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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...
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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.
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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™...
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 •...
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...
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 •...
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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.
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...
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.
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CUTMASTER A40, A60 This page intentionally blank. GENERAL INFORMATION Manual 0-5120...
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...
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...
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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...
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...
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...
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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.
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.
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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.
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.
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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.
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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.
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.
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.
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 /...
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.
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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.
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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.
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.
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.
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.
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...
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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.
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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.
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.
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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.
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...
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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.
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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...
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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...
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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.
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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)
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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.
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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.
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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)
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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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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...
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...
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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...
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.
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.
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.
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 -...
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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.
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.
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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...
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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...
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...
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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.
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...
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.
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...
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CUTMASTER A40, A60 Art # A-07113 Manual 0-5120 PARTS LIST...
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...
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...
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...
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...
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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...
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...
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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...
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...
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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...
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.
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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...
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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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