is flashing.
• Hand pendant switch held closed 1. Air flow through unit is restricted
• CNC START signal is active low
a) Provide adequate airflow. See Ventilation Clearance
Release the START signal source
Requirements in Section "2.04 Power Supply
2. Problem in the torch and leads switch circuit Specifications" on page 2-2.
a) Check continuity of torch switch circuit at ATC pins 2. Exceeded duty cycle of the power supply.
3 & 4. See previous illustration.
a) Allow unit to remain ON, but at idle, with fan run-
3. Short in CNC cable ning to cool power supply. See "2.04 Power
a) Check continuity Supply Specifications" on page 2-2 for duty cycle
information.
4. Defective Logic PCB (PCB 3)
3. Fan(s) not turning
a) Measure voltage at Main PCB between J2-16 to test
point GND1 for 12VDC. If voltage is present, replace
Logic PCB
5. Defective Main PCB
a) Replace Main PCB.

H. TIP MISSING FAULT. The FAULT Indicator and

80 PSI LED is flashing. Gas solenoid cycles ON
and OFF.
1. Torch Shield Cup is loose.
a) Tighten shield cup by hand. Do not over tighten.
2. Torch tip, electrode, or starter cartridge missing.
a) Turn OFF power supply. Replace missing part(s).
3. Starter Cartridge is stuck.
a) Turn OFF power supply. Bleed down the system.
Remove the shield cup, tip,start cartridge and

Manual 0-4962 5-13 SERVICE

CutMaster 52
a) Measure voltage at plug between J7-1 to J7-2 and 2. Defective Logic PCB
between J81 to J8-2 on Main PCB for 12VDC If a) Measure on Main PCB between J2-12 to test point
voltage is present replace fan. GND1 for 12VDC. If voltage is present, replace Main
4. Defective Main PCB PCB.
a) Measure voltage at plug between J7-1 to J7-2 and 3. Defective Main PCB
between J8-1 to J8-2 on Main PCB for 12VDC. If
a) Replace Main PCB
voltage is missing at either receptacle, replace Main
PCB. N. AC LED ON, TEMP LED OFF, GAS LED ON, Gas
5. Defective Logic PCB does not flow in SET mode using a machine torch
with remote solenoid.
a) Replace Logic PCB
Disconnect the gas solenoid SOL1 from the back of the ATC
J. AC LED ON, TEMP, GAS, DC LED's are OFF, connector.
FAULT Indicator is flashing. MIN PRESSURE If Gas DOES NOT flow out of SOL1 when the unit is in SET
LED is flashing. Gas is not flowing. mode :
1. Gas supply not connected to unit 1. Defective gas solenoid (SOL1)
a) Connect gas supply to unit a) Measure voltage on Main PCB between J5-1 to J5-3
for 12 VDC. If voltage is present, change SOL 1
2. Gas supply not turned ON
2. Defective Logic PCB
a) Turn gas supply ON
a) Measure on Main PCB between J2-12 to test point
3. Gas supply pressure too low.
GND1 for 12VDC. If voltage is present, replace Main
a) Set gas supply pressure to 95-120 psi PCB.

4. Air Pressure Control Regulator set too low. 3. Defective Main PCB

a) Adjust AIR PRESSURE CONTROL to set pressure as a) Replace Main PCB

specified in Setting Operational Pressure in Section
If gas DOES flow out of SOL1 when the unit is in SET mode,
"4.02 Preparations for Operation" on page 4-2.
reconnect SOL1 to the ATC connector.
K. INTERNAL ERROR 4. Defective torch solenoid.
FAULT Indicator and 90 PSI Indicator flashing
a) Measure the coil terminals of the torch mounted
1. There has been a microprocessor problem. gas solenoid SOL2 for 24VAC. If present, replace
SOL2.
a) Turn ON/OFF SWITCH to OFF position and then turn
to ON position to clear the error 5. Defective Main PCB

L. MAX PRESSURE ERROR a) Measure on Main PCB between J2-20 to GND1 for
less than 2VDC.
MAX Pressure LED is lit.
If voltage is 12VDC replace Main PCB
1. Gas pressure set too high b) Measure on Main PCB between J2-11 to GND1 for
less than 2VDC. If voltage is less than 2VDC replace
a) Reduce gas pressure
Main PCB
2. Defective Logic PCB 6. Defective Logic PCB
a) Measure on Main PCB between J2-11 to GND1 for
a) Replace Logic PCB
less than 2VDC. If voltage is 12VDC, replace Logic
M. AC LED ON, TEMP LED OFF, GAS LED ON, Gas PCB.
does not flow in SET mode using a hand torch
O. Cannot adjust gas pressure in the SET mode
or a machine torch without remote solenoid.
1. Inlet gas pressure is too low
1. Defective gas solenoid (SOL1)
a) Increase inlet gas pressure to 95-120 psi
a) Measure voltage on Main PCB between J5-1 to J5-3
for 12 VDC. If voltage is present, change SOL 1 2. Faulty regulator
a) Replace Regulator

SERVICE 5-14 Manual 0-4962

 cutmaster 52
5.09 Pilot Arc Problems
A. AC LED ON, TEMP LED OFF, GAS LED ON.
Nothing happens when torch switch or remote
Upper Groove
switch is closed (Or CNC START signal is active) with Vent Holes
No gas flow, DC LED OFF. Must Remain Open

1. Problem in the torch and leads switch circuit (or remote Upper O-Ring
pendant or CNC signal missing in Correct Groove

a) For hand torches, check continuity of torch switch Threads

circuit at ATC pins 3 & 4. Lower O-Ring Art # A-03725
Negative / Plasma Lead
2. Torch start cartridge is stuck.
a) Turn OFF power supply. Bleed down the system.
Remove the shield cup, tip,start cartridge and
4 Torch Switch
electrode. Check the lower end unit of the start
3 Torch Switch
cartridge for free movement. Replace the cartridge
2 PIP
if the lower end unit does not move freely.
1 PIP
Spring-Loaded Spring-Loaded
Lower End Fitting Lower End Fitting at Reset /
Full Compression Full Extension
Art # A-08124
Pilot Lead

b) For machine torches using a remote pendant, check

continuity of Pendant switch circuit
c) For CNC input see Section "5.07 C i rc u i t F a u l t
Isolation" on page 5-8 Art # A-08064_AC

3. Worn or faulty torch parts

2. Defective Logic PCB
a) Inspect torch consumables parts. Replace if neces-
a) Jumper on Main PCB between J2-16 and test point
sary.
GND1. If gas does not flow, replace Logic PCB
4. Shorted Torch
b) With Torch Switch closed, measure voltage on
Main PCB between test points GND1 to I_DMD1 for a) Disconnect torch from unit. With consumables
1.4VDC. Replace Logic PCB if voltage is not present. removed from the torch, check continuity of torch
at ATC, between negative/plasma lead connection
3. Defective Main PCB
to pilot lead connection.
a) With Torch Switch closed, measure voltage on Main Negative / Plasma Lead
PCB between test points GND1 to I_DMD1 for 1.4
VDC. Replace Main PCB if voltage is present.

B. SHORTED TORCH FAULT 4 Torch Switch

3 Torch Switch
After torch switch is closed, gas flows for two (2) seconds 2 PIP
then momentarily shuts OFF then back ON, FAULT INDICA- 1 PIP
TOR flashes, and 85 PSI LED flashes.
1. Upper O-Ring on torch head is in the wrong position. Art # A-08124
Pilot Lead
a) Remove shield cup from torch; check position of
the upper o-ring and correct if needed. C. AC LED ON, TEMP LED OFF, GAS LED ON, gas
flowing, DC LED OFF, Fault Indicators OFF, No
arc in torch
1. Defective Logic PCB
a) Measure voltage at Main PCB between test point
GND1 to J2-10.
Voltage is normally 12VDC and should drop to less than
2VDC two (2) seconds after torch switch is depressed. If
voltage does not drop replace Logic PCB

Manual 0-4962 5-15 SERVICE

CutMaster 52
b) While pilot arc is established, measure voltage on B. Main arc transfers but current cannot be adjusted
Main PCB between test points GND1 to I_DMD1 for
1.4 VDC. If voltage is low or not present, replace 1. Defective Logic PCB
Logic PCB. a) While main arc is transferred,measure voltage on
2. Defective Main PCB Main PCB between test points GND1 to I_DMD1.

a) Measure voltage at Main PCB between test point b) Adjust CURRENT CONTROL POTENTIOMETER from
GND1 to J2-10. maximum to minimum. Voltage should vary from
4VDC at max to 1 VDC at min
Voltage is normally 12VDC and should drop to less than
If voltage does not vary with CURRENT CONTROL POTEN-
2VDC two (2) seconds after torch switch is depressed. If
TIOMETER, replace Logic PCB
voltage does not drop to less than 2VDC for approximately
one (1) second then replace Main PCB 2. Defective Main PCB
D. AC LED ON, TEMP LED OFF, GAS LED ON, gas a) Replace Main PCB
flowing, DC LED ON, Fault Indicators OFF, No
arc in torch. C. In LATCH mode, when the torch switch is
released the arc shuts OFF immediately.
1. Defective Main PCB
1. Defective Logic PCB
a) Install jumper on Main PCB between test point GND1
to terminal TIP1. a) Replace Logic PCB

b) Close torch switch. If Pilot starts, replace Main PCB D. In RAPID AUTO RESTART mode, with torch switch
closed, the pilot does not start immediately when
E. AC LED ON, TEMP LED OFF, GAS LED ON, gas the cutting arc extinguishes
flowing, DC LED ON, Fault Indicators OFF, Pilot
Arc is intermittent. 1. Defective Logic PCB

1. Defective Logic PCB a) Replace Logic PCB

a) Measure for 12VDC on Main PCB between test Point E. INTERNAL ERROR FAULT INDICATOR AND 90
GND1 to J2-8. If 12VDC is present, replace Logic PSI INDICATOR FLASHING
PCB
1. There has been a microprocessor problem.
2. Defective Main PCB
a) Turn ON/OFF SWITCH to OFF position and then turn
a) Replace Main PCB to ON position to clear the error

F. INTERNAL ERROR FAULT INDICATOR AND 90 5.11 CNC Interface Problems

PSI INDICATOR FLASHING
1. There has been a microprocessor problem. A. Nothing happens when jumper is installed
between J2-3 to J2-4.
a) Turn ON/OFF SWITCH to OFF position and then turn
to ON position to clear the error 1. Defective Automation Interface PCB (PCB 4)
a) Measure voltage on PCB 4 between J1-6 to J1-8 for
5.10 Main Arc and Controls 12VDC.
Problems If 12VDC is present replace PCB 4
A. Main arc will not establish, LED D59 ON Main 2. Defective Main PCB
PCB remains ON while pilot arc is striking the
a) Measure voltage on Main PCB between J1-6 to J1-8
work piece.
for less than 2VDC.
1. Work Cable not connected.
If voltage is less than 2VDC, replace PCB 1
a) Connect cable to work piece
B. No OK-TO-MOVE signal while cutting.
2. Work cable open / broken.
1. Defective Main PCB (PCB 1)
a) Check continuity of work cable. Insure connection
of cable to clamp is secure.

SERVICE 5-16 Manual 0-4962

 cutmaster 52
a) Measure voltage on PCB 4 between J1-1 to J1-3 for B. Input Diode Module Test
12VDC while cutting.
1. Using an ohmmeter perform the tests in the chart
If 12VDC is present, replace PCB 1
Input Diode Module
2. Defective Automation Interface PCB (PCB 4) Meter (+) Meter (-) Indication
a) Measure voltage on PCB 4 between J1-1 to J1-3 for AC1 MTH 2 Forward Bias
less than 2VDC while cutting. AC2 MTH 2 Forward Bias
If voltage is less than 2VDC, replace PCB 4. AC3 MTH 2 Forward Bias
MTH 2 AC1 Reverse Bias
C. ARC VOLTS signals are low or not present MTH 2 AC2 Reverse Bias
1. Defective Automation Interface PCB (PCB 4) MTH 2 AC3 Reverse Bias
MTH 5 AC1 Forward Bias
a) Replace PCB 4
MTH 5 AC2 Forward Bias
5.12 Test Procedures MTH 5 AC3 Forward Bias
AC1 MTH 5 Reverse Bias
A. Main Contactor (W1) Test AC2 MTH 5 Reverse Bias
1. Check continuity between: AC3 MTH 5 Reverse Bias
2. If the test reveals a failed component, replace Main PCB
L1 to T1
and perform main contactor test – Section 5.11-A.
L2 to T2
L3 to T3
L4 to T4
The contacts should be open – no continuity.
CutMaster 52 & 82
Cover Screws W1 contactor wired for 1PH

Actuator Button
T1
T2 L1
Actuator Arm T3 L2
T4 L3
L4

Jumpers

Main Contactor
Input
Art # A-08157_AB
Side

2. Retest continuity between terminals while engaging the

contacts manually. This can be done by pushing down
on the recessed actuator button on the top of W1 or
pushing down on the actuator arm on the side of W1.
L1 to T1
L2 to T2
L3 to T3
L4 to T4
The contacts should be closed – Continuity
3. Visually check W1 contact points. To take the cover
OFF, remove the two cover screws shown in the previ-
ous illustration. Replace if contacts are stuck together
or show excessive arcing

Manual 0-4962 5-17 SERVICE

CutMaster 52
C. Input Capacitor PCB Test PRI 4 (D) MTH 5 Reverse Bias
1. Using an ohmmeter check continuity between the fol- MTH 6 PRI 4 (D) Reverse Bias
lowing points: MTH 5 PRI 4 (D) Forward Bias

Input Capacitors 3. If the test reveals a failed component, replace Main PCB
and perform main contactor test – Section 5.11-A. If
Meter (+) Meter (-) Indication
no problem is found, reconnect the transformer wires
MTH 2 MTH 4 Charging to Main PCB.
MTH 4 MTH 5 Open
E. Output Diode Module Test
MTH 6 MTH 5 Charging
1. Disconnect transformer wires from Main PCB terminal
Most meters will show a charging action. Initially a low SEC 1.
resistance will be shown and then the resistance will start 2. Using an ohmmeter perform the tests in the chart
to increase. If the meter probes are reversed the reading will
decrease to zero, then start charging in the opposite polarity. Output Diode Module
Meter (+) Meter (-) Indication
2. If a short is found replace Capacitor PCB assembly.
SEC 1 WORK 1 Forward Bias
3. Check continuity between the following points SEC 1 CHOKE 1 Reverse Bias
Input relays Indication WORK 1 SEC 1 Reverse Bias
MTH 2 MTH 6 Open CHOKE 1 SEC 1 Forward Bias
MTH 4 MTH 6 Open SEC 2 WORK 1 Forward Bias
MTH 4 MTH 5 Open SEC2 CHOKE 1 Reverse Bias
4. If a short is found, replace Capacitor PCB assembly WORK 1 SEC2 Reverse Bias
CHOKE 1 SEC 2 Forward Bias
D. IGBT Modules Test
3. If the test reveals a failed component, replace Main PCB.
1. Disconnect transformer wires from Main PCB terminals If no problem is found, reconnect the transformer wires
PRI 1 (A) and PRI 4 (D). to Main PCB.
2. Using an ohmmeter perform the following checks
IGBT A
Meter (+) Meter (-) Indication
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

SERVICE 5-18 Manual 0-4962

 cutmaster 52
F. Pilot IGBT Test
1. Disconnect wire from Main PCB terminal TIP1
2. Measure continuity on Main PCB between test point
GND1 to terminal TIP1
3. If the test reveals a failed component, replace Main PCB.
If no problem is found, reconnect wire to Main PCB.
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.

Manual 0-4962 5-19 SERVICE

CutMaster 52
J3*

MTH8 MTH7 MTH5 MTH6 MTH1 MTH3 MTH4 MTH2

Art # A-08841
*J3 CONNECTOR PINOUT

1 2 3

SERVICE 5-20 Manual 0-4962

 cutmaster 52
CAPACITOR PCB SIGNALS Signal Source-Destination

J1-1 Capacitor bank A+

J1-5 Capacitor bank A-
J2-1 Capacitor Bank B+
J2-5 Capacitor Bank B-
J3-1 +12 VDC M-C
J3-2 /460 Active low for 460VAC input M-C
J3-3 /230 Active low for 230VAC input M-C
MTH 1,2 Capacitor bank A+
MTH 3,4 Capacitor bank A-
MTH 6,8 Capacitor Bank B+
MTH 5,7 Capacitor Bank B-

Manual 0-4962 5-21 SERVICE

CutMaster 52
LOGIC PCB LAYOUT
PCB3

D1 TP3

TP4

TP1

TP7 J1*

TP2

D2

D3
TP6
D4

D5

D6

D7

D8

D9

TP5

D10 D12 D14

D11 D13

*J1 Pinout
1 37

Art # A-08179
4 40

SERVICE 5-22 Manual 0-4962

 cutmaster 52
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 /460V_IN Active low with 460VAC primary input voltage L-M
J1-5 /230V_IN Active low with 230VAC primary input voltage L-M
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
3VDC = 460 VAC / 1.5VDC = 230VAC
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 PCB = 1.7VDC 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
J1-35 For Factory Use M-L
J1-36 For Factory Use M-L
J1-37 For Factory Use M-L
J1-38 GND M-L
J1-39 For Factory Use M-L
J1-40 Not Used

Manual 0-4962 5-23 SERVICE

CutMaster 52
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

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)

SERVICE 5-24 Manual 0-4962

 cutmaster 52

This Page Intentionally Blank

Manual 0-4962 5-25 SERVICE

 CutMaster 52
*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

SERVICE 5-26 Manual 0-4962

 cutmaster 52
MAIN PCB SIGNALS LED INDICATORS
J1-1 L1 Primary AC Line D59 PCR Indicates Pilot IGBT gate signal is ON
D78 CSR Indicates cutting arc has been established
J1-2 Not used
J1-3 Not used
MAIN PCB TEST POINTS
J1-4 Not used
GND1 Common
J1-5 L2 Primary AC Line GND2 Common
J3-1 /230VAC GND3 Common
+12V1 +12VDC
J3-2 Common
+48V1 +48VDC
J4 For factory use I_DMD1 0-4VDC Current Demand Signal
J5-1 +12VDC
J5-2 Not used
J5-3 /SOLENOID
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
J12-1 +12VDC
J12-2 /460VAC
J12-3 /230VAC

Manual 0-4962 5-27 SERVICE

CutMaster 52

This Page Intentionally Blank

SERVICE 5-28 Manual 0-4962

 cutmaster 52
SECTION 5 TORCH:
SERVICE
Upper Groove
5T.01 General Maintenance with Vent Holes
Must Remain Open
NOTE
Upper O-Ring
Refer to previous "Section 5 System" for com- in Correct Groove
mon and fault indicator descriptions.
Threads
Cleaning Torch Lower O-Ring Art # A-03725

Even if precautions are taken to use only clean air with a Torch Head O-Ring
torch, eventually the inside of the torch becomes coated
with residue. This buildup can affect the pilot arc initiation
ATC Male Connector
and the overall cut quality of the torch.

WARNING
Disconnect primary power to the system be-
fore 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 electrical con-

Gas Fitting
tact cleaner using a cotton swab or soft wet rag. In severe
cases, the torch can be removed from the leads and cleaned
more thoroughly by pouring electrical contact cleaner into
the torch and blowing it through with compressed air.

CAUTION
Dry the torch thoroughly before reinstalling. Art #A-03791 O-Ring

O-Ring Lubrication ATC O-Ring

An o-ring on the Torch Head and ATC Male Connector NOTE

requires lubrication on a scheduled basis. This will allow DO NOT use other lubricants or grease, they
the o-rings to remain pliable and provide a proper seal. may not be designed to operate within high
The o-rings will dry out, becoming hard and cracked if the
temperatures or may contain “unknown ele-
lubricant is not used on a regular basis. This can lead to
potential performance problems.
ments” that may react with the atmosphere.
This reaction can leave contaminants inside
It is recommended to apply a very light film of o-ring lubri- the torch. Either of these conditions can lead
cant (Catalog # 8-4025) to the o-rings on a weekly basis. to inconsistent performance or poor parts life.

Manual 0-4962 5T-1 SERVICE

CutMaster 52
5T.02 Inspection and Replacement 4. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Clean or replace
of Consumable Torch Parts the tip if necessary.
Good Tip Worn Tip

WARNING
Disconnect primary power to the system be-
fore 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 Example of Tip Wear
ON. 5. Remove the starter cartridge. Check for excessive wear,
plugged gas holes, or discoloration. Check the lower
Remove the consumable torch parts as follows: end fitting for free motion. Replace if necessary.
Spring-Loaded Spring-Loaded
NOTE Lower End Fitting Lower End Fitting at Reset /
The shield cup holds the tip and starter car- Full Compression Full Extension
tridge 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
Art # A-08064_AC

Slag built up on the shield cup that cannot be 6. Pull the Electrode straight out of the Torch Head. Check
removed may effect the performance of the the face of the electrode for excessive wear. Refer to
system. the following figure.
2. Inspect the cup for damage. Wipe it clean or replace if
damaged.
New Electrode

Art # A-08067
Worn Electrode
Shield Cups Art # A-03284

Electrode Wear
3. On torches with a shield cup body and a shield cap or
deflector, ensure that the cap or deflector is threaded 7. Reinstall the Electrode by pushing it straight into the
snugly against the shield cup body. In shielded drag torch head until it clicks.
cutting operations (only), there may be an O-ring be-
tween the shield cup body and drag shield cap. Do not 8. Reinstall the desired starter cartridge and tip into the
lubricate the O-ring. torch head.
Drag Shield Cap 9. Hand tighten the shield cup until it is seated on the torch
head. If resistance is felt when installing the cup, check
Shield the threads before proceeding.
Cup Body
This completes the parts replacement procedures.

O-Ring No. 8-3488

Art # A-03878

SERVICE 5T-2 Manual 0-4962

 cutmaster 52
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section "6.03 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
authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly, as
listed in the parts list for each type item. Also include the model and serial number of the power supply.
Address all inquiries to your authorized distributor.
6.03 Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, input
power cable, gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster 52 Power Supply
208/230 - 460VAC, Single or 3 Phase, 60Hz,
with 230V 1PH input power cable and plug 3-5130-1
460VAC, Single or 3 Phase, 60Hz,
with input power cable 3-5130-2
600VAC, 3 Phase, 60Hz,
with input power cable 3-5130-5

Manual 0-4962 6-1 PARTS LIST

 CutMaster 52
6.04 Major External Replacement Parts
Item # Qty Description Catalog #
1 1 Cover with labels 9-0120
2 1 Base Enclosure Assembly 9-0118
3 1 Tube, roll handle 9-0121
4 1 Front Panel 9-0100
5 1 Rear Panel 9-0101
1

4
3

Art # A-08120

NOTE
Illustration may vary slightly from unit.

PARTS LIST 6-2 Manual 0-4962

 cutmaster 52
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

Art # A-08123

NOTE
Illustration may vary slightly from unit.

Manual 0-4962 6-3 PARTS LIST

 CutMaster 52
6.06 Left Side Replacement Parts
Item # Qty Description Ref Catalog #
1 1 Main PCB Assembly non 600V PCB 1 9-0108
1 1 Main PCB Assembly 600V Only PCB 1 9-0165
2 1 Logic PCB PCB 3 9-0107*
2 1 Logic PCB (for 600V systems) PCB 3 9-0169
3 1 Center Chassis Molded Plastic 9-0102
4 1 Fan, MOT 1, MOT 2 9-0104
5 1 Transformer, Main Non 600V T1 9-0106
5 1 Transformer, Main 600V Only T1 9-0170
6 1 Inductor, Output L1 9-0105
Not Shown:
1 Power Cable Strain Relief, for all units 9-0111
1 Input Power Cable with plug 230V 1PH 3m, 9-8596
1 Input Power Cord for 460/600 V Power Supply 9-8593
1 Hi/Lo voltage selection switch 9-0110
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 fit-
ting. 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
Illustration may vary slightly from unit.

PARTS LIST 6-4 Manual 0-4962

 cutmaster 52
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 non 600V PCB 2 9-0167
7 1 Assembly, PCB, Input Capacitors 600V Only PCB 2 9-0163
8 1 Filter, Auto Drain 9-0116
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

Art # A-08121

NOTE
Illustration may vary slightly from unit.

Manual 0-4962 6-5 PARTS LIST

 CutMaster 52
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) 9-9387
1 Two - Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable (50 ft / 15.2 m) with Clamp 9-8529
1 Multi - Purpose Cart 7-8888
1 Automation Interface Kit 9-8311
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008
1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011
1 Nylon Dust Cover 9-7071

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
(Cat. No. 9-7743) Assembled Filter First & Second
Stage
Cover Cartridges
(as marked)
Barbed
Fitting Art # A-02476 Art # A-02942

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

PARTS LIST 6-6 Manual 0-4962

 cutmaster 52
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 SL60, 50 - foot Leads Assembly with ATC connector 4-7835
1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836
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

5
6
3

Art # A-07993_AB

Manual 0-4962 6-7 PARTS LIST

 CutMaster 52
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 Automated Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7850
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7851
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7852
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7853
6 Unshielded Mechanized Leads Assemblies with ATC connectors
1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842
1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843
1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844
1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845
7 1 11” / 279 mm Rack 9-7041
8 1 11” / 279 mm Mounting Tube 9-7043
9 1 End Cap Assembly 9-7044
10 2 Body, Mounting, Pinch Block 9-4513
11 1 Pin, Mounting, Pinch Block 9-4521
12 1 Torch Holder Sleeve 7-2896
13 1 PIP Plunger and Return Spring Kit 9-7045
1 Pinion Assembly (Not shown) 7-2827
1 5” / 126 mm Positioning Tube (Not shown) 9-7042

PARTS LIST 6-8 Manual 0-4962

 cutmaster 52

10

10

1
2 11
3
12
4

13

5&6

A-07994_AB

Manual 0-4962 6-9 PARTS LIST

 CutMaster 52
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
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
O-Ring No. 8-3488 Shield Cap, Drag
DRAG SHIELD
CUTTING Shield 50-60A 9-8235
50-60A Tips:
Cup Body,
Shield Cap, Deflector
CUTTING 9-8237
9-8243
Start
Cartridge 50-55A 9-8209
Shield Cup Standoff Guide
9-8213 60A 9-8210 9-8281
9-8218
STANDOFF
CUTTING

DRAG SHIELD O-Ring No. 8-3488

Shield Cap, Drag
Electrode CUTTING Shield 70-100A 9-8236
9-8215 70-120A Tips: Cup Body,
CUTTING 9-8237 Shield Cap, Deflector
9-8243

70A 9-8231
80A 9-8211 Shield Cup Standoff Guide
90/100A 9-8212 9-8218 9-8281
120A 9-8253
STANDOFF CUTTING

40-120A
GOUGING Shield Shield Cap, Gouging
Cup Body, 9-8241
9-8237
Tips:
Tip Gouging A 9-8225 (40 Amps Max.)
NOTE
Tip Gouging B 9-8226 (50 - 100 Amps) CutMaster 52 uses 60A and less
CutMaster 82 uses 80A and less
Art # A-08065_AE CutMaster 102 uses 100A and less
Tip Gouging C 9-8227 (60 - 120 Amps)
CutMaster 152 uses 120A and less
Tip Gouging D 9-8228 (60 - 120 Amps)

Tip Gouging E 9-8254 (60 - 120 Amps)

PARTS LIST 6-10 Manual 0-4962

 cutmaster 52
SECTION 7: REPLACEMENT B. Procedure
1. Open the wrist strap and unwrap the first
PROCEDURES 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 pro- 3. Attach the copper foil to a convenient and
cedures which may be performed on the CutMas- exposed electrical ground.
ter 52 Power Supply. 4. Connect the equipment primary cable
Under no circumstances are field repairs to be ground to the same electrical ground as the
attempted on Printed Circuits or other subassem- wrist strap.
blies of this unit. Evidence of unauthorized repairs 5. Open the equipment enclosure and remove
may void the factory warranty. the failed PC board.
7.02 Anti-Static Handling 6. Carefully open the ESD protective bag and
Procedures remove the replacement PC Board.
7. Install the replacement PC Board in the
A. General equipment and make all necessary connec-
tions.
8. Place the failed PC Board in the ESD protec-
CAUTION tive bag and seal for return shipping.
9. Replace the power supply cover.
PC Boards can be irreparably damaged by
10. Remove the grounding wrist strap from
improper handling due to electrostatic dis-
charge (ESD). your wrist and from the electrical ground
connection before reconnecting primary
Replacement PC Boards are shipped in a pro- power to the equipment.
tective enclosure to prevent damage from electro-
static discharge (ESD) during shipping. A ground 7.03 Parts Replacement - General
strap is included with each replacement board to Information
prevent static damage during installation. The parts replacement procedures described
in this manual, except for filter replacement, re-
! WARNING
quire that the Power Supply be disassembled. The
part to be replaced will determine to what extent
Read and understand these instructions and the Power Supply must be disassembled.
the instructions on the grounding wrist strap Before removing any connection mark each
package before opening the equipment enclo- wire with the connection designation. When reas-
sure or removing the replacement PC board sembling make sure the wires go to the proper
from its protective enclosure. terminals.
Disconnect primary power to the system be- Note the routing of wires and make sure the
fore disassembling the torch, torch leads, or wires are put back in the same place when re-
power supply enclosure. assembling the unit.
Each subsection is referenced to Section 6 for
Where these instructions include specific
parts lists and overall detailed drawings.
torquing instructions, failure to torque prop-
erly will cause component damage.
Do not operate the equipment or test equip- WARNING
ment under power while wearing the ground- Disconnect primary power from the source
ing wrist strap. before opening or disassembling the power
supply.

Manual 0-4962 7-1 PARTS REPLACEMENT

 CutMaster 52
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
Tools required: T20 Torx Driver unit.
1. Remove the upper and lower screws which 2. Remove the cover per subsection 7.04-A.
secure the cover to the main assembly. Do 3. Remove the screws securing the tube
not loosen the lower screws inside the cut handles to the base of the unit.
out slots in the bottom of the cover.
NOTE
NOTE Some of the earliest manufactured units have
The upper screws and lower screws are not the Tube Handles that are joined together under
same. Do not mix them. The upper screws are the base of the unit. Later versions are not
for threading into the plastic of the front and joined together.
rear panels. DO NOT use the finer threaded 4. Remove the power supply from the Tube
lower screws for this.
Handles.
5. Replace the Tube Handles by reversing the
Upper
Screws above steps.
6. Reinstall the power supply cover.
Lower D. Disconnecting Front and Rear Panels
Screws
from the base
In many of the replacement procedures, it
Slots may be helpful to disconnect the front or rear panel
Lower from the base in order to allow more room to ac-
Screws cess the parts.
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 models do not and there is enough
room to perform this procedure without
removing them.
3. While grasping the panel close to the base,
Art # A-07947
pull the panel directly from the base to
2. Carefully pull the Cover up and away from release the locking tabs.
the unit. 4. To re-engage the panel, position the panel
so that the locking tabs are above the base,
B. Cover Installation then push the panel back onto the base until
1. Reverse previous procedures for cover the locking tabs engage the mating holes in
installation. the base.
NOTE 5. For complete removal of panel, disconnect
any other item still attached to the panel and
When installing the upper screws, attempt to
reuse the original threads. The easiest way another component of the power supply.
to do this is by turning the screw counter-
clockwise until you feel the threads line up,
then begin to turn the screw clockwise to
tighten. Do not over tighten.

PARTS REPLACEMENT 7-2 Manual 0-4962

 cutmaster 52
7.05 Front Panel Parts Replacement D. Air Regulator Replacement
Tools required: T20 Torx Driver
Refer to Section "6.05 Front Panel Replace-
1. Remove the cover per subsection 7.04-A.
ment Parts" and an overall detailed drawing.
2. Remove the three (3) air hoses from the
A. Current Control Potentiometer (A) regulator per subsection 7.05-C.
Knob Replacement 3. Pull Air Regulator adjusting knob from shaft
Tools required: Flat Screw Driver 4. Loosen and remove the locking nut secur-
1. Turn the potentiometer fully clockwise and ing the Air Regulator to the front Panel, then
note the location of the pointer mark on the remove the regulator.
knob. 5. Install replacement Air Regulator by revers-
2. Loosen the screw securing the Current ing the above steps.
Control Knob to the potentiometer shaft and 6. Reinstall the power supply cover
remove the knob. E. Gas Solenoid Replacement
3. Replace the knob on the potentiometer shaft Tools required: T20 Torx Driver, Flat Screw
with the pointer in the same position as Driver
noted in step 1. 1. Remove the cover per subsection 7.04-A.
B. Function Control Switch Knob 2. Disconnect J5 connector from the Main PCB.
Replacement 3. Remove the air hose from Gas Solenoid per
Tools required: Flat Screw Driver subsection 7.05-C.
1. Turn the Function Control Switch until the 4. The Solenoid utilizes the same type locking
pointer on the knob is in the LATCH posi- fitting as the gas hoses. Using a flat blade
tion. screw driver, push the locking ring towards
2. Loosen the screw securing the knob to the the Solenoid while pulling the Solenoid away
switch shaft and remove the knob. from the ATC.
3. Replace the knob on the switch shaft with 5. Install the replacement Gas Solenoid by
the pointer in the position noted in step 1. reversing the above steps
6. Reinstall the power supply cover
C. Replacing Gas Hoses
Tools required: T20 Torx Driver F. Logic PCB (PCB 3) Replacement
1. Remove the cover per subsection 7.04-A. Tools required: T20 Torx Driver Flat Screw
2. Push the gas fitting locking ring back. A Driver, ½” wrench
small open end wrench works well for this. 1. Remove the cover per subsection 7.04-A.
2. Remove the two large and one small gas
1 2 hoses from the pressure regulator per sub-
section 7.05-C.
3. Unplug the connector J2 from the Main PCB.
4. Remove the Current Control Potentiometer
Knob and nut securing the potentiometer
shaft to the front panel per subsection 7.05-A
3
5. Remove the Function Control Switch Knob
Art # A-08150
and the nut securing the switch shaft to the
front panel per subsection 7.05-B.
3. Pull the hose from the fitting. 6. Pull the top of the front panel forward
slightly and carefully remove the Logic PCB
4. Replace the hose by pushing the hose back
from the unit.
into the fitting until it fully seats. Check it by
7. Install the replacement Logic PCB by revers-
pulling on the hose. If done correctly it will
ing the above steps.
not pull out.
8. Reinstall the power supply cover.
5. Reinstall the power supply cover
G. ON/OFF Switch (SW1) Replacement
Tools required: T20 Torx Driver
Manual 0-4962 7-3 PARTS REPLACEMENT
 CutMaster 52
1. Remove the cover per subsection 7.04-A. 7.06 Left Side Internal Parts
2. Disconnect the wires on the rear of the Replacement
switch, noting the location and orientation
of each wire as shown below. A. Fan Replacement
Tools required: T20 Torx Driver
Switch
1. Remove the Cover per subsection 7.04-A.
2. Unplug J7 and J8 connectors from Main
PCB.

Art # A-08169
4 3 3. Carefully feed the fan wires through the
center chassis wire slot.
4. Remove the fan by pushing the fan retain-
ing clips apart and pulling the fan out of the
2 1 center chassis.
3. Squeeze together the clips on the back of 5. On the replacement fan(s) note the direction
the switch, then remove the switch through of air flow as labeled on the fan housing and
the front panel. orient so fan will blow air into the unit.
4. Install the replacement switch by reversing 6. Install replacement fan by reversing the
the above steps. above steps.
5. Reinstall the power supply cover 7. Reinstall the power supply cover
H. Work Cable Replacement B. Main Transformer (T1) Replacement
Tools required: T20 Torx Driver Tools required: T20 Torx Driver, ½” Nut
1. Remove the Cover per subsection 7.04-A. Driver
2. Disconnect the work cable from the WORK1 1. Remove the Cover per subsection 7.04-A.
terminal on the Main PCB. 2. Remove the Tube Handle per subsection
3. Squeeze the top and bottom of the Work 7.04-C.
Cable Strain Relief and remove from the 3. Remove the two large and one small gas
front panel. hoses per subsection 7.05-C.
4. Install the replacement Work Cable by re- 4. Remove the Gas Solenoid per subsection
versing the above steps. 7.05-E.
5. Reinstall the power supply cover 5. Disconnect the transformer wires from ter-
minals PRI 1 (A), PRI 2 (B), PRI 3 (C), PRI
4 (D), SEC1, SEC2 on the Main PCB.
6. Disconnect J2 & J3 connectors from Main
PCB.
7. Remove the two screws securing the Center
Chassis to the base.
8. Loosen the two screws on the Input Power
Cable strain relief.
9. Disengage the Rear panel from the base per
subsection 7.04-D.
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.
PARTS REPLACEMENT 7-4 Manual 0-4962
 cutmaster 52
13. Remove the two screws securing the Main 7.07 Rear Panel Parts Replacement
Transformer to the base.
14. Remove the Main Transformer, carefully A. Filter Element Assembly Replacement
guiding all its wires through from the right The Filter Element Assembly is in the rear
side of the unit. panel. For better system performance, the filter
15. Install replacement Transformer by revers- element should be checked per the Maintenance
ing the above steps. Schedule (Subsection 5.02), and either cleaned or
16. Reinstall the power supply cover replaced.
1. Remove power from the power supply; turn
C. Output Inductor (L1)
OFF the gas supply and bleed down the
Tools required: T20 Torx Driver, ½” Nut
system.
Driver
2. Remove the system cover. See "A. Cover
1. Remove the Cover per subsection 7.04-A.
Removal" in this section.
2. Remove the Tube Handle per subsection
3. Locate the internal air line and the fitting
7.04-C.
from the filter assembly. Number 1 in the
3. Remove the two large and one small gas
following illustration.
hoses per subsection 7.05-C.
4. Hold a wrench or similar tool against the
4. Remove the Gas Solenoid per subsection
locking ring on the filter assembly fitting,
7.05-E.
then pull on the hose to release it. (Num-
5. Disconnect J2 & J3 connectors from Main
bers 2 and 3 in the following illustration).
PCB.
6. Disconnect Output Inductor wire from ter-
minal Choke1 on the Main PCB.
7. Disconnect Output inductor wire from ATC
connector. 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 subsection 7.04-D.
11. Guide the rear panel back six (6) inches
away from the base. Art # A-07989
12. Guide the Center Chassis towards the
center of the base to disengage the bottom
locking tabs securing the Chassis to the
base.
13. Carefully guide the Center Chassis up far 2
enough to lay the Chassis down towards the
right side of the unit.
14. Remove the two screws securing the Out-
put Inductor to the base.
15. Remove the Output Inductor, carefully
guiding its wires through from the right side 3 4
5
of the unit.
16. Install replacement Output Inductor by
reversing the above steps. 6mm
17. Reinstall the power supply cover.

Manual 0-4962 7-5 PARTS REPLACEMENT

 CutMaster 52
5. Remove the fitting from the filter element C. Input Power Cable Replacement
assembly by inserting a 6 mm hex wrench Tools required: T20 Torx Driver, Phillips
into the internal hex fitting and turning it Head Screwdriver, Flathead Screwdriver,
counter clock-wise (left). Numbers 4 and 5 1. Remove the Cover per subsection 7.04-A.
in the previous illustration. 2. Disconnect the input cable wires from the
6. Disconnect the input line from the filter ele- W1 contactor terminals and ground lug.
ment assembly. 3. Loosen the two screws in the cable strain
7. Remove the filter element assembly through relief
the rear opening. 4. Remove cable through the rear panel.
NOTE 5. Install replacement Input Power Cable by
reversing above steps.
If replacing or cleaning just the filter element 6. Reinstall the power supply cover
refer to the following illustration for disas-
sembly. D. 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 automati-
Filter Element cally 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
Art # A-07990
Element.
8. Install the new or cleaned assembly by 3. Disconnect gas supply hose.
reversing these procedures. 4. Turn the Filter Housing Cover counter-
9. Turn ON the air supply and check for leaks clockwise and remove it. The Filter Element
before reinstalling the cover. is located inside the Housing.
B. Voltage Selection Switch Replacement
Tools required: T20 Torx Driver, 9/16” Housing
wrench
1. Remove the Cover per subsection 7.04-A.
2. Disconnect J3 from the Logic PCB Filter
3. Remove retaining nut securing the switch to Element
(Cat. No. 9-7741)
the rear panel.
4. Feed the wires and connectors out of the Spring
panel
O-ring
5. Install replacement filter by reversing above (Cat. No. 9-7743) Assembled Filter
steps.
Cover

Barbed
Fitting Art # A-02476

Optional Single-Stage Filter Element Replacement

PARTS REPLACEMENT 7-6 Manual 0-4962

 cutmaster 52
5. Remove the Filter Element from the Housing 7.08 Right Side Internal Parts
and set Element aside to dry. Replacement
6. Wipe inside of housing clean, then insert
the replacement Filter Element open side A. Capacitor PCB (PCB 2) Replacement
first. Tools required: T20 Torx Driver
7. Replace Housing on Cover. 1. Remove the Cover per subsection 7.04-A.
8. Reattach gas supply. 2. Remove the eight screws securing PCB 2 to
9. Reinstall the power supply cover the Main PCB.
NOTE 3. Install the replacement PCB by reversing the
above steps.
If unit leaks between housing and cover,
inspect the O-Ring for cuts or other damage. B. Main PCB (PCB 1) Replacement
Tools required: T20 Torx Driver
1. Remove the Cover per subsection 7.04-A.
2. Remove the two large gas hoses per sub-
section 7.05-C.
3. Remove the Gas Solenoid per subsection
5.05-E.
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.
9. Reinstall the power supply cover
C. Main Contactor (W1) Replacement
Tools required: T20 Torx Driver
1. Remove the Cover per subsection 7.04-A.
2. Remove all wires from W1, noting the loca-
tion and orientation of each wire
3. Loosen the two (2) Torx head screws secur-
ing the Main Contactor to the base.
4. Slide the contactor towards the rear of the
unit slightly to allow the contactor to clear
the mounting screws.
5. Lift Main Contactor up and out of the unit.
6. Install the replacement Contactor by revers-
ing the above steps.
7. Reinstall the power supply cover.

Manual 0-4962 7-7 PARTS REPLACEMENT

 CutMaster 52

This Page Intentionally Blank

PARTS REPLACEMENT 7-8 Manual 0-4962

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

is used for specific applications

(torch switch can be released
after main arc transfer).

ACTION: RESULT: Gas flow stops.

Connect work cable to workpiece.

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

Main arc stops.

Pilot arc automatically
ACTION:
restarts.
Protect eyes and activate
Torch switch (START) PILOT ARC
RESULT:

Fans turn on. Gas flows briefly, ACTION:

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

Main arc transfers.

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

Manual 0-4962 A-1 APPENDIX

CutMaster 52
APPENDIX 2: DATA TAG INFORMATION

West Lebanon, NH USA 03784 Manufacturer's Name and/or

Logo, Location, Model and
Model: Revision Level, Serial Number
S/N
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 1
1Ø 3Ø
Supply Current

Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)

NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288
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 0-4962

 cutmaster 52
APPENDIX 3: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram
ATC Male Connector ATC Female Receptacle
Negative / Front View Front View Negative /
Plasma Plasma

4 - Green / 8 - Open 8 - Ground

Switch 4 - Switch

7 - Open 7 - Open 3 - Switch

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector UNSHIELDED MACHINE TORCH ATC Female Receptacle
Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP

5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot

Art # A-03799

Manual 0-4962 A-3 APPENDIX

CutMaster 52
APPENDIX 4: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
5 5
6 6
Torch Green 4 4 To Power Supply
Switch White 3 3 Circuitry
8 8
7 7
Negative / Plasma Negative / Plasma
Pilot
Pilot

Art # A-03797

B. Mechanized Torch Connection Diagram

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

Art # A-03798

APPENDIX A-4 Manual 0-4962

 cutmaster 52

This Page Intentionally Blank

Manual 0-4962 A-5 APPENDIX

CutMaster 52
APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS
5 4 3 2

J3

1
2
3
T1

K5, K6 K1-K4

J12

1
2
3
PRI 2 PRI 1 PRI 4 PRI 3
+12VDC
D
BIAS B A D C

/460
/230
SUPPLY
J1 MTH1 MTH2
SW1
1 3 1
2
3 Q1
4
2 4 5
K1
RESISTORS
INRUSH

C1-C4* +
/INRUSH

D1

MTH3 MTH4
W1
* PRIMARY L1 7
AC1

AC INPUT L1 T1
L2 8
AC2
K1 K2 K5 K6 K3 K4
L2 T2
JUMPER
L3 9
AC3

L3 T3
GND 7A
L4 T4 MTH6 MTH8
Q2
C

*PRIMARY POWER CONNECTIONS:

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

1PH USE L1, L2 & GND -

INSTALL JUMPER BETWEEN L2 TO L3

SW2
J3 MTH5 MTH7

1 460_IN
2
INPUT VOLTAGE SELECTOR * CM52 & A40
(Closed for 230VAC input) C3 & C5 not installed

24VAC
PCB2 INPUT CAPACITOR PCB
5
J6
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D

PCB1 MAIN PCB ASSY

/SOLENOID

J2 J5
1
2
3

40 CIRCUIT
RIBBON CABLE
J1

40 PIN RIBBON CABLE SIGNALS

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

J3
39 D M-L +5VDC
1
2
3

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

5 4 3 2

APPENDIX A-6 Manual 0-4962

 cutmaster 52

CM82 / A60 ONLY

TS1

1TORCH
L1
PIP SWITCH
J11

1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH

TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1

-
E64
ELECTRODE1
D3
+
TIP1 E35
Q5

PILOT IGBT

WORK1
WORK

J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7

CNC INTERFACE STANDARD ON A40 & A60 UNITS

CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS

J2

J10 P10 14

1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1

B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3

J7 J8 To -V OUT 1 J3
1
2

1
2

on PCB1
E1 J2
1
2
P10 3
J1 +12VDC
4 } /START / STOP
1 1 5 (-)
+ FAN - + FAN - 2 2 6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
}(+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14

AUTOMATION
PCB4 INTERFACE PCB

A-09131_AB A

Rev Revisions By Date PCB No:

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

Manual 0-4962 A-7 APPENDIX

CutMaster 52
APPENDIX 6: SYSTEM SCHEMATIC, 600V UNITS
5 4

PRI 2 PRI 1 PRI 4 PRI 3

D
BIAS B A D C
SUPPLY
J1 MTH1 MTH2
SW1
1 3 +12VDC
1
2
3 Q1
4
2 4 5
K1

RESISTORS
*CHOKE + C1-C4*
INRUSH

EMI
/INRUSH

* CEONLY
UNITS D1

*FILTER
EMI
W1
MTH4 MTH3

AC1
7
L1 1 1
L1 T1
AC2
8
L2 2 2
L2 T2
AC3
9
L3 3 3
L3 T3

7A
GND 4 4 L4 T4 MTH6 MTH8
Q2
C
380/400/415V
OR 600V
3 PH AC INPUT
PRIMARY POWER CONNECTIONS: + C5-C8*
USE L1, L2, L3 & GND

MTH7 MTH5

PCB2
INPUT CAPACITOR PCB
24VAC
5 *CM52/12mm/20mm/A40
J6
C3 & C5 may not be installed
TEST POINTS
W1 1
2 24 VAC RETURN
GND1 COMMON
GND2 COMMON
GND3 COMMON
6 +12V1 +12 VDC SUPPLY
48V1 +48 VDC SUPPLY
I_DMD_1 CURRENT DEMAND
J4 D59 PCR TIP_SEN TIP DRAG SENSE
1 3.3VDC
2 TXD
SERIAL PORT RXD
3
4 D78 CSR +12VDC
B 5 D

PCB1 MAIN PCB ASSY

/SOLENOID

J2 J5
1
2
3

40 CIRCUIT
RIBBON CABLE
J1

40 PIN RIBBON CABLE SIGNALS

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

J3
39 D M-L +5VDC
1
2
3

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

5 4

APPENDIX A-8 Manual 0-4962

 cutmaster 52

3 2 1

TS1

T1
1TORCH
L1
PIP SWITCH
J11

1
2
SEC1 SEC2 CHOKE1
D
+12VDC
TORCH SWITCH

TEMP
/OVERTEMP
CIRCUIT ATC CONNECTOR
J1
1 1 AUTOMATION
2 2 TORCH SOLENOID
3 3
4 4
NTC 5 5
6 6
7 7
8 8
-V OUT 1

-
E64
ELECTRODE1
D3
+
TIP1 E35
Q5

PILOT IGBT

WORK1
WORK

J9
78 C
/PIP 1
79
2 80
/START 3
81
4
24VAC RETURN 82
5
6 83
24VAC SUPPLY 7

CNC INTERFACE STANDARD ON A40 & A60 UNITS

CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS

J2

J10 P10 14

1 1
13
12
} OK TO MOVE
(5A @250VAC / 30VDC) J2 PINOUT
OK-TO-MOVE 2 2 11
3 3 10 3 1
4 4 9
5 5 8 7 4
+12VDC
6 6 7 11 8
7 7 6 14 12
8 8 5
4
3
} /START / STOP
(Sink 50mA @12VDC)
2
1

B
FULL FEATURED AUTOMATION INTERFACE PCB OPTION
+12VDC +12VDC
/FAN /FAN * * To configure DIVIDED ARC VOLTS signal output
No jumper installed for ARC VOLTS /16.67
Jumper pins 1 & 2 for ARC VOLTS / 30
Jumper pins 2 & 3 for ARC VOLTS / 50
1
2
3
J7 J8 To -V OUT 1 J3
1
2

1
2

on PCB1
E1 J2

1
2
P10 3
J1 +12VDC
4
} /START / STOP
1 1 5 (-)
+ FAN - + FAN - 2 2 6 } (+) *DIVIDED ARC VOLTS
3 3 K1 7 (-)
MOT1 MOT2
4
5
4
5
8
9
} (+) (W/ARC VOLTS
100K IN SERIES (2))
6 6 10
7 7 11
8 8 12
K1 13 } OK-TO-MOVE
14

AUTOMATION
PCB4 INTERFACE PCB

A-09133_AC A

Rev Revisions By Date PCB No:

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

Manual 0-4962 A-9 APPENDIX

CutMaster 52
APPENDIX 7: Publication History
Cover Date Rev. Change(s)

Oct. 1, 2007 AA Manual released.

Apr. 15, 2008 AB Per ECOB752 updated firmware changes to pgs. 4-1 and 5-5. Per ECOB845 correct ed drag
cutting statement to ¼” pg. 4T-5. Per ECOB803 releasing 400 – 460V systems.
May 7, 2008 AC Per ECOB890 Updated system schematic to Rev. AB. Updated Section 2 spec chart and input
wiring chart per ECOB880 for CSA approval.
May 16, 2008 AD Added information to Section 6 about regulator - logic PCB kit upgrade for older systems per
ECOB908.
July 17, 2008 AE Updated input power and cable charts in Section 2. Updated 208/460V System schematic.
Added Hi / Lo voltage selection switch part number Section 6 per ECOB1001.
Jan 27, 2009 AF Corrected pressure "NOTE" at the end of each cut chart section in Section 4T. Corrected art
sizing in Section 3 to show missing information per ECOB1248.
Apr. 24, 2009 AG Added 600V system information Section 2, 6 and Appendix per ECOB1346.
May 29, 2009 AH Updated 400V/600V schematic in appendix per ECOB1399. Updated 230/460v schematic per
ECOB1357
Sept. 2, 2009 AI Updated Section 6 with 600v PCB numbers per ECOB1520
Feb. 25, 2010 AJ Updated CNC cable part numbers in Section 6 per ECOB1637.
Aug. 31, 2010 AK Add one line for logic PCB to include 600V systems part numbers in Section 6 per ECOB1800.
Feb. 8, 2011 AL Per ECOB1859 corrected Schematics with art number A-09131 and A-09133 to show proper
ARC Volts for Automation Interface PCB.
Mar. 20, 12 AM Changed COO text per ECOB2149.
April 25, 2012 AN Updated ART A-07994 per ECOB2136.
Nov. 27, 2012 AO Changed logo on Front Cover and Inside Front Cover from "Thermal Dynamics" to "Victor
Thermal Dynamics", modified Prop 65 text Section 1, Changed wording for NOTE below 3T.02
pg. 3T-1 and deleted NOTE text pg. 6-8 per ECO-B2342.

APPENDIX A-10 Manual 0-4962

This Page Intentionally Blank
 THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-426-1888 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178

Miami, FL USA
Sales Office, Latin America
Ph: 1-954-727-8371
Fax: 1-954-727-8376

Oakville, Ontario, Canada

Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)

EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800

Milan, Italy
Customer Care
Ph: +39 0236546801
Fax: +39 0236546840

ASIA/PACIFIC
Cikarang, Indonesia
Customer Care
Ph: 6221-8990-6095
Fax: 6221-8990-6096

Rawang, Malaysia
Customer Care
Ph: +603 6092-2988
Fax: +603 6092-1085

Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488

Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
Singapore
Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812

TECHNOLOGIES ™
INNOVATION TO SHAPE THE WORLD™

U.S. Customer Care: 800-426-1888 / FAX 800-535-0557 • Canada Customer Care: 905-827-4515 / FAX 800-588-1714
International Customer Care: 940-381-1212 / FAX 940-483-8178

© 2012 Victor Technologies International, Inc. victortechnologies.com Printed in Mexico