ESAB Cutmaster 30 Plus Plasma Cutter Instruction Manual

Instruction Manual for ESAB models including: Cutmaster 30 Plus Plasma Cutter, Cutmaster 30 Plus, Plasma Cutter, Cutter

CUTMASTER 30

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0700 400 977

OUTPUT

MAX OUTPUT
30

VOLTAGE
120240V

INPUT POWER

CUTMASTER® 30+
PLASMA CUTTING SYSTEM

OPERATING MANUAL

Revision: AB Issue Date: Nov., 2022 Manual No.: 0700 400 977
esab.com

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.esab.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for ESAB.
We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced 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 judgment, the Manufacturer

assumes no liability for its use.

Plasma Cutting Power Supply CutMaster® 30+ SL60TM 1TorchTM Operating Manual Number 0700 400 977
Published by: ESAB Group Incorporated 2800 Airport Rd. Denton, Texas 76207

www.esab.com
© Copyright 2022 by Thermal Dynamics an ESAB brand.

All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Original Publication Date: 30 March, 2022 Revision Date: 9 Nov., 2022
See website for Warranty Information.
Record the following information for Warranty purposes:
Where Purchased:____________________________________________________
Purchase Date:__________________________ ____________________________
Power Supply Serial #:_______________________________ _________________
Torch Serial #:______________________________ _________________________

Be sure this information reaches the operator. You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L'OPÉRATEUR. VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOUR-
NISSEUR.
MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous n'avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l'arc et l'équipement de coupage, nous vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non qualifiées d'installer, d'opérer ou de faire l'entretien de cet équipement. Ne tentez PAS d'installer ou d'opérer cet équipement avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas bien les instructions, communiquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de Sécurité avant d'installer ou d'opérer cet équipement.
RESPONSABILITÉS DE L'UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d'accompagnement et/ou les feuillets d'information si l'équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez faire une vérification périodique de l'équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n'est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés sans permission préalable écrite par le fabricant. L'utilisateur de l'équipement sera le seul responsable de toute défaillance résultant d'une utilisation incorrecte, un entretien fautif, des dommages, une réparation incorrecte ou une modification par une personne autre que le fabricant ou un centre de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D'UTILISATION AVANT D'INSTALLER OU D'OPÉRER L'UNITÉ. PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION.......................................................... 11
1.01 Notes, Cautions and Warnings ................................................................................. 11
SECTION 1 : INFORMATIONS GÉNÉRALES ................................................... 13 1.01 Remarques, avertissements et mises en garde ........................................................ 13
SECTION 2 SYSTEM: INTRODUCTION ......................................................... 15 2.01 How To Use This Manual .......................................................................................... 15 2.02 Equipment Identification......................................................................................... 15 2.03 Receipt Of Equipment.............................................................................................. 15 2.04 Power Supply Specifications ETL.............................................................................. 16 2.04.01 Additional Power Supply Specifications ..........................................................16 2.05 Input Wiring Specifications ETL................................................................................ 17 2.06 Power Supply Specifications CE ............................................................................... 18 2.06.01 Additional Power Supply Specifications ..........................................................18 2.07 Input Wiring Specifications CE ................................................................................. 18 2.08 Generator Recommendations.................................................................................. 19 2.09 Power Supply Features ............................................................................................ 19
SECTION 2 TORCH: INTRODUCTION ........................................................... 23 2T.01 Scope of Manual...................................................................................................... 23 2T.02 General Description ................................................................................................. 23 2T.03 Specifications ......................................................................................................... 23
SECTION 3 SYSTEM: INSTALLATION ........................................................... 25 3.01 Unpacking ............................................................................................................... 25 3.02 Lifting Options......................................................................................................... 25 3.03 Gas Connections ...................................................................................................... 26 3.04 Primary Input Power Connections ........................................................................... 27 3.05 Work Lead Connections ........................................................................................... 28
SECTION 3 TORCH: INSTALLATION ......................................................................................... 29
3T.01 Torch Connections.................................................................................................... 29
SECTION 4 SYSTEM: OPERATION ............................................................... 31 4.01 Front Panel Controls / Features ................................................................................ 31 4.02 Preparations for Operation ...................................................................................... 37
SECTION 4 TORCH: OPERATION.................................................................. 39 4T.01 Torch Parts Selection ............................................................................................... 39 4T.02 Hand Torch Operation .............................................................................................. 39 4T.03 Gouging................................................................................................................... 43

TABLE OF CONTENTS SECTION 5 SYSTEM: SERVICE..................................................................... 45
5.01 General Maintenance .............................................................................................. 45 5.02 Maintenance Schedule ............................................................................................ 45 5.03 Common Faults........................................................................................................ 46 5.04 Basic Troubleshooting Guide.................................................................................... 47 5.05 Power Supply Basic Parts Replacement ................................................................... 48
SECTION 5 TORCH: SERVICE ...................................................................... 49 5T.01 General Maintenance .............................................................................................. 49 5T.02 Inspection and Replacement of Consumable Torch Parts ......................................... 50
SECTION 6: PARTS LISTS ........................................................................... 51 6.01 Introduction ............................................................................................................ 51 6.02 Ordering Information .............................................................................................. 51 6.03 Power Supply Replacement..................................................................................... 51 6.04 Replacement Parts .................................................................................................. 52 6.05 Options and Accessories .......................................................................................... 53 6.06 Replacement Parts for SL60 Hand Torch .................................................................. 54 6.07 Torch Consumable Parts (SL60)................................................................................ 55
APPENDIX 1: DATA TAG INFORMATION ...................................................... 57
APPENDIX 2: TORCH PIN - OUT DIAGRAMS ................................................ 58
APPENDIX 3: TORCH CONNECTION DIAGRAMS ........................................... 59

SECTION 1: GENERAL INFORMATION

CUTMASTER 30+

1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:
NOTE! An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION A procedure which, if not properly followed, may cause damage to the equipment.

WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

WARNING Gives information regarding possible electrical shock injury.

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GENERAL INFORMATION

CUTMASTER 30+

WARNING

AVERTISSEMENT

1. Cutting sparks can cause explosion 1. Les étincelles de coupage peuvent

or fire.

provoquer une explosion ou un

1.1 Do not cut near flammables.

incendie.

1.2 Have a fire extinguisher nearby and 1.1 Ne pas couper près des matières

ready to use.

inflammables.

1.3 Do not use a drum or other closed 1.2 Un extincteur doit être à proximité

container as a cutting table.

et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre

contenant fermé comme table de

coupage.

2. Plasma arc can injure and burn; 2. L'arc plasma peut blesser et brûler;

point the nozzle away from

éloigner la buse de soi. Il s'allume

yourself. Arc starts instantly when instantanément quand on l'amorce.

triggered.

2.1 Couper l'alimentation avant de

2.1 Turn off power before disassembling démonter la torche.

torch.

2.2 Ne pas saisir la pièce à couper de la

2.2 Do not grip the workpiece near the trajectoire de coupage.

cutting path.

2.3 Se protéger entièrement le corps.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric 3. Tension dangereuse. Risque de

shock or burn.

choc électrique ou de brûlure.

3.1 Wear insulating gloves. Replace

3.1 Porter des gants isolants. Remplacer

gloves when wet or damaged.

les gants quand ils sont humides ou

3.2 Protect from shock by insulating

endommagés.

yourself from work and ground. 3.2 Se protéger contre les chocs en

3.3 Disconnect power before servicing. s'isolant de la pièce et de la terre.

Do not touch live parts.

3.3 Couper l'alimentation avant

l'entretien. Ne pas toucher les pièces

sous tension.

4. Plasma fumes can be hazardous. 4.1 Do not inhale fumes. 4.2 Use forced ventilation or local
exhaust to remove the fumes. 4.3 Do not operate in closed spaces.
Remove fumes with ventilation.

4. Les fumées plasma peuvent être dangereuses.
4.1 Ne pas inhaler les fumées. 4.2 Utiliser une ventilation forcée ou un
extracteur local pour dissiper les fumées. 4.3 Ne pas couper dans des espaces clos. Chasser les fumées par ventilation.

5. Arc rays can burn eyes and injure skin.
5.1 Wear correct and appropriate protective equipment to protect head, eyes, ears, hands, and body. Button shirt collar. Protect ears from noise. Use welding helmet with the correct shade of filter.

5. Les rayons d'arc peuvent brûler les yeux et blesser la peau.
5.1 Porter un bon équipement de protection pour se protéger la tête, les yeux, les oreilles, les mains et le corps. Boutonner le col de la chemise. Protéger les oreilles contre le bruit. Utiliser un masque de soudeur avec un filtre de nuance appropriée.

6. Become trained.

6. Suivre une formation.

Only qualified personnel should

Seul le personnel qualifié a

operate this equipment. Use torches le droit de faire fonctionner cet

specified in the manual. Keep

équipement. Utiliser exclusivement

non-qualified personnel and children les torches indiquées dans le manual.

away.

Le personnel non qualifié et les

enfants doivent se tenir à l'écart.

7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.

7. Ne pas enlever, détruire ni couvrir cette étiquette. La remplacer si elle est absente, endommagée ou usée.
Art # A-13294

GENERAL INFORMATION

0700 400 977

SECTION 1 : INFORMATIONS GÉNÉRALES

CUTMASTER 30+

1.01 Remarques, avertissements et mises en garde Le présent manuel est ponctué de remarques, d'avertissements et de mises en garde qui attirent l'attention sur des informations importantes. Ces repères sont classés comme suit :
REMARQUE : Fonction, procédé ou renseignement de base qui nécessite une plus grande attention ou contribue au bon fonctionnement du système.

ATTENTION Procédé qui, s'il n'est pas suivi correctement, peut endommager l'équipement.

AVERTISSEMENT Procédé qui, s'il n'est pas suivi correctement, peut causer des lésions à l'utilisateur ou aux personnes

dans la zone d'exploitation.

AVERTISSEMENT Fournit des renseignements relatifs à d'éventuelles blessures se devant à une décharge électrique.

0700 400 977

GENERAL INFORMATION

CUTMASTER 30+

WARNING

AVERTISSEMENT

1. Cutting sparks can cause explosion 1. Les étincelles de coupage peuvent

or fire.

provoquer une explosion ou un

1.1 Do not cut near flammables.

incendie.

1.2 Have a fire extinguisher nearby and 1.1 Ne pas couper près des matières

ready to use.

inflammables.

1.3 Do not use a drum or other closed 1.2 Un extincteur doit être à proximité

container as a cutting table.

et prêt à être utilisé.

1.3 Ne pas utiliser un fût ou un autre

contenant fermé comme table de

coupage.

2. Plasma arc can injure and burn; 2. L'arc plasma peut blesser et brûler;

point the nozzle away from

éloigner la buse de soi. Il s'allume

yourself. Arc starts instantly when instantanément quand on l'amorce.

triggered.

2.1 Couper l'alimentation avant de

2.1 Turn off power before disassembling démonter la torche.

torch.

2.2 Ne pas saisir la pièce à couper de la

2.2 Do not grip the workpiece near the

trajectoire de coupage.

cutting path.

2.3 Se protéger entièrement le corps.

2.3 Wear complete body protection.

3. Hazardous voltage. Risk of electric 3. Tension dangereuse. Risque de

shock or burn.

choc électrique ou de brûlure.

3.1 Wear insulating gloves. Replace

3.1 Porter des gants isolants. Remplacer

gloves when wet or damaged.

les gants quand ils sont humides ou

3.2 Protect from shock by insulating

endommagés.

yourself from work and ground. 3.2 Se protéger contre les chocs en

3.3 Disconnect power before servicing. s'isolant de la pièce et de la terre.

Do not touch live parts.

3.3 Couper l'alimentation avant

l'entretien. Ne pas toucher les pièces

sous tension.

4. Plasma fumes can be hazardous. 4.1 Do not inhale fumes. 4.2 Use forced ventilation or local
exhaust to remove the fumes. 4.3 Do not operate in closed spaces.
Remove fumes with ventilation.

6. Become trained.

6. Suivre une formation.

Only qualified personnel should

Seul le personnel qualifié a

operate this equipment. Use torches le droit de faire fonctionner cet

specified in the manual. Keep

équipement. Utiliser exclusivement

non-qualified personnel and children les torches indiquées dans le manual.

away.

Le personnel non qualifié et les

enfants doivent se tenir à l'écart.

7. Do not remove, destroy, or cover this label. Replace if it is missing, damaged, or worn.

7. Ne pas enlever, détruire ni couvrir cette étiquette. La remplacer si elle est absente, endommagée ou usée.
Art # A-13294

GENERAL INFORMATION

0700 400 977

SECTION 2 SYSTEM: INTRODUCTION

CUTMASTER 30+

2.01 How To Use This Manual

This Owner's Manual applies to just product(s) listed on page i.
To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.
Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by registering on the ESAB web site listed below and clicking on "Product Support" / "ESAB Documentation": / "Download Library", then navigate to "Plasma Equipment" and then "Manual". You must first be logged in.
http://www.esab.com

2.02 Equipment Identification

The unit's identification number (specification or part number), model, and serial number appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely attached card or the shipping container. Record these numbers on the bottom of page i for future reference.

2.03 Receipt Of Equipment

ETL

Included items:

· CutMaster 30+ Power Supply

· SL60TM Torch and Leads

· Work Lead with Work Clamp

· Spare Parts Kit ( 2 Electrodes, 2 Cutting Tips, 1 Gouging Tip, 1 Shield Cap, 1 Start Cartridge, 1 Shield Cup Body, 1 Deflector Shield Cup, 1 Standoff Cutting Guide and 1 Shield cup)

· 50 Amp to 20 Amp Adapter

· Air fitting 1/4" NPT EU type

· 20 Amp to 15 Amp Adapter

· Quick Start Guide

· Air fitting 1/4" NPT Milton type D
Move the equipment to the installation site before un-boxing the unit. Use care to avoid damaging the equipment when opening the box.

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INTRODUCTION

CUTMASTER 30+
2.04 Power Supply Specifications ETL

CM 30+ 120-240 VAC 1 Phase Power Supply Specifications

Input Power

120 - 240 VAC, Single Phase, 50/60 Hz

1 Phase Input Power Cable ETL

Power Supply includes 3 M single phase 12AWG 3/C input cable with NEMA 6-50P Plug

Output Current

10 - 30 Amps, Continuously Adjustable

Power Supply Gas Filtering Ability

Particulates to 5 Microns

Inlet Pressure

90-125 PSI (6.2-8.6 bar / 620-862 Kpa)

2.04.01 Additional Power Supply Specifications

CM 30+ Power Supply Duty Cycle *

Ambient Air Temperature

Duty Cycle Ratings @ 40° C (104° F) Operating Range 0° - 50° C

Rating

Duty Cycle*

40%

60%

120 VAC Units

Current DC Voltage

25 Amps** 120

21 Amps 120

Duty Cycle*

40%

60%

208-240 VAC Units

Current DC Voltage

30 Amps 120

25 Amps 120

100% 16 Amps
120 100% 20 Amps 120

* 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: 25 Amps is for a 20 Amp circuit ONLY!
DO NOT exceed a 21 Amp output setting on a 15 Amp circuit!

INTRODUCTION

0700 400 977

2.05 Input Wiring Specifications ETL 1 Phase Input Cable Wiring Requirements

CUTMASTER 30+

1 Phase Cutmaster 30+ Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input

Suggested Sizes

Volts 120 / 15A

Hz 50/60

Fuse

Flexible Cord

kVA

I max I1eff (amps)

(Min. AWG)

3.02

25.5 19.6

12 AWG

120 / 20A 50/60

3.7

30.3 19.1

12 AWG

1 Phase

208

50/60

4.3

21 13.2

220

50/60

4.3

19.9 12.6

230

50/60

4.2

19 12

240

50/60

4.2

18.2 11.5

Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code

12 AWG 12 AWG 12 AWG 12 AWG

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.
0700400951

NOTE! Due to circuitry, age and condition two generators with the same ratings may produce different results. Adjust the amperage accordingly.

CM 30+ cut capacity Pierce Capacity Standard Edge Cutting Capacity Maximum Severance Cutting Capacity

Thickness

inches

3/8

1/2

5/8

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INTRODUCTION

CUTMASTER 30+
2.06 Power Supply Specifications CE

CM 30+ 230 VAC 1 Phase Power Supply Specifications

Input Power

230 VAC, Single Phase, 50 Hz

1 Phase Input Power Cable CE

Power Supply includes 3 M single phase 2.5mm² input cable with Schuko plug

Output Current

10 - 30 Amps, Continuously Adjustable

Power Supply Gas Filtering Ability

Particulates to 5 Microns

Inlet Pressure

90-125 PSI (6.2-8.6 bar / 620-862 Kpa)

2.06.01 Additional Power Supply Specifications

CM 30+ Power Supply Duty Cycle *

Ambient Air Temperature

Duty Cycle Ratings @ 40° C (104° F) Operating Range 0° - 50° C

Rating

Duty Cycle*

40%

60%

100%

230 VAC Units

Current

30 Amps 25 Amps

20 Amps

DC Voltage

120

* 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.

2.07 Input Wiring Specifications CE 1 Phase Input Cable Wiring Requirements

1 Phase Cutmaster 30+ Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input

Suggested Sizes

Fuse

Flexible Cord

Volts

kVA

I max I eff (amps)

(Min. AWG)

1 Phase

230

4.2

19 12

2.5mm2

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.

INTRODUCTION

0700 400 977

2.08 Generator Recommendations

CUTMASTER 30+

When using generators to power the CM 30+ Plasma Cutting System, the following ratings are a minimum and are to be used along with the ratings previously listed.

CM 30+ Generator Specifications

Generator Output Rating CM 30+ Output Current Arc Characteristic

3 kW / 120V

20 A on 15 A circuit

Full

5 kW / 120V

25 A on 20 A circuit

Full

5 kW / 230V

30 A

Full

NOTE: If Generator is equipped with an idle mode it will need to be in "Run" mode to operate at 30 amps.

NOTE! Due to circuitry, age and condition two generators with the same ratings may produce different results. Adjust the amperage accordingly.

CM 30+ cut capacity Pierce Capacity Standard Edge Cutting Capacity Maximum Severance Cutting Capacity

Thickness

inches

3/8

1/2

5/8

2.09 Power Supply Features

Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Work Lead Receptacle

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INTRODUCTION

CUTMASTER 30+

Gas Inlet Port

Input Power Main Switch Input Power Cord

Weights and Dimensions

8" 203.29 mm

12.25" 311.21 mm

18.82" 478.07 mm 24.25 lb / 11 kg
Power Supply Dimensions & Weight

INTRODUCTION

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Clearances for Operation and Ventilation

CUTMASTER 30+

6" 150 mm

15" 381 mm

6" 150 mm

Ventilation Clearance Requirements

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INTRODUCTION

CUTMASTER 30+
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INTRODUCTION

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SECTION 2 TORCH: INTRODUCTION

D. Parts - In - Place (PIP)

CUTMASTER 30+

2T.01 Scope of Manual
This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Model SL60TM Plasma Cutting Torch. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.
2T.02 General Description

CAUTION

Torch Leads are flexible but internal wires can

be broken. Do not exceed a 2" radius bend and

avoid repeated tight bends when possible.

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

Torch Head has built - in switch 27.5±1.5 VDC circuit rating E. Type Cooling Combination of ambient air and gas stream through torch. F. Torch Ratings

Manual Torch Ratings

Ambient Temperature

104° F 40° C

Duty Cycle

100% @ 60 Amps @ 400 scfh

Maximum Current

60 Amps

Voltage (Vpeak)
Arc Striking Voltage

500V 500V

G. Gas Requirements

Manual Torch Gas Specifications

2T.03 Specifications
A. Torch Configurations 1. Hand/Manual Torch, Models The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly.
10.125" (257 mm)

Gas (Plasma and Secondary) Compressed Air

Operating Pressure Refer to NOTE

90 - 120 psi 6.2 - 8.3 bar

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

5 - 8.3 SCFM 300 - 500 scfh 142 - 235 lpm

3.75" (95 mm)

Art # A-03322_AB

WARNING
! This Torch is not to be used with oxygen (O2). The SL60QD torch should not be used on an HF system.

1.17" (29 mm)

B. Hand Torches are available as follows:

· 20 ft / 6.1 m

7-5200

NOTE! Operating pressure varies with torch model, operating amperage, and torch leads length. Refer to gas pressure settings charts for each model.

C. Torch Parts

H. Direct Contact Hazard

Starter Cartridge, Electrode, Tip, Shield Cup

For standoff tip the recommended standoff is 3/16 inches / 4.7 mm.

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INTRODUCTION

CUTMASTER 30+
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INTRODUCTION

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SECTION 3 SYSTEM: INSTALLATION

CUTMASTER 30+

3.01 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.
3.02 Lifting Options
The Power Supply includes handles for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNING Do not touch live electrical parts. Disconnect input power cord before moving unit. FALLING EQUIPMENT can cause serious personal injury and can damage equipment. HANDLES are not for mechanical lifting.
· Only persons of adequate physical strength should lift the unit. · Lift unit by the handles, using two hands. Do not use straps for lifting. · Use optional cart or similar device of adequate capacity to move unit.

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INSTALLATION

CUTMASTER 30+
3.03 Gas Connections
Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders.
1. Connect the air line to the quick connect inlet port. The following illustration shows typical gas line with quick connect fittings as an example.
NOTE! For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.. Do not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Applying Thread Sealant

Air Connection to Inlet Port

INSTALLATION

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CUTMASTER 30+
2. IF using high pressure cylinders, or your supply pressure exceeds 125 psi, you MUST use regulator to lower pressure to between 90-125 psi before introducing air to the system.

WARNING Failure to regulate inbound air pressure below 125 psi may cause damage to the unit.

3.04 Primary Input Power Connections

CAUTION
! Check your power source for correct voltage before connecting the unit to input power. The primary power source, fuse,
and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.

Power Cords Included With the Power Supply
Power cords come attached on all systems. For North America it will come with a 50 amp plug for use on 208-240V/50A circuit. For Europe it will come with a 2.5mm2 cable and a Schuko plug for use on a 230V circuit.
Also included for ETL systems ONLY, are two adapters. One is a cable with a 120V/20A NEMA 5-20P plug which attaches to the power supply input cord via a NEMA 6-50R plug. The other is a NEMA 5-20R to NEMA 5-15P adapter plug that attaches to the other adapter.
CAUTION When using the 120V/20A adapter cord (ETL systems ONLY), do not exceed a current output setting of 25 Amps on the power supply or the input power circuit breaker may trip.

CAUTION The equipment (CE system ONLY) is intended for use only in premises having a service current capacity equal to or greater than 100A per phase.

WARNING When using the 15A adapter in conjunction with the 20A adapter (ETL systems ONLY), extreme caution should be used to not exceed a current output setting of 21 Amps on the power supply. Failure to do so may result in the input power circuit breaker tripping or branch circuit overheating.

Input Voltage
120 V, 15 A Circuit (ETL) 120 V, 20 A Circuit (ETL) 208-240 V, 50 A Circuit (ETL) 230 V (CE)

Rated Output Amps (RMS) input at

kVA

rated output, 60 Hz,

single-phase

21 A, 120 V

25.5

3.1

25 A, 120 V

30.3

3.7

30 A, 120 V

18.2-21

4.2

30 A, 120 V

4.2

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INSTALLATION

CUTMASTER 30+
ETL ONLY

0700400951

3.05 Work Lead Connections
Connect the Work Lead to the power supply and the work piece.
1. Attach the Dinse type connection of the work lead to the power supply front panel as shown below.
2. Push in and turn clockwise to the right until tight.
3. Connect the work clamp to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the work piece; do not connect to the part to be cut off.
3

2 1
See section 3T for torch installation.

INSTALLATION

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SECTION 3 TORCH: INSTALLATION

CUTMASTER 30+

3T.01 Torch Connections
Connect the torch to the Power Supply. Connect only the ESAB model SL60 torch to this power supply. Maximum torch leads length is 50 feet/15m, including extensions.

WARNING Disconnect primary power at the source before connecting the torch.
1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together. Do not use tools to secure the connection.

2 1
Connecting the Torch to the Power Supply

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INSTALLATION

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This Page Intentionally Blank

INSTALLATION

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SECTION 4 SYSTEM: OPERATION
4.01 Front Panel Controls / Features See Illustration for numbering Identification

CUTMASTER 30+

30A

120V 66.7PSI
2T

1. Control Knob To select the Menu or change values.

To adjust the cutting current:
· Turn clockwise to increase the cutting current. · Turn counterclockwise to reduce the cutting current. To select an option in the menu displayed, press the control knob to enter the menu screen. After entering the menu screen, the options are highlighted in sequence at each turn.

· · 0700 400 977

To select the icon on the menu screen and exit menu screen.

To change the selection.

OPERATION

CUTMASTER 30+
2. Work lead Dinse type receptacle
Align Dinse type connector on work lead with receptacle, press in and turn clockwise to the right until tight.
3. Torch Quick Disconnect Receptacle
Torch Leads are connected here by aligning the connectors, pressing in and turning locking ring clockwise-to-the-right to secure. Connection should only be snug with no tools used.

Negative / Plasma

8 - Open

4 - Switch

7 - Open 8

3 - Switch

6 - Open

2 - PIP

7 8

5 - Open

1 - PIP

Pilot

PIP Switch Trigger Switch
Electrode

4. LCD screen
The front panel has an LCD screen to display the cutting mode, cutting current, cutting voltage, air pressure, and error information.
WELCOME SCREEN
The welcome screen is displayed for 3 seconds while the equipment turns ON.

After the welcome screen, the model name is displayed for 3 seconds.

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MAIN SCREEN

CUTMASTER 30+

30A

Current

Arc Cutting Voltage Cutting mode

120V 66.7PSI
2T

Output air pressure Gas purge

Trigger mode

MENU SCREEN
To enter the menu screen, press the control knob. In the menu screen, the user may adjust the cutting mode, trigger mode, and gas purge. To exit the menu screen, rotate the control knob to main screen.
1) CUTTING MODE SELECTION SCREEN
To enter the cutting mode selection, press the control knob, the cutting mode is highlighted.
To change the selection, press the knob, the cutting mode changes between plate cutting mode and grid cutting mode.
To confirm the selection, rotate the control knob to exit cutting mode selection menu.

30A
120V 66.7PSI
2T

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OPERATION

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2) TRIGGER MODE SELECTION SCREEN
To enter the cutting mode selection, press the control knob to enter menu screen. Turn the knob clockwise to enter trigger mode screen. The trigger mode is highlighted. To change the selection, press the knob, the trigger mode changes between2T(normal) mode and 4T (lock mode) mode. Rotate the control knob to exit the trigger mode selection screen to confirm the selection.
Note that 4T trigger mode is only available at plate cutting mode. When grid cutting mode is selected, 4T trigger mode can't be selected.

30A 30A

120V 66.7PSI
2T

120V 66.7PSI
4T

3) GAS PURGE SCREEN
To enter gas purge, press the control knob to enter menu screen. Turn the knob clockwise to enter gas purge screen.
Press the control knob to active the gas purge, press control knob again to stop the gas purge, and rotate the control knob to exit the gas purge screen.

30A
120V 66.7PSI
2T

OPERATION

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Error screen

CUTMASTER 30+

There are several error warnings screens to indicate errors. When an error happens, the communication screen will display and cut off the output until the error is cleared.

1) OVERHEATING COMMUNICATION SCREEN

The cutting equipment is protected by a temperature sensor. The overheating communication screen is displayed if the machine is overheated, which normally occurs if the equipment work cycle is exceeded.

If the overheating communication screen displays the machine output shall be deactivated. Let the equipment ON to allow the internal components to cool down. When the equipment is cool enough, the overheating communication screen disappears automatically.

Notice that the main switch must remain in the I position, so that the fan continues to operate and allow the equipment to cool down enough.

2) AIR PRESSURE COMMUNICATION SCREEN The air pressure communication screen is displayed when the output air pressure is out of range.

3) TORCH INSTALLATION OR COVER ASSEMBLY COMMUNICATION SCREEN
The torch installation or incorrect cover assembly communication screen is displayed when the torch or torch consumable is not installed correctly.

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OPERATION

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4) ELECTRODE OR NOZZLE INSTALLATION Communication screen The electrode or cutting nozzle installation communication screen is displayed when the electrode or cutting nozzle is not installed correctly or wear seriously. Check or replace the worn cutting nozzle and electrode.
5) UNDER VOLTAGE COMMUNICATION SCREEN The under voltage communication screen is displayed when the input voltage is under 85 V, check that the input voltage is not less than 100 V.
(6) START ERROR COMMUNICATION SCREEN Start signal is active when ON/ OFF SWITCH is turned to ON position. Start can be active for the following:
· Hand torch switch held closed

OPERATION

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4.02 Preparations for Operation At the start of each operating session:

CUTMASTER 30+

WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (30 amps maximum at 230V or 25 amps at 120V). Refer to Section 4T.01 for torch parts order.
Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics models SL60 Manual Torches may be connected to this Power Supply. See Section 3T.01 of this manual.
Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Air Source
Ensure source meets requirements (refer to Section 2). Check connections and turn air supply ON.
Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The work cable clamp 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-04509

Power ON

Place the Power Supply main switch to the I (right) position. LCD turns ON. The Main Board performs several tests to determine the system is ready to operate.

If there are no issues detected the output current setting will be displayed from 10 to 30 amps.

The cooling fan will turn ON for one second as the unit is turned ON and will auto to run when the unit is working normally.

Set Operating Pressure

Gas pressure cannot be set at the power supply and must be set at the source, from 90 - 125 PSI / 6.2 - 8.6 bar / 620 - 862 Kpa.

NEVER EXCEED 125 PSI / 8.62 bar / 862 kPa.

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OPERATION

CUTMASTER 30+
Cutting Operation
Once the cutting arc is established, it should continue to cut until the trigger is released, the torch is moved too far from the work piece or the duty cycle has been exceeded causing the system to go into an over temperature mode. In the first two instances release the torch trigger, ensure that the torch tip is close to the work piece, activate the trigger and reestablish the cutting arc. In the event of an over temperature fault, release the trigger, allow the unit to run so it will cool down. When the fault clears you can begin cutting again.
Typical Cutting Speeds
Cutting speeds vary according to torch output amperage, gas pressure, the type of material being cut, and operator skill.
Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality. As thickness of metal being cut increases cutting speed will need to slow. The opposite is true. As thickness of metal being cut decreases, allowable cutting speed can increase.
Postflow
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 30 seconds. During post - flow, if the user quickly presses and releases the trigger, the gas will shut off. If the user continues to hold the trigger and not release it, the pilot arc starts. The main arc will transfer to the workpiece if the torch tip is within transfer distance.
Shutdown
Turn the main switch to O, to the left as you face the unit from the rear. After a short delay all Power Supply indicators and fan shut OFF. Unplug the input power cord or disconnect input power. Power is removed from the system.
NOTE! To maximize the longevity of the internal electronics, allow the power supply to continue running (without cutting) for a few minutes before turning OFF. This will allow them to cool faster.

OPERATION

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SECTION 4 TORCH: OPERATION

CUTMASTER 30+

4T.01 Torch Parts Selection
Depending on the type of operation to be done determines the torch parts to be used.
Type of operation:

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.
4. Install the start cartridge and desired tip for the operation into the torch head.

Drag cutting, standoff cutting or gouging
Torch parts:
Shield Cup, Cutting Tip, Electrode and Start Cartridge
NOTE! Refer to Section 4T.07 and following for additional information on torch parts.
Change the torch parts for a different operation as follows:

5. Hand tighten the shield cup assembly until it is seated on the torch head, being careful to not cross thread the shield cup while screwing onto the torch. Once it reaches end of threads, no need to further tighten, as the O-rings maintain seals and proper gas flows to front of torch.. If resistance is felt when installing the cup, check the threads before proceeding.
4T.02 Hand Torch Operation
Standoff Cutting With Hand Torch

WARNING Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies.

NOTE! For best performance and parts life, always use the correct parts for the type of operation.

NOTE! The shield cup holds the tip and start cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup assembly from the torch head.
2. Remove the Electrode by pulling it straight out of the Torch Head.

Torch Head

Large O-Ring Small O-Ring

Electrode

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.
NOTE! The tip should never come in contact with the workpiece except during drag cutting operations with the drag shield in place. See the consumable chart on your parts kit box for diagram.

Start Cartridge

Tip

Shield Cup

A-03510_AB

Torch Parts

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TORCH OPERATION

CUTMASTER 30+
2. Depending on the cutting operation, do one of the following:
a. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.
b. For standoff cutting, hold the torch 1/8 - 3/8 in (3-9 mm) from the workpiece as shown below.
Torch

Shield Cup

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

A-00024_AB
Standoff Distance 3. Hold the torch away from your body.
4. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Trigger

Trigger Release

A-02986

5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
NOTE! The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.

Trigger

Trigger Release

1 2

3
4
Art # A-03383
6. Cut as usual. Simply release the trigger assembly to stop cutting.
7. Follow normal recommended cutting practices as provided in the power supply operator's manual.
NOTE! When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.
8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

Shield Cup Standoff Guide Torch Tip
Workpiece

Art # A-04034

TORCH OPERATION

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Shield Cup With Straight Edge
The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.

CUTMASTER 30+
5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

WARNING The straight edge must be non - conductive.

Trigger

Non-Conductive Straight Edge Cutting Guide
A-03539
Using Drag Shield Cup With Straight Edge
The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface. Drag Cutting With a Hand Torch Drag cutting works best on metal 1/4" (6 mm) thick or less.
NOTE! For best parts performance and life, always use the correct parts for the type of operation.

Trigger Release

A-02986

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.

NOTE! The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.

Trigger

Trigger Release

1 2

1. Install the drag cutting tip and set the output current.
2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.
3. Keep the torch in contact with the workpiece during the cutting cycle.
4. Hold the torch away from your body.

3
4
Art # A-03383
7. Cut as usual. Simply release the trigger assembly to stop cutting.
8. Follow normal recommended cutting practices as provided in the power supply operator's manual.

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TORCH OPERATION

CUTMASTER 30+

NOTE! When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the shield cup against the torch head or torch handle can damage components.

6. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
NOTE! The gas preflow and postflow are a characteristic of the power supply and not a function of the torch.

Piercing With Hand Torch
1. Hold the torch away from your body.
2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.
NOTE! The tip should never come in contact with the workpiece except during drag cutting operations.

7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.
Cutting speed depends on material, thickness, and the operator's ability to accurately follow the desired cut line. The following factors may have an impact on system performance:
· Torch parts wear
· Air quality
· Line voltage fluctuations
· Torch standoff height
· Proper work cable connection Rolling Pierce

Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

A technique that can work on thinner materials is a rolling pierce. A Rolling Pierce begins cutting with the torch head placed at an angle to the work surface. Splatter/dross are blown away from the work area as the torch cuts. The torch head

4. In a portion of the unwanted metal start rotates towards vertical as the cut grows deeper

the pierce off the cutting line and then and pierces the workpiece.

continue the cut onto the line. Hold the

torch perpendicular to the workpiece

after the pierce is complete.

5. Slide the trigger release toward the back of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Art # A-13353

Trigger

Trigger Release

A-02986

TORCH OPERATION

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4T.03 Gouging

Lead Angle

CUTMASTER 30+

WARNING
! Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator's body comes in contact with the workpiece when the torch is activated. Disconnect primary power to the system before disassembling the torch, leads, or power supply.

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 than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

CAUTION
! Sparks from plasma gouging can cause damage

Torch Head

to coated, painted or other surfaces such as glass,

plastic, and metal.

Check torch parts. The torch parts must

correspond with the type of operation. Refer to

35°

Section 4T.07, Torch Parts Selection.

Gouging Parameters
Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff ).

A-00941_AB

Standoff Height Workpiece Gouging Angle and Standoff Distance

CAUTION Touching the torch tip or shield cup to the work

surface will cause excessive parts wear.

Torch Travel Speed

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

Standoff Distance
The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).
Current Setting
Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

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

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TORCH OPERATION

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TORCH OPERATION

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SECTION 5 SYSTEM: SERVICE

CUTMASTER 30+

5.01 General Maintenance

Warning!

Maintain more often if used under severe

Disconnect input power before maintaining. conditions

Each Use

Visual check of torch tip and electrode

Weekly

Visually inspect the torch body, consumables and Quick Connect

Visually inspect the cables and leads. Replace as needed
3 Months

Replace all broken parts

Clean exterior of power supply

5.02 Maintenance Schedule
NOTE! The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours: 1. Check torch consumable parts, replace if damaged or worn. 2. Check plasma and secondary supply and pressure/flow.
Weekly or Every 30 Cutting Hours: 1. Check fan for proper operation and adequate air flow. 2. Inspect torch for any cracks or exposed wires, replace if necessary. 3. Inspect input power cable for damage or exposed wires, replace if necessary.

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SERVICE

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Six Months or Every 720 Cutting Hours:
1. Check cables and hoses for leaks or cracks, replace if necessary.

CAUTION Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere

with sensitive electrical components and cause damage to the unit.

5.03 Common Faults

Problem Symptom Insufficient Penetration
Main Arc Extinguishes
Excessive Dross
Formation
Short Torch Parts Life
Difficult Starting

Common Cause
1. Cutting speed too fast. 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts. 5. Cutting current too low. 6. Non - Genuine Thermal Dynamics parts used 7. Incorrect gas pressure. Line pressure 90-125 psi (6.2-8.6 bar / 620-862 Kpa).
1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3. Cutting current too high. 4. Work cable disconnected. 5. Worn torch parts. 6. Non - Genuine Thermal Dynamics parts used. 7. Line voltage drop due to extension cord or supply line being too long.
1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3. Worn torch parts. 4. Improper cutting current. 5. Non - Genuine Thermal Dynamics parts used. 6. Incorrect gas pressure.
1. Oil or moisture in air source. 2. Exceeding system capability (material too thick). 3. Excessive pilot arc time. 4. Gas pressure too low. 5. Improperly assembled torch. 6. Non - Genuine Thermal Dynamics parts used.
1. Worn torch parts. 2. Non - Genuine Thermal Dynamics parts used. 3. Incorrect gas pressure. 4. Line voltage too low. 5. Wrong parts for current selection. 6. Hose restriction.

SERVICE

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5.04 Basic Troubleshooting Guide

CUTMASTER 30+

WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

Problem Symptom

Possible Cause

Recommended Action

Main Switch is ON 1. Primary power disconnect is in OFF

but the LCD does position.

not light

2. Primary fuses / breakers are blown

or tripped.

3. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.
2. a) Have qualified person check primary fuses / breakers. b) Connect unit to known good primary power receptacle.
3. Return to authorized service center for repair or replacement.

Overheating communication screen

1. Air flow through or around the unit is obstructed. 2. Duty cycle of the unit has been exceeded. 3. Failed components in unit.

1. Refer to clearance information see Section "2.04 Power Supply Specifications" on page 16. 2. Allow unit to cool.
3. Return to authorized service center for repair or replacement.

Air pressure communication screen

1. Gas supply not connected to unit. 2. Gas supply not turned ON. 3. Gas supply pressure too low.

4. Failed components in unit.

1. Connect gas supply to unit. 2. Turn gas supply ON. 3. Set air supply inlet pressure to unit to 120 psi. Set leads length to match the actual length being used. 4. Return to authorized service center for repair or replacement.

Torch installation or cover assembly communication screen

1. Shield Cup loose.

1. Hand tighten the shield cup until it is snug.

2. Torch not properly connected to power 2. Insure torch ATC is securely fastened to unit.

supply.

3. Problem in torch and leads PIP circuit. 3. Replace torch and leads or return to authorized service center for

repair or replacement.

4. Failed components in unit.

4. Return to authorized service center for repair or replacement.

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SERVICE

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5.05 Power Supply Basic Parts Replacement
Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement filter element catalog number.
1. Remove power from power supply. 2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter
Element. 3. Disconnect gas supply hose. 4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located
inside the Housing.
Housing

Filter Element (Cat. No. 9-7741)
Spring
O-ring (Cat. No. 9-7743)

Assembled Filter

Cover
Barbed Fitting

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry. 6. Wipe inside of housing clean, then insert the replacement Filter Element open side first. 7. Replace Housing on Cover. 8. Reattach gas supply. Check for leaks.

NOTE! If unit leaks between housing and cover, inspect the O-ring for cuts or other damage.
This completes the parts replacement procedures.

SERVICE

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SECTION 5 TORCH: SERVICE
5T.01 General Maintenance
NOTE! Refer to Previous "Section 5: System" for common and fault indicator descriptions.
Cleaning Torch
Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

CUTMASTER 30+

Upper Groove with Vent Holes Must Remain Open

Upper O-Ring in Correct Groove

Threads Lower O-Ring

Art # A-03725

Torch Head O-Ring

ATC Male Connector

WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

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

Gas Fitting

CAUTION Dry the torch thoroughly before reinstalling.

O-Ring Lubrication
An O-Ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis. This will allow the O-Rings to remain pliable and provide a proper seal. The O-Rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems.
It is recommended to apply a very light film of O-Ring lubricant (Catalog # 8-4025) to the O-Rings on a weekly basis.

Art #A-03791_AB

ATC O-Ring

O-Ring #8-0525

NOTE! DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain "unknown elements" that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

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SERVICE

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5T.02 Inspection and Replacement of Consumable Torch Parts
WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE! The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE! Slag built up on the shield cup that cannot be removed may effect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace if damaged.

4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary.

Good Tip

Worn Tip

A-03406
Example of Tip Wear
5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion. Replace if necessary.

Spring-Loaded Lower End Fitting Full Compression

Spring-Loaded Lower End Fitting at Reset / Full Extension

Art # A-08064_AC
6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following figure.

Art # A-08067

New Electrode

Shield Cups

3. On torches with a shield cup body and a shield cap or deflector, ensure that the cap or deflector is threaded snugly against the shield cup body. In shielded drag cutting operations (only), there may be an O-Ring between the shield cup body and drag shield cap. Do not lubricate the O-Ring.

Shield Cup Body

Drag Shield Cap

Art # A-03284

Worn Electrode
Electrode Wear

7. Reinstall the Electrode by pushing it straight into the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into the torch head.

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

This completes the parts replacement procedures.

O-Ring No. 8-3488

Art # A-03878
50

SERVICE

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SECTION 6: PARTS LISTS

CUTMASTER 30+

6.01 Introduction

A. Parts List Breakdown The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

6.03

Power Supply Replacement

6.04

Replacement Parts

6.05

Options and Accessories

6.06

Replacement Parts for SL60 Hand Torch

6.07

Torch Consumable Parts (SL60)

NOTE! Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, input power cable adapters (2), gas pressure regulator / filter, SL60 Torch, spare parts kit, and operating manual.

Qty

Description

CUTMASTER 30+ Plasma cutting machine

package Thermal Dynamics ETL

Catalog # 1-3000-1

CUTMASTER 30+ Plasma cutting machine

package Thermal Dynamics CE

1-3000-4

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PARTS LIST

CUTMASTER 30+
6.04 Replacement Parts

Item # Qty

Description
TOP HANDLE KIT HANDLE COVER PANEL, RH CM40 TD_AEB ASS'Y PANEL FRONT CM30+/40+ PANEL, LH CM 30+ TD_AEB ASS'Y, PANEL REAR CM30+/40+ TD_AEB TOP PANEL ASS'Y PCB DISPLAY CM30+ Main PCBA board assembly Control PCBA board assembly EMI PCBA board assembly Inbuilt air regulator assembly, AW2000-02D Fan, 0.61A, RUNDA Adapter connector Y shape, 8MM-8MM-G1/4 Adapter connector L shape, 8MM-G1/8 Pressure sensor, XGZP6161D102V Power switch, 690V 20A Input cable ETL, 3.3 MM2, 3.5 M Solenoid assembly, V3221-08E4 Air fitting EU Type 1/4 NPT (not shown) Air fitting Milton type D 1/4 NPT (not shown) Input cable CE, 2.5 MM2, 3.5 M (not shown) Screw, black, full thread, M5X12 Screw, black, self-tapping, 4.8X16

Catalog #
0464565880 0465952001 9-4440 0700400929 0700400930 0700400934 0465951001 0700400936 0700400937 0700400938 0700400939 0700400940 0700400941 0700400942 0700400943 0700400944 0700400945 0700400946 0700400947 0700400997 0700400917 0700400990 0700400995 0700400996

PARTS LIST

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6.05 Options and Accessories

Qty

Description

1 Single - Stage Filter Kit (includes Filter & Hose) 1 Replacement Filter Body 1 Replacement Filter Hose (not shown) 2 Replacement Filter Element 1 Work Cable #8 with 50mm Dinse plug 1 Multi - Purpose Cart 1 Shoulder strap kit

CUTMASTER 30+
Catalog # 7-7507 9-7740 9-7742 9-7741 9-9692 7-8888 0445197880

Housing

Filter Element (Cat. No. 9-7741)
Spring
O-ring (Cat. No. 9-7743)
Cover
Barbed Fitting

Assembled Filter
Art # A-02476

Optional Single - Stage Filter Kit

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PARTS LIST

CUTMASTER 30+
6.06 Replacement Parts for SL60 Hand Torch

Item # Qty

Description

Catalog #

Torch Handle Replacement Kit (includes items No. 2 & 3)

9-7030

Trigger Assembly Replacement Kit

9-7034

Handle Screw Kit (5 each, 6-32 x 1/2" cap screw, and wrench) 9-8062

Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219

Large O-Ring

8-3487

Small O-Ring

8-3486

Leads Assemblies with ATC connectors (includes switch assemblies)

SL100, 20 - foot / 6.1m Leads Assembly with ATC connector 4-7836

SL100, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7837

Switch Kit

9-7031

Complete SL60 20'/6.1m torch assembly (not shown)

7-5200

8 2 4

5 6
3
7

Art # A-07993_AB

PARTS LIST

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6.07 Torch Consumable Parts (SL60)

CUTMASTER 30+

A
0700400998 REV AA

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PARTS LIST

CUTMASTER 30+
This Page Intentionally Blank

PARTS LIST

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CUTMASTER 30+ APPENDIX 1: DATA TAG INFORMATION

Manufacturer's Name and/or Logo, Location

Production Code

Type of Power Supply (Note 1)

Serial Number
Regulatory Standard Covering This Type of Power Supply

Output Current Type Rated Supply
Plasma Cutting Symbol

Output Range (Amperage/ Voltage)
Duty Cycle Data (Note 3)

Input Power Symbol

Rated No- Conventional Conventional Load Voltage Load Current Load Voltage

Duty Cycle Factor
Regulatory Standard Covering This Type of Power Supply

Degree of Protection Input Power Rated Supply Specifications Voltage (Note 2) (Phase, AC or DC Hertz Rating)

Rated Maximum Supply Current Country of
Manufacturer

Maximum

Manufacturer's

Effective

Revision Level

Supply Current

NOTES: 1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output. 2. Indicates input voltages for this power supply. Most power
supplies carry a label on the bottom of the unit showing input voltage requirements for the power supply as built. 3. Top row: Duty cycle values.
Duty cycle values meet or exceed the IEC specified rating. 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.

Standard Symbols AC DC
Ø Phase

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APPENDIX

CUTMASTER 30+ APPENDIX 2: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

Negative / Plasma

ATC Male Connector Front View

4 - Green / Switch

3 - White /

Switch

2- Orange /

PIP

1 - Black /
PIP Pilot

8 - Open

7 - Open 8

6 - Open

5 - Open

ATC Female Receptacle Front View

Negative / Plasma

8 - Open

7 - Open 8

6 - Open

5 - Open

Pilot

4 - Switch

3 - Switch 4

3 2

2 - PIP

1 - PIP

A-03701_AB

APPENDIX

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CUTMASTER 30+ APPENDIX 3: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

Torch: SL60 Leads: Torch Leads with ATC Connector Power Supply: CM30+

Torch Head
PIP Switch

Torch Leads
Black
Orange

Torch Switch

Green White

Negative / Plasma Pilot

Male ATC Leads Connector

ATC Female Receptacle

Power Supply

To Power Supply Circuitry
To Power Supply Circuitry
Negative / Plasma Pilot

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APPENDIX

ESAB / esab.com

References

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