Thermal Dynamics A40 Operating Manual
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Thermal Dynamics A40 Operating Manual

Cutmaster automated plasma cutting system
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Download this manual See also: Operating Manual
A40
A60
operating manual
CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AC
Date: October 20, 2009
Operating Features:
A40
A60
™
Art # A-08697
Manual # 0-5120
80%
40
Duty
AMP
Cycle
80%
60
Duty
AMP
Cycle
380-
400
380-
400

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Summary of Contents for Thermal Dynamics A40

  • Page 1 CutmASteR ™ AutomAted PLASmA CuttING SYStem Art # A-08697 operating manual Rev. AC Date: October 20, 2009 Manual # 0-5120 Operating Features: 380- Duty Cycle 380- Duty Cycle...
  • Page 2 1888, 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.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ A40 SL100SV Torch™ Operating Manual No.: 0-5120 CutMaster™ A60 SL100SV Torch™...
  • Page 4 This Page Intentionally Blank...

  • Page 5: Table Of Contents

    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...
  • Page 6 TABLE OF CONTENTS PATENT INFORMATION ...................... 4T-28 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..................

  • Page 7: Section 1:General Information

    CUTMASTER A40, A60 SECTION 1: or welding any metals which may contain one or more of the following: GENERAL INFORMATION Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium 1.01 Notes, Cautions and Warnings Beryllium Lead Silver Cadmium Manganese Vanadium Throughout this manual, notes, cautions, and warnings are used to •...

  • Page 8: Publications

    CUTMASTER A40, A60 • Provide a fire watch when working in an area where fire 1.03 Publications hazards may exist. Refer to the following standards or their latest revisions for more • Hydrogen gas may be formed and trapped under aluminum...

  • Page 9: Note, Attention Et Avertissement

    CUTMASTER A40, A60 1.04 Note, Attention et Avertissement • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz. Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont •...
  • Page 10 CUTMASTER A40, A60 BRUIT INCENDIE ET EXPLOSION Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés Les incendies et les explosions peuvent résulter des scories chaudes, de soudage à l’arc de plasma peuvent provoquer des niveaux sonores des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma supérieurs aux limites normalement acceptables.

  • Page 11: Documents De Reference

    CUTMASTER A40, A60 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPA- Consultez les normes suivantes ou les révisions les plus récentes RATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET ayant été...

  • Page 12: Declaration Of Conformity

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

  • Page 13: Statement Of Warranty

    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.
  • Page 14 CUTMASTER A40, A60 This page intentionally blank. GENERAL INFORMATION Manual 0-5120...

  • Page 15: Section 2 System:introduction

    CUTMASTER A40, A60 SECTION 2 SYSTEM: INTRODUCTION 2.01 How To Use This Manual 2.02 Equipment Identification This Owner’s Manual applies to just specification or part The unit’s identification number (specification or part numbers listed on page i. To ensure safe operation, read...

  • Page 16: Power Supply Specifications

    20 - 80 Amps, Continuously Adjustable Current Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster A40 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Rating...
  • Page 17 CUTMASTER A40, A60 Power Supply Dimensions & Weight Ventilation Clearance Requirements 10" 254 mm Art # A-08305 13.78" Art # A-07925 350 mm 24" 20.8" 0.6 m 0.528 m 43 lb / 19.5 kg 6" 150 mm Manual 0-5120 INTRODUCTION...

  • Page 18: Input Wiring Specifications

    CUTMASTER A40, A60 2.05 Input Wiring Specifications CutMaster A40 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts Fuse (amps) (Min. mm2) 50/60 10.3 3 Phase 50/60 10.8 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 19: Power Supply Features

    CUTMASTER A40, A60 2.06 Power Supply Features Control Panel Art # A-08306 Torch Leads Receptacle Mounting Rails Work Cable and Clamp Automation Interface Cable Port Input Power Selection Filter Assembly Gas Inlet Port Input Power Cord Art # A-08318 Manual 0-5120...
  • Page 20 CUTMASTER A40, A60 This page intentionally blank. INTRODUCTION Manual 0-5120...

  • Page 21: Section 2 Torch:introduction

    CUTMASTER A40, A60 18.875" / 479 mm SECTION 2 TORCH: 12.285" / 312 mm INTRODUCTION 2.875” / 73 mm 1.375" / 35 mm 2T.01 Scope of Manual 1.175" / 30 mm 1.75" / 4.95" / 126 mm 0.625" / 44.5 mm...

  • Page 22: 04 Options And Accessories

    CUTMASTER A40, A60 2T.05 Introduction to Plasma F. Torch Ratings Automated / Machine Torch Ratings A. Plasma Gas Flow Ambient 104° F Plasma is a gas which has been heated to an ex- Temperature 40° C tremely high temperature and ionized so that it...
  • Page 23 CUTMASTER A40, A60 B. Gas Distribution Remote Pendant The single gas used is internally split into plasma and secondary gases. The plasma gas flows into the torch through the PIP Switch Shield Cup To ATC negative lead, through the starter cartridge, around the electrode, and out through the tip orifice.
  • Page 24 CUTMASTER A40, A60 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-5120...

  • Page 25: Section 3 System: Installation

    CUTMASTER A40, A60 3.03 Power Supply location and SECTION 3 SYSTEM: Mounting INSTALLATION NOTE It is recommended that the unit be secured to a 3.01 Unpacking suitable surface using the mounting rails. 1. Use the packing lists to identify and account 1.
  • Page 26 CUTMASTER A40, A60 A. Cover Removal C. Input Power Connections 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 CAUTION in the bottom of the cover.

  • Page 27: Gas Connections

    CUTMASTER A40, A60 3.05 Gas Connections 5. Pass the cable being used through the access opening in the back panel of the power supply. Refer to Section 2 for power cable specifica- Connecting Gas Supply to Unit tions. The connection is the same for compressed air or high pressure cylinders.
  • Page 28 CUTMASTER A40, A60 Installing Optional Single - Stage Air Filter Using High Pressure Air Cylinders An optional filter kit is recommended for improved When using high pressure air cylinders as the air filtering with compressed air, to keep moisture and supply: debris out of the torch.
  • Page 29 CUTMASTER A40, A60 Installing Optional Two - Stage Air Filter Kit Using High Pressure Air Cylinders This optional two - stage air line filter is also for use on When using high pressure air cylinders as the air compressed air shop systems. Filter removes moisture supply: and contaminants to at least 5 microns.
  • Page 30 CUTMASTER A40, A60 This Page Intentionally Blank INSTALLATION Manual 0-5120...

  • Page 31: Section 3 Torch: Installation

    If necessary, connect the torch to the Power Supply. 3. Place a welding filter lens in front of the torch Connect only the Thermal Dynamics model SL100SV and turn on the air. Do not start an arc! / Automation, SL100 / Mechanical or SL60 / Manual Any oil or moisture in the air will be visible on Torch to this power supply.

  • Page 32: 03 Setting Up Automation Or Machine Torch

    CUTMASTER A40, A60 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.

  • Page 33: Section 4 System: Operation

    CUTMASTER A40, A60 SECTION 4 SYSTEM: AC Indicator OPERATION 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 4.01 Front Panel Controls /...

  • Page 34: Preparations For Operation

    Check that the torch is properly connected. Only exists and for a ten (10) minute period once Thermal Dynamics model SL60 / Manual, SL100 the condition is cleared. / Mechanical or SL100 / SV Automation Torches may be connected to this Power Supply.
  • Page 35 CUTMASTER A40, A60 3. For Drag cutting, adjust gas pressure from Set Operating Pressure 75 - 95 psi / 5.2 - 6.5 bar (LED's in center of 1. Place the Power Supply Function Control control panel). Refer to the Drag Cutting chart for pressure setting details.
  • Page 36 CUTMASTER A40, A60 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.

  • Page 37: Section 4 Torch:operation

    CUTMASTER A40, A60 For optimum smooth surface quality, the travel SECTION 4 TORCH: speed should be adjusted so that only the leading edge of the arc column produces the cut. If the OPERATION travel speed is too slow, a rough cut will be pro- duced as the arc moves from side to side in search of metal for transfer.

  • Page 38: 02 Machine And Hand Torch Parts Selection

    CUTMASTER A40, A60 4T.02 Machine and Hand Torch Parts Selection WARNING Depending on the type of operation to be done determines Disconnect primary power at the source before the torch parts to be used. assembling or disassembling torch parts, or Type of operation: torch and leads assemblies.

  • Page 39: 03 Automation Torch Parts Selection

    CUTMASTER A40, A60 Shown) Kerf Width Cut Surface Bevel Angle 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 Spatter the operation into the torch head.

  • Page 40: 05 General Cutting Information

    CUTMASTER A40, A60 4T.05 General Cutting Information Left Side Cut Angle Right Side Cut Angle WARNINGS Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Frequently review the Important Safety Precau- A-00512 tions at the front of this manual. Be sure the...
  • Page 41 CUTMASTER A40, A60 2. Depending on the cutting operation, do one of Trigger the following: a. For edge starts, hold the torch perpendicu- lar to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.
  • Page 42 CUTMASTER A40, A60 Shield Cup With Straight Edge 4. Keep the torch in contact with the workpiece during the cutting cycle. The drag shield cup can be used with a non con- 5. Hold the torch away from your body.

  • Page 43: 07 Gouging

    CUTMASTER A40, A60 When the shield cup is properly installed, there as provided in the power supply operator's is a slight gap between the shield cup and the manual. torch handle. Gas vents through this gap as NOTE part of normal operation. Do not attempt to When the shield cup is properly installed, there force the shield cup to close this gap.
  • Page 44 CUTMASTER A40, A60 Torch Head CAUTION Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal. 35° Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4T.09, Torch Parts Selection.
  • Page 45 CUTMASTER A40, A60 This page intentionally blank. Manual 0-5120 4T-9 OPERATION...

  • Page 46: 08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip 4T-10

    CUTMASTER A40, A60 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch...
  • Page 47 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 48 CUTMASTER A40, A60 Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness...
  • Page 49 CUTMASTER A40, A60 Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Gas Pressure Material Travel Pierce Kerf Width Working Piercing (Air) Thickness...
  • Page 50 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 51 CUTMASTER A40, A60 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air)
  • Page 52 CUTMASTER A40, A60 Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 53 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 54 CUTMASTER A40, A60 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air)

  • Page 55: 09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip 4T-19

    CUTMASTER A40, A60 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width...
  • Page 56 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 57 CUTMASTER A40, A60 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage Speed...
  • Page 58 CUTMASTER A40, A60 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 59 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 60 CUTMASTER A40, A60 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage Speed...
  • Page 61 CUTMASTER A40, A60 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 62 CUTMASTER A40, A60 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 63 CUTMASTER A40, A60 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage Speed...

  • Page 64: Patent Information

    CUTMASTER A40, 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...
  • Page 65 CUTMASTER A40, A60 Other Pat(s) Pending Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235 Shield Cap...
  • Page 66 CUTMASTER A40, A60 This Page Intentionally Blank OPERATION 4T-30 Manual 0-5120...

  • Page 67: Section 5 System:service

    CUTMASTER A40, A60 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Warning! There are extremely dangerous voltage and power levels present inside this product. Do not attempt to open or repair unless you are a qualified electrical tradesperson and you have had training in power measurements Maintain more often and troubleshooting techniques.

  • Page 68: Maintenance Schedule

    CUTMASTER A40, A60 5.02 Maintenance Schedule 5.03 Common Faults NOTE Problem - Common Cause Symptom The actual frequency of maintenance may Insufficient 1. Cutting speed too fast. need to be adjusted according to the operating Penetration 2. Torch tilted too much.

  • Page 69: Fault Indicator

    CUTMASTER A40, A60 5.04 Fault Indicator Explanation of Faults " UNDER PRESSURE: Indicates that operating At initial power up, two lights will temporarily illu- pressure is set too low and power supply output minate for 2-3 seconds to show the version of software power will be disabled.

  • Page 70: Basic Troubleshooting Guide

    CUTMASTER A40, 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 -...
  • Page 71 CUTMASTER A40, A60 Problem - Possible Cause Recommended Action Symptom FAULT & 80 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. PSI indicators 2. Torch tip, electrode or 2. Turn off power supply. Remove shield cup. Install flashing.

  • Page 72: Circuit Fault Isolation

    CUTMASTER A40, A60 5.06 Circuit Fault Isolation B. Cover Installation 1. Reverse previous procedures for cover instal- lation. WARNING NOTE The following procedures should not be at- When installing the upper screws, attempt to re- tempted by anyone who has not had proper use the original threads.
  • Page 73 CUTMASTER A40, A60 Disconnect the input line from the filter element assembly. Remove the filter element assembly through the rear opening. NOTE If replacing or cleaning just the filter element refer to the following illustration for disas- sembly. Art # A-07989...
  • Page 74 CUTMASTER A40, A60 Optional Single-Stage Filter Element Optional Two-Stage Filter Element Replacement Replacement These instructions apply to power supplies where the The Two-Stage Air Filter has two Filter Elements. optional Single-Stage Filter has been installed. When the Filter Elements become dirty the Power...

  • Page 75: Section 5 Torch:service

    CUTMASTER A40, A60 SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE Upper O-Ring Refer to Previous "Section 5 System" for com- in Correct Groove mon and fault indicator descriptions. Threads Cleaning Torch...
  • Page 76 CUTMASTER A40, A60 Spring-Loaded NOTE Spring-Loaded Lower End Fitting Lower End Fitting at Reset / Slag built up on the shield cup that cannot Full Compression 1/8”(3mm) Full Extension be removed may effect the performance of the system. 2. Inspect the cup for damage. Wipe it clean or replace if damaged.

  • Page 77: Section 6:Parts Lists

    CUTMASTER A40, 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 Complete Power Supply Replacement Section 6.04 Replacement Parts Section 6.05 Options and Accessories...

  • Page 78: Replacement Power Supply Parts

    CUTMASTER A40, A60 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115* Filter Assembly Replacement Element 9-0116 NOTE: *9-0115 regulator, If the serial number of the power supply is prior to #05078755 then kit number 9-0201 will be needed to replace not only the regulator (9-0115) but the logic PCB as well. Another way to tell if the kit is needed is to see if the regulator has a small diameter tube coming out of the bottom fitting.
  • Page 79 CUTMASTER A40, A60 Intentionally Blank Manual 0-5120 PARTS LIST...

  • Page 80: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    CUTMASTER A40, A60 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring...
  • Page 81 CUTMASTER A40, A60 Art # A-07113 Manual 0-5120 PARTS LIST...

  • Page 82: Torch Consumable Parts Automation / Machine (Sl100)Torch

    CUTMASTER A40, A60 6.07 Torch Consumable Parts Automation / Machine (SL100)Torch Ohmic Clip 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208 Drag Shield Cup...

  • Page 83: Replacement Parts - For Machine Torches

    CUTMASTER A40, A60 6.08 Replacement Parts - for Machine Torches Item No. Qty Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486 PIP Switch Kit...

  • Page 84: Torch Consumable Parts Manual (Sl60)Torch

    CUTMASTER A40, A60 6.09 Torch Consumable Parts Manual (SL60)Torch Tips: Shield DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 9-8243 CUTTING 20A 9-8205 30A 9-8206 Shield Cup 40A 9-8207 9-8218 60A 9-8252 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD...

  • Page 85: Replacement Parts For Hand Torch

    CUTMASTER A40, A60 6.10 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.
  • Page 86 CUTMASTER A40, A60 Intentionally Blank PARTS LIST 6-10 Manual 0-5120...

  • Page 87: Appendix 1: Sequence Of Operation(Block Diagram

    CUTMASTER A40, A60 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / Rapid Auto Restart / ON / OFF switch to ON Close external RUN / SET / LATCH disconnect switch. Rapid Auto Restart / switch to RUN...

  • Page 88: Appendix 2: Data Tag Information

    CUTMASTER A40, A60 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering...

  • Page 89: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER A40, A60 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Automation SL100SV Torch Pin - Out Diagram ATC Female Receptacle - ATC Male Connector - Front View Front View Negative / Plasma Negative / Plasma 4 - Not Used...

  • Page 90: Appendix 4: Torch Connection Diagrams

    CUTMASTER A40, A60 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Automation (SL100SV) Torch Connection Diagram Automated CutMaster Power Supply with ATC Torch Receptacle, Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector ATC Female ATC Male Torch Receptacle...
  • Page 91 CUTMASTER A40, A60 C. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power Torch Supply Torch Head Leads Black To Power Supply...

  • Page 92: Appendix 5: System Schematic, 208/460V Units

    1PH USE L1, L2 & GND - INSTALL JUMPER BETWEEN L2 TO L3 MTH5 MTH5 MTH7 MTH7 460_IN INPUT VOLTAGE SELECTOR * CM52 & A40 (Closed for 230VAC input) C3 & C5 not installed 24VAC PCB2 INPUT CAPACITOR PCB TEST POINTS 24 VAC RETURN...
  • Page 93 WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN 24VAC SUPPLY CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS OK TO MOVE (5A @250VAC / 30VDC) J2 PINOUT OK-TO-MOVE +12VDC /START / STOP...

  • Page 94: Appendix 6: System Schematic, 380V, 400V Units

    CUTMASTER A40, A60 APPENDIX 6: SYSTEM SCHEMATIC, 380V, 400V UNITS PRI 2 PRI 2 PRI 1 PRI 1 PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY MTH1 MTH1 MTH2 MTH2 +12VDC + C1-C4* + C1-C4* CHOKE /INRUSH CE UNITS...
  • Page 95 WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN 24VAC SUPPLY CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS OK TO MOVE (5A @250VAC / 30VDC) J2 PINOUT OK-TO-MOVE +12VDC /START / STOP...

  • Page 96: Appendix 7: Publication History

    CUTMASTER A40, A60 APPENDIX 7: Publication History Cover Date Rev. Change(s) Dec. 10, 2008 Manual released. May 29, 2009 Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V schematic per ECOB1357. Oct. 20, 2009 Updated Electrode part numbers in charts per ECOB1494 changing 9-8215 to 9-8232.
  • Page 97 GLOBAL CUSTOMER SERVICE CONTACT Thermadyne Asia Sdn Bhd Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085...
  • Page 98 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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