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Thermal Dynamics A40 CUTMASTER Operating Manual

Automated plasma cutting system
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A40

operating manual

CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AA
Date: July 15, 2008
Operating Features:
60%
Duty
Cycle
™
Manual # 0-4978
40
380-
400

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Summary of Contents for Thermal Dynamics A40 CUTMASTER

  • Page 1: Operating Manual

    CutmASteR ™ AutomAted PLASmA CuttING SYStem operating manual Rev. AA Date: July 15, 2008 Manual # 0-4978 Operating Features: 380- 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™ A40 SL100 ™ SV Automated Torch Operating Manual Number 0-4978 Published by:...
  • 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 PATENT INFORMATION ...................... 4T-34 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 Circuit Fault Isolation ..................5-6 SECTION 5 TORCH:SERVICE ....................5T-1 5T.01 General Maintenance ..................

  • 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 fi tness 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 0-4978...

  • 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...

  • Page 16: Power Supply Specifications

    Output Current 20 - 60 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster A40 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Opperating Range 0° - 50° C Rating...

  • Page 17: Input Wiring Specifications

    2.05 Input Wiring Specifications CutMaster A40 Power Supply Input Cable Wiring Requirements Power Input voltage Freq Suggested Sizes Input Fuse Flexible Cord Volts I max I eff (amps) (Min. AWG) 1 Phase 50/60 3 Phase 50/60 50/60 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 18: Power Supply Features

    NEVER use replaceable element fuses like UL Class H, or “one-time” fuses like UL Class K5. 2.06 Power Supply Features Control Panel Art # A-08306 Torch Leads Receptacle Mounting Rails Work Cable and Clamp Automation Interface Cable Port...

  • 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 H. Direct Contact Hazard Starter Cartridge, Electrode, Tip, Shield Cup For standoff tip the recommended standoff is 3/16 inches / 4.7 mm. D. Parts - In - Place (PIP) 2T.04 Options And Accessories Torch Head has built - in switch For options and accessories, see section 6.
  • 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 0-4978...

  • 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 • Remove the copper bus bar jumper from L2 and L3 on the contactor. See Inlet Port previous illustration. • Green / Yellow wire to Ground. • Remaining wires to L1, L2 and L3 in- Hose Clamp put.
  • 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

    (up) position. If necessary, connect the torch to the Power Sup- 2. Put the Function Control switch in the SET ply. Connect only the Thermal Dynamics model position. SL100SV / Automation, SL100 / Mechanical or SL60 / 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 SL60 / Manual, SL100 / knob to the SET position. Gas will Mechanical or SL100 / SV Automation Torches may be connected to this Power Supply.
  • Page 33 LATCH position the main cutting arc will be main- STANDOFF tained after the torch switch is released. CutMaster A40 Gas Pressure Settings Typical Cutting Speeds SL100 Leads SL60/SL100 (Mechanized Torch) Cutting speeds vary according to torch output am-...
  • Page 34 This Page Intentionally Blank OPERATION Manual 0-4978...

  • 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: 03 Machine And Hand Torch Parts Selection

    3. Install the replacement Electrode by push- 4T.03 Machine and Hand Torch Parts ing it straight into the torch head until it Selection clicks. Depending on the type of operation to be done . Install the starter cartridge and desired tip determines the torch parts to be used.

  • Page 38: 05 General Cutting Information

    Bevel Angle Piloting The angle between the surface of the cut edge and Piloting is harder on parts life than actual cutting a plane perpendicular to the surface of the plate. because the pilot arc is directed from the electrode A perfectly perpendicular cut would result in a 0°...

  • Page 39: 06 Hand Torch Operation

    2. Depending on the cutting operation, do one Dross of the following: When dross is present on carbon steel, it is com- a. For edge starts, hold the torch perpen- monly referred to as either “high speed, slow speed, dicular to the workpiece with the front or top dross”.
  • Page 40 NOTE Shield Cup With Straight Edge The gas preflow and postflow are a characteristic The drag shield cup can be used with a non conduc- of the power supply and not a function of the tive straight edge to make straight cuts by hand.
  • Page 41 6. Slide the trigger release toward the back Piercing With Hand Torch of the torch handle while simultaneously 1. The torch can be comfortably held in one squeezing the trigger. The pilot arc will hand or steadied with two hands. Position start.

  • Page 42: 07 Gouging

    6. Bring the torch within transfer distance to 4T.07 Gouging the work. The main arc will transfer to the work, and the pilot arc will shut off. NOTES WARNINGS The gas preflow and postflow are a characteristic Be sure the operator is equipped with proper...
  • Page 43 Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed. The recommended lead angle is 35°. At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch.

  • Page 44: 08 Recommended Cutting Speeds For Machine And Automated Torches With Exposed Tip

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

    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 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) 3266 2239 1794 1651 5.2 (7.6) 1578 5.5 (15.2)
  • Page 58 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 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) 1670 1140 5.2 (7.6) 5.5 (15.2) BOLD TYPE indicates maximum piercing parameters.
  • Page 60 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 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) 7660 3490 2350 5.2 (7.6) 2170 5.5 (15.2)
  • Page 62 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 63 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 64 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 65 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 66 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 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) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...

  • Page 68: 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 69 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 70 This Page Intentionally Blank OPERATION 4T-36 Manual 0-4978...

  • Page 71: Section 5 System:service

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

  • Page 72: 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 dam- 7. Incorrect gas pressure aged, worn or when cut performance has demi- Main Arc 1.

  • Page 73: Fault Indicator

    5.04 Fault Indicator Explanation of Faults " UNDER PRESSURE: Indicates that operating pres- At initial power up, two lights will temporarily illu- sure is set too low and power supply output minate for 2-3 seconds to show the version of software power will be disabled.

  • Page 74: 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 75 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 76: Circuit Fault Isolation

    5.06 Circuit Fault Isolation B. Cover Installation 1. Reverse previous procedures for cover installa- tion. WARNING NOTE The following procedures should not be attempted When installing the upper screws, attempt to by anyone who has not had proper training or reuse the original threads.
  • Page 77 7. Remove the filter element assembly through the rear opening. NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly. Filter Element Art # A-07989 Art # A-07990 8. Install the new or cleaned assembly by reversing these procedures.
  • Page 78 Optional Single-Stage Filter Element Optional Two-Stage Filter Element Replacement Replacement These instructions apply to power supplies where the The Two-Stage Air Filter has two Filter Elements. When optional Single-Stage Filter has been installed. the Filter Elements become dirty the Power Supply will...

  • Page 79: 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 80: 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 81: Section 6:Parts Lists

    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...

  • Page 82: 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 9-8596 Input Power Cord for 400 V Power Supply 9-8562 Input Power Cord for 460 V Power Supply 9-8563 6.05 Options and Accessories...
  • Page 83 Intentionally Blank Manual 0-4978 PARTS LIST...

  • Page 84: 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 85 Art # A-07113 Manual 0-4978 PARTS LIST...

  • Page 86: Torch Consumable Parts Automation / Machine (Sl100 Sv)Torch

    6.07 Torch Consumable Parts Automation / Machine (SL100 SV)Torch 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:...
  • Page 87 Intentionally Blank Manual 0-4978 PARTS LIST...

  • Page 88: Replacement Parts - For Machine Torches

    6.08 Replacement Parts - for Machine Torches Item No. Qty Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486 PIP Switch Kit...
  • Page 89 A-07994 Manual 0-4978 PARTS LIST...

  • Page 90: Torch Consumable Parts Manual (Sl60)Torch

    6.09 Torch Consumable Parts Manual (SL60)Torch Tips: Shield DRAG TIP Cup Body, Shield Cap, Deflector 9-8237 CUTTING 9-8243 20A 9-8205 30A 9-8206 Shield Cup 40A 9-8207 9-8218 60A 9-8252 O-Ring No. 8-3488 Shield Cap, Drag DRAG SHIELD 40A 9-8244...

  • Page 91: Replacement Parts For Hand Torch

    6.10 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 92 Intentionally Blank PARTS LIST 6-12 Manual 0-4978...

  • Page 93: 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 94: 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 95: Appendix 3: Torch Pin - Out Diagrams

    APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Automation SL100SV Torch Pin - Out Diagram ATC Female Receptacle - ATC Male Connector - Front View Front View Negative / Plasma Negative / Plasma 4 - Not Used 8 - Open...
  • Page 96 C. 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 97: Appendix 4: Torch Connection Diagrams

    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 98 C. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Power Connector Receptacle Torch Supply Torch Head Leads Black To Power Supply...
  • Page 99 This Page Intentionally Blank Manual 0-4978 APPENDIX...

  • Page 100: Appendix 5: System Schematic, 208/460V Units

    460_IN *CM A40 C1 & C6 INPUT VOLTAGE SELECTOR not installed (Closed for 230VAC input) CAPACITOR PCB 24VAC PCB2 CM A40 19X2410 / CAT# 9-0167 CM A60 19X2426 / CAT# 9-0126 TEST POINTS 24 VAC RETURN GND1 COMMON GND2 COMMON...
  • Page 101 <OrgAddr3> <OrgAddr3> <OrgAddr3> Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Thursday, March 27, 2008 Thursday, March 27, 2008 Thursday, March 27, 2008 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 102: Appendix 6: System Schematic, 400V Units

    460_IN *CM A40 C1 & C6 INPUT VOLTAGE SELECTOR PCB2 not installed (Closed for 230VAC input) CAPACITOR PCB 24VAC CM A40 19X2410 / CAT# 9-0167 CM A60 19X2426 / CAT# 9-0126 TEST POINTS 24 VAC RETURN GND1 COMMON GND2 COMMON...
  • Page 103 DWG No: DWG No: TITLE: TITLE: TITLE: 42X1322 42X1322 42X1322 CUTMASTER A40 & A60 400VAC CUTMASTER A40 & A60 400VAC CUTMASTER A40 & A60 400VAC Last Modified: Last Modified: Last Modified: Thursday, July 03, 2008 Thursday, July 03, 2008 Thursday, July 03, 2008...

  • Page 104: Appendix 7: Publication History

    APPENDIX 7: Publication History Cover Date Rev. Change(s) July 15, 2008 Manual released. APPENDIX A-12 Manual 0-4978...
  • Page 105 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 106 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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