Thermal Dynamics A80 CUTMASTER Operating Manual
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Thermal Dynamics A80 CUTMASTER Operating Manual

Automated plasma cutting system
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A80
Operating Manual
CUTMASTER
AUTOMATED PLASMA
CUTTING SYSTEM
Rev. AJ
Date: June 22, 2011
Operating Features:
™
Art # A-08954_AB
Manual # 0-4985
460
600
208-
380-
230
400

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Summary of Contents for Thermal Dynamics A80 CUTMASTER

  • Page 1 CUTMASTER ™ AUTOMATED PLASMA CUTTING SYSTEM Art # A-08954_AB Operating Manual Rev. AJ Date: June 22, 2011 Manual # 0-4985 Operating Features: 208- 380-...
  • Page 2 Distributed by: Trick-Tools 80 Truman Road Pella, IA 50219 Phone:1-877-VAN-SANT E-mail: sales@trick-tools.com Here at Trick Tools we believe that our customers deserve the best value in their tool and equipment purchases. We are constantly at work searching out a variety of high quality, high performance tools to offer at the best prices possible.
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ A80 SL100 1Torch™ Operating Manual Number 0-4985 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2008, 2009, 2010 by Thermadyne Corporation All rights reserved.
  • 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...
  • Page 6 TABLE OF CONTENTS 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 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip 4T-10 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip 4T-32 PATENT INFORMATION .......................4T-51...

  • Page 7: General Information

    CUTMASTER A80 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 or welding any metals which may contain one or more of the following: 1.01 Notes, Cautions and Warnings...

  • Page 8: Publications

    CUTMASTER A80 • 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. 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, • Hydrogen gas may be formed and trapped under aluminum obtainable from the Superintendent of Documents, U.S. workpieces when they are cut underwater or while using a water Government Printing Office, Washington, D.C. 20402 table.

  • Page 9: Note, Attention Et Avertissement

    CUTMASTER A80 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. Vous devez prendre soin lorsque utilisés pour mettre en relief des informations à caractère important. vous coupez ou soudez tout métal pouvant contenir un ou plusieurs Ces mises en relief sont classifiées comme suit : des éléments suivants:...
  • Page 10 CUTMASTER A80 produit du métal, des 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. Protégez toute telle matière qu’il de soudage à...

  • Page 11: Documents De Reference

    CUTMASTER A80 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 faites à celles-ci pour de plus amples renseignements : RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 1.

  • Page 12: Declaration Of Conformity

    * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director...

  • 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. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation...
  • Page 14 CUTMASTER A80 GENERAL INFORMATION Manual 0-4985...

  • 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 0-4985...

  • Page 16: Power Supply Specifications

    CUTMASTER A80 2.04 Power Supply Specifications CutMaster A80 Power Supply Specifications Input Power 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz...

  • Page 17: Input Wiring Specifications

    CUTMASTER A80 2.05 Input Wiring Specifications CutMaster A80 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Flexible Cord Volts I max eff Fuse (amps) (Min. AWG) (Min. mm 20.6 4 Type W 25 Type W 1 Phase 21.9 4 Type W 25 Type W...

  • Page 18: Power Supply Features

    CUTMASTER A80 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 0-4985...

  • Page 19: Section 2 Torch: Introduction

    CUTMASTER A80 SECTION 2 TORCH: 2T.03 Specifications INTRODUCTION A. Torch Configurations 1. Automation Torch, Model The standard automation torch has a position- 2T.01 Scope of Manual ing tube with rack & pinch block assembly and a solenoid valve. This manual contains descriptions, operating instructions and maintenance procedures for the 18.875"...

  • Page 20: 04 Options And Accessories

    CUTMASTER A80 NOTE C. Torch Parts 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. Torch Head has built - in switch H.
  • Page 21 CUTMASTER A80 By forcing the plasma gas and electric arc through a E. Parts - In - Place (PIP) 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 CUTMASTER A80 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4985...

  • Page 23: Section 3 System: Installation

    CUTMASTER A80 SECTION 3 SYSTEM: 3.03 Power Supply location and 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 ac- 1.
  • Page 24 CUTMASTER A80 A. Cover Removal C. Input Power Selection Set the Input Voltage Selection Switch at the rear 1. Remove the upper and lower screws which secure the cover to the main assem- of the unit based on the primary input voltage it is connected to.
  • Page 25 CUTMASTER A80 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

    CUTMASTER A80 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 CUTMASTER A80 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 CUTMASTER A80 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 SL60 / Manual Torch to this power supply.
  • Page 30 CUTMASTER A80 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

    CUTMASTER A80 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 position. Gas will / Mechanical Torches may be connected to this knob to the SET Power Supply.
  • Page 33 CUTMASTER A80 Pre-flow STANDOFF With hand or mechanical torch, there will be a .5 CutMaster A80 Gas Pressure Settings second pre-flow of the gas. Pre-flow does not apply SL100 to automation torch use. Leads SL100 (Mechanized Torch) Length (Hand Torch) SL 100 SV Cutting Operation (Automated Torch)
  • Page 34 CUTMASTER A80 This Page Intentionally Blank OPERATION Manual 0-4985...

  • Page 35: Section 4 Torch: Operation

    CUTMASTER A80 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 travel OPERATION speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for transfer.

  • Page 36: 02 Automation Torch Parts Selection

    CUTMASTER A80 4T.02 Automation Torch Parts Torch Head Art # A-04173_AB Selection Electrode Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator’s chosen amperage level. The torch parts Start Cartridge must correspond with the type of operation.

  • Page 37: 04 Cut Quality

    CUTMASTER A80 NOTE 4T.04 Cut Quality 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 follows: the workpiece, cutting speed, gas pressures, and operator ability.

  • Page 38: 05 General Cutting Information

    CUTMASTER A80 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- may require secondary cleanup operations after ing) the edge of the workpiece at the point where cutting.

  • Page 39: 06 Hand Torch Operation

    CUTMASTER A80 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 NOTE start. For best performance and parts life, always use the correct parts for the type of operation.
  • Page 40 CUTMASTER A80 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 CUTMASTER A80 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. Trigger Release 5.

  • Page 42: 07 Gouging 4T-8

    CUTMASTER A80 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 CUTMASTER A80 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: T.08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    CUTMASTER A80 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 Initial Kerf Width Material Gas Pressure...
  • Page 45 CUTMASTER A80 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) 1100...
  • Page 46 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 47 CUTMASTER A80 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 CUTMASTER A80 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 49 CUTMASTER A80 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) 1015...
  • Page 50 CUTMASTER A80 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 Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 51 CUTMASTER A80 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 2465 0.20...
  • Page 52 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 53 CUTMASTER A80 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 2195...
  • Page 54 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 55 CUTMASTER A80 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 4010...
  • Page 56 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 57 CUTMASTER A80 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 3325...
  • Page 58 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 59 CUTMASTER A80 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 3410...
  • Page 60 CUTMASTER A80 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 61 CUTMASTER A80 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 8420 0.00 0.10 7170 5710 0.20 0.20...
  • Page 62 CUTMASTER A80 Mild Steel 100A Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8212 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 63 CUTMASTER A80 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 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 64 CUTMASTER A80 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 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 65 CUTMASTER A80 This Page Intentionally Blank Manual 0-4985 4T-31 OPERATION...

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

    CUTMASTER A80 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 Gas Pressure Material Arc Voltage Working...
  • Page 67 CUTMASTER A80 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) 3266 2239 1794 1651 5.2 (7.6) 1578 5.5 (15.2) 1256...
  • Page 68 CUTMASTER A80 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air) Thickness Height...
  • Page 69 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height...
  • Page 70 CUTMASTER A80 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height...
  • Page 71 CUTMASTER A80 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 2794 0.20...
  • Page 72 CUTMASTER A80 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air) Thickness Height...
  • Page 73 CUTMASTER A80 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 1850...
  • Page 74 CUTMASTER A80 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 Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air) Thickness Height Height...
  • Page 75 CUTMASTER A80 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 3335...
  • Page 76 CUTMASTER A80 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 Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height...
  • Page 77 CUTMASTER A80 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 3300...
  • Page 78 CUTMASTER A80 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 Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height...
  • Page 79 CUTMASTER A80 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 4010...
  • Page 80 CUTMASTER A80 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8211 9-8232 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height...
  • Page 81 CUTMASTER A80 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 9020 0.00 7595 0.10 6165 0.20 5045 3955...
  • Page 82 CUTMASTER A80 Mild Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8233 9-8213 9-8232 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height...
  • Page 83 CUTMASTER A80 Stainless Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8232 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height...
  • Page 84 CUTMASTER A80 Aluminum 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8232 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height...

  • Page 85: Patent Information

    CUTMASTER A80 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: Catalog # Description Patent(s) 9-8215 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8232 Electrode US Pat No(s) 6163008; 6987238 Other Pat(s) Pending 9-8213 Cartridge...
  • Page 86 CUTMASTER A80 Catalog # Description Patent(s) 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512: Catalog # Description 9-8235...

  • Page 87: Section 5 System: Service

    CUTMASTER A80 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 Visually inspect the torch body tip, electrode, start cartridge and shield cup 3 Months...

  • Page 88: Maintenance Schedule

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

  • Page 89: Fault Indicator

    CUTMASTER A80 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 90: Basic Troubleshooting Guide

    CUTMASTER A80 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem - Symptom Possible Cause Recommended Action ON / OFF Switch is on 1.
  • Page 91 CUTMASTER A80 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 92 CUTMASTER A80 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. WARNING Remove power from the power supply;...
  • Page 93 CUTMASTER A80 Remove the fitting from the filter element as- Optional Single-Stage Filter Element 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 94 CUTMASTER A80 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 95: Section 5 Torch: Service

    CUTMASTER A80 It is recommended to apply a very light film of o- SECTION 5 TORCH: ring lubricant (Catalog # 8-4025) to the o-rings on a weekly basis. SERVICE 5T.01 General Maintenance NOTE Upper Groove Refer to Previous "Section 5 System" for common with Vent Holes Must Remain Open and fault indicator descriptions.

  • Page 96: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER A80 Remove the tip. Check for excessive wear (indi- 5T.02 Inspection and Replacement 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 97: Parts Lists

    CUTMASTER A80 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 Power Supply Parts Section 6.05 Options and Accessories Section 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Section 6.07 Torch Consumable Parts (SL100 SV)

  • Page 98: Replacement Power Supply Parts

    CUTMASTER A80 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 9-0216 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter &...
  • Page 99 CUTMASTER A80 This Page Intentionally Blank Manual 0-4985 PARTS LIST...

  • Page 100: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    CUTMASTER A80 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 PIP Plunger and Return Spring Kit...
  • Page 101 CUTMASTER A80 Art # A-07113 Manual 0-4985 PARTS LIST...

  • Page 102: Torch Consumable Parts (Sl100 Sv)

    CUTMASTER A80 6.07 Torch Consumable Parts (SL100 SV) Ohmic Clip 9-8224 Shield 20-40A 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 9-8235 Shield 50-60A Tips: Shield Cap, Machine Cup Body,...

  • Page 103: Replacement Parts For Hand Torch

    CUTMASTER A80 6.08 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 104 CUTMASTER A80 This Page Intentionally Blank PARTS LIST Manual 0-4985...

  • Page 105: Appendix 1: Sequence Of Operation (Block Diagram

    CUTMASTER A80 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 RESULT: SET / LATCH switch RESULT:...

  • Page 106: Appendix 2: Data Tag Information

    CUTMASTER A80 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 Made in USA Date of Mfr: Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...

  • Page 107: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER A80 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 / Switch 4 - Switch 3 - Switch...

  • Page 108: Appendix 4: Torch Connection Diagrams

    CUTMASTER A80 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 Head Leads Black...
  • Page 109 CUTMASTER A80 This Page Intentionally Blank Manual 0-4985 APPENDIX...

  • Page 110: Appendix 5: System Schematic, 208/460V Units

    CUTMASTER A80 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2 MTH2 /INRUSH +12VDC...
  • Page 111 Date: Date: Date: ECO B1357 RWH 03/31/09 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. JANUARY 31, 2008 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 112: Appendix 6: System Schematic, 400V/600V Units

    CUTMASTER A80 APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2 MTH2 CHOKE /INRUSH...
  • Page 113 ECO B1611 05/05/09 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. MARCH 30, 2009 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 114: Appendix 7: Raw Arc Voltage

    CUTMASTER A80 APPENDIX 7: RAW ARC VOLTAGE If raw arc voltage is necessary for the torch height control, the customer must supply an 18 AWG (1.0 mm2), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes.
  • Page 115 CUTMASTER A80 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control . Manual 0-4985 A-11 APPENDIX...

  • Page 116: Appendix 8: Publication History

    CUTMASTER A80 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) June 30, 2008 Manual released. Sept. 19, 2008 Added CE information per ECOB. Jan. 27, 2009 Updated art in section 3 to show all the information for the two stage filter per ECOB1248.

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