Thermal Dynamics A40 CUTMASTER Operating Manual

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CUTMASTER

AUTOMATED PLASMA CUTTING SYSTEM

Operating Manual

Rev. AA Date: July 15, 2008 Manual # 0-4978 Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-4261888, or visit us on the web at www.thermal-dynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through marketleading, 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.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply CutMaster™ A40 SL100 ™ SV Automated Torch Operating Manual Number 0-4978

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

www.thermal-dynamics.com

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

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

Printed in the United States of America

Origindal Publication Date: July 15, 2008

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ________________

Purchase Date:__________________________________ ________________

Power Supply Serial #:___________________________ ________________

Torch Serial #:___________________________________ ________________

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ...................................................................................1-1

1.01 Notes, Cautions and Warnings ..........................................................................1-1

1.02 Important Safety Precautions ............................................................................1-1

1.03 Publications .......................................................................................................1-2

1.04 Note, Attention et Avertissement .......................................................................1-3

1.05 Precautions De Securite Importantes ...............................................................1-3

1.06 Documents De Reference .................................................................................1-5

1.07 Declaration of Conformity ..................................................................................1-6

1.08 Statement of Warranty ......................................................................................1-7

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

2.01 How To Use This Manual ...................................................................................2-1

2.02 Equipment Identiﬁcation ....................................................................................2-1

2.03 Receipt Of Equipment ....................................................................................... 2-1

2.04 Power Supply Speciﬁcations .............................................................................2-2

2.05 Input Wiring Speciﬁcations ................................................................................2-3

2.06 Power Supply Features .....................................................................................2-4

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

2T.01 Scope of Manual ............................................................................................. 2T-1

2T.02 General Description ........................................................................................2T-1

2T.03 Speciﬁcations ................................................................................................. 2T-1

2T.04 Options And Accessories ................................................................................ 2T-2

2T.05 Introduction to Plasma ....................................................................................2T-2

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

3.01 Unpacking .........................................................................................................3-1

3.02 Lifting Options ...................................................................................................3-1

3.03 Power Supply location and Mounting ................................................................3-1

3.04 Primary Input Power Connections .....................................................................3-1

3.05 Gas Connections ...............................................................................................3-4

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

3T.01 Torch Connections .......................................................................................... 3T-1

3T.02 CNC Connection ............................................................................................. 3T-1

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

4.01 Front Panel Controls / Features ........................................................................4-1

4.02 Preparations for Operation ................................................................................4-2

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

4T.01 Machine and Automated Torch Operation ....................................................... 4T-1

4T.02 Automation Torch Parts Selection ...................................................................4T-2

4T.03 Machine and Hand Torch Parts Selection .......................................................4T-3

4T.04 Cut Quality ......................................................................................................4T-3

4T.05 General Cutting Information ............................................................................ 4T-4

4T.06 Hand Torch Operation .....................................................................................4T-5

4T.07 Gouging........................................................................................................... 4T-8

4T.08 Recommended Cutting Speeds for Machine and Automated Torches With

Exposed Tip ............................................................................................ 4T-10

4T.09 Recommended Cutting Speeds for Machine and Automated Torches With

Shielded Tip ............................................................................................ 4T-22

TABLE OF CONTENTS

PATENT INFORMATION ...................................................................................................... 4T-34

SECTION 5 SYSTEM:SERVICE .............................................................................................. 5-1

5.01 General Maintenance ........................................................................................5-1

5.02 Maintenance Schedule ......................................................................................5-2

5.03 Common Faults .................................................................................................5-2

5.04 Fault Indicator....................................................................................................5-3

5.05 Basic Troubleshooting Guide .............................................................................5-4

5.06 Circuit Fault Isolation .........................................................................................5-6

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

5T.01 General Maintenance ...................................................................................... 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts .............................. 5T-2

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

6.01 Introduction .......................................................................................................6-1

6.02 Ordering Information .........................................................................................6-1

6.03 Power Supply Replacement ..............................................................................6-1

6.04 Replacement Power Supply Parts .....................................................................6-2

6.05 Options and Accessories ..................................................................................6-2

6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) ..6-4

6.07 Torch Consumable Parts Automation / Machine (SL100 SV)Torch ...................6-6

6.08 Replacement Parts - for Machine Torches ........................................................6-8

6.09 Torch Consumable Parts Manual (SL60)Torch................................................6-10

6.10 Replacement Parts for Hand Torch ................................................................6-11

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

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

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

APPENDIX 4: TORCH CONNECTION DIAGRAMS ............................................................... A-5

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS ....................................................... A-8

APPENDIX 6: SYSTEM SCHEMATIC, 400V UNITS ............................................................ A-10

APPENDIX 7: Publication History ......................................................................................... A-12

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

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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.

1.02 Important Safety Precautions

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or ﬂammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all ﬂammable or explosive vapors from the workplace.

Manual 0-4978 1-1 GENERAL INFORMATION

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• Do not cut or weld on containers that may have held combustibles.

• Provide a ﬁre watch when working in an area where ﬁre hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ ASC Z49.1:

Minimum Protective Suggested Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly seen. Experience has shown that lighter ﬁlters may be used when the arc is hidden by the workpiece.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California

Health & Safety Code § 25249.5 et seq.)

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT- TING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN- ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-4978

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classiﬁées comme suit :

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• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efﬁcacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Aﬁn d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les ﬁches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

Manual 0-4978 1-3 GENERAL INFORMATION

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma

cutmaster a40

produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inﬂammables.

• Soyez certain qu’aucune matière combustible ou inﬂammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inﬂammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enﬂammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts aﬁn d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores aﬁn d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.

Il fau t s e l a v er les main s a p rès tout e m a n ipula t i on.

(Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant ﬁssure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les ﬁltres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

GENERAL INFORMATION 1-4 Manual 0-4978

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Ofﬁce, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

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14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

Manual 0-4978 1-5 GENERAL INFORMATION

cutmaster a40

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA

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

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/ EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Speciﬁcations

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

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

* For environments with increased hazard of electrical shock, Power Supplies bearing the mark conform to EN50192 when used in

conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufacturing process.

This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as speciﬁed. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design speciﬁcations.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward

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

Operations Director

GENERAL INFORMATION 1-6 Manual 0-4978

CUTMASTER A40

1.08 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser

that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon notiﬁ cation thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ speciﬁ cations, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or ﬁ tness for a particular purpose.

Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notiﬁ ed within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.

Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

U.S. Non U.S. CUTMASTER™ A40 4 Years 3 Years 1 Year CUTMASTER™ A60 4 Years 3 Years 1 Year CUTMASTER™ A80 4 Years 3 Years 1 Year

CUTMASTER™ A120 4 Years 3 Y ears 1 Year

This warranty does not apply to:

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

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

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

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

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective September 4, 2007

Manual 0-4978 1-7 GENERAL INFORMATION

cutmaster a40

GENERAL INFORMATION 1-8 Manual 0-4978

cutmaster a40

SECTION 2 SYSTEM:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specication

or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

2.02 Equipment Identiﬁcation

The unit’s identication number (specication or

part number), model, and serial number usually 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 identied only by the specication or part number

printed on loosely attached card or the shipping container. Record these numbers on the bottom of page 1 for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the car-

rier immediately to le a claim. Furnish complete

information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identication numbers as

described above along with a full description of the parts in error. Move the equipment to the installation site before un-crating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermadyne at the address and phone number in your area listed in the inside back cover of this manual. Include the Owner’s Manual number and equipment

identication numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: http://www.thermal-dynamics.com

Manual 0-4978 2-1 INTRODUCTION

cutmaster a40

20.8"

0.528 m

43 lb / 19.5 kg

10"

254 mm

13.78"

350 mm

Art # A-08305

150 mm

24"

0.6 m

150 mm

Art # A-07925

2.04 Power Supply Speciﬁcations

CutMaster A40 Power Supply Speciﬁcations

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz

230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz

Input Power

380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

460 VAC (414 - 506 VAC), Single Phase, 60 Hz

460 VAC (414 - 506 VAC), Three Phase, 60 Hz

Input Power Cable

Power Supply includes input cable. Cable for 208/230V input power includes molded plug.

Output Current 20 - 60 Amps, Continuously Adjustable

Power Supply Gas

Filtering Ability

Particulates to 5 Microns

CutMaster A40 Power Supply Duty Cycle *

Ambient Temperature

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

IEC

Rating

IEC

Rating

IEC

Rating

Duty Cycle 40% 60% 100%

All Units

Current 60 Amps 55 Amps 50 Amps

DC Voltage 104 102 100

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low

or the output voltage (DC) is higher than shown in this chart.

NOTE

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

Power Supply Dimensions & Weight Ventilation Clearance Requirements

INTRODUCTION 2-2 Manual 0-4978

2.05 Input Wiring Speciﬁcations

CutMaster A40 Power Supply Input Cable Wiring Requirements

cutmaster a40

Input voltage Freq

Volts Hz kVA I max I eff

Power

Input

Suggested Sizes

Fuse

Flexible Cord

(amps)

(Min. AWG)

208 60 10 47 30 50 10

1 Phase

230 60 10 45 29 50 10

460 60 14 31 20 35 12

208 60 10 26 17 30 12

230 50/60 10 24 16 30 12

3 Phase

380 50/60 11 16 11 20 14

400 50/60 11 16 11 20 14

460 60 13 16 10 20 12

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

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on ﬂexible power cable with power plug installations. For hard-wired installations refer to local or national codes.

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be used to minimize damage to Plasma Cutting, Welding or power distribution equipment.

Manual 0-4978 2-3 INTRODUCTION

cutmaster a40

Art # A-08306

Mounting Rails

Torch Leads Receptacle

Control Panel

Work Cable and Clamp

Input Power Cord

Automation Interface Cable Port

Gas Inlet Port

Filter Assembly

Input Power Selection

Art # A-08318

NEVER use replaceable element fuses like UL Class H, or “one-time” fuses like UL Class K5.

2.06 Power Supply Features

INTRODUCTION 2-4 Manual 0-4978

cutmaster a40

Art # A-07402_AB

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" / 16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

2.875” / 73 mm

Art # A-02998

1.75" /

44.5 mm

1.375" / 35 mm

15.875" / 403 mm

0.625" / 16 mm

4.95" / 126 mm

1.175" / 30 mm

9.285" / 236 mm

10.125" (257 mm)

3.75"

(95 mm)

1.17" (29 mm)

Art # A-03322_AB

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60/Manual, SL100/Mechanized and SL100 SV Automated Plasma Cutting Torches. Service of this equipment is restricted to

properly trained personnel; unqualied personnel

are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2T.02 General Description

2T.03 Speciﬁcations

A. Torch Conﬁgurations

1. Automation Torch, Model

The standard automation torch has a positioning tube with rack & pinch block assembly and a solenoid valve.

2. Machine /Mechanized Torch, Model

The standard machine torch has a positioning tube with rack & pinch block assembly.

Plasma torches are similar in design to the automotive spark plug. They consist of negative and positive sections separated by a center insulator. Inside the torch, the pilot arc starts in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of

gas ows through the small orice in the torch tip,

which is focused on the metal to be cut. A single torch lead provides gas from a single source to be used as both the plasma and second-

ary gas. The air ow is divided inside the torch

head. Single - gas operation provides a smaller sized torch and inexpensive operation.

NOTE

Refer to Section 2T.05, Introduction To Plasma, for a more detailed description of plasma torch operation.

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

3. Hand/Manual Torch, Models

The hand torch head is at 75° to the torch handle. The hand torches include a torch handle and torch trigger assembly.

B. Torch Leads Lengths

Hand Torches are available as follows:

• 20 ft / 6.1 m, with ATC connectors

• 50 ft / 15.2 m, with ATC connectors Machine / Automation Torches are available

as follows:

Manual 0-4978 2T-1 INTRODUCTION

• 5 foot / 1.5 m, with ATC connectors

• 10 foot / 3.05 m, with ATC connectors

• 25 foot / 7.6 m, with ATC connectors

• 50 foot / 15.2 m, with ATC connectors

cutmaster a40

A-08331

Workpiece

Power

Supply

C. Torch Parts

Starter Cartridge, Electrode, Tip, Shield Cup

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch.

F. Torch Ratings

Automated / Machine Torch Ratings

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

Ambient

Temperature

Duty Cycle

Maximum Current

Voltage (V

Arc Striking Voltage

)

peak

Manual Torch Ratings

)

peak

100% @ 100 Amps @ 400 scfh

80% @ 120 Amps @ 400 scfh

100% @ 60 Amps @ 400 scfh

104° F

40° C

120 Amps

500V

7kV

104° F

40° C

60 Amps

500V

7kV

G. Gas Requirements

H. Direct Contact Hazard

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

2T.04 Options And Accessories

For options and accessories, see section 6.

2T.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.

While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

Automated, Manual and Machine Torch Gas

Specications

Gas (Plasma and Secondary) Compressed Air

Operating Pressure

Refer to NOTE

Maximum Input Pressure 125 psi / 8.6 bar

Gas Flow (Cutting and Gouging)

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh

142 - 235 lpm

WARNING

This torch is not to be used with oxygen (O2).

NOTE

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

INTRODUCTION 2T-2 Manual 0-4978

Typical Torch Head Detail

cutmaster a40

PIP Switch

Shield Cup

To ATC

CNC Start

PIP Switch

Shield Cup

PIP Switch

Shield Cup

Remote Pendant

Automation Torch

To ATC

Art # A-08168

A-02997

Torch Trigger

PIP Switch

Shield Cup

To Control

Cable Wiring

Torch Switch

By forcing the plasma gas and electric arc through a small oriﬁce, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.

Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.

B. Gas Distribution

The single gas used is internally split into plasma and secondary gases.

The plasma gas ﬂows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip oriﬁce.

The secondary gas ﬂows down around the outside of the torch starter cartridge, and out between the tip and shield cup around the plasma arc.

C. Pilot Arc

E. Parts - In - Place (PIP)

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

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

D. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.

Parts - In - Place Circuit Diagram for Machine

Torch

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4978 2T-3 INTRODUCTION

cutmaster a40

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4978

cutmaster a40

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 hand holds in the front and rear panels 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.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handles, using two hands. Do not use straps for lifting.

• Use optional cart or similar device of adequate capacity to move unit.

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

3.03 Power Supply location and Mounting

NOTE

It is recommended that the unit be secured to a suitable surface using the mounting rails.

1. First choose an appropriate location for mounting the power supply. Choose one that allows for free movement of torch leads, complies with ventilation per section

2.04 and provides a safe rm surface where

the unit can be secured.

2. Place the unit in the desired position and mark where the four keyway holes

in the mounting rails touch.

3. Remove the unit and using these markings, prepare holes for mounting hardware.

4. Insert proper hardware. If using hardware that screws into the mounting surface, leave all four loose enough for the thickness of the rail to slide under the head and washer if used.

5. Lower the power supply over the mounting hardware and slide forward or backward until the keyway stops against the mounting hardware.

6. Secure the hardware to the rail.

3.04 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. Check the Voltage Selector at the rear of the unit for correct setting before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as speciﬁed in Section 2.

Manual 0-4978 3-1 INSTALLATION

Most units are shipped from the factory with a 230Volt input power cable wired to the input

contactor in the single - phase conguration.

The following illustrations and directions are for

changing that conguration to a different voltage

and or to three - phase operation or back again if a change had already been made.

cutmaster a40

Upper Screws

Lower Screws

Art # A-08317

Slots

Art # A-08316

Art # A-07984_AB

Single-Phase (1ø) and Jumper Settings

Jumper L1 -L4

Jumper L2-L3

GND

Art # A-07983_AB

Three-Phase (3ø) and Jumper Settings

Jumper L1 -L4

GND

Store copper jumper in spare parts box

A. Cover Removal

1. Remove the upper and lower screws which secure the cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover.

Note

The upper screws and lower screws are not the same. Do not mix them. The upper screws are for threading into the plastic of the front and rear panels. DO NOT use the ﬁner threaded lower screws for this.

C. Input Power Selection

Set the Input Voltage Selection Switch at the rear of the unit based on the primary input voltage it is connected to. Low is 208/230 VAC and high is 460 VAC.

D. Quick Guide to Phase Wiring

2. Carefully pull the Cover up and away from the unit.

B. Cover Installation

1. Reverse previous procedures for cover installation.

When installing the upper screws, attempt to reuse the original threads. The easaiest way to do this is by turning the screw counter-clockwise until you feel the threads lign up, then begin to turn the screw clockwise to tighten. Do not over

tighten.

NOTE

Single Phase Input Power Wiring

Three Phase Input Power Wiring

NOTE

There is only one jumper setting that changes between the single and three phase settings. To change from single phase to three phase, the copper bus bar jumper connected to L2 and L3 needs to be removed and placed in a safe place for re-use. We suggest the spare parts box in the power supply. See previous illustrations.

INSTALLATION 3-2 Manual 0-4978

cutmaster a40

E. Connections to Single Phase Input Power

WARNING

Disconnect input power from the power supply and input cable before attempting this procedure.

These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Single - Phase input power.

1. Remove the Power Supply cover per instructions found in this subsection A.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out of the power supply.

4. If the power cable being used is not the factory - supplied cable, use a three - conductor input power cable for the voltage desired and strip back the insulation on the individual wires.

5. Pass the cable being used through the access opening in the back panel of the power supply. Refer to Section 2 for

power cable specications.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2).

6. Connect the wires as follows.

• Set Jumper wire and copper bus bar /

jumper on the contactor. See previous illustrations.

• Green / Yellow wire to Ground.

• Remaining wires to L1 and L2 input. It

does not matter what order these wires are attached.

7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover see subsection B.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

10. Connect the input power cable (or close

the main disconnect switch) to supply power.

F. Connections to Three Phase Input Power

WARNING

Disconnect input power from the power supply and input cable before attempting this procedure.

These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Three - Phase input power.

1. Remove the Power Supply cover per instructions found in this subsection A.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out of the power supply.

4. Using a customer supplied four - conductor input power cable for the voltage desired, strip back the insulation on the individual wires.

5. Pass the cable being used through the access opening in the back panel of the power supply. Refer to Section 2 for

power cable specications.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2).

Manual 0-4978 3-3 INSTALLATION

cutmaster a40

Art # A-08320

Inlet Port

Filter Assembly

Hose Clamp

Gas Supply Hose

1/4 NPT or ISO-R to 1/4” (6mm) Fitting

6. Connect the wires as follows.

• Remove the copper bus bar jumper from L2 and L3 on the contactor. See previous illustration.

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2 and L3 input. It does not matter what order these wires are attached. See the previous illustrations.

7. With a little slack in the wires, tighten the through - hole protector to secure the power cable.

8. Reinstall the Power Supply cover see subsection B.

9. Connect the opposite end of individual wires to a customer supplied plug or main disconnect.

10. Connect the input power cable (or close

the main disconnect switch) to supply

power.

3.05 Gas Connections

Connecting Gas Supply to Unit

The connection is the same for compressed air or high pressure cylinders. Refer to the following

subsections if an optional air line lter is to be

installed.

1. Connect the air line to the inlet port. The

illustration shows typical ttings 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.

Air Connection to Inlet Port

Installing Optional Single - Stage Air Filter

An optional lter kit is recommended for improved ltering with compressed air, to keep

moisture and debris out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet Port.

2. Attach the Filter Assembly to the lter

hose.

3. Connect the air line to the Filter. The

illustration shows typical ttings as an

example.

NOTE

For a secure seal, apply thread sealant to the ﬁtting threads, according to the 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. Connect as follows:

INSTALLATION 3-4 Manual 0-4978

cutmaster a40

Art # A-08319

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Inlet Port

Gas Supply Hose

Filter Assembly

Art # A-07945_AB

Regulator/Filter Assembly

Regulator Input

2-Stage Filter Inlet Port (IN)

Outlet Port (OUT)

Two Stage Filter Assembly

Gas Supply Hose

1/4 NPT to 1/4” (6mm) Fitting

Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line lter is also

for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.

Connect the air supply as follows:

1. Attach the Two Stage Filter bracket to the back of the power supply per instructions

supplied with the lter assembly.

NOTE

For a secure seal, apply thread sealant to the ﬁtting threads according to manufacturer's instructions. Do Not use Teﬂon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch.

Optional Single - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specications

for installation and maintenance procedures for high pressure regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briey open each cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high - pressure regulator capable

of outlet pressures up to 100 psi (6.9 bar) maximum and ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm)

I.D.

For a secure seal, apply thread sealant to the ﬁtting threads, according to manufacturer's instructions. Do Not use Teﬂon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Manual 0-4978 3-5 INSTALLATION

2. Connect the two stage lter outlet hose to

the inlet port of the Regulator / Filter Assembly.

3. Use customer - supplied ttings to connect

the air line to the Filter. A 1/4 NPT to 1/4"

hose barbed tting is shown as an example.

Optional Two - Stage Filter Installation

cutmaster a40

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specications

for installation and maintenance procedures for high pressure regulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briey open each cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high - pressure regulator capable

of outlet pressures up to 100 psi (6.9 bar) maximum and ows of at least 300 scfh (141.5 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.

Supply hose must be at least 1/4 inch (6 mm) I.D.

INSTALLATION 3-6 Manual 0-4978

cutmaster a40

Art # A-07885

Automation Interface Cable Port

Art # A-08322

Art # A-08323

Plasma Start / Stop Signal

Cutting Machine OK to Move

SECTION 3 TORCH:

INSTALLATION

3T.01 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100SV / Automation, SL100 / Mechanical or SL60 / Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, 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.

Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON

(up) position.

2. Put the Function Control switch in the SET

position.

3. Place a welding lter lens in front of the

torch and turn on the air. Do not start an arc!

Any oil or moisture in the air will be visible

on the lens.

3T.02 CNC Connection

1. Locate the interface connection port on the rear of the power supply.

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. Note the pin-out of the connector and that the customer supplied connector matches.

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

Manual 0-4978 3T-1 INSTALLATION

3. Connect CNC to the power supply.

cutmaster a40

A-02585

Workpiece

Square

Pinch Block Assembly

3T.03 Setting Up Automation or

Machine Torch

NOTE

An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine or automation torch.

WARNING

Disconnect primary power at the source before disassembling the torch or torch leads.

The Automation and Machine torch include a positioning tube with rack and pinch block assembly.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece.

Automated and Machine Torch Set - Up

3. The proper torch parts (shield cup, tip, start

cartridge, and electrode) must be installed for the type of operation. Refer to Section 4T.08, Torch Parts Selection for details.

INSTALLATION 3T-2 Manual 0-4978

SECTION 4 SYSTEM:

PSI BAR

MAX MAX

MIN MIN

1 2

Art# A-07886

MIN

MAX

PSI BAR

MAX MAX

MIN MIN

5.5

85 5.9

90 6.3

5.2

4.8

4.5

Art # A-08170

OPERATION

4.01 Front Panel Controls / Features

See Illustration for numbering Identiﬁcation

1. Output Current Control

Sets the desired output current. Output settings up to 60 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or higher for standoff cutting.

2. Function Control

Function Control Knob, Used to select between the different operating modes.

cutmaster a40

SET Used to purge the air through the unit and torch and leads and to adjust gas pressure.

RUN Used for general cutting operations

RAPID AUTO RESTART Allows for faster restarting of the Pilot Arc for uninterrupted cutting.

LATCH Used for longer hand held cuts. Once a cutting arc is established, the torch switch can be released. The cutting arc will remain on until the torch is lifted away from the work piece, the torch leaves the edge of the work piece the torch switch is activated again or if one of the system interlocks is activated.

3. On Off Power Switch

ON / OFF Switch controls input power to the power supply. Up is ON, down is OFF.

4. Air/Gas Pressure Control

The Pressure

Control is used in the "SET" mode to adjust the air/gas pressure. Pull the knob out to adjust and push in to lock.

5. AC Indicator

Steady light indicates power supply is ready for op-

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

Manual 0-4978 4-1 OPERATION

6. Temp Indicator

Indicator is normally OFF. Indicator is ON when internal temperature exceeds normal limits. Let the unit cool before continuing operation.

7. Gas Indicator

Indicator is ON when minimum input gas pressure for power supply operation is present. Minimum pressure for power supply operation is not sufﬁcient for torch operation.

8. DC Indicator

Indicator is ON when DC output circuit is active.

9. !Fault Error Indicator

Indicator is ON when Fault circuit is active. See section 5 for explanations of fault lights.

10. Pressure Indicators

The Indicators will illuminate according to the pressure set by the Pressure Control Knob (number 4).

cutmaster a40

Art # A-04509

PSI BAR

MAX MAX

MIN MIN

Art# A-07946

MIN

MAX

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 (60 amps maximum). Refer to Section 4T.07 and following for torch parts selection.

Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics model SL60 / Manual, SL100 / Mechanical or SL100 / SV Automation Torches may be connected to this Power Supply. See Section 3T of this manual.

Power On

Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas

indicator turns on if there is sufﬁcient gas pressure for power supply operation and the cooling fans turn on.

NOTE

Minimum pressure for power supply operation is lower than minimum for torch operation.

The cooling fans will turn on as soon as the unit is turned on. After the unit is idle for ten (10) minutes the fans will turn off. The fans will come back on as soon as the torch switch (Start Signal) is activated or if the unit is turned off, then turned on again. If an over temperature condition occurs, the fans will continue to run while the condition exists and for a ten (10) minute period once the condition is cleared.

Set Operating Pressure

1. Place the Power Supply Function Control

knob to the SET position. Gas will

ow.

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, Specications.

2. Connect the input power cable (or close the

main disconnect switch) to supply power to the system.

Air Source

Ensure source meets requirements (refer to Section

2). Check connections and turn air supply on.

Connect Work Cable

Clamp the work cable to the workpiece or cutting table. The 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.

2. For Standoff cutting, adjust gas pressure

from 70 - 85 psi / 4.8 - 5.9 bar (LED's

in center of control panel). Refer to the Standoff chart for pressure setting details.

OPERATION 4-2 Manual 0-4978

cutmaster a40

STANDOFF

CutMaster A40 Gas Pressure Settings

SL100

Leads

Length

Up to 25'

(7.6 m)

Each

additional

25'

(7.6 m)

SL60/SL100

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

(Mechanized Torch)

and SL100 SV

(Automated Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

3. For Drag cutting, adjust gas pressure from

75 - 95 psi / 5.2 - 6.5 bar (LED's in center

of control panel). Refer to the Drag Cutting chart for pressure setting details.

DRAG

CutMaster A40 Gas Pressure

Settings

Leads

Length

Up to 25'

(7.6 m)

Each

additional 25'

(7.6 m)

SL60/SL100

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

LATCH position the main cutting arc will be maintained after the torch switch is released.

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Section 4T.08 and following for greater details.

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality.

Postﬂow

Release the trigger to stop the cutting arc. Gas continues to ﬂow for approximately 20 seconds. During post - ﬂow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

Shutdown

Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.

Select Current Output Level

1. Place the Function Control Knob in one of the three operating positions available:

RUN ,

RAPID AUTO RESTART

or LATCH . Gas ow stops.

2. Set the output current to desired amperage with the Output Current Control Knob.

Cutting Operation

When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc. With the knob in the RAPID AUTO RESTART position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece. (Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in gouging or trimming operations when an uninterrupted restart is desired). And with the knob in the

Manual 0-4978 4-3 OPERATION

cutmaster a40

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4978

cutmaster a40

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02586

SECTION 4 TORCH:

OPERATION

4T.01 Machine and Automated Torch

Operation

Cutting With Machine or Automated Torch

These torches are activated by remote control pendant or by a remote interface device such as CNC.

1. To start a cut at the plate edge, position the center of the torch along the edge of the plate.

Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A ﬁve degree leading arc is generally recommended for air plasma on mild steel.

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.

Piercing With Machine or Automated Torch

To pierce, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

Automation and Machine Torch Operation

Manual 0-4978 4T-1 OPERATION

cutmaster a40

Art # A-04173

Electrode

Start Cartridge

Tip

Ohmic Clip (If Installed)

Torch Head

Shield Cup Body

Shield Cap

Deflector

4T.02 Automation Torch Parts

Selection

Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator’s chosen amperage level. The torch parts must correspond with the type of operation.

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

NOTE

Refer to Sections 4T.08 and following for additional information on torch parts.

Change the torch parts for a different operation as follows:

WARNING

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

NOTE

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

1. If attached, remove the ohmic clip then unscrew and remove the shield cup assembly from the torch head. Wipe it clean or replace if damaged

2. Remove the Electrode by pulling it straight out of the Torch Head.

Automation Torch Parts

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.

4. Install the starter cartridge and desired tip

for the operation into the torch head.

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

6. If used, attach the ohmic clip to the shield cup.

OPERATION 4T-2 Manual 0-4978

cutmaster a40

A-03510

Electrode

Starter Cartridge

Tip

Shield Cup

Torch Head

Kerf Width

Cut Surface Bevel Angle

Top Edge Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

4T.03 Machine and Hand Torch Parts

Selection

Depending on the type of operation to be done determines the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Starter Cartridge

NOTE

Refer to Section 4T.08 and following for additional information on torch parts.

Change the torch parts for a different operation as follows:

WARNING

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

NOTE

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed.

3. Install the replacement Electrode by pushing it straight into the torch head until it clicks.

4. Install the starter cartridge and desired tip

for the operation into the torch head.

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

4T.04 Cut Quality

NOTES

Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cut-

ting is important when nish cut quality is desired

to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated

in the following gure:

1. Unscrew and remove the shield cup assembly from the torch head.

2. Remove the Electrode by pulling it straight out of the Torch Head.

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

Cut Quality Characteristics

Cut Surface

The desired or speciﬁed condition (smooth or rough) of the face of the cut.

Nitride Build - Up

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups may create difﬁculties if the material is to be welded after the cutting process.

Manual 0-4978 4T-3 OPERATION

cutmaster a40

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Bottom Dross Buildup

Molten material which is not blown out of the cut area and resolidiﬁes on the plate. Excessive dross may require secondary cleanup operations after cutting.

Kerf Width

The width of the cut (or the width of material removed during the cut).

Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose oriﬁce has become elongated.

4T.05 General Cutting Information

WARNINGS

Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

Torch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also signiﬁcantly affect the bevel angle. Reducing standoff will generally result in a more square cut.

Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.

Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

Handle torch leads with care and protect them from damage.

NOTE

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

OPERATION 4T-4 Manual 0-4978

cutmaster a40

A-00024_AB

Shield Cup

Torch

Standoff Distance

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

A-02986

Trigger

Trigger Release

Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difﬁcult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

4T.06 Hand Torch Operation

Standoff Cutting With Hand Torch

NOTE

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

2. Depending on the cutting operation, do one of the following: a. For edge starts, hold the torch perpen-

dicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.

b. For standoff cutting, hold the torch 1/8

- 3/8 in (3-9 mm) from the workpiece as

shown below.

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting operations.

Standoff Distance

3. Hold the torch away from your body.

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

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

Manual 0-4978 4T-5 OPERATION

cutmaster a40

Art # A-03383

Trigger

Trigger Release

Shield Cup

Workpiece

Standoff Guide

Art # A-04034

Torch Tip

A-03539

Non-Conductive

Straight Edge Cutting Guide

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

6. Cut as usual. Simply release the trigger

7. Follow normal recommended cutting

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

8. For a consistent standoff height from the

NOTE

assembly to stop cutting.

practices as provided in the power supply

operator's manual.

NOTE

workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece.

Shield Cup With Straight Edge

The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand.

WARNING

The straight edge must be non - conduc-

tive.

Using Drag Shield Cup With Straight Edge

The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface.

Drag Cutting With a Hand Torch

Drag cutting works best on metal 1/4" (6 mm) thick or less.

NOTE

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

1. Install the drag cutting tip and set the output current.

2. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.

4. Keep the torch in contact with the workpiece during the cutting cycle.

5. Hold the torch away from your body.

OPERATION 4T-6 Manual 0-4978

cutmaster a40

A-02986

Trigger

Trigger Release

Art # A-03383

Trigger

Trigger Release

A-02986

Trigger

Trigger Release

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

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

NOTE

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

Piercing With Hand Torch

1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement.

NOTE

The tip should never come in contact with the workpiece except during drag cutting operations.

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

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

4. Hold the torch away from your body.

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

8. Cut as usual. Simply release the trigger assembly to stop cutting.

9. Follow normal recommended cutting practices as provided in the power supply

operator's manual.

Manual 0-4978 4T-7 OPERATION

NOTE

cutmaster a40

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

NOTES

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

7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which adheres to it.

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage uctuations

• Torch standoff height

• Proper work cable connection

4T.07 Gouging

WARNINGS

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

CAUTION

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.09, Torch Parts Selection.

Gouging Parameters

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

CAUTION

Touching the torch tip or shield cup to the work surface will cause excessive parts wear.

Torch Travel Speed

NOTE

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

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

Current Setting

Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

OPERATION 4T-8 Manual 0-4978

Lead Angle

35˚

Workpiece

Torch Head

Standoff Height

1/8 - 1/4"

A-00941

The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

cutmaster a40

Gouging Angle and Standoff Distance

Standoff Distance

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

Slag Buildup

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

Manual 0-4978 4T-9 OPERATION

cutmaster a40

4T.08 Recommended Cutting Speeds for Machine and Automated Torches

With Exposed Tip

Mild Steel 40A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 111 0.14 55 0.18 0.4 0.06

1/4 0.250 117 0.14 40 0.18 0.5 0.07

3/8 0.375 119 0.14 25 0.18 1.2 0.07

1/2 0.500 120 0.14 15 0.2 2.0 0.07

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.036

0.060 103 0.14 140 0.18 0.0 0.05

0.075 105 0.14 120 0.18 0.1 0.06

0.105 108 0.14 80 0.18 0.2 0.06

0.135 110 0.14 60 0.18 0.3 0.06

70 (25')

75 (50')

Arc Voltage

Volts

101 0.14 160 0.18 0.0 0.05

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-10 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

BOLD TYPE indicates maximum piercing parameters.

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101

105 3.6 2920 4.6 0.1 1.4

109 3.6 1810 4.6 0.3 1.5

110 3.6 1470 4.6 0.3 1.6

112 3.6 1345 4.6 0.4 1.6

116 3.6 1100 4.6 0.5 1.7

118 3.6 815 4.6 1.0 1.7

119 3.6 595 4.6 1.5 1.8

120 3.6 435 5.1 2.0 1.8

Working

Height

3.6

Travel Speed

3990 4.6 0.0 1.1

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-11 OPERATION

cutmaster a40

Stainless Steel 40A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 110 0.19 30 0.20 0.40 0.07

1/4 0.250 120 0.19 18 0.20 0.50 0.08

3/8 0.375 126 0.19 10 0.20 2.00 0.08

1/2 0.500 118 0.19 8 Edge start 0.09

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.050

0.063 100 0.19 50 0.20 0.00 0.07

0.078 105 0.19 45 0.20 0.10 0.07

0.109 110 0.19 40 0.20 0.20 0.07

0.141 108 0.19 35 0.20 0.30 0.07

75 (25')

80 (50')

Arc Voltage

Volts

110 0.19 60 0.20 0.00 0.07

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-12 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

112

105 4.8 1140 5.1 0.1 1.8

109 4.8 980 5.1 0.2 1.8

109 4.8 845 5.1 0.3 1.8

111 4.8 715 5.1 0.4 1.8

118 4.8 525 5.1 0.5 2.0

123 4.8 350 5.1 1.5 2.0

125 4.8 245 5.1 2.0 2.0

120 4.8 215 Edge Start 2.2

Working

Height

4.8

Travel Speed

1670 4.8 0.0 1.7

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-13 OPERATION

cutmaster a40

Aluminum 40A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 116 0.18 75 0.18 0.5 0.07

1/4 0.250 128 0.18 30 0.18 1.0 0.08

3/8 0.375 150 0.18 10 Edge Start 0.09

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.040

0.063 97 0.16 170 0.16 0.0 0.06

0.097 113 0.16 100 0.16 0.2 0.07

0.125 115 0.16 90 0.18 0.3 0.07

0.160 113 0.18 85 0.18 0.4 0.07

70 (25')

75 (50')

Arc Voltage

Volts

95 0.16 300 0.16 0.0 0.06

Tip Starter Cartridge Electrode

9-8208 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-14 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

1.0

2.0 104 4.1 3500 4.1 0.2

3.0 115 4.1 2350 4.6 0.3

4.0 113 4.6 2170 4.6 0.4

5.0 118 4.6 1740 4.6 0.5

6.0 125 4.6 1015 4.6 0.8

8.0 139 4.6 500 Edge Start

10.0 153 4.6 180 Edge Start

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

4.8 (7.6m)

5.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

95 4.1 7620 4.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

1.6

1.7

1.8

1.9

2.0

2.2

Manual 0-4978 4T-15 OPERATION

cutmaster a40

Mild Steel 60A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 121 0.19 100 0.19 0.20 0.08

1/4 0.250 122 0.19 80 0.19 0.30 0.08

3/8 0.375 124 0.19 50 0.19 0.50 0.09

1/2 0.500 132 0.19 26 0.19 0.75 0.10

5/8 0.625 135 0.19 19 Edge Start 0.10

3/4 0.750 136 0.19 14 Edge Start 0.08

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.060

0.075 120 0.19 285 0.19 0.10 0.08

0.120 118 0.19 180 0.19 0.10 0.08

0.135 119 0.19 176 0.19 0.10 0.08

85 (25')

90 (50')

1.000 150 0.19 6 Edge Start 0.11

Arc Voltage

Volts

118 0.19 290 0.19 0.00 0.08

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-16 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

115

120 4.8 7015 4.0 0.10 1.9

118 4.8 4570 4.8 0.10 0.1

120 4.8 3650 4.8 0.20 1.9

121 4.8 2465 4.8 0.20 2.1

122 4.8 2145 4.8 0.30 2.0

123 4.8 1635 4.8 0.40 2.2

125 4.8 1180 4.8 0.60 2.4

130 4.8 795 4.8 0.75 2.4

134 4.8 530 Edge Start 2.4

138 4.8 325 Edge Start 2.2

149 4.8 165 Edge Start 2.7

Working

Height

4.8

Travel Speed

7540 4.8 0 2.1

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-17 OPERATION

cutmaster a40

Stainless Steel 60A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 122 0.19 90 0.20 0.20 0.08

1/4 0.250 123 0.19 65 0.20 0.30 0.09

3/8 0.375 130 0.19 30 0.20 0.50 0.09

1/2 0.500 132 0.19 21 0.20 0.90 0.08

5/8 0.625 132 0.19 14 Edge Start 0.11

3/4 0.750 135 0.19 10 Edge Start 0.10

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.063

0.078 116 0.19 300 0.20 0.10 0.07

0.125 123 0.19 150 0.20 0.10 0.07

0.141 118 0.19 125 0.20 0.10 0.08

85 (25')

90 (50')

Arc Voltage

Volts

119 0.19 350 0.20 0.00 0.05

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-18 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

124

116 4.8 7560 5.1 0.10 1.7

122 4.8 4365 5.1 0.10 1.7

119 4.8 2865 5.1 0.20 2.1

122 4.8 2195 5.1 0.20 2.1

123 4.8 1790 5.1 0.30 2.2

127 4.8 1190 5.1 0.40 2.2

130 4.8 725 5.1 0.50 2.2

132 4.8 580 5.1 0.90 2.1

132 4.8 405 Edge Start 2.6

136

Working

Height

4.8

Travel Speed

10890 5.1 0.00 0.8

230 Edge Start 2.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-19 OPERATION

cutmaster a40

Aluminum 60A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

3/16 0.188 132 0.25 170 0.25 0.20 0.09

1/4 0.250 132 0.25 85 0.25 0.30 0.09

3/8 0.375 141 0.25 45 0.25 0.50 0.10

1/2 0.500 148 0.25 30 0.25 0.80 0.09

5/8 0.625 145 0.19 18 Edge Start 0.08

3/4 0.750 147 0.19 12 Edge Start 0.10

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

0.064

0.079 126 0.25 300 0.25 0.10 0.09

0.120 128 0.25 250 0.25 0.10 0.09

85 (25')

90 (50')

Arc Voltage

Volts

123 0.25 440 0.25 0.00 0.08

Tip Starter Cartridge Electrode

9-8210 9-8213 9-8215

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-20 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

2 126 6.4 7680 6.4 0.10

3 128 6.4 6410 6.4 0.10

4 130 6.4 5230 6.4 0.20

5 132 6.4 4010 6.4 0.20

6 132 6.4 2640 6.4 0.30

8 137 6.4 1630 6.4 0.40

10 142 6.4 1085 6.4 0.60

12 146 6.4 845 6.4 0.70

15 146 4.8 540

20 148 4.8 260

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 17010 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Edge Start

Pierce Delay

Kerf Width

@ Rec.

Speed

1.8

2.3

2.4

2.3

2.1

2.5

Manual 0-4978 4T-21 OPERATION

cutmaster a40

4T.09 Recommended Cutting Speeds for Machine and Automated Torches

With Shielded Tip

Mild Steel 40A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 115 0.16 65 0.16 0.4 0.07

1/4 0.250 118 0.16 45 0.16 0.5 0.07

3/8 0.375 123 0.16 23 0.16 1.2 0.08

1/2 0.500 128 0.16 18 0.16 2.0 0.08

0.036

0.060 113 0.16 120 0.16 0.0 0.06

0.075 108 0.16 90 0.16 0.1 0.06

0.105 111 0.16 75 0.16 0.2 0.06

0.135 114 0.16 65 0.16 0.3 0.07

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts

107 0.16 130 0.16 0.0 0.06

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-22 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

BOLD TYPE indicates maximum piercing parameters.

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

108

108 4.1 2239 4.1 0.0 1.5

112 4.1 1794 4.1 0.1 1.7

114 4.1 1651 4.1 0.2 1.7

115 4.1 1578 4.1 0.3 1.7

117 4.1 1256 4.1 0.4 1.7

121 4.1 853 4.1 0.5 1.7

124 4.1 565 4.1 1.2 1.8

127 4.1 485 4.1 2.0 1.9

Working

Height

4.1

Travel Speed

3266

Initial

Piercing

Height

4.1

Pierce Delay

0.0 1.4

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-23 OPERATION

cutmaster a40

Stainless Steel 40A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 115 0.16 30 4.1 0.4 0.07

1/4 0.250 118 0.16 20 4.1 1.2 0.07

3/8 0.375 125 0.16 15 4.1 1.8 0.08

1/2 0.500 127 0.16 10 4.1 2.0 0.08

0.050

0.063 108 0.16 50 4.1 0.1 0.07

0.078 114 0.16 45 4.1 0.1 0.07

0.109 113 0.16 40 4.1 0.2 0.07

0.141 116 0.16 35 4.1 0.3 0.07

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts

110 0.16 60 4.1 0.0 0.06

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-24 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

BOLD TYPE indicates maximum piercing parameters.

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

109

114 4.1 1140 4.1 0.1 1.8

114 4.1 980 4.1 0.2 1.8

116 4.1 845 4.1 0.3 1.8

115 4.1 725 4.1 0.4 1.8

117 4.1 565 4.1 0.5 2.0

122 4.1 440 4.1 1.5 2.0

125 4.1 360 4.1 1.8 2.0

127 4.1 280 4.1 2.0 2.2

Working

Height

4.1

Travel Speed

1670 4.1 0.0 1.7

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-25 OPERATION

cutmaster a40

Aluminum 40A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8245 9-8237 9-8208 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 128 0.19 70 0.20 0.5 0.07

1/4 0.250 137 0.19 30 0.20 1.0 0.08

3/8 0.375 145 0.19 10 0.20 2.0 0.09

0.040

0.063 113 0.19 170 0.20 0.1 0.07

0.097 120 0.19 100 0.20 0.2 0.07

0.125 125 0.19 90 0.20 0.3 0.07

0.160 126 0.19 85 0.20 0.4 0.07

Gas Pressure

(Air)

PSI

(torch lead

length)

75 (25')

80 (50')

Arc Voltage

Volts

110 0.19 300 0.20 0.0 0.06

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-26 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

1.0

2.0 116 4.8 3490 5.1 0.2

3.0 124 4.8 2350 5.1 0.3

4.0 126 4.8 2170 5.1 0.4

5.0 129 4.8 1630 5.1 0.6

6.0 135 4.8 990

8.0 141 4.8 500 5.1 1.6 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6)

5.5 (15.2)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

110 4.8 7660 5.1 0.0

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

5.1 1.0

Pierce Delay

10.0 146 4.8 180 5.1 2.1 2.3

BOLD TYPE indicates maximum piercing parameters.

Kerf Width

@ Rec.

Speed

1.6

1.8

1.9

Manual 0-4978 4T-27 OPERATION

cutmaster a40

Mild Steel 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 132 0.19 115 0.20 0.20 0.09

1/4 0.250 134 0.19 80 0.20 0.30 0.08

3/8 0.375 132 0.19 34 0.20 0.70 0.10

1/2 0.500 144 0.19 23 0.20 0.75 0.10

5/8 0.625 150 0.19 14 Edge Start 0.10

3/4 0.750 145 0.19 14 Edge Start 0.10

0.060

0.075 129 0.19 237 0.20 0.10 0.09

0.120 126 0.19 200 0.20 0.10 0.08

0.135 128 0.19 142 0.20 0.10 0.09

1.000 160 0.19 4 Edge Start 0.12

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

128 0.19 250 0.20 0.00 0.09

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-28 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

127

129 4.8 5942 5.1 0.10 2.2

126 4.8 5080 5.1 0.10 0.1

130 4.8 3316 5.1 0.20 2.3

132 4.8 2794 5.1 0.20 2.2

134 4.8 2230 5.1 0.30 2.1

133 4.8 1425 5.1 0.40 2.3

134 4.8 822 5.1 0.60 2.5

141 4.8 646 5.1 0.75 2.5

148 4.8 419 Edge Start 2.6

147 4.8 318 Edge Start 2.7

159 4.8 118 Edge Start 3.0

Working

Height

4.8

Travel Speed

6804 5.1 0 2.2

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-29 OPERATION

cutmaster a40

Stainless Steel 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 125 0.13 75 0.20 0.20 0.09

1/4 0.250 127 0.13 60 0.20 0.30 0.08

3/8 0.375 134 0.13 28 0.20 0.50 0.08

1/2 0.500 136 0.19 17 0.25 0.75 0.09

5/8 0.625 131 0.13 14 Edge Start 0.08

3/4 0.750 142 0.19 10 Edge Start 0.11

0.063

0.078 116 0.13 155 0.20 0.10 0.07

0.125 118 0.13 125 0.20 0.10 0.07

0.141 126 0.13 80 0.20 0.10 0.09

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.13 165 0.20 0.00 0.06

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-30 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Torch

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

101

116 3.3 3925 5.1 0.10 1.7

118 3.3 3285 5.1 0.10 1.7

126 3.3 1985 5.1 0.20 2.2

125 3.3 1850 5.1 0.20 2.1

127 3.3 1605 5.1 0.30 2.1

131 3.3 1100 5.1 0.40 2.1

134 3.3 670 5.1 0.50 2.1

136 4.8 490 6.4 0.90 2.2

132 3.3 375 Edge Start 2.6

144

Working

Height

3.3

4.8

Travel Speed

4590 5.1 0.00 1.2

230 Edge Start 2.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4978 4T-31 OPERATION

cutmaster a40

Aluminum 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Electrode

9-8238 9-8237 9-8210 9-8213 9-8215

Material

Thickness

(GA)

(in) inch

3/16 0.188 125 0.13 140 0.20 0.20 0.08

1/4 0.250 132 0.13 80 0.20 0.30 0.08

3/8 0.375 135 0.13 45 0.20 0.50 0.08

1/2 0.500 140 0.13 26 0.20 0.80 0.08

5/8 0.625 148 0.19 18 Edge start 0.10

3/4 0.750 155 0.19 12 Edge start 0.11

0.064

0.079 118 0.13 350 0.20 0.10 0.08

0.120 123 0.13 275 0.20 0.10 0.08

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

118 0.13 350 0.20 0.00 0.07

Torch

Working

Height

(in)

Travel Speed

(ipm) (in) (sec) (in)

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

OPERATION 4T-32 Manual 0-4978

cutmaster a40

Material

Thickness

(mm)

2 118 6.4 8890 6.4 0.10

3 123 6.4 7070 6.4 0.10

4 124 6.4 5095 6.4 0.20

5 126 6.4 3335 6.4 0.20

6 130 6.4 2370

8 134 6.4 1570 6.4 0.40 2.0

Gas Pressure

(Air)

Bar

(torch lead

length)

5.9 (7.6m)

6.2 (15.2m)

Arc Voltage

Volts (mm) (mm/min) (mm) (sec) (mm)

118 6.4 8890 6.4 0.00

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

6.4 0.30

Pierce Delay

10 136 6.4 1070 6.4 0.60 2.0

12 139 6.4 765 6.4 0.70 2.0

15 146 4.8 515 Edge start 2.4

20 157 4.8 260 Edge start 2.7

BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

Kerf Width

@ Rec.

Speed

2.0

2.1

2.0

Manual 0-4978 4T-33 OPERATION

cutmaster a40

PATENT INFORMATION

Plasma Cutting Torch Patents

The following parts are covered under U.S. and Foreign Patents as follows:

Catalog # Description Patent(s)

9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786; 6703581; D496842; D511280; D492709; D499620; D504142 Other Pat(s) Pending 9-8205 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8206 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8207 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8252 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8208 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8209 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8210 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8231 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8211 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8212 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8253 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8225 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8226 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8227 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8228 Tip US Pat No(s) 6774336; 7145099; 6933461 Other Pat(s) Pending 9-8241 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8243 Shield Cap US Pat No(s) 6914211; D493183 Other Pat(s) Pending 9-8235 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8236 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8237 Shield Cup US Pat No(s) 6914211; D501632; D511633 Other Pat(s) Pending 9-8238 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending

OPERATION 4T-34 Manual 0-4978

cutmaster a40

Catalog # Description Patent(s)

9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending

The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:

Catalog # Description

9-8235 Shield Cap 9-8236 Shield Cap 9-8237 Shield Cup 9-8238 Shield Cap 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap

Manual 0-4978 4T-35 OPERATION

cutmaster a40

This Page Intentionally Blank

OPERATION 4T-36 Manual 0-4978

SECTION 5 SYSTEM:

Warning! Disconnect input power before maintaining.

Each Use

Visual check of torch tip and electrode

Weekly

Visually inspect the torch body tip, electrode and shield cup

Visually inspect the cables and leads. Replace as needed

3 Months

Clean exterior of power supply

6 Months

Replace all broken parts

Visually check and Carefully clean the interior

Maintain more often if used under severe conditions

Art # A-07938

5.01 General Maintenance

cutmaster a40

SERVICE

Manual 0-4978 5-1 SERVICE

cutmaster a40

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, worn or when cut performance has deminished.

2. Check plasma and secondary supply and pressure.

3. Purge plasma gas line to remove any moisture build-up.

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.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air ﬁlter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, replace if necessary.

5.03 Common Faults

Problem - Symptom Common Cause

Insufﬁcient Penetration

Main Arc

Extinguishes

Excessive Dross

Formation

Short Torch Parts Life1. Oil or moisture in air source.

1. Cutting speed too fast.

2. Torch tilted too much.

3. Metal too thick.

4. Worn torch parts

5. Cutting current too low.

6. Non - Genuine Thermal Dynamics parts used

7. Incorrect gas pressure

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Cutting current too high.

4. Work cable disconnected.

5. Worn torch parts.

6. Non - Genuine Thermal Dynamics parts used

1. Cutting speed too slow.

2. Torch standoff too high from workpiece.

3. Worn torch parts.

4. Improper cutting current.

5. Non - Genuine Thermal Dynamics parts used

6. Incorrect gas pressure

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

4. Vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

SERVICE 5-2 Manual 0-4978

Difﬁcult Starting 1. Worn torch parts.

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

cutmaster a40

PSI BAR

MAX MAX

MIN MIN

Art# A-07988

MIN

MAX

Art # A-08316

5.04 Fault Indicator

At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used.

To determine the ﬁrst digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 75 psi indicators are on indicating the version would be 2.3.

Explanation of Faults

" UNDER PRESSURE: Indicates that operating pres-

sure is set too low and power supply output power will be disabled.

INPUT POWER: Indicates primary line voltage is

outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit. Low is 208/230 VAC and high is 460 VAC.

PART IN PLACE: Indicates that the shield cup is not

properly installed or tightened.

START ERROR: Indicates that the START SIGNAL

was active (ie. Torch Trigger depressed, hand held pendant switch on or CNC signal for torch on) during one of three conditions:

When the !"Fault" indicator is on or blinking it will be accompanied by one of the pressure indicator lights depending on what the Fault is. Only one of these faults will be displayed at one time. If more than one fault exists, when the ﬁrst fault is corrected and cleared, the next fault will then be displayed. It is possible to have a fault indicated in the function indicators and another fault indictated in the pressure indicators. The following table shows each of the Faults possible.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

Manual 0-4978 5-3 SERVICE

85 Shorted Torch

80 Consumables Missing

75 Start Error

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE

Fault explantions are covered in the following tables.

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

2) When fault which had been disabling the system is cleared.

3) When the FUNCTION CONTROL SWITCH Mode is moved from SET position to any of the other three (3) modes of operation.

CONSUMABLES MISSING: Indicates that the elec-

trode, start cartridge or tip is missing or excessively worn.

SHORTED TORCH: Indicates the torch or lead has

a shorted condition between positive and negative leads.

INTERNAL ERROR: Indicates a microprocessor er-

ror.

OVER PRESSURE: Indicates that operating pressure

is set too high. The Error Indicator will not ﬂash when the pressure is above 95 PSI. This LED will remain on and the system will operate but pilot starting and cut performance may be affected.

NOTE

cutmaster a40

5.05 Basic Troubleshooting Guide

WARNING

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

Problem - Symptom Possible Cause Recommended Action

ON / OFF Switch is on but the A/C Indicator does not light

1. Primary power disconnect is in OFF position.

2. Primary fuses / breakers are blown or tripped.

3. Faulty components in unit.

1. Turn primary power disconnect switch to ON position.

2. a) Have qualiﬁed person check primary fuses / breakers. b) Connect unit to known good primary power receptacle

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

FAULT indicator ﬂashing, 65 PSI indicator ﬂashing

TEMPERATURE indicator on. FAULT indicator ﬂashing.

GAS indicator off, FAULT and MIN pressure indicators ﬂashing.

FAULT and 70 PSI indicators ﬂashing.

1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1. Air ﬂow through or around the unit is obstructed.

2. Duty cycle of the unit has been exceeded

3. Failed components in unit

1. Gas supply not connected to unit.

2. Gas supply not turned on.

3. Gas supply pressure too low.

4. AIR PRESSURE CONTROL regulator set too low.

5. Failed components in unit.

1. Shield Cup loose.

2. Torch not properly connected to power supply.

3. Problem in torch and leads PIP circuit.

4. Failed components in unit.

1. Turn off power to unit then set INPUT VOLTAGE SELECTION SWITCH to match primary input voltage.

2. Have qualiﬁed person check primary voltage to insure it meets unit requirements see section 2.04.

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

1. Refer to clearance information – section 2.04

2. Allow unit to cool.

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

1. Connect gas supply to unit.

2. Turn gas supply on.

3. Set air supply inlet pressure to unit to 120 psi.

4. Adjust regulator to set air pressure - see section 4.02.

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

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

2. Insure torch ATC is securely fastened to unit.

3. Replace torch and leads or return to authorized service center for repair or replacement.

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

FAULT and 75 PSI indicators ﬂashing.

SERVICE 5-4 Manual 0-4978

1. Start signal is active when ON/OFF SWITCH is turned to ON position.

2. Problem in the torch and leads switch circuit.

3. Failed components in unit.

1. Start can be active for one of the following:

• Hand torch switch held closed

• Hand pendant switch held closed

• CNC START signal is active low Release the START signal source

2. Replace torch and leads or return to authorized service center for repair or replacement.

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

Problem - Symptom Possible Cause Recommended Action

FAULT & 80 PSI indicators ﬂashing. Gas ﬂow is cycling on and off.

1. Torch shield cup is loose.

2. Torch tip, electrode or starter cartridge missing.

3. Torch start cartridge is stuck.

4. Open conductor in torch leads.

5. Problem in the torch and leads switch circuit.

6. Failed components in unit.

1. Tighten shield cup by hand. Do not overtighten.

2. Turn off power supply. Remove shield cup. Install missing parts.

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. Replace torch and leads or return to authorized service center for repair or replacement.

5. Replace torch and leads or return to authorized service center for repair or replacement.

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

cutmaster a40

Nothing happens when torch switch or remote switch is closed ( Or CNC START signal is active) No gas ﬂow, DC LED OFF.

FAULT and 85 PSI indicators ﬂashing.

No Fault lights on, no arc in torch.

FAULT and 85 PSI indicators ﬂashing

Pilot arc is on but cutting arc will not establish

1. Problem in the torch and leads switch circuit (Remote pendant switch circuit).

2. CNC Contoller device not providing Start signal.

3. Failed components in unit.

1. Upper O-Ring on torch head is in wrong position.

2. Torch starter cartridge is stuck.

3. Worn or faulty torch parts.

4. Shorted Torch.

5. Temporary Short indicated by 5 blinks per second.

6. Power Supply Failure (Standard rate of blinking)

1. Failed components in unit. 1. Return to an authorized service center for repair.

1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that

1. Work cable not connected to work piece.

2. Work cable/connector broken.

3. Failed components in unit.

1. Take Torch and Leads (Remote Pendant) to Authorized Repair Facility.

2. Contact Controller manufacturer.

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

1. Remove shield cup from torch; check upper O-Ring position; correct if necessary.

2. Turn off power supply. Bleed down system pressure. Remove shield cup, tip and starter cartridge. Check starter cartridge lower end ﬁtting for free movement. Replace if ﬁtting does not move freely.

3. Inspect torch consumable parts. Replace if necessary.

4. Replace torch and leads or return to an authorized service center for repair.

5. Release torch switch and reactivate.

6. Return to autorized service center for repair or replacement.

does not clear the fault, return to an authorized service center for repair.

1. Connect work cable.

2. Replace work cable.

3. Return to an authorized service center for repair.

Torch cutting is diminished

Manual 0-4978 5-5 SERVICE

1. Incorrect current setting.

2. Worn torch consumables.

3. Poor work cable connection to work piece.

4. Torch being moved too fast.

5. Excessive oil or water in torch.

6. Failed components in unit.

1. Check and adjust to proper setting.

2. Check torch consumables and replace as needed.

3. Check the connection of the Work Lead to the work piece.

4. Reduce cutting speed.

5. Refer to "Check air quality" in section 3 Torch.

6. Return to an authorized service center for repair.

cutmaster a40

Upper Screws

Lower Screws

Art # A-08317

Slots

5.06 Circuit Fault Isolation

WARNING

The following procedures should not be attempted by anyone who has not had proper training or authorized to do so.

A. Cover Removal

1. Remove the upper and lower screws which secure the cover to the main assembly. Do not loosen the lower screws inside the cut out slots in the bottom of the cover.

Note

B. Cover Installation

1. Reverse previous procedures for cover installation.

NOTE

C. Filter Element Assembly Replacement

The Filter Element Assembly is in the rear panel. For better system performance, the ﬁlter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced.

1. Remove power from the power supply; turn off the gas supply and bleed down the system.

2. Remove the system cover. See "A Cover Removal" in this section.

3. Locate the internal air line and the ﬁtting from the ﬁlter assembly. Number 1 in the following illustration.

2. Carefully pull the Cover up and away from the unit.

4. Hold a wrench or similar tool against the locking ring on the ﬁlter assembly ﬁtting, then pull on the hose to release it. (Numbers 2 and 3 in the following illustration).

SERVICE 5-6 Manual 0-4978

cutmaster a40

Art # A-07989

6mm

Art # A-07990

Filter Element

7. Remove the ﬁlter element assembly through the rear opening.

NOTE

If replacing or cleaning just the ﬁlter element refer to the following illustration for disassembly.

5. Remove the ﬁtting from the ﬁlter element assembly by inserting a 6 mm hex wrench into the internal hex ﬁtting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous illustration.

6. Disconnect the input line from the ﬁlter element assembly.

8. Install the new or cleaned assembly by reversing these procedures.

9. Turn on the air supply and check for leaks before reinstalling the cover.

Manual 0-4978 5-7 SERVICE

cutmaster a40

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

First & Second Stage Cartridges (as marked)

Art # A-02942

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.

Optional Two-Stage Filter Element

Replacement

The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement ﬁlter element catalog number.

1. Shut off primary input power.

2. Shut off air supply and bleed down system.

WARNING

Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

6. Wipe inside of housing clean, then insert the replacement Filter Element open side ﬁrst.

7. Replace Housing on Cover.

8. Reattach gas supply.

NOTE

If unit leaks between housing and cover, inspect

the "O" Ring for cuts or other damage.

SERVICE 5-8 Manual 0-4978

5. Slide out the old Filter Elements.

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket.

8. Slowly apply air pressure to the assembly, checking for leaks.

NOTE

A small amount of air leakage from the bottom ﬁtting is normal.

This completes the parts replacement procedures.

cutmaster a40

Upper Groove with Vent Holes Must Remain Open

Threads

Upper O-Ring in Correct Groove

Lower O-Ring

Art # A-03725

ATC Male Connector

Art #A-03791

Gas Fitting

O-Ring

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

NOTE

Refer to Previous "Section 5 System" for common and fault indicator descriptions.

Cleaning Torch

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

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

It is recommended to apply a very light ﬁlm of oring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis.

Torch Head O-Ring

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

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

CAUTION

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

An o-ring on the Torch Head and ATC Male Connector requires lubrication on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal. The o-rings will dry out, becoming hard and cracked if the lubricant is not used on a regular basis. This can lead to potential performance problems.

ATC O-Ring

NOTE

DO NOT use other lubricants or grease, they may

not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

Manual 0-4978 5T-1 SERVICE

cutmaster a40

Art # A-08067

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

Good Tip

Worn Tip

A-03406

Art # A-08064

Spring-Loaded Lower End Fitting Full Compression 1/8”

Spring-Loaded Lower End Fitting at Rest / Full Extension

Worn Electrode

New Electrode

Art # A-03284

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

Remove the consumable torch parts as follows:

NOTE

The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup from the torch.

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

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

Example of Tip Wear

5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end ﬁtting for free motion. Replace if necessary.

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

Shield Cups

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

6. Pull the Electrode straight out of the Torch Head. Check the face of the electrode for excessive wear. Refer to the following ﬁgure.

Electrode Wear

7. Reinstall the Electrode by pushing it straight into

the torch head until it clicks.

8. Reinstall the desired starter cartridge and tip into

the torch head.

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

This completes the parts replacement procedures.

SERVICE 5T-2 Manual 0-4978

cutmaster a40

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

Section 6.03 Complete Power Supply Replacement

Section 6.04 Replacement Power Supply Parts

Section 6.05 Options and Accessories

Section 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)

Section 6.07 Torch Consumable Parts Automation / Machine (SL100 SV)Torch

Section 6.08 Replacement Parts - for Machine Torches

Section 6.09 Torch Consumable Parts Manual (SL60)Torch

Section 6.10 Replacement Parts for Hand Torch

NOTE

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

B. Returns

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

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / ﬁlter, and operating manual.

Qty Description Catalog #

1 CutMaster A60 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with input power cable and plug 3-1134-1 460VAC, Single or 3 Phase, 60Hz, with input power cable 3-1134-2 400/415VAC Non CE, Three - Phase, 50 Hz, with input power cable 3-1134-3

Manual 0-4978 6-1 PARTS LIST

cutmaster a40

Art # A-02476

Filter

Element

(Cat. No. 9-7741)

Housing

Cover

Barbed

Fitting

Spring

Assembled Filter

O-ring

(Cat. No. 9-7743)

First & Second Stage Cartridges (as marked)

Art # A-02942

6.04 Replacement Power Supply Parts

Qty Description Catalog #

1 Regulator 9-0115 1 Filter Assembly Replacement Element 9-0116 1 Input Power Cord for 208 / 230 V Power Supply 9-8596 1 Input Power Cord for 400 V Power Supply 9-8562 1 Input Power Cord for 460 V Power Supply 9-8563

6.05 Options and Accessories

Qty Description Catalog #

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

PARTS LIST 6-2 Manual 0-4978

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

cutmaster a40

Intentionally Blank

Manual 0-4978 6-3 PARTS LIST

cutmaster a40

6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 2 1 Large O - Ring 8-3487 3 1 Small O - Ring 8-3486 4 1 PIP Switch Kit 9-7036 5 1 PIP Plunger and Return Spring Kit 9-7045 6 Automated Leads Assemblies with ATC connectors 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-3058 1 35 - foot / 10.6 m Leads Assembly with ATC connector 4-3059 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-3060 7 1 Rack 9-9448 8 1 Mounting Tube 9-9445 9 1 End Cap Assembly 9-7044 10 2 Body, Mounting, Pinch Block 9-4513 11 1 Pin, Mounting, Pinch Block 9-4521 12 1 Torch Holder Sleeve 7-2896 13 1 Pinion Assembly (does not include positioning tube) 7-2827 14 1 Torch Holder Sleeve 7-2896 15 1 Pinion Gear-Short 8-6074 16 1 Handwheel (Torch Holder) 9-4514 17 1 Low Proﬁle Torch Holder (1 3/8 Dia) w/o Hardware 9-4515 18 1 Calibrated Torch Holder Bushing 9-4366 19 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1 20 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1 21 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1 22 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1 23 1 Solenoid Assembly 9-9447 24 1 Solenoid Cover 9-9446

NOTE 1

Purchase these parts locally.

PARTS LIST 6-4 Manual 0-4978

cutmaster a40

Art # A-07113

Manual 0-4978 6-5 PARTS LIST

cutmaster a40

Starter

Cartridge

9-8213

Electrode

9-8215

Shield Cap, Deflector

9-8243

Tip A 9-8225 (40 Amps Max.)

Tip B 9-8226 (50 - 120 Amps)

Tip C 9-8227 (60 - 120 Amps)

Tip D 9-8228 (60 - 120 Amps)

Shield Cup, Gouging

9-8241

Shield Cap, Machine

40A 9-8245

20A 9-8205 30A 9-8206 40A 9-8208

Shield

Cup Body,

9-8237

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cup

9-8218

Shield

Cup Body,

9-8237

50-60A

Tip:

Tips:

40-120A

GOUGING

CUTTING

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine

50-60A 9-8238

Shield Cap, Machine

70-100A 9-8239

Art # A-08066_AB

STANDOFF

CUTTING

STANDOFF

70-120A

CUTTING

STANDOFF

20-40A

Shield Cap, Deflector

9-8243

Ohmic Clip

9-8224

6.07 Torch Consumable Parts Automation / Machine (SL100 SV)Torch

PARTS LIST 6-6 Manual 0-4978

cutmaster a40

Intentionally Blank

Manual 0-4978 6-7 PARTS LIST

cutmaster a40

6.08 Replacement Parts - for Machine Torches

Item No. Qty Description Catalog No.

1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 2 1 Large O - Ring 8-3487 3 1 Small O - Ring 8-3486 4 1 PIP Switch Kit 9-7036 5 Unshielded Mechanized Leads Assemblies with ATC connectors 1 5 - foot / 1.5 m Leads Assembly with ATC connector 4-7842 1 10 - foot / 3.05 m Leads Assembly with ATC connector 4-7843 1 25 - foot / 7.6 m Leads Assembly with ATC connector 4-7844 1 50 - foot / 15.2 m Leads Assembly with ATC connector 4-7845 6 1 11” / 279 mm Rack 9-7041 7 1 11” / 279 mm Mounting Tube 9-7043 8 1 End Cap Assembly 9-7044 9 2 Body, Mounting, Pinch Block 9-4513 10 1 Pin, Mounting, Pinch Block 9-4521 11 1 Torch Holder Sleeve 7-2896 12 1 PIP Plunger and Return Spring Kit 9-7045 1 Pinion Assembly (Not shown) 7-2827 1 5” / 126 mm Positioning Tube (Not shown) 9-7042

NOTE

* Does not include Control Cable Adapter or Through - Hole Protector.

PARTS LIST 6-8 Manual 0-4978

cutmaster a40

A-07994

Manual 0-4978 6-9 PARTS LIST

cutmaster a40

Start

Cartridge

9-8213

Electrode

9-8215

Tips:

20A 9-8205 30A 9-8206 40A 9-8207 60A 9-8252

Tip Gouging A 9-8225 (40 Amps Max.)

Tip Gouging B 9-8226 (50 - 100 Amps)

Tip Gouging C 9-8227 (60 - 120 Amps)

Tip Gouging D 9-8228 (60 - 120 Amps)

Shield Cap, Gouging

9-8241

Shield Cap, Drag

40A 9-8244

40A 9-8208

50-55A 9-8209

60A 9-8210

70A 9-8231

80A 9-8211

90/100A 9-8212

120A 9-8253

Shield Cap, Drag

50-60A 9-8235

Shield Cap, Drag

70-100A 9-8236

Shield

Cup Body,

9-8237

70-120A

50-60A

40A

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Tip:

Tips:

DRAG TIP

CUTTING

40-120A

GOUGING

CUTTING

Art # A-08065_AB

DRAG SHIELD

CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8281

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

Standoff Guide

9-8281

STANDOFF

CUTTING

DRAG SHIELD

CUTTING

STANDOFF CUTTING

Shield Cap, Deflector

9-8243

Shield

Cup Body,

9-8237

Shield Cup

9-8218

O-Ring No. 8-3488

Standoff Guide

9-8251

NOTE CutMaster 52 uses 60A and less CutMaster 82 uses 80A and less CutMaster 102 uses 100A and less CutMaster 152 uses 120A and less

6.09 Torch Consumable Parts Manual (SL60)Torch

PARTS LIST 6-10 Manual 0-4978

cutmaster a40

Art # A-07993

6.10 Replacement Parts for Hand Torch

Item # Qty Description Catalog #

1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 2 1 Trigger Assembly Replacement Kit 9-7034 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219 5 1 Large O - Ring 8-3487 6 1 Small O - Ring 8-3486 7 Leads Assemblies with ATC connectors (includes switch assemblies) 1 SL60, 20 - foot Leads Assembly with ATC connector 4-7834 1 SL60, 50 - foot Leads Assembly with ATC connector 4-7835 1 SL100, 20 - foot Leads Assembly with ATC connector 4-7836 1 SL100 , 50 - foot Leads Assembly with ATC connector 4-7837 8 1 Switch Kit 9-7031 10 1 Torch Control Cable Adapter (includes item # 11) 7-3447 11 1 Through - Hole Protector 9-8103

Manual 0-4978 6-11 PARTS LIST

cutmaster a40

Intentionally Blank

PARTS LIST 6-12 Manual 0-4978

cutmaster a40

ACTION:

ON / OFF switch to ON

RESULT:

AC indicator ON.

Fan(s) ON.

GAS indicator ON

when input

pressure is adequate

for power supply operation.

Power circuit ready.

ACTION:

Protect eyes and activate torch.

RESULT:

Gas flows briefly, then stops.

Gas restarts.

DC indicator ON

Pilot arc established.

Art #A-07979

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

ACTION:

Connect work cable to workpiece.

Set output amperage.

RESULT:

System is ready

for operation.

ACTION:

RUN / Rapid Auto Restart / SET / LATCH switch

to SET

RESULT:

Gas flows to set

pressure.

ACTION:

RUN / Rapid Auto Restart /

SET / LATCH

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

or to

LATCH

is used for specific applications

(torch switch can be released

after main arc transfer).

RESULT: Gas flow stops.

ACTION:

Release torch trigger.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fan(s) shuts off.

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

PILOT ARC

ACTION:

Torch moved away from work (while

still activated).

RESULT:

Main arc stops.

Pilot arc automatically

restarts.

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

Manual 0-4978 A-1 APPENDIX

cutmaster a40

1/3

West Lebanon, NH USA 03784

Made in USA

Model:

1max 1eff

3Ø

3Ø1Ø

1Ø

S/N

Standard Symbols

Phase

NOTES:

1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.

3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission. TDC duty cycle value is determined under the power supply manufacturer's test procedures. Second row: Rated cutting current values. Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas of the power supply.

Art # A-03288

Date of Mfr:

Output Range (Amperage/ Voltage)

Type of Power Supply (Note 1)

Output Current Type

Rated NoLoad Voltage

Plasma Cutting Symbol

Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code

Conventional Load Voltage

Regulatory Standard Covering This Type of Power Supply

Duty Cycle Data (Note 3)

Duty Cycle Factor

Input Power Specifications (Phase, AC or DC Hertz Rating)

Input Power Symbol

Rated Supply Voltage (Note 2)

Rated Maximum Supply Current

Maximum Effective Supply Current

Degree of Protection

Manufacturer's Electrical Schematic File Number and Revision Level

APPENDIX 2: DATA TAG INFORMATION

APPENDIX A-2 Manual 0-4978

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

ATC Female Receptacle -

Front View

ATC Male Connector -

Front View

Negative / Plasma

Pilot

Negative / Plasma

6 - Open

7 - Torch Solenoid

5 - Torch Solenoid

8 - Open

5 - White /

- Torch Solenoid

7 - Green /

- Torch Solenoid

Pilot

3 - Open

2 - Orange / PIP

1 - Black / PIP

4- Open

2 - PIP Circuit

1 - PIP Circuit

3 - Not Used

4 - Not Used

6 - Open

Art # A-07114

ATC Female Receptacle

Front View

ATC Male Connector

Front View

Negative / Plasma

3 - White Pendant Connector

4- Black Pendant Connector

2 - Orange / PIP

1 - Black / PIP

Pilot

2 - PIP

1 - PIP

6 - Open

7 - Open

5 - Open

8 - Ground

8 - Green Pendant Connector Ground

5 - White / Not Used

7 - Green / Not Used

6 - Open

UNSHIELDED MACHINE TORCH

3 - Switch

4 - Switch

Art # A-03799

Negative / Plasma

Pilot

A. Automation SL100SV Torch Pin - Out Diagram

B. Machine SL100 Torch Pin - Out Diagram

cutmaster a40

Manual 0-4978 A-3 APPENDIX

cutmaster a40

ATC Female Receptacle

Front View

Pilot

6 - Open

7 - Open

8 - Open

5 - Open

Negative / Plasma

6 - Open

7 - Open

5 - Open

2 - PIP

3 - Switch

4 - Switch

1 - PIP

4 - Green / Switch

2- Orange / PIP

3 - White / Switch

1 - Black / PIP

Negative / Plasma

8 - Ground

ATC Male Connector

Front View

A-03701

C. Hand Torch Pin - Out Diagram

APPENDIX A-4 Manual 0-4978

APPENDIX 4: TORCH CONNECTION DIAGRAMS

Automated CutMaster Power Supply with ATC Torch Receptacle,

Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector

Power Supply

PIP

Switch

ATC Male

Torch Leads Connector

ATC Female

Torch Receptacle

Negative / Plasma Lead

Pilot Lead

Art # A-07115

Pin No.s

Socket

No.s

4 3 7 6 8

Main PC Board

4 3 7 6 8

White

Black

Orange

Green

Main PC Board

Solenoid

Torch Leads

Torch Head

Not Connected

Main PC Board

Torch: Unshielded Mechanized SL100 Machine Torch Leads: Leads with ATC Connector and Remote Pendant Connector Power Supply: with ATC Female Receptacle

Pilot

Negative / Plasma

Power Supply

To Remote Control

Remote

Pendant

Connector

PIP

Switch

Not

Used

Male

ATC Leads

Connector

ATC Female

Receptacle

Pilot Lead

Negative / Plasma Lead

Torch Leads

Torch

Head

Art # A-03798

To Power Supply

Circuitry

Green

To Power Supply

Circuitry

Black

White

Green

Black

Orange

White

A. Automation (SL100SV) Torch Connection Diagram

cutmaster a40

B. Machine (SL100) Torch Connection Diagram

Manual 0-4978 A-5 APPENDIX

cutmaster a40

Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle

Pilot

Negative / Plasma

Power Supply

PIP

Switch

Male

ATC Leads

Connector

ATC Female

Receptacle

Pilot

Negative / Plasma

Black

Orange

Torch Leads

Torch

Head

To Power Supply

Circuitry

Art # A-03797

Torch

Switch

Green

White

To Power Supply

Circuitry

C. Hand Torch Connection Diagram

APPENDIX A-6 Manual 0-4978

This Page Intentionally Blank

cutmaster a40

Manual 0-4978 A-7 APPENDIX

cutmaster a40

Art # A-08467

D D

C C

A A

24VAC

+12VDC

+5VDC

19X2369 / CAT# 9-0107

CM A40 19X2371 / CAT# 9-0108 CM A60 19X2416 / CAT# 9-0125

CM A40 19X2410 / CAT# 9-0167 CM A60 19X2426 / CAT# 9-0126

24 VAC RETURN

OVER PRESSURE INTERNAL ERROR SHORTED TORCH CONSUMABLES MISSING START ERROR PARTS IN PLACE INPUT POWER UNDER PRESSURE

ERROR IND FAULT

PCB3

PRIMARY POWER CONNECTIONS:

3PH USE L1,L2,L3 & GND REMOVE JUMPER BETWEEN L2 TO L3

1PH USE L1, L2 & GND INSTALL JUMPER BETWEEN L2 TO L3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 34 35

INPUT VOLTAGE SELECTOR (Closed for 230VAC input)

-V_OUT_SIGNAL /TIP_VOLTS /TIP_SENSE /460V_IN /230V_IN CUR_SET /RAR (RAPID AUTO RESTART) /INRUSH /W1_ON

/SHDN /TORCH_SOLENOID /SOLENOID_ON /OK_TO_MOVE /FAN_ON /LATCH_ACTIVE /TORCH_SWITCH /PIP AC_ON CSR /TORCH_SOLENOID_DETECT /OVERTEMP V_IN +12VDC +12VDC COMMON COMMON MAIN_PCB_ID 460_IN +3.3VDC

M-L M-L M-L L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M L-M M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L M-L L-M

*CM A40 C1 & C6 not installed

PCB2

/SOLENOID

PRIMARY AC INPUT

PCB1

40 PIN RIBBON CABLE SIGNALS

460_IN

LATCH

SET

RUN

RAR

40 CIRCUIT

RIBBON CABLE

MAX 90 85 80 75 70 65 MIN

/460

/230

JUMPER

GND

D C

AIR INLET

FILTER

REGULATOR

SOLENOID VALVE

TP1 TP2 TP3 TP4 TP5 TP6 TP7

ATC

MAIN PCB

LOGIC PCB

CAPACITOR PCB

GAS CONTROL

GND +12 VDC +5 VDC

3.3 VDC

0.v - 5.0 VDC / 0-100PSI

1.8 VDC POT. DEMAND

TEST POINTS

GND1 GND2 GND3 +12V1 48V1 I_DMD_1 TIP_SEN

COMMON COMMON COMMON +12 VDC SUPPLY +48 VDC SUPPLY CURRENT DEMAND TIP DRAG SENSE

TEST POINTS

PRESSURE TRANSDUCER

0-100PSI / 0-4.5VDC

INRUSH RESISTORS

/INRUSH

3.3VDC TXD RXD

SERIAL PORT

MTH6MTH6

AC3AC3

K2K2

D59 PCRD59 PCR

7575

PRI 3PRI 3

MTH3MTH3

7070

D1D1

J12J12

123

K1K1

AC2AC2

J1J1

1 2 3 4 5

C1-C4*+C1-C4*

K5K5

MINMIN

ERRORERROR

K1K1

PRI 2 PRI 2

K3K3

K1-K4K1-K4

DCDC

J5J5

123

J6J6

1 2

SW2SW2

8080

C5-C8*+C5-C8*

K5, K6K5, K6

PRI 1 PRI 1

SW1SW1

2 4

W1W1

MTH4MTH4

GASGAS

K4K4

J4J4

1 2 3 4 5

W1W1

8585

MTH8MTH8

ACAC

MTH2MTH2

J3J3

1 2 3

D78 CSRD78 CSR

MTH1MTH1

6565

MAXMAX

K6K6

123

OVERTEMPOVERTEMP

PRI 4 PRI 4

SOL1SOL1

AC1AC1

Current ControlCurrent Control

9090

J3J3

1 2 3

J3J3

1 2

MTH7MTH7MTH5MTH5

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

APPENDIX A-8 Manual 0-4978

Thermal Dynamics A40 CUTMASTER Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual