Thermal Dynamics CUTMASTER A120 Operating Manual
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Thermal Dynamics CUTMASTER A120 Operating Manual

Automated plasma cutting system
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A120
operating manual
CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AB
Date: September 19, 2008
Operating Features:
™
Manual # 0-4989
380-
400

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Summary of Contents for Thermal Dynamics CUTMASTER A120

  • Page 1 A120 CutmASteR ™ AutomAted PLASmA CuttING SYStem operating manual Rev. AB Date: September 19, 2008 Manual # 0-4989 Operating Features: 380-...
  • 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™ A120 SL100 1Torch™ Operating Manual Number 0-4989 Published by: Thermal Dynamics Corporation...
  • 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 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 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...

  • Page 7: Section 1:General Information

    SECTION 1: • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the GENERAL INFORMATION different processes. You must be very careful when cutting...

  • Page 8: Publications

    • Do not cut or weld on containers that may have held combus- 1.03 Publications tibles. Refer to the following standards or their latest revisions for more • Provide a fire watch when working in an area where fire hazards information: may exist.

  • Page 9: Note, Attention Et Avertissement

    1.04 Note, Attention et Avertissement • Les sortes de gaz et de fumée provenant de l’arc de plasma dépen- dent du genre de métal utilisé, des revêtements se trouvant sur le Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont métal et des différents procédés.
  • Page 10 étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables. BRUIT • Soyez certain qu’aucune matière combustible ou inflammable ne Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés se trouve sur le lieu de travail.

  • Page 11: Documents De Reference

    1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT été...

  • Page 12: Declaration Of Conformity

    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:...

  • Page 13: Statement Of Warranty

    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.
  • Page 14 GENERAL INFORMATION Manual 0-4989...

  • Page 15: Section 2 System:introduction

    Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: http://www.thermal-dynamics.com Manual 0-4989...

  • Page 16: Power Supply Specifications

    30 - 120 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster A120 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Duty Cycle...

  • Page 17: Input Wiring Specifications

    2.05 Input Wiring Specifications CutMaster A120 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Fuse Flexible Cord Volts I max I eff (amps) (Min. AWG) 26.2 4 Type W 1 Phase 27.6 4 Type W 21.6...

  • Page 18: Power Supply Features

    2.06 Power Supply Features Art # A-08460 Control Panel 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-08461 INTRODUCTION Manual 0-4989...

  • Page 19: Section 2 Torch:introduction

    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 a solenoid valve.

  • Page 20: 04 Options And Accessories

    C. Torch Parts NOTE Operating pressure varies with torch model, op- Starter Cartridge, Electrode, Tip, Shield Cup erating amperage, and torch leads length. Refer to D. Parts - In - Place (PIP) gas pressure settings charts for each model.
  • Page 21 E. Parts - In - Place (PIP) By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration The torch includes a 'Parts - In - Place' (PIP) circuit. of heat to a small area. The stiff, constricted plasma When the shield cup is properly installed, it closes arc is shown in Zone C.
  • Page 22 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4989...

  • Page 23: Section 3 System: Installation

    SECTION 3 SYSTEM: 3.03 Power Supply location and Mounting INSTALLATION NOTE 3.01 Unpacking It is recommended that the unit be secured to a suitable surface using the mounting rails. 1. Use the packing lists to identify and ac- 1.
  • Page 24 A. Cover Removal C. Input Power Selection 1. Remove the upper and lower screws Set the Input Voltage Selection Switch at the rear which secure the cover to the main assem- of the unit based on the primary input voltage it bly.
  • Page 25 9. Connect the opposite end of individual E. Connections to Single Phase Input Power wires to a customer supplied plug or main disconnect. 10. Connect the input power cable (or close WARNING the main disconnect switch) to supply Disconnect input power from the power power.

  • Page 26: Gas Connections

    6. Connect the wires as follows. Filter Assembly • Wires to L1, L2 and L3 input. It does not matter what order these wires are at- Inlet Port tached. See previous illustration and on label in the power supply.
  • Page 27 Installing Optional Two - Stage Air Filter Kit Filter Assembly This optional two - stage air line filter is also for use on compressed air shop systems. Filter Inlet Port removes moisture and contaminants to at least 5 microns.
  • Page 28 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 proce- dures for high pressure regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material.

  • Page 29: Section 3 Torch: Installation

    3T.01 Torch Connections 2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- ply. Connect only the Thermal Dynamics model position. SL100SV / Automation, SL100 / Mechanical 3. Place a welding filter lens in front of the or SL100 / Manual Torch to this power supply.
  • Page 30 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 oper- ate a machine or automation torch. WARNING Disconnect primary power at the source be- fore disassembling the torch or torch leads.

  • Page 31: Section 4 System: Operation

    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.

  • Page 32: Preparations For Operation

    Set Operating Pressure Check that the torch is properly connected. Only 1. Place the Power Supply Function Control Thermal Dynamics model SL100 / Manual or SL100 knob to the SET position. Gas will / Mechanical Torches may be connected to this Power Supply.
  • Page 33 Pre-flow STANDOFF CutMaster A120 Gas Pressure Settings With hand or mechanical torch, there will be a .5 second pre-flow of the gas. Pre-flow does not apply SL100 to automation torch use. Leads SL100 (Mechanized Torch) Length (Hand Torch)
  • Page 34 This Page Intentionally Blank OPERATION Manual 0-4989...

  • Page 35: Section 4 Torch:operation

    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 36: 02 Automation Torch Parts Selection

    4T.02 Automation Torch Parts Art # A-04173 Torch Head Selection Check the torch for proper consumable parts. The Electrode 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.

  • Page 37: 04 Cut Quality

    4T.04 Cut Quality NOTE Refer to Section 4T.08 and following for additional NOTES information on torch parts. Cut quality depends heavily on setup and Change the torch parts for a different operation as parameters such as torch standoff, alignment with...

  • Page 38: 05 General Cutting Information

    Bottom Dross Buildup Edge Starting Molten material which is not blown out of the cut For edge starts, hold the torch perpendicular to the area and resolidifies on the plate. Excessive dross workpiece with the front of the tip near (not touch-...

  • Page 39: 06 Hand Torch Operation

    4. Slide the trigger release toward the back 4T.06 Hand Torch Operation of the torch handle while simultaneously Standoff Cutting With Hand Torch squeezing the trigger. The pilot arc will start. NOTE For best performance and parts life, always use the correct parts for the type of operation.
  • Page 40 NOTE Drag Cutting With a Hand Torch When the shield cup is properly installed, there Drag cutting works best on metal 1/4" (6 mm) thick is a slight gap between the shield cup and the or less. torch handle. Gas vents through this gap as part NOTE of normal operation.
  • Page 41 3. In a portion of the unwanted metal start the Trigger pierce off the cutting line and then continue the cut onto the line. Hold the torch per- pendicular to the workpiece after the pierce is complete. 4. Hold the torch away from your body.

  • Page 42: 07 Gouging 4T-8

    Cutting speed depends on material, thickness, Torch Travel Speed and the operator’s ability to accurately follow the NOTE desired cut line. The following factors may have Refer to Appendix Pages for additional information an impact on system performance: as related to the Power Supply used.
  • Page 43 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.
  • Page 44 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 9-8215 9-8237 Torch Initial...
  • Page 45 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (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 46 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 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 47 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (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 48 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 49 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (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 50 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 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 51 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 7540 7015 0.10 4570 0.10 3650 0.20...
  • Page 52 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 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 53 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 10890 0.00 7560 0.10 4365 0.10 2865 0.20...
  • Page 54 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 55 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 17010 0.00 7680 0.10 6410 0.10 5230 0.20...
  • Page 56 Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8211 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 57 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8915 0.00 7415 0.10 5915 0.10 4095 0.30...
  • Page 58 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8211 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 59 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 9020 0.00 8380 0.00 7730 0.10 5865 0.20...
  • Page 60 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8211 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 61 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 8890 8420 0.00 0.10 7170 5710 0.20...
  • Page 62 Mild Steel 100A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8212 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 63 Stainless Steel 100A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8212 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 64 Aluminum 100A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8212 9-8213 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 65 This Page Intentionally Blank Manual 0-4989 4T-31 OPERATION...
  • Page 66 Mild Steel 120A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8253 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 67 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 3990 2950 10.0 2100 12.0 1860 5.5 (7.6m)
  • Page 68 Stainless Steel 120A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8253 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 69 Aluminum 120A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8253 9-8215 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 70 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 9-8215 Torch Initial Kerf Width Gas Pressure...
  • Page 71 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 72 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air)
  • Page 73 This Page Intentionally Blank Manual 0-4989 4T-39 OPERATION...
  • Page 74 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 75 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 6804 5942 0.10 5080 0.10 3316 0.20...
  • Page 76 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 77 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 4590 0.00 3925 0.10 3285 0.10 1985 0.20...
  • Page 78 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air)
  • Page 79 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...
  • Page 80 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8211 9-8215 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 81 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 7895 6395 0.10 4895 0.10 4025 0.30...
  • Page 82 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8211 9-8215 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 83 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9410 8120 0.00 6830 0.10 5635 0.20...
  • Page 84 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8211 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air)
  • Page 85 0.00 9020 0.00 7595 0.10 6165 0.20 5045 5.9 (7.6m) 0.20 3955 2905 0.30 6.2 (15.2m) 2010 0.40 1430 0.50 1045 0.60 0.75 Edge Start BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only. Manual 0-4989...
  • Page 86 Mild Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8253 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 87 Stainless Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8212 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 88 Aluminum 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 89 Mild Steel 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8256 9-8237 9-8253 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 90 Stainless Steel 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8256 9-8237 9-8253 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 91 Aluminum 120A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8256 9-8237 9-8253 9-8215 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.

  • Page 92: Patent Information

    PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge US Pat No(s) 6903301; 6717096; 6936786;...
  • Page 93 Catalog # Description Patent(s) 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235 Shield Cap 9-8236 Shield Cap 9-8237...
  • Page 94 This Page Intentionally Blank OPERATION 4T-60 Manual 0-4989...

  • Page 95: Section 5 System:service

    SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Manual 0-4989 SERVICE...

  • Page 96: Maintenance Schedule

    4. Worn torch parts Daily Operational Checks or Every Six Cutting 5. Cutting current too low. Hours: 6. Non - Genuine Thermal Dynamics parts used Check torch consumable parts, replace if damaged 7. Incorrect gas pressure or worn. Main Arc 1.

  • Page 97: Fault Indicator

    5.04 Fault Indicator At initial power up, two lights will temporarily illu- minate 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.

  • Page 98: Basic Troubleshooting Guide

    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...
  • Page 99 Problem - Symptom Possible Cause Recommended Action FAULT & 80 PSI 1. Torch shield cup is loose. 1. Tighten shield cup by hand. Do not overtighten. indicators flashing. 2. Torch tip, electrode or starter 2. Turn off power supply. Remove shield cup. Install missing Gas flow is cycling on cartridge missing.
  • Page 100 5.06 Power Supply Basic Parts C. Filter Element Assembly Replacement 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.
  • Page 101 Optional Single-Stage Filter Element 5. Remove the fitting from the filter element as- sembly by inserting a 6 mm hex wrench into Replacement the internal hex fitting and turning it counter These instructions apply to power supplies where the clock-wise (left).
  • Page 102 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 unac- ceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

  • Page 103: Section 5 Torch:service

    SECTION 5 TORCH: It is recommended to apply a very light film of o- ring lubricant (Catalog # 8-4025) to the o-rings on a SERVICE weekly basis. 5T.01 General Maintenance NOTE Upper Groove with Vent Holes Refer to Previous "Section 5 System" for common Must Remain Open and fault indicator descriptions.

  • Page 104: 02 Inspection And Replacement Of Consumable Torch Parts

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

  • Page 105: Section 6: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 # CutMaster A120 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with 208/230 single phase input power cable and plug 3-1734-1...

  • Page 106: Replacement Power Supply Parts

    6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230 V Power Supply 8-4384 Input Power Cord for 400 V Power Supply 9-8562 6.05 Options and Accessories...
  • Page 107 This Page Intentionally Blank Manual 0-4989 PARTS LIST...

  • Page 108: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    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...
  • Page 109 Art # A-07113 Manual 0-4989 PARTS LIST...

  • Page 110: Replacement Parts - For Machine Torches With Unshielded Leads

    6.07 Replacement Parts - for Machine Torches with Unshielded Leads 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...
  • Page 111 A-07994 Manual 0-4989 PARTS LIST...

  • Page 112: Torch Consumable Parts (Sl100)

    6.08 Torch Consumable Parts (SL100) Ohmic Clip 9-8224 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 Shield 50-60A Tips: Shield Cap, Machine Cup Body,...

  • Page 113: Replacement Parts For Hand Torch

    6.09 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 114 This Page Intentionally Blank PARTS LIST 6-10 Manual 0-4989...

  • Page 115: Appendix 1: Sequence Of Operation(Block Diagram

    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 116: Appendix 2: Data Tag Information

    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 Supply (Note 1)

  • Page 117: Appendix 3: Torch Pin - Out Diagrams

    APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green /...

  • Page 118: Appendix 4: Torch Connection Diagrams

    APPENDIX 4: TORCH CONNECTION DIAGRAMS A. 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 Torch Supply...
  • Page 119 This Page Intentionally Blank Manual 0-4989 APPENDIX...

  • Page 120: Appendix 5: System Schematic, 208/460V Units

    APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS PRI 4 PRI 4 PRI 3 PRI 3 PRI2 PRI2 PRI 2 PRI 2 J1 J1 PRE-CHARGE PRI1 PRI1 PRI 1 PRI 1 RELAYS MTH1 MTH1 MTH2 MTH2 C3,C4,C7,C8* C3,C4,C7,C8* PRIMARY POWER CONNECTIONS: 3PH USE L1,L2,L3 &...
  • Page 121 Scale Supersedes Supersedes Supersedes Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 122: Appendix 6: System Schematic, 400V Units

    1 /OVERTEMP +12VDC 2 /FAN_ON 3 /CSR 4 CUR_SET PCB1 MAIN PCB 5 MAIN_PCB_ID A100 19X2371 / CAT# 9-0108 6 COMMON A120 19X2416 / CAT# 9-0125 J1 J1 K3,K4 K3,K4 +12VDC J2 J2 J4 J4 J3 J3 PRI 1 PRI 1...
  • Page 123 Last Modified: Last Modified: Last Modified: Thursday, July 03, 2008 Thursday, July 03, 2008 Thursday, July 03, 2008 CUTMASTER A80 & A120 400 VAC CUTMASTER A80 & A120 400 VAC CUTMASTER A80 & A120 400 VAC 09:02:19 09:02:19 09:02:19 Manual 0-4989...

  • Page 124: Appendix 7: Publication History

    APPENDIX 7: Publication History Cover Date Rev. Change(s) June 30, 2008 Manual released. Sept. 19, 2008 Added CE information Per ECOB. APPENDIX A-10 Manual 0-4989...
  • Page 125 GLOBAL CUSTOMER SERVICE CONTACT Thermadyne USA Thermadyne Asia Sdn Bhd Lot 151, Jalan Industri 3/5A 2800 Airport Road Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Telephone: 603+ 6092 2988 Fax: 800-535-0557 Fax : 603+ 6092 1085...
  • Page 126 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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