INPUT POWER VOLTAGE

120-
240V
OUTPUT MAX OUTPUT

40

CUTMASTER® 40+
PLASMA CUTTING SYSTEM

SERVICE
MANUAL

Revision: AA Issue Date: August, 2022 Manual No.: 0700 401 188

esab.com
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB 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 exten-
sive 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 ESAB
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.
ESAB is a Global Brand of manual and automation Plasma Cutting Products.

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® 40+
SL60™ 1Torch™
Service Manual Number 0700 401 188

Published by:
ESAB Group Incorporated
2800 Airport Rd.
Denton, Texas 76207

www.esab.com

© Copyright 2022 by
ESAB

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 August, 2022

Revision Date: 30 August, 2022

See website for Warranty Information.

Record the following information for Warranty purposes:

Where Purchased:_____________________________________________________

Purchase Date:_______________________________________________________

Power Supply Serial #:_________________________________________________

Torch Serial #:________________________________________________________

i
 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 equip-
ment. 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 mainte-
nance, 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!
This Page Intentionally Blank
 TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION............................................................ 9
1.01 Notes, Cautions and Warnings.................................................................................... 9

SECTION 2 SYSTEM: INTRODUCTION .......................................................... 11

2.01 How To Use This Manual........................................................................................... 11
2.02 Equipment Identification.......................................................................................... 11
2.03 Receipt Of Equipment............................................................................................... 11
2.04 Power Supply Specifications ETL............................................................................... 12
2.04.01 Additional Power Supply Specifications...........................................................12
2.05 Input Wiring Specifications ETL................................................................................ 13
2.06 Power Supply Specifications CE................................................................................ 14
2.06.01 Additional Power Supply Specifications...........................................................14
2.07 Input Wiring Specifications CE.................................................................................. 14
2.08 Generator Recommendations................................................................................... 15
2.09 Power Supply Features ............................................................................................ 16

SECTION 2 TORCH: INTRODUCTION ............................................................ 19

2T.01 Scope of Manual....................................................................................................... 19
2T.02 General Description.................................................................................................. 19
2T.03 Specifications .......................................................................................................... 19

SECTION 3 SYSTEM: INSTALLATION ............................................................ 21

3.01 Unpacking................................................................................................................ 21
3.02 Lifting Options.......................................................................................................... 21
3.03 Gas Connections....................................................................................................... 22
3.04 Primary Input Power Connections............................................................................ 23
3.05 Work Lead Connections............................................................................................ 24

SECTION 3 TORCH:
INSTALLATION.......................................................................................... 25
3T.01 Torch Connections.................................................................................................... 25

SECTION 4 SYSTEM: OPERATION................................................................ 27

4.01 Front Panel Controls / Features................................................................................. 27
4.02 Preparations for Operation....................................................................................... 28

SECTION 4 TORCH: OPERATION................................................................... 31

4T.01 Torch Parts Selection................................................................................................ 31
4T.02 Hand Torch Operation............................................................................................... 31
4T.03 Gouging................................................................................................................... 35

SECTION 5 SYSTEM: SERVICE...................................................................... 37

READ THIS FIRST.................................................................................................................. 37
What is ESD?....................................................................................................................... 39
5.01 General Maintenance............................................................................................... 40
5.02 Maintenance Schedule............................................................................................. 40
 TABLE OF CONTENTS
5.03 Common Faults......................................................................................................... 41
5.04 Fault Indicator.......................................................................................................... 42
5.05 Basic Troubleshooting Guide..................................................................................... 44
5.06 Power Supply Filter Replacement............................................................................. 45
5.07 Circuit....................................................................................................................... 46
5.08 Advanced Troubleshooting....................................................................................... 48
5.09 Main PCB Removal................................................................................................... 53
5.10 Main PCB Installation............................................................................................... 58
5.11 In-Service, Maintenance And Periodic Inspection Procedure.................................... 62

SECTION 5 TORCH: SERVICE....................................................................... 69

5T.01 General Maintenance............................................................................................... 69
5T.02 Inspection and Replacement of Consumable Torch Parts.......................................... 70

SECTION 6: PARTS LISTS............................................................................ 71

6.01 Introduction............................................................................................................. 71
6.02 Ordering Information............................................................................................... 71
6.03 Power Supply Replacement...................................................................................... 71
6.04 Options and Accessories........................................................................................... 72
6.05 Replacement Parts................................................................................................... 73
6.06 Replacement Parts for SL60 Hand Torch ................................................................... 74
6.07 Torch Consumable Parts (SL60)................................................................................. 75

APPENDIX 1: DATA TAG INFORMATION....................................................... 77

APPENDIX 2: TORCH PIN - OUT DIAGRAMS................................................. 78
APPENDIX 3: TORCH CONNECTION DIAGRAMS............................................ 79
APPENDIX 4: SYSTEM SCHEMATIC CE & ETL................................................. 80
APPENDIX 5: MAIN PCB............................................................................ 81
 CUTMASTER 40+
SECTION 1: GENERAL INFORMATION

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.

0700 401 188 GENERAL INFORMATION 9

CUTMASTER 40+

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. Les fumées plasma peuvent être

4.1 Do not inhale fumes. dangereuses.
4.2 Use forced ventilation or local 4.1 Ne pas inhaler les fumées.
exhaust to remove the fumes. 4.2 Utiliser une ventilation forcée ou un
4.3 Do not operate in closed spaces. extracteur local pour dissiper les
Remove fumes with ventilation. fumées.
4.3 Ne pas couper dans des espaces clos.
Chasser les fumées par ventilation.
5. Arc rays can burn eyes and injure 5. Les rayons d’arc peuvent brûler les
skin. yeux et blesser la peau.
5.1 Wear correct and appropriate 5.1 Porter un bon équipement de
protective equipment to protect protection pour se protéger la tête,
head, eyes, ears, hands, and body. les yeux, les oreilles, les mains et le
Button shirt collar. Protect ears from corps. Boutonner le col de la chemise.
noise. Use welding helmet with the Protéger les oreilles contre le bruit.
correct shade of filter. 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 7. Ne pas enlever, détruire ni couvrir
this label. cette étiquette.
Replace if it is missing, damaged, La remplacer si elle est absente,
or worn. endommagée ou usée.
Art # A-13294

10 GENERAL INFORMATION 0700 401 188

 CUTMASTER 40+
SECTION 2 SYSTEM: INTRODUCTION

2.01 How To Use This Manual

This Service 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 regis-
tering 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 CE

Included items: Included items:

• CutMaster 40+ Power Supply • CutMaster 40+ Power Supply

• SL60™ Torch and Leads • SL60™ Torch and Leads
• Work Lead with Work Clamp • Work Lead with Work Clamp
• Spare Parts Kit (2 Electrodes, 2 Cutting • Spare Parts Kit (2 Electrodes, 2 Cutting
Tips, 1 Gouging Tip, 1 Shield Cap, 1 Start Tips, 1 Gouging Tip, 1 Shield Cap, 1 Start
Cartridge, 1 Shield Cup Body, 1 Deflector Cartridge, 1 Shield Cup Body, 1 Deflector
Shield Cup, 1 Standoff Cutting Guide and Shield Cup, 1 Standoff Cutting Guide and
1 Shield cup) 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
• 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.

0700 401 188 INTRODUCTION 11

CUTMASTER 40+
2.04 Power Supply Specifications ETL

CM 40+ 120-240 VAC 1 Phase Power Supply Specifications

Input Power 120 - 240 VAC, Single Phase, 50/60 Hz
Power Supply includes 3 M single phase 12AWG 3/C input cable with NEMA
1 Phase Input Power Cable ETL
6-50P Plug
Output Current 10 - 40A, 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 40+ Power Supply Duty Cycle *

Duty Cycle Ratings @ 40° C (104° F)
Ambient Air Temperature
Operating Range 0° - 50° C
Rating
Duty Cycle* 40% 60% 100%
120 VAC Units Current 25A** 21A 16A
DC Voltage 120V 120V 120V
Duty Cycle* 40% 60% 100%
208-240 VAC Units Current 40A 30A 20A
DC Voltage 135V 120V 120V

* 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: 25A is for a 20A circuit ONLY!
DO NOT exceed a 17A output setting on a 15A circuit!

12 INTRODUCTION 0700 401 188

 CUTMASTER 40+
2.05 Input Wiring Specifications ETL

1 Phase Input Cable Wiring Requirements

1 Phase Cutmaster 40+ Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Fuse Flexible Cord
Volts (AC) Hz kVA I max I1eff (amperage) (Min. AWG)
120V 50/60 2.3 19.2A 14.8A 20A 12 AWG

120V 50/60 3.7 30.3A 19.1A 35A 12 AWG

208V 50/60 6.4 30A 18.9A 50A 12 AWG

1 Phase
220V 50/60 6.37 28.3A 17.8A 50A 12 AWG
230V 50/60 6.37 27A 17A 50A 12 AWG
240V 50/60 6.37 26.2A 15.3A 50A 12 AWG
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.

0700400952

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

Thickness
CM 40+ cut capacity
mm inches
Pierce Capacity 12 1/2

Standard Edge Cutting Capacity 16 5/8

Maximum Severance Cutting Capacity 25 1

0700 401 188 INTRODUCTION 13

CUTMASTER 40+
2.06 Power Supply Specifications CE

CM 40+ 230 VAC 1 Phase Power Supply Specifications

Input Power 230 VAC, Single Phase, 50 Hz
Power Supply includes 3 M single phase 2.5mm² input
1 Phase Input Power Cable CE
cable with Schuko plug
Output Current 10 - 40A, Continuously Adjustable

Power Supply Gas Filtering Ability Particulates to 5 Microns

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

Idle power 30W

Power Factor 0.98

Efficiency 86.8%

2.06.01 Additional Power Supply Specifications

CM 40+ Power Supply Duty Cycle *

Duty Cycle Ratings @ 40° C (104° F)
Ambient Air Temperature
Operating Range 0° - 50° C
Rating
Duty Cycle* 35% or 40% 60% 100%
230 VAC Units Current 40A 30A 20A
DC Voltage 135V 120V 120V
* 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 40+ Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes
Duty Fuse Flexible Cord
Volts (AC) Hz kVA Cycle I max I1eff (amperage) (Min. mm²)
1 Phase 230 50 6.37 35% 27A 15.9A 16A 2.5mm2
1 Phase 230 50 6.37 40% 27A 17A 32A 2.5mm2
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code

14 INTRODUCTION 0700 401 188

 CUTMASTER 40+
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.

0700401186

2.08 Generator Recommendations

When using generators to power the CM 40+ Plasma Cutting System, the following ratings are a
minimum and are to be used along with the ratings previously listed.

CM 40+ Generator Specifications

Generator Output Rating CM 40+ Output Current Arc Characteristic

3 kW / 120 VAC 17A on 15A circuit Full

5 kW / 120 VAC 25A on 20A circuit Full
8 kW / 230 VAC 40A Full
NOTE: If Generator is equipped with an idle mode it will need to be in "Run" mode to operate at 40 Amps.

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

Thickness
CM 40+ cut capacity
mm inches
Pierce Capacity 12 1/2

Standard Edge Cutting Capacity 16 5/8

Maximum Severance Cutting Capacity 25 1

0700 401 188 INTRODUCTION 15

CUTMASTER 40+

2.09 Power Supply Features

Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Work Lead Receptacle

Gas Inlet Port

Input Power Main Switch

Input Power Cord

16 INTRODUCTION 0700 401 188

 CUTMASTER 40+

Weights and Dimensions

8”
203.29 mm

12.25"
311.21 mm

18.82"
478.07 mm
24.35 lb / 11.5 kg

Power Supply Dimensions & Weight

Clearances for Operation and Ventilation

15"
381 mm

6"
150 mm

15" 6"
381 mm 150 mm

Ventilation Clearance Requirements

0700 401 188 INTRODUCTION 17

CUTMASTER 40+

This Page Intentionally Blank

18 INTRODUCTION 0700 401 188

 CUTMASTER 40+
SECTION 2 TORCH: INTRODUCTION D. Parts - In - Place (PIP)

Torch Head has built - in switch

2T.01 Scope of Manual 27.5±1.5 VDC circuit rating
This manual contains descriptions, operating E. Type Cooling
instructions and maintenance procedures for the
1Torch Model SL60™ Plasma Cutting Torch. Service Combination of ambient air and gas stream
of this equipment is restricted to properly trained through torch.
personnel; unqualified personnel are strictly cau-
tioned against attempting repairs or adjustments F. Torch Ratings
not covered in this manual, at the risk of voiding
the Warranty. Manual Torch Ratings
Read this manual thoroughly. A complete under- Ambient 104° F
standing of the characteristics and capabilities Temperature 40° C
of this equipment will assure the dependable Duty Cycle 100% @ 60A @ 400 scfh
operation for which it was designed.
Maximum
60A
Current
2T.02 General Description
Voltage (Vpeak) 500 VDC
CAUTION Arc Striking
500 VDC
! Torch Leads are flexible but internal wires can Voltage
be broken. Do not exceed a 2" radius bend and
avoid repeated tight bends when possible. G. Gas Requirements

Refer to the Appendix Pages for

additional specifications as related Manual Torch Gas Specifications
to the Power Supply used.
Gas (Plasma and Secondary) Compressed Air
2T.03 Specifications
Operating Pressure 90 - 120 psi
A. Torch Configurations Refer to NOTE 6.2 - 8.3 bar
1. Hand/Manual Torch, Models Maximum Input Pressure 125 psi / 8.6 bar
The hand torch head is at 75° to the torch
5 - 8.3 SCFM
handle. The hand torches include a torch Gas Flow (Cutting and
300 - 500 scfh
handle and torch trigger assembly. Gouging)
142 - 235 lpm
10.125" (257 mm)

WARNING
! This Torch is not to be used with oxygen (O2).
The SL60QD torch should not be used on an HF
system.
3.75"
(95 mm)
Art # A-03322_AB

1.17" (29 mm) NOTE!

Operating pressure varies with torch model, oper-
ating amperage, and torch leads length. Refer to
B. Hand Torches are available as follows:
gas pressure settings charts for each model.
• 20 ft / 6.1 m 7-5200
C. Torch Parts H. Direct Contact Hazard

Starter Cartridge, Electrode, Tip, Shield Cup For standoff tip the recommended standoff
is 3/16 inches / 4.7mm.

0700 401 188 INTRODUCTION 19

CUTMASTER 40+

This Page Intentionally Blank

20 INTRODUCTION 0700 401 188

 CUTMASTER 40+
SECTION 3 SYSTEM: INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account for each item.

2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor
and / or shipping company before proceeding with the installation.

3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name,
in the information block at the front of this manual.

3.02 Lifting Options

The Power Supply includes 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.

0700 401 188 INSTALLATION 21

CUTMASTER 40+
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

22 INSTALLATION 0700 401 188

 CUTMASTER 40+
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
! Inlet air pressure above 125 psi causes 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 208-240 VAC/50A circuit. For Europe it will come with a 2.5mm2 cable and a Schuko plug for use
on a 230V/16A circuit.

Also included for ETL systems ONLY, are two adapters. One is a cable with a 120 VAC/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 120 VAC/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 17A on the power supply. Failure to do so may result in the input power
circuit breaker tripping or branch circuit overheating.

Input Voltage Rated Output Amperage (RMS) input kVA

ARC Amperage at rated output, 60 Hz,
\ ARC Voltage single-phase
120 VAC, 15A Circuit (ETL) 17A, 120 VDC 19.2A 2.3
120 VAC, 20A Circuit (ETL) 25A, 120 VDC 30.3A 3.7
208-240 VAC, 50A Circuit (ETL) 40A, 135 VDC 26.2-30A 6.4
230 VAC (CE) 40A, 135 VDC 27A 6.37

0700 401 188 INSTALLATION 23

CUTMASTER 40+
ETL ONLY

0700400952

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.

See section 3T for torch installation.

24 INSTALLATION 0700 401 188

 CUTMASTER 40+
SECTION 3 TORCH:
INSTALLATION

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

0700 401 188 INSTALLATION 25

CUTMASTER 40+

This Page Intentionally Blank

26 INSTALLATION 0700 401 188

 CUTMASTER 40+
SECTION 4 SYSTEM: OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identification

4 40A
135V 66.7PSI

2T

2 3

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.

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

• To change the selection.

0700 401 188 OPERATION 27

CUTMASTER 40+
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 clock-
wise-to-the-right to secure. Connection should only be snug with no tools used.

Negative /
Plasma
PIP Switch
8 - Open
4 - Switch 1
2
3
7 - Open
8 4
3 - Switch
4
Trigger Switch
7 3 5
6 - Open 6 2 6
5 1 7
2 - PIP
8
5 - Open Electrode
1 - PIP
Pilot

4. LCD screen

The front panel has an LCD screen to display the cutting mode, cutting current, cutting voltage, air
pressure, and error information.

4.02 Preparations for Operation

At the start of each operating session:

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

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 (40 amps maximum
at 230 VAC or 25 amps at 120 VAC). 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.

28 OPERATION 0700 401 188

 CUTMASTER 40+
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 40 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.

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 follow-
ing 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.

0700 401 188 OPERATION 29

CUTMASTER 40+
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.

30 OPERATION 0700 401 188

 CUTMASTER 40+
SECTION 4 TORCH: OPERATION
4T.01 Torch Parts Selection 3. Install the replacement Electrode by
pushing it straight into the torch head
Depending on the type of operation to be done until it clicks.
determines the torch parts to be used.
4. Install the start cartridge and desired tip
Type of operation: for the operation into the torch head.

Drag cutting, standoff cutting or goug- 5. Hand tighten the shield cup assembly
ing until it is seated on the torch head, being
careful to not cross thread the shield cup
Torch parts: while screwing onto the torch. Once
it reaches end of threads, no need to
Shield Cup, Cutting Tip, Electrode and
further tighten, as the O-rings maintain
Start Cartridge
seals and proper gas flows to front of
torch. If resistance is felt when install-
NOTE! ing the cup, check the threads before
Refer to Section 4T.07 and following for additional proceeding.
information on torch parts.
4T.02 Hand Torch Operation
Change the torch parts for a different operation
as follows: Standoff Cutting With Hand Torch

WARNING
Disconnect primary power at the source before NOTE!
assembling or disassembling torch parts, or For best performance and parts life, always use
torch and leads assemblies. the correct parts for the type of operation.

1. The torch can be comfortably held in

NOTE! one hand or steadied with two hands.
The shield cup holds the tip and start cartridge Position the hand to press the Trigger on
in place. Position the torch with the shield cup the torch handle. With the hand torch,
facing upward to keep these parts from falling out the hand may be positioned close to the
when the cup is removed. torch head for maximum control or near
the back end for maximum heat protec-
1. Unscrew and remove the shield cup tion. Choose the holding technique that
assembly from the torch head. feels most comfortable and allows good
control and movement.
2. Remove the Electrode by pulling it
straight out of the Torch Head.
NOTE!
Large O-Ring The tip should never come in contact with the
Torch Head Small O-Ring workpiece except during drag cutting operations
with the drag shield in place. See the consum-
able chart on your parts kit box for diagram.
Electrode

Start Cartridge

Tip

Shield Cup

A-03510_AB

Torch Parts
0700 401 188 TORCH OPERATION 31
CUTMASTER 40+
2. Depending on the cutting operation, do Trigger
one of the following:

a. For edge starts, hold the torch per- 1

pendicular to the workpiece with 2
the front of the tip on the edge of
the workpiece at the point where Trigger Release
the cut is to start.

b. For standoff cutting, hold the torch

1/8 - 3/8 in (3-9 mm) from the work-
piece as shown below. 3

Torch
4

Art # A-03383

6. Cut as usual. Simply release the trigger

assembly to stop cutting.

Shield Cup Standoff Distance

7. Follow normal recommended cutting
1/8" - 3/8" (3 - 9mm) practices as provided in the power
supply operator's manual.

A-00024_AB
NOTE!
When the shield cup is properly installed, there
Standoff Distance is a slight gap between the shield cup and the
3. Hold the torch away from your body. torch handle. Gas vents through this gap as part
of normal operation. Do not attempt to force the
4. Slide the trigger release toward the back shield cup to close this gap. Forcing the shield
of the torch handle while simultaneous- cup against the torch head or torch handle can
ly squeezing the trigger. The pilot arc damage components.
will start.
8. For a consistent standoff height from the
workpiece, install the standoff guide by
sliding it onto the torch shield cup. In-
stall the guide with the legs at the sides
of the shield cup body to maintain good
visibility of the cutting arc. During oper-
Trigger ation, position the legs of the standoff
guide against the workpiece.

Trigger Release
A-02986

5. Bring the torch within transfer distance

to the work. The main arc will transfer to
Shield Cup
the work, and the pilot arc will shut OFF.
Standoff Guide

NOTE! Torch Tip

The gas preflow and postflow are a characteristic Workpiece Art # A-04034

of the power supply and not a function of the

torch.

32 TORCH OPERATION 0700 401 188

 CUTMASTER 40+
Shield Cup With Straight Edge 5. Slide the trigger release toward the back
of the torch handle while simultaneous-
The drag shield cup can be used with a non ly squeezing the trigger. The pilot arc
conductive straight edge to make straight cuts will start.
by hand.

WARNING
The straight edge must be non - conductive.

Trigger

Trigger Release
Non-Conductive A-02986
Straight Edge
Cutting Guide
6. Bring the torch within transfer distance
to the work. The main arc will transfer to
A-03539 the work, and the pilot arc will shut OFF.

Using Drag Shield Cup With Straight Edge NOTE!

The gas preflow and postflow are a characteristic
The crown shield cup functions best when of the power supply and not a function of the
cutting 3/16 inch (4.7 mm) solid metal with torch.
relatively smooth surface.

Drag Cutting With a Hand Torch

Trigger
Drag cutting works best on metal 1/4" (6
mm) thick or less.
1
2
NOTE!
Trigger Release
For best parts performance and life, always use
the correct parts for the type of operation.

1. Install the drag cutting tip and set the 3

output current.

2. The torch can be comfortably held in

4
one hand or steadied with two hands.
Position the hand to press the Trigger on
the torch handle. With the hand torch, Art # A-03383

the hand may be positioned close to the

torch head for maximum control or near 7. Cut as usual. Simply release the trigger
the back end for maximum heat protec- assembly to stop cutting.
tion. Choose the holding technique that
feels most comfortable and allows good
control and movement.

3. Keep the torch in contact with the work-

piece during the cutting cycle.

4. Hold the torch away from your body.

0700 401 188 TORCH OPERATION 33

CUTMASTER 40+
8. Follow normal recommended cutting
practices as provided in the power
supply operator's manual.

NOTE!
When the shield cup is properly installed, there Trigger
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 Trigger Release
shield cup to close this gap. Forcing the shield A-02986
cup against the torch head or torch handle can
damage components.
6. Bring the torch within transfer distance
Piercing With Hand Torch to the work. The main arc will transfer to
the work, and the pilot arc will shut OFF.
1. Hold the torch away from your body.

2. The torch can be comfortably held in NOTE!

one hand or steadied with two hands. The gas preflow and postflow are a characteristic
Position the hand to press the Trigger on of the power supply and not a function of the
the torch handle. With the hand torch, torch.
the hand may be positioned close to
7. Clean spatter and scale from the shield
the torch head for maximum control or
cup and the tip as soon as possible.
near the back end for maximum heat
Spraying the shield cup in anti - spatter
protection. Choose the technique that
compound will minimize the amount of
feels most comfortable and allows good
scale which adheres to it.
control and movement.
Cutting speed depends on material, thickness,
NOTE! and the operator’s ability to accurately follow the
The tip should never come in contact with the desired cut line. The following factors may have
workpiece except during drag cutting operations. an impact on system performance:
(with the drag shield in place). See the consum-
able chart on your parts kit box for diagram. • Torch parts wear
• Air quality
3. Angle the torch slightly to direct blow-
back particles away from the torch tip • Line voltage fluctuations
(and operator) rather than directly back • Torch standoff height
into it until the pierce is complete.
• Proper work cable connection
4. In a portion of the unwanted metal start Rolling Pierce
the pierce off the cutting line and then
continue the cut onto the line. Hold the A technique that can work on thinner materials
torch perpendicular to the workpiece is a rolling pierce. A Rolling Pierce begins cutting
after the pierce is complete. with the torch head placed at an angle to the
work surface. Splatter/dross are blown away from
5. Slide the trigger release toward the back the work area as the torch cuts. The torch head
of the torch handle while simultaneous- rotates towards vertical as the cut grows deeper
ly squeezing the trigger. The pilot arc and pierces the workpiece.
will start.

Art # A-13353

34 TORCH OPERATION 0700 401 188

 CUTMASTER 40+
4T.03 Gouging Lead Angle

The angle between the torch and workpiece

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

CAUTION
! Sparks from plasma gouging can cause damage
to coated, painted or other surfaces such as glass,
Torch Head

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
Standoff Height
Gouging performance depends on parame-
ters such as torch travel speed, current level,
Workpiece
lead angle (the angle between the torch and
A-00941_AB
workpiece), and the distance between the
torch tip and workpiece (standoff ). Gouging Angle and Standoff Distance

CAUTION Standoff Distance

! Touching the torch tip or shield cup to the work
The tip to work distance affects gouge qual-
surface will cause excessive parts wear.
ity and depth. Standoff distance of 1/8 - 1/4
Torch Travel Speed inch (3 - 6 mm) allows for smooth, consistent
metal removal. Smaller standoff distances
may result in a severance cut rather than a
NOTE!
gouge. Standoff distances greater than 1/4
Refer to Appendix Pages for additional informa-
inch (6 mm) may result in minimal metal
tion as related to the Power Supply used.
removal or loss of transferred main arc.

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

0700 401 188 TORCH OPERATION 35

CUTMASTER 40+

This Page Intentionally Blank

36 TORCH OPERATION 0700 401 188

 CUTMASTER 40+
SECTION 5 SYSTEM: SERVICE

READ THIS FIRST

Maintenance and repair work should be performed by an authorized ESAB service technician. Use only
recommended replacement parts.

This service manual is intended for use by technicians with electrical/electronic training for help in
connection with fault-tracing and repair.

Before and after service, repair and maintenance work are performed, the safety procedure described
in the Safety test manual must be followed! The Safety test manual can be downloaded from the
Internet: manuals.esab.com

The circuit boards are divided into numbered blocks. Component names in the wiring diagram are
listed in the component description.

Use the spare parts list as a guide to where the components are located in the equipment. The spare
parts list is published as a separate document, see the "PARTS LISTS" chapter in this manual.

CAUTION!
! Repair and electrical work should be performed by an authorized
ESAB service technician. Use only ESAB original spare and wear
parts.

CAUTION!
! STATIC ELECTRICITY can damage circuit boards and electronic
components.
• Observe precautions for handling electro-
static sensitive devices.

• Use proper static-proof bags and boxes.

0700 401 188 SERVICE 37

CUTMASTER 40+
Service aid

ESAB can offer a number of service tools that will simplify the service.

Antistatic service kit

Ordering no. 0740 511 001

The kit makes it easier to protect sensitive

components from electrostatic discharge.

Contents:

• A conductive mat (size 610×610 mm / 24×24 in.)

• A 1.5 m (3.28 ft) long ground cable with a crocodile clip

• An adjustable wrist strap and cable with a built-in

protective resistor

Recommended measuring devices:

• For safety test( insulation tester): Fluke 1503, Fluke 1507, Fluke 1577 and Fluke 1587.

• For measurements(digital multimeter): Fluke 175, Fluke 177 and Fluke 179 or with equal performance.

• Tools for disassembly and reassembly: T-25 driver, a #2 Philips driver and needle nose pliers.

CAUTION!
! STATIC ELECTRICITY can damage circuit boards and electronic
components.
• Observe precautions for handling electro-
static sensitive devices.

• Use proper static-proof bags and boxes.

38 SERVICE 0700 401 188

 CUTMASTER 40+
What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESD stands for Electro-
static Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to people. ESD
damage occurs when an ungrounded person or object with a static charge comes into contact with a
component or assembly that is grounded. A rapid discharge can occur, causing damage. This damage
can take the form of immediate failure, but it is more likely that system performance will be affected
and the component will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from building up on
you or on anything at your work station, then there cannot be any static discharges. Nonconductive
materials (e.g. fabrics), or insulators (e.g. plastics) generate and hold static charge, so you should not
bring unnecessary nonconductive items into the work area. It is obviously difficult to avoid all such
items, so various means are used to drain off any static discharge from persons to prevent the risk of
ESD damage. This is done by simple devices: wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use only antistatic packaging
materials. Overall, handling of ESD-sensitive devices should be minimized to prevent damage.

0700 401 188 SERVICE 39

CUTMASTER 40+
5.01 General Maintenance

Maintain more often

Warning! if used under severe
Disconnect input power before maintaining. conditions

Each Use

Visual check of
torch tip and electrode

Weekly

Visually inspect the

cables and leads.
Visually inspect the torch body, Replace as needed
consumables and Quick Connect

3 Months

Replace all
Clean
broken parts
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.

40 SERVICE 0700 401 188

 CUTMASTER 40+
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 - Common Cause

Symptom
Insufficient 1. Cutting speed too fast.
Penetration 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).
Main Arc 1. Cutting speed too slow.
Extinguishes 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.

Excessive 1. Cutting speed too slow.

Dross 2. Torch standoff too high from workpiece.
Formation 3. Worn torch parts.
4. Improper cutting current.
5. Non - Genuine Thermal Dynamics parts used.
6. Incorrect gas pressure.
Short Torch 1. Oil or moisture in air source.
Parts Life 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.
Difficult 1. Worn torch parts.
Starting 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.

0700 401 188 SERVICE 41

CUTMASTER 40+
5.04 Fault Indicator

Error screen

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.

42 SERVICE 0700 401 188

 CUTMASTER 40+
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 VAC, check
that the input voltage is not less than 100 VAC.

(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

0700 401 188 SERVICE 43

CUTMASTER 40+
5.05 Basic Troubleshooting Guide

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

Problem - Possible Cause Recommended Action

Symptom
Main Switch is ON 1. Primary power disconnect is in OFF 1. Turn primary power disconnect switch to ON position.
but the LCD does position.
not light 2. Primary fuses / breakers are blown 2. a) Have qualified person check primary fuses / breakers.
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.
Overheating 1. Air flow through or around the unit is 1. Refer to clearance information – see Section "2.04 Power Supply
communication obstructed. Specifications" on page 12.
screen 2. Duty cycle of the unit has been 2. Allow unit to cool.
exceeded.
3. Failed components in unit. 3. Return to authorized service center for repair or replacement.
Air pressure 1. Gas supply not connected to unit. 1. Connect gas supply to unit.
communication 2. Gas supply not turned ON. 2. Turn gas supply ON.
screen 3. Gas supply pressure too low. 3. Set air supply inlet pressure to unit to 120 psi. Set leads length to
match the actual length being used.
4. Failed components in unit. 4. Return to authorized service center for repair or replacement.
Torch installation 1. Shield Cup loose. 1. Hand tighten the shield cup until it is snug.
or cover assembly 2. Torch not properly connected to power 2. Ensure torch ATC is securely fastened to unit.
communication supply.
screen (PIP) 3. Replace torch and leads or return to authorized service center for
3. Problem in torch and leads PIP circuit. repair or replacement.
4. Failed components in unit. 4. Return to authorized service center for repair or replacement.
Electrode or nozzle 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not over tighten.
installation error 2. Torch tip, electrode or starter cartridge 2. Turn OFF power supply. Remove shield cup. Install missing parts.
communication missing.
screen (PIC) 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. Unit inlet gas pressure is too high 4. Decrease gas supply pressure to 120 PSI or less.
causing continuous gas flow.
5. Open conductor in torch leads. 5. Replace torch and leads or return to authorized service center for
repair or replacement.
6. Problem in the torch and leads switch 6. Replace torch and leads or return to authorized service center for
circuit. repair or replacement.
7. Failed components in unit. 7. Return to authorized service center for repair or replacement
Nothing happens 1. Problem in the torch and leads circuit. 1. Take Torch and Leads to Authorized Repair Facility.
when torch switch 2. Failed components in unit.
is closed,no gas 3. Gas pressure too high. 2. Return to authorized service center for repair or replacement.
flow 3. Reduce gas pressure.

No Fault occours, 1. Failed components in unit. 1. Return to authorized service center for repair or replacement.
no arc in torch.
Pilot arc is ON but 1. Work cable not connected to work 1. Connect work cable.
cutting arc will not 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.

44 SERVICE 0700 401 188

 CUTMASTER 40+
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 work 3. Check the connection of the Work Lead to the work piece.
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.

5.06 Power Supply Filter 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.

0700 401 188 SERVICE 45
CUTMASTER 40+
5.07 Circuit

Circuit description

The standard CutMaster 40+ is a single phase 120/240 VAC model. There are also specific single phase
230 VAC models to meet CE requirements.

The basic system includes an input PCB (EMI & Rectifier), a Main PCB that includes a Bias Supply, Power
Factor Correction circuit, Inverter and sec-rectifier circuit , a Control PCB, and a TFT module. The ETL
& CE (European) units both have an EMI/RFI filter before the input rectifier seen here below. Both can
be seen in the Appendix section of this manual.

46 SERVICE 0700 401 188

 CUTMASTER 40+
Single phase 120/240 VAC input power enters through an ON/OFF power switch located on the rear
panel. AC power goes first to the input EMI&Rectifier PCB. The Bias Supply is located on the Main PCB.
Initially the rectified DC power passes through inrush PTC on the main PCB to limit the current while
charging the bulk capacitors. The rectified DC voltage from the input bridge diode varies with the
incoming line voltage but the Power Factor Control (PFC) & circuit accepts the rectified DC from any AC
line voltage, 120 VAC to 240 VAC, and boosts it to the same regulated 400 VDC at the bulk capacitors.

The Inverter (Located on the Main PCB) takes the 400 VDC and converts it to a high frequency square
wave for the transformer primary. Signals from the Display board and control circuitry control the
pulse width of the square wave to regulate the output current. At the transformer secondary the high
frequency is rectified back to DC by the output diodes and filtered by the output inductor to provide
clean DC current for the plasma torch. The Inverter also accepts inputs such as the torch trigger (START),
Parts in Place (PIP), Parts in Contact (PIC) and output current signal from the Hall Effect current sensor
passing them to the Control circuitry on the Main PCB. Also controlled is a transistor (IGBT) switch to
turn the pilot on and off at the correct times.

The Control PCB holds the microprocessor with the program that operates the system. Along with the
Display it allows setting the output current, modes and dispalying any fault.

CM40+ turn ON sequence

1. Turn the input power switch ON, located on the rear panel of unit.

a. The bias supply will turn on, using a multimeter to measure 0V (TP20), +15V (TP21, ±10%), -13V (TP22, ±10%) and
+28V(TP24, ±10%), 0V (TP23), which can be seen on the upper right back side of the main PCB by removing the left
plastic side panel. (With meter - lead on TP20, when meter + lead is on TP21, the DC voltage is +15V; when meter +
lead is on TP22, the DC voltage is -13V. With meter - lead on TP23, when meter + lead is on TP24, the DC voltage is +28
V.)

b. If none of the bias supply voltages are measured correctly after turning the rear panel power switch on, measure to see
if there is DC voltage on the bulk capacitors as follows. Using a multimeter to measure the DC Voltage between TP10
(meter +) test point and TP4 (meter - )test point. Normally the DC BUS voltage will read approx. 400 VDC, if the PFC is
functioning properly. If the PFC is not functioning, the DC BUS should measure approx. 170 VDC with 120 VAC input or
approx. 325 VDC with 230 VAC input line voltage.

c. If the DC BUS voltage is near zero volts, the input voltage is not getting to the input bridge diodes. Verify whether the
units power cord is plugged into a working 120 VAC/230 VAC source, and check the fuse/circuit breaker for the voltage
source. Check for continuity between the input power cord AC1 and AC2 on the EMI and Rectifier PCB. With the rear
input power switch turned on, you should measure <1 ohm between each phase wire of the input power cord and AC1
and AC2.

2. The unit’s output cut current setting will then be displayed on the front panel. The cut current
setting will depend on the position of the current control knob and the input voltage. For
120 VAC input voltage the cut current range will be 10 to 25 Amps, and for 230 VAC input
voltage the cut current range will be 10 to 40 Amps.

3. When the plasma cutting system has input power, press the torch trigger and the internal
cooling fan will run. Let the plasma cutting system idle for about 10 minutes. The fan will
automatically stop running, and the plasma cutting system enters into idle standby mode.

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Cutting sequence

1. Push and hold on the torch switch located on the torch handle.

2. Air will flow through the torch separating the Tip and Electrode for less than 1 second.

3. The air will shut off allowing the tip and Electrode to come back in contact.

4. The inverter will then turn on as the air flow through the torch starts the pilot arc. As long
as the torch switch is pressed, the pilot arc should remain on.

5. When the pilot arc is close to the metal piece (TIP approximately 3/8” from metal, the arc will
transfer to the metal piece and become a transferred arc as the pilot arc turns off.

6. As the transferred arc is pulled away from the metal piece, the pilot arc will restart as the
transferred arc ends as long as the torch switch remains on (only in grid cutting mode, pilot
will reattach).

7. If the torch switch is turned off, the pilot arc will stop, air flow through the torch will continue
to flow for 30s before turning off.

5.08 Advanced Troubleshooting

NOTE!
Circuit diagrams and Main PCB layouts with test points can found in the Appendix section of this manual.

READ FIRST

Some of the following tests require a multimeter with both a resistance (ohms), preferable X1, scale
and diode measuring scale. You need to become familiar with how your meter measures diodes. Most
meters apply a positive voltage on the + or red lead. I will refer to + and – leads. For + use whichever
color your meter applies the + voltage.
Art # A-00307

0.75

Forward Bias
Diode Conducting

Diode Test Symbol

VR COM A
+ _
Anode

Cathode

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Diodes will conduct in one direction, referred to as the “forward” direction and show an open or high
resistance in the reverse direction.

You need to be familiar with how your meter reads the forward direction of a diode on the diode
measuring scale. Some digital meters such as Fluke show a voltage, usually 0.3 to 0.5V for forward
resistance of a power diode such as we will be measuring here. Other meters may show a different
number. Replace the values shown here with what is typical with your meter if it is different. We will
refer to this measurement as resistance/voltage to cover either type of meter. Smaller diodes usually
read a little higher, perhaps 0.6-0.7V. Whatever your meter reads for one diode in the forward direction
expect twice that for two diodes in series.

When measuring diodes connected to capacitors, as many of these are, the reverse direction may show
a low resistance/voltage at first but the reading gradually rises as the capacitor charges. Reversing
the meter will slowly discharge the capacitors, reading going down, then increasing in the opposite
direction until the value stabilizes. Let the reading come to a stable value or go off scale before you
decide what the actual reading is.

On all of these measurements measure on the terminal or the PCB pad, not the screw head. The screw
has a coating that may not be conductive.

Power on problems

These checks to be performed with the rear input power switch to OFF position and with the power
cord not plugged in:

Input bridge diode tests

1. Meter + lead on (Bridge -) and - lead to (Phase 1 and then Phase 2). Normal should measure
as one diode in the forward direction (about 0.4V to 0.5V with Fluke meter).

2. Reversing the leads, - lead on (Bridge -) and + lead to (Phase 1 and Phase 2), should measure
higher with voltage/resistance increasing (charging a capacitor).

3. Now repeat the measurement for the (Bridge +) lead with the leads as follows: Meter – lead
on (Bridge +) and the +lead on (Phase 1 and then Phase 2), normal should measure as one
diode in the forward direction (about 0.4V to 0.5V) with Fluke meter.

4. Reversing the leads, - lead on (Bridge +) and - lead (Phase 1 and Phase 2), should measure
higher with voltage/resistance increasing (charging a capacitor).

NOTE!
If any of these read the same in either direction, high (open) or low or near zero then remove and replace the EMI&Rec-
tifier PCB.

PFC Bus Test

Under normal conditions the DC bus voltage should be approximately 400 VDC. If the input line voltage
is too low (less than 100 VAC input), the PFC circuit is either damaged or not enabled.

1. Verify the input line voltage is at least 100 VAC. If it is, next perform the following tests to
verify the condition of the PFC power devices.

2. PFC Board Diode Test. Measure between TP9 and TP10.

3. With meter + lead on TP9 and meter – lead on TP10 meter on diode scale should read as a
diode in the forward direction, a bit lower resistance than the bridge diodes (About 0.3V to
0.4V on Fluke meter).

4. Reverse the leads, meter - lead on TP9 and meter + lead on TP10. Meter should show slowly
increasing resistance/voltage (capacitor charging) until meter goes over range.

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PFC IGBT Test

1. Measure between TP9 to TP12.

2. With meter on the diode scale place + meter lead on TP12 and – lead on TP9. Should read
as a diode in the forward direction with value similar to the PFC Diode, a little lower than the
bridge rectifier (step 2) (about 0.3V to 0.4V on Fluke meter).

3. If reading is much lower (short) replace the Main PCB board.

4. If the reading is higher or slowly increasing, capacitor charging, you may have mixed up your+
and – meter leads. Reverse them and if the reading is still high in both directions, replace
the Main PCB board.

NOTE!
If either or both of these read a short or an open in both directions replace the Main PCB board.

Fan

As soon as the Bias Supply starts up the fan should start for 2s and auto run for as long as the unit is
working.

Control

After the unit powers up, the MCU and Power Driver IC on the control PCB will work.The MCU commu-
nicate with TFT, control solenoid, pilot arc IGBT, measure the air pressure, cutting current and so on.
Power driver IC control the inverter IGBT, it determines the Pulse Width and output current.

1. Control board Power is supplied by main Board, if the main Board's bias supply is unnormal,
you can take off P1 connector of control board, if it comes to be normal (refer to " 5.07 CM40+
turn on sequence."), replace the control board.

2. The power of MCU: measure between "+3.3" and"GND" of Debug connector, in close to
MCU. Place + meter lead on "+3.3" and – lead on "GND", the DC voltage should be +3.3V, if
not replace the main control board.

P2
DEBUG

DEBUG
P2

P1

P1

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Display

After the unit powers up, the front TFT panel display will show the state of the unit and the output
current. If the unit has a error fault, the fault will be displayed full screen.

1. TFT's power is supplied by Main Control board,and connected with P1; Take off P1 connector,-
place + meter lead on "+5.0V" point and – lead on "GND" of DEBUG, the DC voltage should
be approximately +5 VDC, if not replace control board; if DC voltage is normal, repalce TFT
board.

P2
DEBUG
.......
P2

P1
DEBUG

P1
+5.0 V

HI Over Temp Communication

Over temperature status will be shown on TFT if the combination of duty cycle (greater than 40%) and/
or the environment the unit is being used in exceeds 40° C.

1. Let the unit sit idle with the cooling fan running to cool the internal components and allow
the over temperature circuit to reset. Verify the internal cooling fan is running, the fan should
run all the time when the unit is in over Temp status. If not replace the fan.

2. If after 6 minutes has passed and over temperature status is still shown on TFT, measure the
NTC1 and NTC2 of the Main PCB. Remove the connection of NTC1 or NTC2, using a multi-
meter set to measure resistance. Place both leads + and – to pins 1 and 2 of the NTC, the
resistance should measure about 11.5k ohms (20° C). If the NTC is bad, usually it will measure
an open. (Note:The leads of the multimeter have some amount of resistance, short the leads
together to verify the leads measure close to zero ohms, up to approx. 0.3 ohms is normal.
If the measured resistance is greater than 0.3 ohms sometimes removing the leads from the
meter and reattaching the leads to the multimeter will lower the shorted leads test.)

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Gas Purge

The unit has an internal solenoid, which controls the gas flow/pressure.

If there is no gas flow, or low gas flow (insufficient to separate the torch parts), the display will show
AIR PRESSURE ERROR icon. If it does show this ERROR iocn most likely either the gas supply is not
connected to the rear panel gas inlet or the gas supply is not sufficient to separate the torch parts?
(Input gas pressure range is 90 to 120 PSI)

1. Confirm the input gas pressure is in the range of 90 to 120 PSI. If not connect the unit to a
90 to 120 PSI gas source.

2. Disconnect the solenoid connected to QF on the Main PCB. Measure for 170 ohms +/- 10%
between the two wires connected to the solenoid. Replace the solenoid if the measured
resistance is outside 170 +/-10% ohms.

3. If the solenoid is OK, next measure for +24 VDC on QF. Disconnect the solenoid from QF, with
the multimeter set to VDC, connect the red lead to QF-pin 1 and the black lead to J1-pin.
Next turn on the torch switch but only for about 1 second then release the torch switch, this
should not start the pilot but turn on the solenoid for approximately 10 seconds (post flow).
If the voltage measured on QF is not 24 VDC +/- 10%, replace the Main PCB.

4. If the solenoid coil measures OK and the 24 VDC on QF measures OK, it’s possible the sole-
noid is not functioning properly or the gas regulator is not functioning properly or either is
blocked. If so replace the gas system assembly.

If the Pilot arc does not start or the pilot arc does not transfer onto the work piece properly, turn the
unit off, unplug from the power source and perform the following inverter power device tests.

Inverter IGBT Test

1. With meter on diode scale place + lead on TP4 and – lead on TP10 . Normal reading should
be two times that of a diode in the forward direction, as it is measuring 2 diodes in series.
(About 0.6 V to 0.75 V with Fluke.)

2. Half of that, one forward diode, while rare, may indicate one shorted IGBT. If that is the case
replace the Main PCB. If you measure an open, some or all of the IGBTs are damaged and
you will need to replace the Main PCB.

Sec-Rectifier Output Diode Test

1. With torch removed, measure Work to NEG at the front panel ATC connector.

2. With meter on diode scale place the + lead on the negative terminal of the ATC connector
and the – lead on the Work lead Dinse receptacle.

3. Normal reading is that of a diode in the forward direction. (0.6V to 0.75V with Fluke.) If shorted
replace the Main PCB.

4. If above reads open, reverse the leads, you may have gotten + and – leads reversed.

5. Lower resistance/voltage including at or near zero indicate shorted Diodes, replace the Main
PCB.

6. If the reading is higher or slowly increasing, capacitor charging, you may have mixed up your
+ and – meter leads. Reverse them and if the reading is still high in both directions, indicates
open IGBTs, replace the Main PCB.

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Pilot IGBT Test

1. Measure Tip to Work. (Torch removed from ATC).

2. With meter on diode scale place the + lead on the pilot terminal of the ATC connector and
the – lead on the Work lead Dinse receptacle.

3. Normal reading is that of a diode in the forward direction. (0.3V to 0.5V with Fluke.) If shorted,
replace the main PCB.

4. If above reads open, reverse the leads, you may have gotten + and – leads reversed. If open
in both directions check the connection from the ATC to the Inverter board terminal labeled
TIP. If OK replace the main PCB.

5.09 Main PCB Removal

WARNING
Do not attempt to replace this PCB while connected to input power. Dangerous voltages may be present.

NOTE!
Removal of the Main PCB board will require the removal and tear down of most of this system. Be careful to keep track
of all screws, nuts, harnesses and wire connection points.

Tools needed - An 8mm socket or nut driver, T-25 driver, a #2 Philips driver and needle nose pliers.

1. Remove/disconnect power from the power supply.

Remove Side Panels

2. Remove both side panels by removing the 4 screws holding each in place.

3. Remove the 2 screws in the front and 2 in the rear.

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4. The only thing holding the handle cover assembly in place are 4 plastic loops, 2 on each side.
Using your fingers and facing the front of the unit, pull outward on the front 2 loops while
also pulling up on the assembly just enough to release them. Do the same to the rear and
you can then remove the handle cover assembly.

Making room for the Main PCB to be removed

5. Disconnect the 1hose (blue) and 3 harness (red) coming from heat sink and PCB.

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6. Remove the 3 bottom screws on the rear panel and loosen the screw holding the power cord
in place.

7. There are two loops in the bottom corners holding the rear panel in place just like the top
cover. Using your fingers only, pull them back and the rear panel enough to release them
both. You may need to work on one side at a time while helping to feed the power cord in
through the panel. You are only trying to get some extra room to remove the Main PCB.

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8. Disconnect the 1 hose (blue) and 5 harness(red) coming from heat sink and Control, Power
PCB.

9. Remove the 2 bottom screws on the front panel.

10. There are two loops in the bottom corners holding the front panel in place just like the top
cover. Using your fingers only, pull them back and the front panel enough to release them
both. You are only trying to get some extra room to remove the Main PCB.

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Remove the Gas regulator assembly.

11. Disconnect the 1hose (blue) and 4 harness (red) coming from heat sink and Control, Power
PCB.

12. Then remove the 12 screws on top (red arrows) and remove the assembly.

13. Then remove three screws on Fan and remove the Gas regulator assembly.

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14. Remove the 2 screws along the bottom of the Main PCB. Using anti static measures, remove
the Main PCB.

5.10 Main PCB Installation

WARNING
Do not attempt to replace this PCB while connected to input power. Dangerous voltages may be present.

Tools needed - An 8mm socket or nut driver, T-25 driver, a #2 Philips driver and needle nose pliers.

NOTE!
Read the anti static precautions and handling instructions that came with the Main PCB before attempting installation.

CAUTION
! When securing the transformer and inductor assembly to the main PCB, be sure that the fan and foam are properly
alligned with each other and the rear panel. Failure to do so could cause the fan to stall.

CAUTION
! When installing the Input Bridge Rectifier PCB, clean the bridge diodes and the heat sinks. Apply a complete and even
layer of the thermal paste to each of the two diodes before securing to the heat sinks on the Main PCB. Wipe off any
excess paste. Failure to apply the paste completely and evenly will result in failure of the PCB and possibly the PFD.

1. To install the Main PCB simply reverse these procedures in subsection 5.09 taking special
note of the "Warning, Note and Cautions" on this page.

2. Use the following diagrams to determine torque specs. Double check all connections when
done before applying power to the system.

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2.3 Nm

2.3 Nm

2 Nm
2.3 Nm

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1.3 Nm

2.3 Nm
2.3 Nm

1.3 Nm

0.2 Nm 1.3 Nm

0.2 Nm

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2.3 Nm

0.5 Nm

2.3 Nm

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5.11 In-Service, Maintenance And Periodic Inspection Procedure

NOTE!
The following pages should be kept together with the test report for the complete equipment set.

Cleaning the equipment

After the visual inspection has been performed and before making the electrical test the equipment
shall be cleaned!

NOTE!
The equipment shall be disconnected from the mains supply!

Check that the equipment is not clogged with dirt.

Remove the side panels to be able to reach all necessary compartments.

Which cleaning methods apply depend on: the cutting process, arc time, placement and the surround-
ing environment.

It is preferable to use an industrial vacuum cleaner to remove dust and dirt.

Using compressed air can be used with reduced pressure but may collect dust in contactors, transform-
ers and terminals. This may also cause clogged or blocked air inlets/outlets and result in overheating.

Replacing and cleaning

• Blow the inside of cabinet clean with compressed air (reduced pressure).
• Wipe and clean the inside and the feeding mechanism with a dry cloth, do not use solvents that can react or harm plastic parts.
Passed
Not passed (see remark in protocol)

After repair, inspection, and test

After repair, inspection and test shall be carried out according to manufacturer’s instructions and local
regulations. The after repair, inspection and test consists of:
• Visual inspection (see section "Visual inspection in accordance with 5.1 IEC 60974-4", page 62)
• Electrical test (see section "Electrical test", page 64)
• Functional test (see section "Functional test", page 65)
The inspection and test shall be documented in a test report (see section "Labelling and report", page 67)

A signed and dated label shall be attached to the equipment after an approved test.

Visual inspection in accordance with 5.1 IEC 60974-4

Turn off and disconnect the mains power supply to the power source. Note each unit’s serial no. in the
test report for identification.

This operation is recommended to be made currently with calibration of the equipment, ref IEC 60974-
14 General information 7.3.1.

During visual Inspection, each safety related function judged as relevant by the test personnel, shall
be checked for correct operation.

During visual inspection, the items listed in the sub-sections below shall be checked.

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Intermediate cables
• defective, damaged cable
• deformed, faulty or thermally damaged plug/socket
• deformed, faulty or thermally damaged sleeves/pins
• ineffective, cable anchorage
• cables and coupler unsuitable for the intended use and performance
Passed
Not passed (see remark in protocol)
Enclosure
• missing or damaged parts
• unauthorized modifications
• cooling openings blocked or missing air filters
• signs of overload and improper use
• missing of defective protective covers
• conductive objects put in the enclosure
• distance between live parts and enclosure
Passed
Not passed (see remark in protocol)
Return clamp
• missing or defective insulation
• defective connections
• defective, damaged switches
• other damage
Passed
Not passed (see remark in protocol)
Cutting torch
• Are all parts securely attached (torch, torch mount, cable assembly)?
• Are all hoses connected correctly and protected from damage?
• Is the ATC connector fastened tightly?
• Is the cable assembly length correct and suitable for the installation?
• The cable must not be bent sharply, any risk of the cable catching on another object must be eliminated.
• Is the wire liner clean and properly assembled?
Passed
Not passed (see remark in protocol)
Cutting circuit
• defective damaged cable
• deformed, faulty or thermally damaged connector/sockets
• cables and connectors unsuitable for the intended use and performance
Passed
Not passed (see remark in protocol)
General condition
• defective gas hoses and connections
• poor readability of markings and labelling
• other damage or signs of improper use
• cooling fans
Passed
Not passed (see remark in protocol)
Magnetic gas valve
• Function. Operate the trigger of the torch and check by means of the gas flow whether the magnetic gas valve operates.
• Leakage. Pressurize the system and verify there is no leak, for example, there is no pressure drop. Note! Flexible gas hoses and their
connections can be sources of leaks.
Passed
Not passed (see remark in protocol)
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Controls and indicators
• defective switches, LCD
• incorrect fuses accessible from outside of the enclosure
Passed
Not passed (see remark in protocol)

Electrical test

1. Disconnect the power source from the mains supply.

2. Check the continuity of the protective circuit: Remove the left side panel and top panel.

Measure the resistance of the protective circuit from the middle panel to the protective earth connection in the mains plug.

During the measurement the cable should be bent, flexed and twisted along the whole length in order to detect interruptions in
the protective conductor.

Required value for cables up to 3 m: Max 0.3 Ω

3. Check the insulation resistance using an insulation tester with the measurement voltage set to 500 V DC:

a) Turn the power source mains switch to position ON.

b) Measure between the supply pins in the mains plug and the welding outlets.

Required value: 5 MΩ or more

c) Measure between the outlets and the protective earth connection in the mains plug.

Required value: 2.5 MΩ or more

d) Measure between the supply pins in the mains plug and the protective earth connection in the mains plug.

Required value: 2.5 MΩ or more

e) Turn the power source mains switch to position OFF.

PIP Test

1. Keep the torch away from your body.

2. Take off the shield cup and keep the electrode; Torch connected to ATC connector.

3. Connect the air line to the quick connect inlet port and supply enough gas pressure.

4. Turn ON the Power and the PIP error icon should display.

5. Measure Electrode to Work. With meter on DC voltage scale, place the + lead on the work lead Dinse receptacle and - lead on the
Electrode of the torch. You can read about 10VDC, this is PIC signal.

6. Press the trigger and the power doesn't work, make sure the voltage is no higher than 10VDC.

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Functional test

1. Each safety related function judged as relevant by the test personnel shall be checked for correct operation.

Conformity shall be checked by operating the device and by checking whether the welding power source operates correctly.

2. Check the supply circuits on/off switching device:

a) Disconnect the welding power source from the mains supply.

b) Remove the side panels and top panel of the power source.

c) Turn the welding power source mains switch to position OFF.

d) Perform the following resistance measurements between the supply pins of the mains plug and connector AC1,AC2 and
GND on the EMI & Rectifier board:

– Between L1 in the mains plug and AC1. Required value: Open circuit

– Between L2 in the mains plug and AC2. Required value: Open circuit

– Between Earth in the mains plug and GND. Required value: Less than 0.5 Ω

e) Turn the welding power source mains switch to position ON.

f) Perform the following resistance measurements between the supply pins of the mains plug and connector X4, X5 and
X6 on the input rectifier module:

– Between L1 in the mains plug and AC1. Required value: Less than 0.5 Ω

– Between L2 in the mains plug and AC2. Required value: Less than 0.5 Ω

– Between Earth in the mains plug and GND. Required value: Less than 0.5 Ω

<0.5Ω

<0.5Ω

<0.5Ω

g) Reattach the side panels and top panel of the power source

3. Check the function of the display by turning on the unit and visually checking the setting panel.

The LCD display will display welcome screen then model name for 3 seconds.

4. Check the cutting function by cutting.

5. Disconnect the power source from the mains supply.

6. Write the test report (see section "Labelling and report", page 66).

7. If the unit passes all tests, attach the appropriate label containing signature and date of the test.

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Labelling and report

Add this visual inspection check-ups in the test report for the complete welding equipment (safety
test report), follow the “IN-SERVICE, MAINTENANCE AND PERIODIC INSPECTION PROCEDURE” chapter
in the service manual for the used welding power source.
• Check the function of the power source by cutting.
• Write the test report.
• The equipment passes all the tests, attach appropriate label with signature and date of the test and/or recommended date for next
inspection.

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Maintenance and inspection procedure

Testing equipment

5.1 VISUAL INSPECTION □ Passed □ Not passed (see

remark in protocol)
ELECTRICAL TEST: Limit Measured values

5.2 Protective conductor ≤ 0.3 Ω

resistance

5.3 Insulation resistance:

d. Supply circuit / welding circuit ≥ 5 MΩ

(500 V DC)
e. Welding circuit/ protective ≥ 2.5 MΩ
circuit (500 V DC)
f. Supply circuit/ protective ≥ 2.5 MΩ
circuit (500 V DC)

6 FUNCTIONAL TEST □ Passed

□ Not passed (see remark in
protocol)
Remarks

Date

Inspected by Signature

Date

Local representative Signature

Testing company

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CUTMASTER 40+

This Page Intentionally Blank

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SECTION 5 TORCH: SERVICE

5T.01 General Maintenance

Upper Groove
with Vent Holes
Must Remain Open
NOTE!
Refer to Previous “Section 5: System” for com- Upper O-Ring
mon and fault indicator descriptions. in Correct Groove

Threads
Cleaning Torch
Lower O-Ring Art # A-03725

Even if precautions are taken to use only

Torch Head O-Ring
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. 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 cot-
ton swab or soft wet rag. In severe cases, Gas Fitting
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_AB O-Ring
#8-0525

ATC O-Ring
O-Ring Lubrication

An O-Ring on the Torch Head and ATC Male NOTE!

Connector requires lubrication on a sched- DO NOT use other lubricants or grease, they may
uled basis. This will allow the O-Rings to not be designed to operate within high tempera-
remain pliable and provide a proper seal. tures or may contain “unknown elements” that
The O-Rings will dry out, becoming hard may react with the atmosphere. This reaction
and cracked if the lubricant is not used on can leave contaminants inside the torch. Either
a regular basis. This can lead to potential of these conditions can lead to inconsistent
performance problems. performance or poor parts life.

It is recommended to apply a very light film

of O-Ring lubricant (Catalog # 8-4025) to the
O-Rings on a weekly basis.

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5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive
Consumable Torch Parts wear (indicated by an elongated or
oversized orifice). Clean or replace the
tip if necessary.
WARNING Good Tip Worn Tip
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.
A-03406

Remove the consumable torch parts as follows: Example of Tip Wear

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

NOTE!
Slag built up on the shield cup that cannot be
removed may effect the performance of the Art # A-08064_AC

system.
6. Pull the Electrode straight out of the
2. Inspect the cup for damage. Wipe it Torch Head. Check the face of the elec-
clean or replace if damaged. trode for excessive wear. Refer to the
following figure.

New Electrode
Art # A-08067

Shield Cups
Worn Electrode
Art # A-03284
3. On torches with a shield cup body and
a shield cap or deflector, ensure that Electrode Wear
the cap or deflector is threaded snugly 7. Reinstall the Electrode by pushing it
against the shield cup body. In shielded straight into the torch head until it clicks.
drag cutting operations (only), there
may be an O-Ring between the shield 8. Reinstall the desired starter cartridge
cup body and drag shield cap. Do not and tip into the torch head.
lubricate the O-Ring.
9. Hand tighten the shield cup until it is
Drag Shield Cap seated on the torch head. If resistance
is felt when installing the cup, check the
Shield
Cup Body
threads before proceeding.

This completes the parts replacement procedures.

O-Ring No. 8-3488

Art # A-03878

70 SERVICE 0700 401 188

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SECTION 6: PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

6.03 Power Supply Replacement

6.04 Options and Accessories
6.05 Replacement Parts
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 Catalog #

1 CUTMASTER 40+ Plasma cutting machine
package ESAB ETL 0559141001

1 CUTMASTER 40+ Plasma cutting machine

package ESAB CE 0559141004

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6.04 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 Work Cable #8 with 50mm Dinse plug 9-9692
1 Multi - Purpose Cart 7-8888
1 Shoulder strap kit 0445197880

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 Kit

72 PARTS LIST 0700 401 188

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6.05 Replacement Parts

Item # Qty Description Catalog #

1 1 TOP HANDLE KIT 0464565880
2 1 HANDLE COVER 0465952001
3 1 PANEL, RH CM40 ESAB 0559094440
4 1 ASS'Y PANEL FRONT CM30+/40+ 0700400929
5 1 PANEL, LH CM40+ ESAB 0700400933
6 1 ASS'Y,PANEL REAR CM30+/40+ ESAB 0700400935
7 1 TOP PANEL 0465951001
8 1 ASS'Y PCB DISPLAY CM40+ 0700401192
9 1 Main PCBA board assembly CM40+ 0700401189
10 1 Control PCBA board assembly CM40+ 0700401190
11 1 EMI PCBA board assembly 0700400939
12 1 Inbuilt air regulator assembly, AW2000-02D 0700400940
13 1 Fan, 0.61A, RUNDA 0700400941
14 1 Adapter connector Y shape, 8MM-8MM-G1/4 0700400942
15 1 Adapter connector L shape, 8MM-G1/8 0700400943
16 1 Pressure sensor, XGZP6161D102V 0700400944
17 1 Power switch, 690V 25A 0700401191
18 1 Input cable ETL, 3.3 MM2, 3.5 M 0700400946
19 1 Solenoid assembly, V3221-08E4 0700400947
20 1 Air fitting EU Type 1/4 NPT (not shown) 0700400997
21 1 Air fitting Milton type D 1/4 NPT (not shown) 0700400917
22 1 Input cable CE, 2.5 MM2, 3.5 M (not shown) 0700400990
23 16 Screw, black, full thread, M5X12 0700400995
24 12 Screw, black, self-tapping, 4.8X16 0700400996

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6.06 Replacement Parts for SL60 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 / 6.1m Leads Assembly with ATC connector 4-7834
1 SL60, 50 - foot / 15.2m Leads Assembly with ATC connector 4-7835
8 1 Switch Kit 9-7031
9 1 Complete SL60 20'/6.1m torch assembly (not shown) 7-5200

5
6
3

Art # A-07993_AB

74 PARTS LIST 0700 401 188

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6.07 Torch Consumable Parts (SL60)

23x6414 REV AA
A

0700 401 188 PARTS LIST 75

CUTMASTER 40+

This Page Intentionally Blank

76 PARTS LIST 0700 401 188

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APPENDIX 1: DATA TAG INFORMATION

Manufacturer's Name and/or Logo, Location

Production
Code

Serial Number

Type of Power
Supply (Note 1)

Regulatory Standard Covering

This Type of Power Supply

Output Current Type Rated Supply Output Range (Amperage/

Voltage)

Plasma Cutting
Symbol Duty Cycle Data (Note 3)

Rated No- Duty Cycle Factor

Conventional Conventional
Load Voltage Load Current Load Voltage

Regulatory Standard Covering

Input Power
This Type of Power Supply
Symbol

Rated Maximum
Degree of Protection Supply Current Maximum Manufacturer's
Input Power Rated Supply Country of Effective Revision Level
Specifications Voltage (Note 2) Manufacturer Supply Current
(Phase, AC or DC
Hertz Rating)

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
DC
supplies carry a label on the bottom of the unit showing input
voltage requirements for the power supply as built. Ø Phase
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.

0700 401 188 APPENDIX 77

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APPENDIX 2: 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 - Open

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_AB

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APPENDIX 3: TORCH CONNECTION DIAGRAMS

A. Hand Torch Connection Diagram

Torch: SL60
Leads: Torch Leads with ATC Connector
Power Supply: CM40+ 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

0700 401 188 APPENDIX 79

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APPENDIX 4: SYSTEM SCHEMATIC CE & ETL

80 APPENDIX 0700 401 188

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APPENDIX 5: MAIN PCB

0700 401 188 APPENDIX 81

ESAB / esab.com