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

Thermal Dynamics CUTMASTER A80 Operating Manual

Automated plasma cutting system
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See also: Operating Manual
A80
A120
operating manual
CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AC
Date: October 20, 2009
Operating Features:
A80
A120
™
Art # A-08625
Manual # 0-5119
80%
80
Duty
AMP
Cycle
80%
120
Duty
AMP
Cycle
380-
400
380-
400

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  • Page 1 A120 CutmASteR ™ AutomAted PLASmA CuttING SYStem Art # A-08625 operating manual Rev. AC Date: October 20, 2009 Manual # 0-5119 Operating Features: 380- Duty Cycle 380- A120 Duty Cycle...
  • Page 2 1888, or visit us on the web at www.thermal-dynamics.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern.
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster™ A80 SL100SV Torch™ Operating Manual No.: 0-5119 CutMaster™ A120 SL100SV Torch™...
  • Page 4 This Page Intentionally Blank...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1:GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..................1-1 1.02 Important Safety Precautions ..................1-1 1.03 Publications ........................1-2 1.04 Note, Attention et Avertissement ..................1-3 1.05 Precautions De Securite Importantes ................1-3 1.06 Documents De Reference ....................1-5 1.07 Declaration of Conformity .....................1-6 1.08 Statement of Warranty ....................1-7 SECTION 2 SYSTEM:INTRODUCTION ...................2-1...
  • Page 6 TABLE OF CONTENTS SECTION 5 SYSTEM:SERVICE ......................5-1 5.01 General Maintenance ....................5-1 5.02 Maintenance Schedule ....................5-2 5.03 Common Faults ......................5-2 5.04 Fault Indicator .......................5-3 5.05 Basic Troubleshooting Guide ..................5-4 5.06 Power Supply Basic Parts Replacement ..............5-6 SECTION 5 TORCH:SERVICE ......................5T-1 5T.01 General Maintenance ....................

  • Page 7: Section 1:General Information

    CUTMASTER A80, A120 SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the Throughout this manual, notes, cautions, and warnings are used to different processes.

  • Page 8: Publications

    CUTMASTER A80, A120 FIRE AND EXPLOSION LEAD WARNING Fire and explosion can be caused by hot slag, sparks, or the plasma This product contains chemicals, including lead, or otherwise pro- arc. duces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm.

  • Page 9: Note, Attention Et Avertissement

    CUTMASTER A80, A120 14. American Welding Society Standard AWSF4.1, RECOM- MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING FUMÉE et GAZ THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, La fumée et les gaz produits par le procédé...
  • Page 10 CUTMASTER A80, A120 • Utilisez la nuance de lentille qui est suggèrée dans le recom- • Montez et maintenez le matériel conformément au Code élec- trique national des Etats-Unis. (Voir la page 5, article 9.) mendation qui suivent ANSI/ASC Z49.1: Nuance Minimum Nuance Suggerée...

  • Page 11: Documents De Reference

    CUTMASTER A80, A120 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPA- Consultez les normes suivantes ou les révisions les plus récentes RATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET ayant été...

  • Page 12: Declaration Of Conformity

    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

    Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
  • Page 14 CUTMASTER A80, A120 This page intentionally blank. GENERAL INFORMATION Manual 0-5119...

  • Page 15: Section 2 System:introduction

    A c r o b a t P D F f o r m a t b y g o i n g t o t h e Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: http://www.thermal-dynamics.com...

  • Page 16: Power Supply Specifications

    30 - 100 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster A80 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Duty Cycle...
  • Page 17 CUTMASTER A80, A120 Power Supply Dimensions & Weight Ventilation Clearance Requirements 10" 254 mm Art # A-08459 Art # A-07925 13.78" 350 mm 24" 26.3" 0.6 m 0.668 m 63 lb / 28.6 kg 6" 150 mm Manual 0-5119 INTRODUCTION...

  • Page 18: Input Wiring Specifications

    CUTMASTER A80, A120 2.05 Input Wiring Specifications CutMaster A80 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts Fuse (amps) (mm2) 18.4 3 Phase 18.7 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 19: Power Supply Features

    CUTMASTER A80, A120 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 Manual 0-5119...
  • Page 20 CUTMASTER A80, A120 This page intentionally blank. INTRODUCTION Manual 0-5119...

  • Page 21: Section 2 Torch:introduction

    CUTMASTER A80, A120 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 positioning tube with rack & pinch block assembly and a This manual contains descriptions, operating solenoid valve.

  • Page 22: 04 Options And Accessories

    CUTMASTER A80, A120 C. Torch Parts G.Gas Requirements Automated, Manual and Machine Torch Gas Starter Cartridge, Electrode, Tip, Shield Cup Specifications D. Parts - In - Place (PIP) Gas (Plasma and Secondary) Compressed Air Torch Head has built - in switch...

  • Page 23: 05 Introduction To Plasma

    CUTMASTER A80, A120 2T.05 Introduction to Plasma Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the A. Plasma Gas Flow cut allowing for a fast, slag - free cut.
  • Page 24 CUTMASTER A80, A120 E. Parts - In - Place (PIP) The torch includes a 'Parts - In - Place' (PIP) cir- cuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.

  • Page 25: Section 3 System: Installation

    CUTMASTER A80, A120 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 26 CUTMASTER A80, A120 A. Cover Removal C Primary Input Power Connections 1. Remove the upper and lower screws which secure the cover to the main assembly. Do CAUTION not loosen the lower screws inside the cut out slots in the bottom of the cover.

  • Page 27: Gas Connections

    CUTMASTER A80, A120 5. Pass the cable being used through the ac- 3.05 Gas Connections cess opening in the back panel of the power Connecting Gas Supply to Unit supply. Refer to Section 2 for power cable specifications. The connection is the same for compressed air or high pressure cylinders.
  • Page 28 CUTMASTER A80, A120 Installing Optional Single - Stage Air Filter Using High Pressure Air Cylinders An optional filter kit is recommended for improved When using high pressure air cylinders as the air filtering with compressed air, to keep moisture and supply: debris out of the torch.
  • Page 29 CUTMASTER A80, A120 Installing Optional Two - Stage Air Filter Kit Using High Pressure Air Cylinders This optional two - stage air line filter is also When using high pressure air cylinders as the air for use on compressed air shop systems. Filter...
  • Page 30 CUTMASTER A80, A120 This Page Intentionally Blank INSTALLATION Manual 0-5119...

  • Page 31: Section 3 Torch: Installation

    2. Put the Function Control switch in the SET If necessary, connect the torch to the Power Sup- position. ply. Connect only the Thermal Dynamics model 3. Place a welding filter lens in front of the SL100SV / Automation, SL100 / Mechanical torch and turn on the air.
  • Page 32 CUTMASTER A80, A120 NOTE An adapter is required to be installed in the power supply if converting a hand torch system to operate a machine or automation torch. WARNING Disconnect primary power at the source before disassembling the torch or torch leads.

  • Page 33: Section 4 System: Operation

    CUTMASTER A80, A120 SECTION 4 SYSTEM: AC Indicator OPERATION Steady light indicates power supply is ready for operation. Blinking light indicates unit is in protective interlock mode. Shut unit off, shut off 4.01 Front Panel Controls / or disconnect input power, correct the fault, and Features restart the unit.

  • Page 34: Preparations For Operation

    Check that the torch is properly connected. Only Set Operating Pressure Thermal Dynamics model SL100 / Manual or SL100 / Mechanical Torches may be connected 1. Place the Power Supply Function Control to this Power Supply. See Section 3T of this manual.
  • Page 35 CUTMASTER A80, A120 Select Current Output Level 1. Place the Function Control Knob in one of the three operating positions available: RAPID AUTO RESTART Gas flow stops. or LATCH 2. Set the output current to desired amper- age with the Output Current Control Knob.
  • Page 36 CUTMASTER A80, A120 This Page Intentionally Blank OPERATION Manual 0-5119...

  • Page 37: Section 4 Torch:operation

    CUMASTER A80, A120 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 pro- duced as the arc moves from side to side in search 4T.01 Machine and Automated...

  • Page 38: 02 Automation Torch Parts Selection

    CUTMASTER A80, A120 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 opera- Start Cartridge tion.

  • Page 39: 04 Cut Quality

    CUMASTER A80, A120 4T.04 Cut Quality NOTE Refer to Section 4T.08 and following for NOTES additional information on torch parts. Cut quality depends heavily on setup and Change the torch parts for a different operation parameters such as torch standoff, alignment...

  • Page 40: 05 General Cutting Information

    CUTMASTER A80, A120 Bottom Dross Buildup Edge Starting Molten material which is not blown out of the For edge starts, hold the torch perpendicular to cut area and resolidifies on the plate. Excessive the workpiece with the front of the tip near (not...

  • Page 41: 06 Hand Torch Operation

    CUMASTER A80, A120 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 42 CUTMASTER A80, A120 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) is a slight gap between the shield cup and the thick or less.
  • Page 43 CUMASTER A80, A120 7. Bring the torch within transfer distance to NOTE the work. The main arc will transfer to the The tip should never come in contact with work, and the pilot arc will shut off. the workpiece except during drag cutting operations.

  • Page 44: 07 Gouging 4T-8

    CUTMASTER A80, A120 7. Clean spatter and scale from the shield cup 4T.07 Gouging and the tip as soon as possible. Spraying the shield cup in anti - spatter compound will minimize the amount of scale which WARNINGS adheres to it.
  • Page 45 CUMASTER A80, A120 Lead Angle The angle between the torch and workpiece de- pends 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 46: T.08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

    CUTMASTER A80, A120 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch...
  • Page 47 CUMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Arc Voltage Working Piercing @ Rec.
  • Page 48 CUTMASTER A80, A120 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 Travel Pierce Arc Voltage Working Piercing @ Rec.
  • Page 49 CUMASTER A80, A120 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 Initial Kerf Width Gas Pressure Material Torch Working Travel Pierce Arc Voltage Piercing @ Rec.
  • Page 50 CUTMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Arc Voltage Working Piercing Pierce Delay @ Rec.
  • Page 51 CUMASTER A80, A120 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air)
  • Page 52 CUTMASTER A80, A120 Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 53 CUMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Arc Voltage Working Piercing @ Rec.
  • Page 54 CUTMASTER A80, A120 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8211 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air)
  • Page 55 CUMASTER A80, A120 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 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 56 CUTMASTER A80, A120 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 Travel Pierce Working Piercing @ Rec.
  • Page 57 CUMASTER A80, A120 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 Travel Pierce Working Piercing @ Rec.
  • Page 58 CUTMASTER A80, A120 Mild Steel CUTMASTER A120 120A Air Plasma / Air Shield ONLY Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 Torch Initial Material Travel Pierce Kerf Width Pressure Working...
  • Page 59 CUMASTER A80, A120 Stainless Steel CUTMASTER A120 120A Air Plasma / Air Shield ONLY Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce...
  • Page 60 CUTMASTER A80, A120 Aluminum CUTMASTER A120 120A Air Plasma / Air Shield ONLY Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8213 9-8243 9-8233 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.

  • Page 61: T.09 Recommended Cutting Speeds For Machine And Automated Torches With Shielded Tip

    CUMASTER A80, A120 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width...
  • Page 62 CUTMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Arc Voltage Working Piercing Pierce Delay @ Rec.
  • Page 63 CUMASTER A80, A120 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage Speed...
  • Page 64 CUTMASTER A80, A120 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 65 CUMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 66 CUTMASTER A80, A120 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage Speed...
  • Page 67 CUMASTER A80, A120 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Working Piercing Pierce Delay @ Rec. (Air) Thickness...
  • Page 68 CUTMASTER A80, A120 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 69 CUMASTER A80, A120 Aluminum Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Arc Voltage Working Piercing @ Rec. (Air) Thickness...
  • Page 70 CUTMASTER A80, A120 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 Gas Pressure Material Travel Pierce Arc Voltage Working Piercing @ Rec.
  • Page 71 CUMASTER A80, A120 Stainless Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8239 9-8237 9-8212 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness...
  • Page 72 CUTMASTER A80, A120 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 Gas Pressure Material Travel Pierce Working Piercing @ Rec. (Air) Thickness Voltage...
  • Page 73 CUMASTER A80, A120 Mild Steel CUTMASTER A120 120A Air Plasma / Air Shield ONLY Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8213 9-8256 9-8237 9-8233 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 74 CUTMASTER A80, A120 Stainless Steel CUTMASTER A120 120A Air Plasma / Air Shield ONLY Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8256 9-8237 9-8233 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.
  • Page 75 CUMASTER A80, A120 Aluminum CUTMASTER A120 120A Air Plasma / Air Shield ONLY Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8256 9-8237 9-8233 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Travel Pierce Working Piercing @ Rec.

  • Page 76: Patent Information

    CUTMASTER A80, A120 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 77 CUMASTER A80, A120 Plasma Cutting Torch Patents The following parts are covered under U.S. and Foreign Patents as follows: 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:...
  • Page 78 CUTMASTER A80, A120 This page intentionally blank. OPERATION 4T-42 Manual 0-5119...

  • Page 79: Section 5 System:service

    CUTMASTER A80, A120 SECTION 5 SYSTEM: SERVICE 5.01 General Maintenance Manual 0-5119 SERVICE...

  • Page 80: Maintenance Schedule

    CUTMASTER A80, A120 5.02 Maintenance Schedule 5.03 Common Faults Problem - Symptom Common Cause NOTE Insufficient 1. Cutting speed too fast. The actual frequency of maintenance may Penetration 2. Torch tilted too much. need to be adjusted according to the operating 3.

  • Page 81: Fault Indicator

    CUTMASTER A80, A120 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 indica- tors left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bot- tom to top, 0 through 7.

  • Page 82: Basic Troubleshooting Guide

    CUTMASTER A80, A120 5.05 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. Problem -...
  • Page 83 CUTMASTER A80, A120 Problem - Possible Cause Recommended Action Symptom 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 Gas flow is cycling cartridge missing.

  • Page 84: Power Supply Basic Parts Replacement

    CUTMASTER A80, A120 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 85 CUTMASTER A80, A120 Optional Single-Stage Filter Element 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 86 CUTMASTER A80, A120 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 87: Section 5 Torch:service

    CUTMASTER A80, A120 SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE Refer to Previous "Section 5 System" for com- mon and fault indicator descriptions. Upper Groove with Vent Holes Cleaning Torch Must Remain Open Even if precautions are taken to use only clean air...

  • Page 88: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER A80, A120 5T.02 Inspection and Replacement Drag Shield Cap of Consumable Torch Parts Shield Cap, WARNINGS Machine Disconnect primary power to the system before Shield disassembling the torch or torch leads. Cup Body DO NOT touch any internal torch parts while...

  • Page 89: 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 A80 400VAC, Non CE Power Supply With 400V, 3 Phase input power cable 3-1334-3 CutMaster A120 400VAC, Non CE Power Supply...

  • Page 90: Replacement Power Supply Parts

    CUTMASTER A80, A120 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 400 V Power Supply 9-8562 6.05 Options and Accessories Description Catalog # Single - Stage Filter Kit (includes Filter & Hose)
  • Page 91 CUTMASTER A80, A120 This Page Intentionally Blank Manual 0-5119 PARTS LIST...

  • Page 92: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    CUTMASTER A80, A120 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring...
  • Page 93 CUTMASTER A80, A120 Art # A-07113 Manual 0-5119 PARTS LIST...

  • Page 94: Replacement Parts - For Machine Torches With Unshielded Leads

    CUTMASTER A80, A120 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...
  • Page 95 CUTMASTER A80, A120 A-07994 Manual 0-5119 PARTS LIST...

  • Page 96: Replacement Shielded Machine Torch Leads Assemblies

    CUTMASTER A80, A120 6.08 Replacement Shielded Machine Torch Leads Assemblies Item No. Qty Description Catalog No. Mechanized Shielded Leads Assemblies with ATC Connectors 5 - foot / 1.5 m Leads Assembly with ATC Connector 4-7846 10 - foot / 3.05 m Leads Assembly with ATC Connector 4-7847 25 - foot / 7.6 m Leads Assembly with ATC Connector...

  • Page 97: Torch Consumable Parts (Sl100)

    CUTMASTER A80, A120 6.09 Torch Consumable Parts (SL100) Ohmic Clip 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206 9-8243 9-8218 9-8208 Drag Shield Cup 9-8235 50-60A Shield...

  • Page 98: Replacement Parts For Hand Torch

    CUTMASTER A80, A120 6.11 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 99: Appendix 1: Sequence Of Operation(Block Diagram

    CUTMASTER A80, A120 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 100: Appendix 2: Data Tag Information

    CUTMASTER A80, A120 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering...

  • Page 101: Appendix 3: Torch Pin - Out Diagrams

    CUTMASTER A80, A120 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Automation SL100SV Torch Pin - Out Diagram ATC Female Receptacle - ATC Male Connector - Front View Front View Negative / Plasma Negative / Plasma 4 - Not Used...

  • Page 102: Appendix 4: Torch Connection Diagrams

    CUTMASTER A80, A120 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Automation (SL100SV) Torch Connection Diagram Automated CutMaster Power Supply with ATC Torch Receptacle, Automated SL100SV Torch (w/ Solenoid on Positioning Tube), Torch Lead with ATC Connector ATC Female ATC Male Torch Receptacle...
  • Page 103 CUTMASTER A80, A120 C. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Female ATC Leads Connector Receptacle Power Torch Torch Supply Head Leads Black To Power Supply...

  • Page 104: Appendix 5: System Schematic, 208/460V Units

    PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1 MTH2 MTH2 /INRUSH +12VDC BIAS SUPPLY C3,C4,C7,C8* C3,C4,C7,C8* * CM102 & A80 MTH7 MTH7 C7 & C10 not installed MTH4 MTH4 80A_AC1 80A_AC1 80A_AC2 80A_AC2 PRIMARY AC INPUT 80A_AC3 80A_AC3...
  • Page 105 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS OK TO MOVE CNC PINOUT OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 106: Appendix 6: System Schematic, 380V/400V-600V Units

    CUTMASTER A80, A120 APPENDIX 6: SYSTEM SCHEMATIC, 380V/400V-600V UNITS PRI 3 PRI 3 PRI 4 PRI 4 BIAS SUPPLY PRI 2 PRI 2 PRI 2 PRI 2 INRUSH +12VDC RESISTORS PRI 1 PRI 1 PRI 1 PRI 1 MTH1 MTH1...
  • Page 107 PILOT IGBT WORK1 WORK1 WORK WORK /PIP /START 24VAC RETURN CNC INTERFACE STANDARD ON A80 & A120 UNITS 24VAC SUPPLY CNC INTERFACE OPTIONAL ON CM102 & CM152 UNITS OK TO MOVE CNC PINOUT OK-TO-MOVE (5A @ 250VAC / 30VDC) +12VDC...

  • Page 108: Appendix 7: Publication History

    CUTMASTER A80, A120 APPENDIX 7: Publication History Cover Date Rev. Change(s) Dec. 10, 2008 Manual released. May 29, 2009 Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V schematic per ECOB1357. Corrected part numbers in section 6 per ECOB1201.
  • Page 109 GLOBAL CUSTOMER SERVICE CONTACT Thermadyne Asia Sdn Bhd Thermadyne USA Lot 151, Jalan Industri 3/5A 2800 Airport Road Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085...
  • Page 110 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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