Thermal Dynamics A40i Operating Manual
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Thermal Dynamics A40i Operating Manual

Thermal Dynamics A40i Operating Manual

Plasma cutting system
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40
60
208-
380-
480V
415V
A40i, A60i
PLASMA CUTTING SYSTEM
OPERATING
MANUAL
Revision: AB
Issue Date: 7/3/2018
Manual No.: 0-5466
thermal-dynamics.com

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Summary of Contents for Thermal Dynamics A40i

  • Page 1 208- 380- 480V 415V A40i, A60i PLASMA CUTTING SYSTEM OPERATING MANUAL Revision: AB Issue Date: 7/3/2018 Manual No.: 0-5466 thermal-dynamics.com...
  • Page 2 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 1-866-279-2628, or visit us on the web at www.Thermal-Dynamics.com.
  • 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 Supplies A40i, A60i SL100SV 1Torch™ Operating Manual Number 0-5466 Published by: Thermal Dynamics 2800 Airport Rd.
  • Page 4 Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equip- ment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...
  • Page 5 ASSUREZ-VOUS QUE CE DOCUMENT D’INFORMATION EST DISTRIBUÉ À L’OPÉRATEUR. DES COPIES SUPPLÉMENTAIRES SONT DISPONIBLES CHEZ VOTRE FOURNISSEUR. MISE EN GARDE Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité...
  • Page 6 This Page Intentionally Blank...
  • Page 7 The RoHS Directive 2011/65/EU, entering into force 2 January 2013 Type of equipment PLASMA CUTTING SYSTEM Type designation etc. A40i and A60i, from serial number MX1723XXXXXX Brand name or trade mark Thermal Dynamics Manufacturer or his authorised representative Name, address, telephone No: ESAB Group Inc.
  • Page 8 This Page Intentionally Blank...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ........................1-1 1.01 Notes, Cautions and Warnings ......................1-1 WARRANTY: .............................. W-1 Statement of Warranty ............................W-1 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 .........................
  • Page 10 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-1 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-5 4T.07 Gouging .............................4T-8 4T.08...
  • Page 11 TABLE OF CONTENTS APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ..........................A-1 APPENDIX 2: DATA TAG INFORMATION ......................A-2 APPENDIX 3: TORCH PIN - OUT DIAGRAMS ....................A-3 APPENDIX 4: TORCH CONNECTION DIAGRAMS ....................A-4 APPENDIX 5: CNC CABLE COLOR CODE ......................A-5 APPENDIX 6: AUTOMATION INTERFACE ......................
  • Page 12 TABLE OF CONTENTS This Page Intentionally Blank...

  • Page 13: General Information

    A40i, A60i SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high- lights are categorized as follows: NOTE! An operation, procedure, or background information which requires additional emphasis or is helpful in efficient opera- tion of the system.
  • Page 14 A40i, A60i WARNING AVERTISSEMENT 1. Cutting sparks can cause explosion 1. Les étincelles de coupage peuvent or fire. provoquer une explosion ou un incendie. 1.1 Do not cut near flammables. 1.2 Have a fire extinguisher nearby and 1.1 Ne pas couper près des matières ready to use.

  • Page 15: Warranty

    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 : 1. Repair of the defective product.
  • Page 16 A40i, A60i This Page Intentionally Blank WARRANTY INFORMATION Manual 0-5466...

  • Page 17: Section 2 System

    Additional copies of this manual may be purchased by contacting Thermal Dynamics at the address and phone number in your area listed on back cover of this manual. Include the Operating Manual number and equipment identification numbers.

  • Page 18: Receipt Of Equipment

    Output Current 10 - 40 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability A40i Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Operating Range 0° - 50° C Rating...

  • Page 19: Input Wiring Specifications

    11.8 10.5 14 AWG (2.5 mm2) Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code A40i Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord (Min.

  • Page 20: Power Supply Features

    A40i, A60i 2.06 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Work Lead Receptacle Input Power ON/OFF Switch Input Power Cord Port for Optional Automation Interface Cable Gas Inlet Port Filter Assembly 2.07 Power Supply Placement 7.847...

  • Page 21: Section 2 Torch

    A40i, A60i SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Automation Torch, Model 2T.01 Scope of Manual The standard automation torch has a position- ing tube with rack & pinch block assembly and This manual contains descriptions, operating instruc- a solenoid valve.

  • Page 22: 04 Quick Connection Torch

    A40i, A60i F. Torch Ratings 2T.04 Quick Connection Torch Automated / Machine Torch Ratings The new SL60QD™ (Quick Disconnect) torch allows Ambient 104° F for a quick change of the torch handle assembly from Temperature 40° C the leads. To change the torch handle assembly do...
  • Page 23 A40i, A60i C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting or gouging 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.
  • Page 24 A40i, A60i This Page Intentionally Blank INTRODUCTION Manual 0-5466 2T-4...

  • Page 25: Section 3 System

    A40i, A60i 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.

  • Page 26: Opening The Main Switch Cover

    A40i, A60i 3.04 Opening the Main Switch Cover Systems are configured for and come with power cord connected for single phase configuration. The input power switch is located on the rear panel along the top. To access the input locations, remove the screw at the top of the cover and flip down.

  • Page 27: Primary Input Power Connections, Three Phase

    3.06 Primary Input Power Connections, THREE Phase WARNING Each A40i or A60i system is a dedicated 1 Phase OR 3 Phase system and cannot be reconfigured to the other. Personal injury could occur if changing the phase is attempted.. CAUTION...

  • Page 28: Gas Connections

    A40i, A60i 3.07 Gas Connections Connecting Gas Supply to Unit The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed. 1. Connect the air or argon line to the inlet port. The illustration shows typical fittings as an example.
  • Page 29 A40i, A60i Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port 1/4" NPT of the system filter.
  • Page 30 A40i, A60i Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter 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.

  • Page 31: Work Lead Connections

    A40i, A60i NOTE! Filter replacement part numbers can be found in Section 6 of this manual Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators.
  • Page 32 A40i, A60i This Page Intentionally Blank INSTALLATION Manual 0-5466...

  • Page 33: Section 3 Torch

    3T.01 Torch Connections or torch leads. If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60, The mechanical torch includes a positioning tube with SL60QD™ or SL100 / Mechanical Torch to this power rack and pinch block assembly.
  • Page 34 A40i, A60i This Page Intentionally Blank INSTALLATION Manual 0-5466 3T-2...

  • Page 35: Section 4 System

    A40i, A60i SECTION 4 SYSTEM: OPERATION 4.01 Front Panel Controls / Features See Illustration for numbering Identification Art # A-13250 Numeric Display • Displays software revision at start up • Displays amperage values (Factory default) • Displays error codes • Displays pre-set (preview) maintenance functions AC Indicator Steady light indicates power supply is ready for operation.
  • Page 36 A40i, A60i Set Mode Indicator Indicator is ON when unit is flowing gas and pressure can be set. Shield Cup In Place Indicator Indicator is Blinking when any of the following are not in place or connected: Shield Cup, ATC leads or Quick Disconnect.
  • Page 37 A40i, A60i Gas Pressure Indicator Indicator used to show low, optimal and high gas pressure. Torch type, lead length, cutting mode and amperage should all be set prior to setting the gas pressure. (90 - 125 PSI / 6.2 - 8.6 bar) One of 7 segments will always be on when unit is on.

  • Page 38: Preparations For Operation

    Torch Connection Check that the torch is properly connected. Only Thermal Dynamics models SL60, SL60QD™ / Manual or SL100 / Me- chanical Torches may be connected to this Power Supply. See Section 3T of this manual.
  • Page 39 A40i, A60i 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.
  • Page 40 A40i, A60i Select Cutting Mode Art # A-13251 1. Press and release the upper knob without turning to enter the mode selection menu. Place the system in one of the four cutting modes available by pressing and releasing the knob until you reach the desired mode.:...
  • Page 41 A40i, A60i Set Operating Pressure NOTE! Before the gas pressure is set, the torch type, leads length, type of cutting and amperage should all be set as they will affect the pressures required. If any of those are changed, the pressure should be checked again to make sure it is optimized.

  • Page 42: Marking

    A40i, A60i 4.03 Marking Gas Type 1. The first thing you will want to do is determine which type of gas to use. When marking, you will use either air or argon and they both have their advantages and disadvantages. This chart helps to make the best choice.
  • Page 43 A40i, A60i Marking with Argon: 2. Place the proper consumables in the torch for marking. Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8241 9-8237 9-8225 9-8213 9-8215 Travel Speed Pierce Delay Torch Working Height...
  • Page 44 A40i, A60i Types of Marking Light Marking: This will consist of lines that are clean, thin and with very little depth and no slag. This type of marking can usually be removed with secondary operations and are not as long lasting.

  • Page 45: Section 4 Torch

    A40i, A60i SECTION 4 TORCH: For optimum smooth surface quality, the travel speed should be adjusted so that only the leading OPERATION 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 4T.01 Machine and Automated Torch...

  • Page 46: 03 Machine And Hand Torch Parts Selection

    A40i, A60i 4T.03 Machine and Hand Torch Parts NOTE! Selection The shield cup holds the tip and start cartridge in place. Position the torch Depending on the type of operation to be done deter- with the shield cup facing upward to mines the torch parts to be used.

  • Page 47: 04 Cut Quality

    A40i, A60i Shown) Cut Quality Characteristics 3. Install the replacement Electrode by pushing it Cut Surface straight into the torch head until it clicks. The desired or specified condition (smooth or rough) 4 . Install the starter cartridge and desired tip for of the face of the cut.

  • Page 48: 05 General Cutting Information

    A40i, A60i Edge Starting Top Spatter (Dross) For edge starts, hold the torch perpendicular to the Top spatter or dross on the top of the cut caused by workpiece with the front of the tip near (not touch- slow travel speed, excess cutting height, or cutting ing) the edge of the workpiece at the point where tip whose orifice has become elongated.

  • Page 49: 06 Hand Torch Operation

    A40i, A60i heavy bead, but does not adhere tightly to the cut Torch 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...
  • Page 50 A40i, A60i Trigger Shield Cup Trigger Release Standoff Guide Torch Tip Workpiece Art # A-04034 Shield Cup With Straight Edge The drag shield cup can be used with a non conduc- tive straight edge to make straight cuts by hand.
  • Page 51 A40i, A60i 1. Install the drag cutting tip and set the output 9. Follow normal recommended cutting practices as current. provided in the power supply operator's manual. 2. The torch can be comfortably held in one hand NOTE! or steadied with two hands. Position the hand to When the shield cup is properly in- press the Trigger on the torch handle.

  • Page 52: 07 Gouging

    A40i, A60i 4T.07 Gouging 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. WARNING Be sure the operator is equipped with NOTE! proper gloves, clothing, eye and ear...
  • Page 53 A40i, A60i 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.

  • Page 54: 08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    A40i, A60i 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208...
  • Page 55 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2920 1810 1470 4.8 (7.6m) 1345 5.2 (15.2m)
  • Page 56 A40i, A60i Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 57 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 58 A40i, A60i Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working...
  • Page 59 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7620 3500 2350 4.8 (7.6m) 2170 1740 5.2 (15.2m)
  • Page 60 A40i, A60i Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 61 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7540 7015 0.10 4570 0.10 3650 0.20...
  • Page 62 A40i, A60i Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage...
  • Page 63 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 10890 0.00 7560 0.10 4365 0.10 2865 0.20...
  • Page 64 A40i, A60i Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working...
  • Page 65 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 17010 0.00 7680 0.10 6410 0.10 5230 0.20...

  • Page 66: 09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip

    A40i, A60i 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277...
  • Page 67 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3266 2239 1794 1651 5.2 (7.6) 1578 5.5 (15.2)
  • Page 68 A40i, A60i Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 69 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) BOLD TYPE indicates maximum piercing parameters.
  • Page 70 A40i, A60i Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 71 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7660 3490 2350 5.2 (7.6) 2170 1630 5.5 (15.2)
  • Page 72 A40i, A60i Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 73 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 6804 5942 0.10 5080 0.10 3316 0.20...
  • Page 74 A40i, A60i Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed...
  • Page 75 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4590 0.00 3925 0.10 3285 0.10 1985 0.20...
  • Page 76 A40i, A60i Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 77 A40i, A60i Initial Kerf Width Torch Material Gas Pressure Piercing Pierce Delay @ Rec. Arc Voltage Working Travel Speed Thickness (Air) Height Speed Height (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...

  • Page 78: Patent Information

    A40i, A60i 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 79 A40i, A60i 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:...
  • Page 80 A40i, A60i This Page Intentionally Blank 4T-36 OPERATION Manual 0-5466...

  • Page 81: Section 5 System

    A40i, A60i SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed...

  • Page 82: Maintenance Schedule

    A40i, A60i 5.02 Maintenance Schedule NOTE! The actual frequency of maintenance may need to be adjusted according to the oper- ating environment. Daily Operational Checks or Every Six Cutting Hours: 1. Check torch consumable parts, replace if damaged or worn.

  • Page 83: Common Faults

    Penetration 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts 5. Cutting current too low. 6. Non - Genuine Thermal Dynamics parts used 7. Incorrect gas pressure Main Arc 1. Cutting speed too slow. Extinguishes 2. Torch standoff too high from workpiece.

  • Page 84: Fault Indicator

    A40i, A60i 5.04 Fault Indicator At initial power up, the system goes through a series of self checks before it is ready for use. If during those checks it detects something is not within proper operating parameters, a fault will occur. If that happens the Fault indicator will light followed by the Error Code , and number in the digital display.

  • Page 85: Basic Troubleshooting Guide

    A40i, A60i 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 measure- ment and troubleshooting techniques. Problem - Symptom Possible Cause...
  • Page 86 A40i, A60i Problem - Symptom Possible Cause Recommended Action FAULT indicators 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. flashing. Gas flow is 2. Torch tip, electrode or starter 2. Turn OFF power supply. Remove shield cup. Install missing cycling ON and OFF.

  • Page 87: Power Supply Basic Parts Replacement

    A40i, A60i 5.06 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.
  • Page 88 A40i, A60i 3. Remove the filter element and clean or replace.. NOTE! If replacing or cleaning just the filter ele- ment refer to the following illustration for disassembly. Filter Element Art # A-07990 4. Install the new or cleaned assembly by reversing these procedures.
  • Page 89 A40i, A60i 4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing. Housing Filter Element (Cat. No. 9-7741) Spring O-ring (Cat. No. 9-7743) Assembled Filter Cover Barbed Fitting Art # A-02476 Optional Single-Stage Filter Element Replacement 5.
  • Page 90 A40i, A60i Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

  • Page 91: Section 5 Torch

    A40i, A60i 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 in Correct Groove common and fault indicator descriptions. Threads Lower O-Ring Art # A-03725...

  • Page 92: 02 Inspection And Replacement Of Consumable Torch Parts

    A40i, A60i 5T.02 Inspection and Replacement of 4. Remove the tip. Check for excessive wear (indi- Consumable Torch Parts cated by an elongated or oversized orifice). Clean or replace the tip if necessary. WARNING Worn Tip Good Tip Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 93: Parts Lists

    The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # A40i Power Supply 208-480V, Single Phase 3-5634-1 A40i Power Supply 208-480V Three Phase...
  • Page 94 A40i, A60i 6.04 Replacement Power Supply Parts Description Catalog # Filter Assembly Replacement Element 9-0116 Input Power Cord for 208/480 V Power Supply 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507...
  • Page 95 A40i, A60i This Page Intentionally Blank Manual 0-5466 PARTS LIST...

  • Page 96: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    A40i, A60i 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 8-3486 PIP Switch Kit 9-7036...
  • Page 97 A40i, A60i Art # A-07113 Manual 0-5466 PARTS LIST...

  • Page 98: Replacement Parts - For Machine Torches With Unshielded Leads

    A40i, A60i 6.07 Replacement Parts - for Machine Torches with Unshielded Leads 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 8-3486 PIP Switch Kit 9-7036 Unshielded Automated Leads Assemblies with ATC connectors 5 - foot / 1.5 m Leads Assembly with ATC connector...
  • Page 99 A40i, A60i 5 & 6 A-07994_AB Manual 0-5466 PARTS LIST...

  • Page 100: Torch Consumable Parts Automation / Machine (Sl100)Torch

    A40i, A60i 6.08 Torch Consumable Parts Automation / Machine (SL100)Torch Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 20A 9-8205 Shield Cap, De ector Shield Cup...

  • Page 101: Appendix 1: Sequence Of Operation

    A40i, A60i APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: ON / OFF switch to ON Close external Select desired Operating mode Set Torch Type and disconnect switch. Lead Length. Select RESULT: RUN, RESULT: SET/PURGE mode AC indicator Power to system.

  • Page 102: Appendix 2: Data Tag Information

    A40i, A60i APPENDIX 2: DATA TAG INFORMATION Hermosillo, Sonora, Mexico Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in Mexico Type of Power Regulatory Standard Covering 1 or 3...

  • Page 103: Appendix 3: Torch Pin - Out Diagrams

    A40i, A60i 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 8 - Open...

  • Page 104: Appendix 4: Torch Connection Diagrams

    A40i, A60i 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 Leads Connector...

  • Page 105: Appendix 5: Cnc Cable Color Code

    A40i, A60i APPENDIX 5: CNC CABLE COLOR CODE 3 Red - START (+) 4 Black - START (-) 5 Yellow - DIVIDED ARC V (-) 6 Blue - DIVIDED ARC V (+) 10 Brown PLATE CONTACT GND 11 Orange - PLATE CONTACT OUT...

  • Page 106: Appendix 6: Automation Interface

    A40i, A60i APPENDIX 6: Automation Interface The Automation Interface PCB with Ohmic Sense features several selectable divided voltage ratios. The divided output signal is isolated allowing connection of either signal polarity to ground. The board also has Plate Contact “Ohmic” sensing for use with the iHC XT and iCNC height controls via either the exposed torch tip (selectable) or via a separate connection to the torch shield cup using the available sensing clip.
  • Page 107 A40i, A60i Indicators: Red LED, D12, indicates PLATE CONTACT whenever contact with the plate is detected.. Rating: The OK to Move and the Plate Contact Out are relay contacts rated for maximum of 30VAC or DC at 1 amp maximum.

  • Page 108: Appendix 7: System Schematic, 208/480V 1Phase

    A40i, A60i APPENDIX 7: SYSTEM SCHEMATIC, 208/480V 1PHASE (16) PFC PCB INPUT & BIAS SUPPLY PCB IND1 OUT D300 1 (+) RECT+ 7 (K) IND2 OUT 6 (G) BLUE BUS_+ J301 208-480 VAC +/- 10% (16) 1 Phase. CONTROL J305...
  • Page 109 A40i, A60i HCT1 1TORCH INVERTER PCB J401 PIP SW J601 +15V TORCH TRIGGER -15V IN_+ SOL * J606 PRI 1 AUTOMATION D633 J607 TORCH ONLY ELECTRODE SEC 1 Q608 PRI 2 D635 GND_PRI Work GND PRI SEC 2 WORK J604 - HIPOT...

  • Page 110: Appendix 8: System Schematic, 400V 3Phase Ce

    A40i, A60i APPENDIX 8: SYSTEM SCHEMATIC, 400V 3PHASE CE Art # A-13478 APPENDIX Manual 0-5466 A-10...
  • Page 111 A40i, A60i Art # A-13478 Manual 0-5466 APPENDIX A-11...

  • Page 112: Appendix 9: System Schematic, 208/480V 3Phase

    A40i, A60i APPENDIX 9: SYSTEM SCHEMATIC, 208/480V 3PHASE Art # A-13479 APPENDIX Manual 0-5466 A-12...
  • Page 113 A40i, A60i Art # A-13479 Manual 0-5466 APPENDIX A-13...

  • Page 114: Appendix 10: Publication History

    A40i, A60i APPENDIX 10: Publication History Cover Date Rev. Change(s) Nov. 16, 2017 Manual released. Mar. 7, 2018 Remove excess translations of safety section. Add a Duty Cycle section 2, update marking table section 4, correct two "Shielded" cut charts section 4T per ECR-03048.
  • Page 115 This Page Intentionally Blank...
  • Page 116 Fax: +86 21-64483032 Singapore Sales Office Ph +65 6832-8066 Fax: +65 6763-5812 U.S. Customer Care: 866-279-2628 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178 Printed in Mexico © 2018 Thermal Dynamics . www.Thermal-Dynamics.com...

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