Thermal Dynamics cutmaster A60 Operating Manual

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A60

™

CUTMASTER

AUTOMATED PLASMA CUTTING SYSTEM

Operating Manual

Art # A-08952_AC

Rev. AR Date: Dec. 17, 2012 Manual # 0-4981 Operating Features:

60%

Duty

Cycle

400

460

600

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 Victor Technologies International, 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.

WARNING

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

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

Plasma Cutting Power Supply CutMaster™ A60 SL100 ™ SV Automated Torch Operating Manual Number 0-4981

Published by: Victor Technologies International, Inc. 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.

Original Publication Date: January 7, 2008 Revision Date: Dec. 17, 2012

Record the following information for Warranty purposes:

Where Purchased:_______________________________ ____________

Purchase Date:__________________________________ ____________

Power Supply Serial #:___________________________ _____________

Torch Serial #:___________________________________ ___________

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 Opening the Contactor Cover .......................................................................... 3-1

3.05 Primary Input Power Connections .................................................................. 3-2

3.06 Gas Connections ............................................................................................. 3-4

SECTION 3 TORCH:

INSTALLATION ......................................................................................3T-1

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

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

3T.03 Setting Up Automation or Machine Torch ......................................................3T-3

SECTION 4 SYSTEM:

OPERATION .......................................................................................... 4-1

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

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

TABLE OF CONTENTS

SECTION 4 TORCH:

OPERATION ..........................................................................................4T-1

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

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

4T.03 Machine and Hand Torch Parts Selection .......................................................4T-2

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

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

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

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

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

posed Tip .....................................................................................................4T-10

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

Shielded Tip .................................................................................................4T-28

PATENT INFORMATION ................................................................................. 4T-46

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 (w/Solenoid on Mounting Tube) .... 6-4

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

6.08 Torch Consumable Parts Manual (SL60)Torch ................................................ 6-8

6.09 Replacement Parts for Hand Torch ................................................................ 6-9

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .................................................................................. A-1

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

TABLE OF CONTENTS

SECTION 1:

cutmaster a60

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efﬁcient operation of the system.

CAUTION

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

WARNING

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

WARNING

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

1.02 Important Safety Precautions

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.

• 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.)

WARNING

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.

Manual 0-4981 1-1 GENERAL INFORMATION

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.

cutmaster a60

• Besurethereisnocombustibleorammablematerialinthe

workplace. Any material that cannot be removed must be protected.

• Ventilateallammableorexplosivevaporsfromtheworkplace.

• Donotcutorweldoncontainersthatmayhaveheldcombus-

tibles.

• Providearewatchwhenworkinginanareawherere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

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

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 birth defects and other reproductive harm.

Wash hands after handling.

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 0-4981

1.04 Note, Attention et Avertissement

cutmaster a60

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 :

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.

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.

• 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.

• 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:

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

• Liseztoujourslesches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.

AVERTISSEMENT

Fournit l'information concernant des dommages possibles de choc électrique. Des avertissements seront enfermés dans une boîte de ce type.

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.

• 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.

Manual 0-4981 1-3 INFORMATIONS GÉNÉRALES

cutmaster a60

• 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.

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

inammables.

• Soyezcertainqu’aucunematièrecombustibleouinammable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inammables

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enammé.

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.

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 dúez 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an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

RAYONS D’ARC DE PLASMA

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

• Pourprotégervosyeux,porteztoujoursuncasqueou unécran

de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portezdesgantsdesoudeuretunvêtementprotecteurapproprié

pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenezvotrecasqueetvoslunettesdeprotectionenbonétat.

Remplacez toute lentille sale ou comportant ﬁssure ou rognure.

• Protégezlesautrespersonnes setrouvantsurla zonedetravail

contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

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

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 malformations fœtales ou d’autres problèmes de reproduction.

Il faut se laver les mains après toute manipulation.

INFORMATIONS GÉNÉRALES 1-4 Manual 0-4981

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

cutmaster a60

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 0-4981 1-5 INFORMATIONS GÉNÉRALES

cutmaster a60

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.

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

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

National Standard and Technical Speciﬁcations

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

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

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

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

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

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

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

Manufacturers responsible representative: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire ,

England PR6 7BX

GENERAL INFORMATION 1-6 Manual 0-4981

cutmaster a60

1.08 Statement of Warranty

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

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

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

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

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

LIMITED WARRANTY PERIOD

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 Years 1 Year

This warranty does not apply to:

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

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

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

1. Repair of the defective product.

2. Replacement of the defective product.

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

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

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Victor Technologies 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 0-4981 1-7 GENERAL INFORMATION

cutmaster a60

This Page Intentionally Blank

GENERAL INFORMATION 1-8 Manual 0-4981

cutmaster a60

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:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efﬁcient operation of the system.

CAUTION

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

WARNING

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

WARNING

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

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

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 i 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 carrier

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.

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

identication numbers.

Manual 0-4981 2-1 INTRODUCTION

cutmaster a60

2.04 Power Supply Speciﬁcations

CutMaster A60 Power Supply Speciﬁcations

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power

Input Power Cable

Output Current 20 - 80 Amps, Continuously Adjustable

Power Supply Gas

Filtering Ability

Ambient Temperature

400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630), Three Phase, 60 Hz

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

CutMaster A60 Power Supply Duty Cycle *

input power includes molded plug.

Particulates to 5 Microns

Duty Cycle Ratings @ 40° C (104° F)

Operating Range 0° - 50° C

IEC

Rating

IEC

Rating

IEC

Rating

Duty Cycle 40% 60% 100%

All Units

Current

DC Voltage

80 Amps 65 Amps 50 Amps

112 106 100

* 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

10"

254 mm

Art # A-08305

Art # A-07925_AB

13.78"

350 mm

150 mm

24"

610 mm

20.8"

43 lb / 19.5 kg

INTRODUCTION 2-2 Manual 0-4981

0.528 m

150 mm

2.05 Input Wiring Speciﬁcations

CutMaster A60 Power Supply Input Cable Wiring Requirements

Input voltage Freq Power Input Suggested Sizes

Volts Hz kVA I max I eff Fuse (amps)

208 60 16 75 48 100 6

cutmaster a60

Flexible Cord

(Min. AWG)

1 Phase

3 Phase

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.

230 60 17 72 46 100 6 460 60 20 44 28 50 10 208 60 16 40 26 50 8 230 50/60 16 39 25 50 10 380 50/60 11.8 17 11 20 12 400 50/60 11.8 17 11 20 12 460 60 17 21 14 25 12 600 60 9.6 16 10 20 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTE

Manual 0-4981 2-3 INTRODUCTION

cutmaster a60

Automation Interface

2.06 Power Supply Features

Art # A-08306

Mounting Rails

Cable Port

Input Power Selection

Filter Assembly

Control Panel

Torch Leads Receptacle

Work Cable and Clamp

Gas Inlet Port

Input Power Cord

Art # A-08318

INTRODUCTION 2-4 Manual 0-4981

cutmaster a60

18.875" / 479 mm

SECTION 2 TORCH:

INTRODUCTION

2T.01 Scope of Manual

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

nel; 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

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.

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.

2.875” / 73 mm

1.75" /

44.5 mm

0.625" / 16 mm

2. Machine Torch, Model

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

15.875" / 403 mm

1.375" / 35 mm

1.75" /

44.5 mm

0.625" / 16 mm

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.

3.75"

(95 mm)

1.17" (29 mm)

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:

12.285" / 312 mm

1.375" / 35 mm

4.95" / 126 mm

9.285" / 236 mm

1.175" / 30 mm

4.95" / 126 mm

10.125" (257 mm)

Art # A-03322_AB

1.175" / 30 mm

Art # A-07402_AC

Art # A-02998

Manual 0-4981 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 a60

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

100% @ 60 Amps @ 400 scfh

104° F

40° C

120 Amps

500V

7kV

104° F

40° C

60 Amps

500V

7kV

G. Gas Requirements

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)

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.

60 - 95 psi

4.1 - 6.5 bar

300 - 500 scfh 142 - 235 lpm

H. Direct Contact Hazard

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

Power

Supply

Workpiece

A-08331

Typical Torch Head Detail

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.

INTRODUCTION 2T-2 Manual 0-4981

cutmaster a60

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

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.

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.

Remote Pendant

To AT C

PIP Sw itch

CNC Start

PIP Sw itch

Sh ield Cup

Art # A-08168

Automation To rch

To AT C

PIP Sw itch

Sh ield Cup

Parts - In - Place Circuit Diagram for Machine Torch

To Control

Torch Switch

Cable Wiring

PIP Switch

A-02997

Torch Trigger

Shield Cup

Parts - In - Place Circuit Diagram for Hand Torch

Manual 0-4981 2T-3 INTRODUCTION

cutmaster a60

This Page Intentionally Blank

INTRODUCTION 2T-4 Manual 0-4981

cutmaster a60

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.

leads, complies with ventilation per Sec-

tion 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 Opening the Contactor Cover

The input power cord is connected to the main contactor, the contactor is located inside a box with a snap on cover. The cover is held in place with two or more snap lock tabs. To remove the cover release the front latch and tilt the cover up about ½ inch. Then squeeze both sides of the cover and lift it straight up. See the Primary Input Power Connections section for the necessary changes to the Contactor. Remember to replace the Contactor Cover when the changes are complete.

• 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

Manual 0-4981 3-1 INSTALLATION

Art# A-11478

Contactor cover

cutmaster a60

3.05 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.

Most units are shipped from the factory with a

230 Volt 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.

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.

Upper Screws

Lower Screws

Slots

Lower Screws

Art # A-08317

2. Carefully pull the Cover up and away from

the unit.

B. Cover Installation

1. Reverse previous procedures for cover installation.

NOTE

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

tighten.

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.

Art # A-08316

INSTALLATION 3-2 Manual 0-4981

cutmaster a60

D. Quick Guide to Phase Wiring

Single-Phase (1ø) and Jumper Settings

L3 L4

GND

Single Phase Input Power Wiring

Three-Phase (3ø) and Jumper Settings

Store copper jumper in spare parts box

L3 L4

GND

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.

Jumper L1 -L4

Jumper L2-L3

Art # A-07984_AB

Jumper L1 -L4

Art # A-07983_AB

E. Connections to Single Phase Input Power

WARNING

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

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 "2.04 Power Supply Specications" 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 "B.

Cover Installation".

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

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. See "A. Cover Removal".

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.

Manual 0-4981 3-3 INSTALLATION

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. See "A. Cover Removal".

2. Disconnect the original input power cable

cutmaster a60

Filter Assembly

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 "2.04 Power Supply Specications" 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.

• 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 in-

put. 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 "B.

Cover Installation".

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.

3.06 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.

Inlet Port

Hose Clamp

Gas Supply Hose

Art # A-08320

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

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 0-4981

Inlet Port

Filter Assembly

Regulator/Filter

Art # A-08319

Hose Clamp

Gas Supply Hose

Optional Single - Stage Filter Installation

1/4 NPT to 1/4"

(6mm) Fitting

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.

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.

NOTE

cutmaster a60

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.

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.

Assembly

Regulator Input

Hose Clamp

Gas Supply Hose

1/4 NPT to 1/4” (6mm) Fitting

Optional Two - Stage Filter Installation

Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s 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.

2-Stage Filter Inlet Port (IN)

Outlet Port (OUT)

Two Stage Filter Assembly

Art # A-07945_AC

Manual 0-4981 3-5 INSTALLATION

cutmaster a60

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 0-4981

cutmaster a60

Automation Interface

Plasma

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.

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.

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.

Cable Port

Art # A-08322

2. Note the pin-out of the connector and that

the customer supplied connector matches.

Manual 0-4981 3T-1 INSTALLATION

Art # A-07885

Connecting the Torch to the Power Supply

3. The system is now ready for operation.

Start / Stop Signal

Cutting Machine

Art # A-08323

OK to Move

cutmaster a60

There are three options for Divided Arc Voltage signal supplied from the automation interface

pcb. This is selected by connecting the black Jumper Plug on the P1 connector as follows: Arc voltage / 16.67 Jumper not installed Arc voltage / 30 Jumper Pins 1 & 2 Arc voltage / 50 Jumper Pins 2 & 3

FULL FEATURED AUTOMATION INTERFACE PCB OPTION

To -V OUT 1 on PCB1

P10P10

1 2 3 4 5 6 7 8

123

J3J3

E1E1

J1J1

+12VDC

1 2 3 4 5 6 7 8

K1K1

PCB4

AUTOMATION INTERFACE PCB

To configure DIVIDED ARC VOLTS signal output No jumper installed for ARC VOLTS /16.67 Jumper pins 1 & 2 for ARC VOLTS / 30 Jumper pins 2 & 3 for ARC VOLTS / 50

J2J2

1 2

3 4 5 6 7 8 9 10 11 12 13 14

/START / STOP

}

(-)

DIVIDED ARC VOLTS

}

(+)

(-)

ARC VOLTS

}

(W/ 100K IN SERIES (2))

(+)

OK-TO-MOVE

}

Art # A-09819_AB

3. Connect CNC to the power supply.

INSTALLATION 3T-2 Manual 0-4981

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.

cutmaster a60

Pinch Block Assembly

Square

Workpiece

A-02585

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.03 Machine and Hand Torch Parts

Selection" for details.

Manual 0-4981 3T-3 INSTALLATION

cutmaster a60

This page intentionally blank

INSTALLATION 3T-4 Manual 0-4981

cutmaster a60

SECTION 4 SYSTEM:

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.

SET and torch and leads and to adjust gas pressure.

RUN

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

Used to purge the air through the unit

Used for general cutting operations

Allows for faster

MAX

MIN

PSI BAR

Temp Indicator

MAXMAX

MINMIN

Art# A-07886

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

7. Gas Indicator

LATCH 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 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 operation. 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.

Used for longer hand held cuts.

Control is used in the "SET"

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

PSI BAR

MAX MAX

90 6.3

85 5.9

MINMIN

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

5.5

5.2

4.8

4.5

Art # A-08170

The Indicators will illuminate

Manual 0-4981 4-1 OPERATION

cutmaster a60

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 (80 amps maximum). Refer to Section "4T.03 Machine and Hand 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.

Check Primary Input Power Source

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.

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 on the next page for pressure setting details.

MIN

MAX

PSI BAR

MAXMAX

MINMIN

Art# A-07946

Art # A-04509

OPERATION 4-2 Manual 0-4981

cutmaster a60

STANDOFF

CutMaster A60 Gas Pressure Settings

SL100

Leads

Length

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

SL60

(Hand Torch)

75 psi

5.2 bar

Add 5 psi

0.4 bar

(Mechanized Torch)

SL 100 SV

(Automation 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 A60 Gas Pressure Settings

Leads

Length

Up to 25'

(7.6 m)

Each additional

25' (7.6 m)

SL60

(Hand Torch)

80 psi

5.5 bar

Add 5 psi

0.4 bar

Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Sections "4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip" 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 LATCH position the main cutting arc will be maintained after the torch switch is released.

Manual 0-4981 4-3 OPERATION

cutmaster a60

This Page Intentionally Blank

OPERATION 4-4 Manual 0-4981

cutmaster a60

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.

Direction of Torch Travel

Standoff Distance

Straight Arc

Trailing Arc

A-02586

Leading Arc

Automation and Machine Torch Operation

Manual 0-4981 4T-1 OPERATION

cutmaster a60

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.02 Automation Torch Parts Selection" 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.

To rch Head

Electrode

Art # A-04173_AB

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.

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.03 Machine and Hand Torch Parts Selection" 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.

Start Cartridge

Tip

Ohmic Clip (If installed)

Shield Cup Body

Shield Cap

OPERATION 4T-2 Manual 0-4981

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

2. Remove the Electrode by pulling it straight

out of the Torch Head.

Deﬂector

cutmaster a60

Kerf Width

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

A-03510_AB

Torch Parts (Drag Shield Cap & Shield Cup Body

Shown)

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

Cut Surface Bevel Angle

Top

Spatter

Top Edge

Rounding

Dross

Build-Up

Cut Surface

Drag Lines

A-00007

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.

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

NOTE

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:

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.

Manual 0-4981 4T-3 OPERATION

cutmaster a60

Left Side

4T.05 General Cutting Information

WARNING

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.

NOTE

Handle torch leads with care and protect them from damage.

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

Cut Angle

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.

Right Side

Cut Angle

A-00512

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.

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.

OPERATION 4T-4 Manual 0-4981

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.

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.

cutmaster a60

Tr igger

NOTE

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

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.

Torch

Shield Cup

A-00024_AB

Standoff Distance

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

Standoff Distance

3. Hold the torch away from your body.

4. Slide the trigger release toward the back

of the torch handle while simultaneously squeezing the trigger. The pilot arc will start.

Trigger

NOTE

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

Tr igger Release

Art # A-03383

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

7. Follow normal recommended cutting

practices as provided in the power supply

operator's manual.

NOTE

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

8. For a consistent standoff height from the

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

Trigger Release

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 0-4981 4T-5 OPERATION

A-02986

Shield Cup

Standoff Guide

Torch Tip

Workpiece

Art # A-04034

cutmaster a60

Tr igger

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 - conductive.

Non-Conductive

Straight Edge Cutting Guide

A-03539

Using Drag Shield Cup With Straight Edge

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

Drag Cutting With a Hand Torch

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

NOTE

Trigger

Trigger Release

A-02986

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.

Tr igger Release

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

1. Install the drag cutting tip and set the 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.

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

Art # A-03383

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.

NOTE

OPERATION 4T-6 Manual 0-4981

cutmaster a60

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 op-

erator) 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.

NOTE

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

Trigger Release

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.

Manual 0-4981 4T-7 OPERATION

Trigger

A-02986

cutmaster a60

4T.07 Gouging

WARNING

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

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

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.03 Machine and Hand 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).

Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater 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.

Torch Head

35°

Standoff Height

Workpiece

A-00941_AB

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.

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 infor-

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.

mation 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 0-4981

cutmaster a60

This Page Intentionally Blank

Manual 0-4981 4T-9 OPERATION

cutmaster a60

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

9-8208

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-10 Manual 0-4981

cutmaster a60

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 0-4981 4T-11 OPERATION

cutmaster a60

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

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

9-8208

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

1/2 0.500 118 0.19 8 Edge start 0.09

OPERATION 4T-12 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

12 120 4.8 215 Edge Start 2.2

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

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

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

Torch

Working

Height

4.8

Travel Speed

1670 4.8 0.0 1.7

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-13 OPERATION

cutmaster a60

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

9-8208

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-14 Manual 0-4981

cutmaster a60

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 0-4981 4T-15 OPERATION

cutmaster a60

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

1 1.000 150 0.19 6 Edge Start 0.11

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 0.07

85 (25')

90 (50')

Arc Voltage

Volts

118 0.19 290 0.19 0.00 0.08

Tip

9-8210

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-16 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

15 134 4.8 530 Edge Start 2.4

20 138 4.8 325 Edge Start 2.2

25 149 4.8 165 Edge Start 2.7

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)

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

Torch

Working

Height

4.8

Travel Speed

7540 4.8 0 2.1

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-17 OPERATION

cutmaster a60

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

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

9-8210

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

5/8 0.625 132 0.19 14 Edge Start 0.11

3/4 0.750 135 0.19 10 Edge Start 0.10

OPERATION 4T-18 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

15 132 4.8 405 Edge Start 2.6

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)

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

136 4.8 230 Edge Start 2.5

Torch

Working

Height

4.8

Travel Speed

10890 5.1 0.00 0.8

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-19 OPERATION

cutmaster a60

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

9-8210

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-20 Manual 0-4981

cutmaster a60

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 Edge Start 2.1

20 148 4.8 260 Edge Start 2.5

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

Pierce Delay

Kerf Width

@ Rec.

Speed

1.8

2.3

2.4

2.3

Manual 0-4981 4T-21 OPERATION

cutmaster a60

Mild Steel 80A Air Plasma / Air Shield

Deector

9-8243

Material

Thickness

(GA)

(in) inch

16 0.060

11 0.120

10 0.135

3/16 0.188

1/4 0.250

3/8 0.375 1/2 0.500

5/8 0.625

3/4 0.750

7/8 0.875

1 1.000

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.19 320 0.20

113 0.19 230 0.20

110 0.19 180 0.20

110 0.19 136 0.20

115 0.19 100 0.20

125 0.19 42 0.20 123 0.19 40 0.20

133 0.19 18 0.20

Starter Cartridge

Tip

Heavy Duty Starter

Cartridge

9-8211

Torch

Working

Height

(in)

140 0.25 18 Edge Start

150 0.25 10 Edge Start

152 0.25 8 Edge Start

Travel Speed

9-8213 9-8277

Initial

Piercing

Height

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

Pierce Delay

Electrode

9-8232

Kerf Width

@ Rec.

Speed

0.00

0.10

0.20

0.30

0.40

0.50

0.60 0.09

0.75 0.10

0.06

0.07

0.09

0.11

0.13

OPERATION 4T-22 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

1 2 111 4.8 7415 5.1 0.10 1.7 3 113 4 110 4.8 4095 5.1 0.30 1.7 5 111

6 114

8 120 10 125 12 123

15 130

20 143

25 152

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)

109

Torch

Working

Height

4.8

6.4

Travel Speed

8915 5.1 0.00 1.5

5915

3325 2745 1775 1060 1025

610

395 Edge Start 2.7

210 Edge Start 3.2

Initial

Piercing

Height

5.1

Pierce Delay

0.10 1.8

0.30 1.8

0.40 2.2

0.50 2.3

0.60 2.3

0.75 2.5

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-23 OPERATION

cutmaster a60

Stainless Steel 80A Air Plasma / Air Shield

Deector

9-8243

Thickness

(GA)

Material

(in) inch

0.063

0.125

0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

110 0.19 340 0.25 0.00

115 .0.19 300 0.25 0.10

115 0.19 280 0.25 0.10

115 0.19 140 0.25 0.20

118 0.19 100 0.25 0.30

119 0.19 45 0.25 0.40

124 0.19 26 0.25 0.80 0.10

133 0.19 16 Edge Start 0.10

136 0.19 10 Edge Start 0.11

Tip

9-8211

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Electrode

Cartridge

9-8213

9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

0.06

0.07

0.08

OPERATION 4T-24 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

20 137 4.8 205 Edge Start 3.0

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)

108 111 4.8 8380 6.4 0.00 1.5

114 4.8 7730 6.4 0.10 1.5 115 4.8 5865 6.4 0.20 1.6

115 4.8 3410 6.4 0.20 1.8 117 4.8 2765 6.4 0.30 1.9

119 4.8 1815 6.4 0.40 2.0

120 4.8 1070 6.4 0.60 2.1

123 4.8 765 6.4 0.80 2.3

131 4.8 475 Edge Start 2.5

Torch

Working

Height

4.8

Travel Speed

9020 6.4 0.00 1.5

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-25 OPERATION

cutmaster a60

Aluminum 80A Air Plasma / Air Shield

Deector

9-8243

Thickness

(GA)

Material

(in) inch

0.064

0.120

3/16

1/4

3/8

1/2

5/8

3/4

0.188

0.250

0.375

0.500

0.625

0.750

Standard Shield Cup

Maximum Life Shield Cup

9-8218 9-8237

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

116 0.25 350 0.25 0.00 120 0.25 280 0.25 0.10

124 0.25 180 0.25 0.20

130 0.25 110 0.25 0.30

136 0.25 55 0.25 0.40

139 0.25 38 0.25 0.60

136 0.19 26 0.25 0.75 0.10

150 0.19 14 Edge Start 0.12

Tip

9-8211

Torch

Working

Height

(in)

Starter Cartridge

Heavy Duty Starter

Electrode

Cartridge

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

0.10

0.09

0.11

7/8 0.875 153 0.19 10 Edge Start 0.11

OPERATION 4T-26 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

2 117 6.4 8420 6.4 0.00 2.5

3 120 6.4 7170 6.4

4 122 6.4 5710 6.4 0.20 2.5

5 125 6.4 4315 6.4

6 129 6.4 3190 6.4

8 133 6.4 2070 6.4 10 136 6.4 1330 6.4

12 138 6.4 1060 6.4

15 137 4.8 745 6.4

20 151 4.8 325 Edge Start 3.0

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)

114 6.4 8890 6.4

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.10

0.20

0.30

0.40

0.50

0.75

Kerf Width

@ Rec.

Speed

2.4

2.5

2.4

2.5

2.7

2.9

2.5

Manual 0-4981 4T-27 OPERATION

cutmaster a60

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

With Shielded Tip

Mild Steel 40A Air Plasma / Air Shield

Starter Cartridge

Shield Cap Maximum Life Shield Cup Tip

9-8245 9-8237 9-8208

Heavy Duty Starter

Cartridge

9-8213 9-8277

Electrode

9-8232

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-28 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

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 0-4981 4T-29 OPERATION

cutmaster a60

Stainless Steel 40A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8245 9-8237 9-8208

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

9-8213 9-8277

Initial

Piercing

Height

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

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-30 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

Gas Pressure

(Air)

Bar

(torch lead

length)

5.2 (7.6m)

5.5 (15.2m)

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 0-4981 4T-31 OPERATION

cutmaster a60

Aluminum 40A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

9-8245 9-8237 9-8208

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Electrode

9-8232

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-32 Manual 0-4981

cutmaster a60

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 (7.6m)

5.5 (15.2m)

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 0-4981 4T-33 OPERATION

cutmaster a60

Mild Steel 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

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 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

9-8213 9-8277

Initial

Piercing

Height

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

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-34 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

15 148 4.8 419 Edge Start 2.6

20 147 4.8 318 Edge Start 2.7

25 159 4.8 118 Edge Start 3.0

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)

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

Torch

Working

Height

4.8

Travel Speed

6804 5.1 0 2.2

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-35 OPERATION

cutmaster a60

Stainless Steel 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8238 9-8237 9-8210

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

9-8213 9-8277

Initial

Piercing

Height

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

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-36 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

15 132 3.3 375 Edge Start 2.6

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)

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

144 4.8 230 Edge Start 2.5

Torch

Working

Height

3.3

Travel Speed

4590 5.1 0.00 1.2

Initial

Piercing

Height

Pierce Delay

Kerf Width

@ Rec.

Speed

Manual 0-4981 4T-37 OPERATION

cutmaster a60

Aluminum 60A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

9-8238 9-8237 9-8210

Starter Cartridge

Heavy Duty Starter

Cartridge

9-8213 9-8277

Electrode

9-8232

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-38 Manual 0-4981

cutmaster a60

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 0-4981 4T-39 OPERATION

cutmaster a60

Mild Steel 80A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Material

Thickness

(GA)

(in) inch

3/16 0.188 122 0.19 135 0.20 0.30 0.08

1/4 0.250 127 0.19 100 0.20 0.40 0.09

3/8 0.375 134 0.19 40 0.20 0.50 0.10

1/2 0.500 136 0.19 36 0.20 0.60 0.10

5/8 0.625 145 0.19 18 Edge Start 0.11

3/4 0.750 147 0.19 14 Edge Start 0.11

7/8 0.875 146 0.19 10 Edge Start 0.12

1.000 1.000 152 0.187 8 Edge Start 0.13

0.060

0.120 112 0.13 190 0.20 0.10 0.06

0.135 110 0.13 176 0.20 0.20 0.06

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

115 0.13 280 0.20 0.00 0.06

Torch

Working

Height

(in)

Travel Speed

9-8213 9-8277

Initial Piercing

Height

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

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

OPERATION 4T-40 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

2 114

3 112

4 115 5 123 6 126 4.8 2735 5.1 0.40 2.2 8 131 4.8 1745 5.1 0.50 2.5

10 134 4.8 1000 5.1 0.50 2.6

12 136 4.8 935 5.1 0.60 2.6

15 143 4.8 580 5.1 0.80 2.8

20 147 4.8 325 Edge Start 2.9

25 151 4.8 210 Edge Start 3.2

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)

116

Torch

Working

Height

3.3

4.8

Travel Speed

7895

6395

4895

4025 3300

Initial Piercing

Height

5.1 0.00

5.1

Pierce Delay

0.10 1.6

0.10 1.5

0.30 1.7

0.30 2.0

Kerf Width

@ Rec.

Speed

1.6

Manual 0-4981 4T-41 OPERATION

cutmaster a60

Stainless Steel 80A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

114 0.125 340 0.2 0.00 115 0.125 260 0.2 0.10

116 0.125 250 0.2 0.10

115 0.125 170 0.2 0.20

118 0.125 85 0.2 0.30

127 0.19 45 0.25 0.40

136 0.19 16 0.25 0.75 0.11

143 0.19 10 Edge Start 0.12

146 0.19 8 Edge Start 0.11

(GA)

Material

Thickness

(in) inch

0.063

0.125

0.141

3/16 0.188

1/4 0.250

3/8 0.375

1/2 0.500

5/8 0.625

3/4

0.750

Torch

Working

Height

(in)

9-8213 9-8277

Travel Speed

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

Initial Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

0.06

0.07

0.08

0.09

OPERATION 4T-42 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

15 141 4.8 295 Edge Start 3.0

20 147 4.8 185 Edge Start 2.8

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)

114 114 3.2 8120 5.1 0.00 1.4 115 3.2 6830 5.1 0.10 1.4 116 3.2 5635 5.1 0.20 1.5 115 3.2 4010 5.1 0.20 1.8

117 3.2 2640 5.1 0.30 2.0 123 4.8 1630 6.4 0.40 2.1 128 4.8 1030 6.4 0.60 2.2

134 4.8 565 6.4 0.75 2.6

Torch

Working

Height

3.2

Travel Speed

9410

Initial Piercing

Height

5.1 0.00

Pierce Delay

Kerf Width

@ Rec.

Speed

1.5

Manual 0-4981 4T-43 OPERATION

cutmaster a60

Aluminum 80A Air Plasma / Air Shield

Shield Cap Maximum Life Shield Cup Tip

Starter Cartridge

Heavy Duty Starter

Cartridge

Electrode

9-8239 9-8237 9-8211

Gas Pressure

(Air)

PSI

(torch lead

length)

85 (25')

90 (50')

Arc Voltage

Volts

115 0.13 320 0.2 0.00 120 0.13 240 0.2 0.10

122 0.13 165 0.2 0.20

124 0.13 100 0.2 0.30

140 0.19 60 0.2 0.40

142 0.19 36 0.2 0.60

148 0.19 26 0.2 0.75 0.11

155 0.19 16 Edge Start 0.12

(GA)

Material

Thickness

(in) inch

0.064

0.120

3/16

1/4

3/8

1/2

5/8

3/4

0.188

0.250

0.375

0.500

0.625

0.750

Torch

Working

Height

(in)

9-8213 9-8277

Initial

Travel Speed

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

Piercing

Height

Pierce Delay

9-8232

Kerf Width

@ Rec.

Speed

0.09

0.08

0.10

0.09

0.11

OPERATION 4T-44 Manual 0-4981

cutmaster a60

Material

Thickness

(mm)

2 116 3.3 7595 5.1

3 120 3.3 6165 5.1

4 121 3.3 5045 5.1 5 122 3.3 3955 5.1 6 124 3.3 2905 5.1 0.30 2.3

8 132 4.8 2010 5.1 0.40 2.3 10 140 4.8 1430 5.1 0.50 2.3 12 142 4.8 1045 5.1 0.60 2.6

15 146 4.8 730 5.1 0.75 2.7

20 157 4.8 330 Edge Start 3.2

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)

113 3.3 9020 5.1

Torch

Working

Height

Travel Speed

Initial

Piercing

Height

Pierce Delay

0.00

0.10

0.20

Kerf Width

@ Rec.

Speed

2.4

2.2

2.0

2.1

2.2

Manual 0-4981 4T-45 OPERATION

cutmaster a60

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 9-8232 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 9-8233 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

OPERATION 4T-46 Manual 0-4981

cutmaster a60

Catalog # Description Patent(s)

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 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 0-4981 4T-47 OPERATION

cutmaster a60

This Page Intentionally Blank

OPERATION 4T-48 Manual 0-4981

SECTION 5 SYSTEM:

5.01 General Maintenance

cutmaster a60

SERVICE

Warning! Disconnect input power before maintaining.

Visual check of torch tip and electrode

Visually inspect the torch body tip, electrode, start cartridge and shield cup

Maintain more often if used under severe conditions

Each Use

Weekly

Visually inspect the cables and leads. Replace as needed

Replace all broken parts

3 Months

Clean exterior of power supply

6 Months

Visually check and Carefully clean the interior

Art # A-07938_AB

Manual 0-4981 5-1 SERVICE

cutmaster a60

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 diminished.

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.

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

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.

Difﬁcult Starting 1. Worn torch parts.

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

2. Non - Genuine Thermal Dynamics parts used.

3. Incorrect gas pressure.

CAUTION

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

SERVICE 5-2 Manual 0-4981

cutmaster a60

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.

7 6

4 3 2

MAX

MIN

PSI BAR

MAXMAX

MINMIN

Explanation of Faults

UNDER PRESSURE: Indicates that operating pressure

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.

Art # A-08316

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:

Art# A-07988

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 indicated in the pressure indicators. The following table shows each of the Faults possible.

Pressure

Fault

Indicator

Max Over Pressure

90 Internal Error

85 Shorted Torch

80 Consumables Missing

75 Start Error

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-

ro r.

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

70 Parts in Place

65 Input Power

Min Under Pressure

NOTE

Fault explanations are covered in the following tables.

Manual 0-4981 5-3 SERVICE

cutmaster a60

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 a 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

ashing,65PSI indicatorashing

TEMPERATURE indicator ON. FAULT

indicatorashing.

GAS indicator OFF, FAULT and MIN pressure indicators

ashing.

FAULT and 70 PSI

indicatorsashing.

1. INPUT VOLTAGE SELECTION SWITCH set for incorrect voltage.

2. Primary input voltage problem.

3. Faulty components in unit.

1.Airow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 a 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ashing.

SERVICE 5-4 Manual 0-4981

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ashing. Gasow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 a60

Nothing happens when torch switch or remote switch is closed (Or CNC START signal is

active)Nogasow,

DC LED OFF. FAULT and 85 PSI

indicatorsashing.

No Fault lights ON, no arc in torch.

FAULT and 85 PSI

indicatorsashing

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 authorized 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 0-4981 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 a60

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

Upper Screws

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.

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).

Lower Screws

Slots

Lower Screws

Art # A-08317

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

B. Cover Installation

1. Reverse previous procedures for cover installation.

NOTE

not over tighten.

Art # A-07989

6mm

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.

SERVICE 5-6 Manual 0-4981

cutmaster a60

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

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.

Filter Element

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 Lists, for replacement ﬁlter element catalog number.

1. Remove power from power supply.

2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing.

Housing

Art # A-07990

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.

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter 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.

Manual 0-4981 5-7 SERVICE

NOTE

If unit leaks between housing and cover, inspect the O-Ring for cuts or other damage.

cutmaster a60

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 Lists, 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.

NOTE

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

This completes the parts replacement procedures.

5. Slide out the old Filter Elements.

First & Second Stage Cartridges (as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

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

SERVICE 5-8 Manual 0-4981

SECTION 5 TORCH:

SERVICE

5T.01 General Maintenance

cutmaster a60

Upper Groove with Vent Holes Must Remain Open

NOTE

Refer to Previous "Section 5 System: Service" 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.

WARNING

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

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

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

Lower O-Ring

Torch Head O-Ring

Gas Fitting

Upper O-Ring in Correct Groove

Threads

Art # A-03725

ATC Male Connector

CAUTION

Dry the torch thoroughly before reinstalling.

O-Ring Lubrication

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

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

Manual 0-4981 5T-1 SERVICE

Art #A-03791

O-Ring

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.

cutmaster a60

Good Tip

Worn Tip

Spring-Loaded

5T.02 Inspection and Replacement

of Consumable Torch Parts

WARNING

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

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

Remove the consumable torch parts as follows:

NOTE

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

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

NOTE

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

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

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

A-03406

Example of Tip Wear

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

Lower End Fitting Full Compression

Spring-Loaded Lower End Fitting at Reset / Full Extension

Art # A-08064_AC

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

3. On torches with a shield cup body and a shield

Art # A-08067

Shield Cups

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.

Drag Shield Cap

Shield

Cup Body

O-Ring No. 8-3488

Art # A-03878

New Electrode

Art # A-03284

Worn Electrode

Electrode Wear

. 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 0-4981

cutmaster a60

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

Section "6.03 Power Supply Replacement"

Section "6.04 Replacement Power Supply Parts"

Section "6.05 Options and Accessories"

Section "6.06 Torch Replacement Parts SL100SV Torch (w/Solenoid on Mounting Tube)"

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

Section "6.08 Torch Consumable Parts Manual (SL60)Torch"

Section "6.09 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, 3 Phase, 50Hz, with input power cable 3-1134-3 600VAC, 3 Phase, 60Hz, with input power cable 3-1134-5

Manual 0-4981 6-1 PARTS LIST

cutmaster a60

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 9-0218 1 Input Power Cord for 460/600 V Power Supply 9-8593

NOTE

*9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom ﬁtting. If there is a transducer and wire harness instead of the tube, the kit is not needed.

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 Harness for Start/Stop and OK to move 9-9385 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-1008 1 35' / 10.7 m CNC Cable for Automation Interface Kit 9-1010 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-1011 1 Nylon Dust Cover 9-7071

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second Stage Cartridges (as marked)

Art # A-02942

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

PARTS LIST 6-2 Manual 0-4981

cutmaster a60

Intentionally Blank

Manual 0-4981 6-3 PARTS LIST

cutmaster a60

6.06 Torch Replacement Parts SL100SV Torch (w/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 25 SL100SV Automation Torch and Leads Packages 25 - foot 7-4001 35 - foot 7-4002 50 - foot 7-4003

Purchase these parts locally.

NOTE

PARTS LIST 6-4 Manual 0-4981

cutmaster a60

Manual 0-4981 6-5 PARTS LIST

Art # A-07113

cutmaster a60

6.07 Torch Consumable Parts Automation / Machine (SL100)Torch

Ohmic Clip

Manual Torch

9-8259

Automation To rch

9-8224

Electrode

Auto 9-8232

Manual 9-8215

Starter

Cartridge

9-8213

20-40A

STANDOFF

CUTTING

50-60A

STANDOFF

CUTTING

Heavy Duty

Starter Cartridge

Non HF Only 9-8277

70-120A

STANDOFF

CUTTING

Tip:

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

Tips:

50-55A 9-8209

60A 9-8210

Tips:

70A 9-8231

80A 9-8211

90/100A 9-8212

120A Auto 9-8233

120A Manual 9-8253

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield

Cup Body,

9-8237

Shield Cup

9-8218

Shield Cap, Machine 40A 9-8245

Shield Cap, Deflector 9-8243

Drag Shield Cup 9-8235

Shield Cap, Machine 50-60A 9-8238

Shield Cap, Deflector 9-8243

Drag Shield Cup 70-100A 9-8236

Drag Shield Cup 120A 9-8258

Shield Cap, Machine 70-100A 9-8239

Shield Cap, Machine 120A 9-8256

Shield Cap, Deflector 9-8243

40-120A

GOUGING

Tips:

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)

Art # A-08066_AG

Tip E 9-8254 (60 - 120 Amps)

PARTS LIST 6-6 Manual 0-4981

Shield

Cup Body,

9-8237

Shield Cup, Gouging

9-8241

Thermal Dynamics cutmaster A60 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual