Thermal Dynamics cutmaster A60 Operating Manual
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Thermal Dynamics cutmaster A60 Operating Manual

Thermal Dynamics cutmaster A60 Operating Manual

Automated plasma cutting system
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See also: Service Manual
A60
operating manual
CutmASteR
AutomAted PLASmA
CuttING SYStem
Rev. AR
Operating Features:
60%
60
Duty
Cycle
™
Art # A-08952_AC
Date: Dec. 17, 2012
400
v
Manual # 0-4981
460
600
v
v

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Summary of Contents for Thermal Dynamics cutmaster A60

  • Page 1 CutmASteR ™ AutomAted PLASmA CuttING SYStem Art # A-08952_AC operating manual Rev. AR Date: Dec. 17, 2012 Manual # 0-4981 Operating Features: 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 WARNING Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. 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™...

  • Page 4: 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 ................
  • Page 5 TABLE OF CONTENTS SECTION 4 TORCH: OPERATION ..................4T-1 4T.01 Machine and Automated Torch Operation ............4T-1 4T.02 Automation Torch Parts Selection ..............4T-2 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-4 4T.07 Gouging ......................4T-8...
  • Page 6 TABLE OF CONTENTS...

  • Page 7: General Information

    SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Be sure there is no combustible or flammable material in the 1.03 Publications workplace. Any material that cannot be removed must be protected. Refer to the following standards or their latest revisions for more information: • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combus- 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, tibles.

  • Page 9: Note, Attention Et Avertissement

    1.04 Note, Attention et Avertissement Dans ce manuel, les mots “note”, “attention”, et “avertissement” sont FUMÉE et GAZ utilisés pour mettre en relief des informations à caractère important. La fumée et les gaz produits par le procédé de jet de plasma peuvent Ces mises en relief sont classifiées comme suit : présenter des risques et des dangers de santé.
  • Page 10 Nuance Minimum Nuance Suggerée • Montez et maintenez le matériel conformément au Code électrique Courant Arc Protective Numéro Numéro national des Etats-Unis. (Voir la page 5, article 9.) Moins de 300* • Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation. 300 - 400* • Lisez et respectez toutes les consignes du Manuel de consignes. 400 - 800* * Ces valeurs s’appliquent ou l’arc actuel est observé...

  • 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 LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT Consultez les normes suivantes ou les révisions les plus récentes ayant RENFERMÉ...

  • Page 12: Declaration Of Conformity

    Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 13: Statement Of Warranty

    This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose. Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below.
  • Page 14 This Page Intentionally Blank GENERAL INFORMATION Manual 0-4981...

  • Page 15: Section 2 System: Introduction

    Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format INTRODUCTION by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and 2.01 How To Use This Manual then on the Literature link: This Owner’s Manual applies to just specification...

  • Page 16: Power Supply Specifications

    Output Current 20 - 80 Amps, Continuously Adjustable Power Supply Gas Particulates to 5 Microns Filtering Ability CutMaster A60 Power Supply Duty Cycle * Duty Cycle Ratings @ 40° C (104° F) Ambient Temperature Operating Range 0° - 50° C Rating...

  • Page 17: Input Wiring Specifications

    2.05 Input Wiring Specifications CutMaster A60 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts I max I eff Fuse (amps) (Min. AWG) 1 Phase 50/60 50/60 11.8 3 Phase 50/60 11.8...

  • Page 18: Power Supply Features

    2.06 Power Supply Features Control Panel Art # A-08306 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-08318 INTRODUCTION Manual 0-4981...

  • Page 19: Section 2 Torch

    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

    2T.04 Options And Accessories C. Torch Parts Starter Cartridge, Electrode, Tip, Shield Cup For options and accessories, see Section 6. D. Parts - In - Place (PIP) 2T.05 Introduction to Plasma Torch Head has built - in switch A.
  • Page 21 B. Gas Distribution E. Parts - In - Place (PIP) The single gas used is internally split into plasma The torch includes a 'Parts - In - Place' (PIP) circuit. and secondary gases. When the shield cup is properly installed, it closes a switch.
  • Page 22 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4981...

  • Page 23: Section 3 System: Installation

    Sec- SECTION 3 SYSTEM: tion 2.04 and provides a safe firm surface INSTALLATION where the unit can be secured. 2. Place the unit in the desired position and mark where the four keyway holes 3.01 Unpacking...

  • Page 24: Primary Input Power Connections

    3.05 Primary Input Power Connections Upper Screws Lower Screws CAUTION Check your power source for correct voltage before plugging in or connecting the unit. Check Slots the Voltage Selector at the rear of the unit for Lower correct setting before plugging in or connecting Screws the unit.
  • Page 25 4. If the power cable being used is not the D. Quick Guide to Phase Wiring factory - supplied cable, use a three - con- Single-Phase (1ø) and Jumper Settings ductor input power cable for the voltage desired and strip back the insulation on the Jumper L1 -L4 individual wires.

  • Page 26: Gas Connections

    3.06 Gas Connections chassis ground connection. Connecting Gas Supply to Unit 3. Loosen the through - hole protector on the back panel of the power supply. Pull the The connection is the same for compressed air or high pressure cylinders.
  • 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 3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows of at least 300 scfh (141.5 lpm). 4. Connect supply hose to the cylinder.

  • Page 29: Section 3 Torch

    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 30 There are three options for Divided Arc Voltage signal supplied from the automation interface pcb. This is selected by connecting the black Jumper Plug on the P1 connector as follows: Arc voltage / 16.67 Jumper not installed Arc voltage / 30 Jumper Pins 1 & 2 Arc voltage / 50 Jumper Pins 2 &...

  • Page 31: 03 Setting Up Automation Or Machine Torch

    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 operate a machine or automation torch. WARNING Disconnect primary power at the source before disassembling the torch or torch leads.
  • Page 32 This page intentionally blank INSTALLATION 3T-4 Manual 0-4981...

  • Page 33: Section 4 System

    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 34: Preparations For Operation

    Check that the torch is properly connected. Only Set Operating Pressure Thermal Dynamics model SL60 / Manual, SL100 / 1. Place the Power Supply Function Control Mechanical or SL100 / SV Automation Torches may be connected to this Power Supply.
  • Page 35 Typical Cutting Speeds STANDOFF CutMaster A60 Gas Pressure Settings Cutting speeds vary according to torch output am- perage, the type of material being cut, and operator SL100 skill. Refer to Sections "4T.08 Recommended Leads SL60 (Mechanized Torch) Cutting Speeds for Machine and Automated Torches...
  • Page 36 This Page Intentionally Blank OPERATION Manual 0-4981...

  • Page 37: Section 4 Torch

    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 38: 02 Automation Torch Parts Selection

    4T.02 Automation Torch Parts Automation Torch Parts 3. Install the replacement Electrode by push- Selection ing it straight into the torch head until it Check the torch for proper consumable parts. The clicks. parts supplied in the torch may not be correct for the .

  • Page 39: 04 Cut Quality

    Kerf Width Cut Surface Torch Head Bevel Angle Spatter Electrode Top Edge Rounding Start Cartridge Dross Build-Up Cut Surface A-00007 Drag Lines Cut Quality Characteristics Shield Cup Cut Surface A-03510_AB Torch Parts (Drag Shield Cap & Shield Cup Body...

  • Page 40: 05 General Cutting Information

    4T.05 General Cutting Information Left Side Cut Angle Right Side Cut Angle WARNING Disconnect primary power at the source be- fore disassembling the power supply, torch, or torch leads. A-00512 Frequently review the Important Safety Precautions Side Characteristics Of Cut at the front of this manual.
  • Page 41 NOTE NOTE The tip should never come in contact with The gas preflow and postflow are a charac- the workpiece except during drag cutting teristic of the power supply and not a func- operations. tion of the torch.
  • Page 42 Shield Cup With Straight Edge The drag shield cup can be used with a non conduc- tive straight edge to make straight cuts by hand. Trigger WARNING The straight edge must be non - conductive. Trigger Release A-02986 7.
  • Page 43 Piercing With Hand Torch NOTE 1. The torch can be comfortably held in one The gas preflow and postflow are a charac- hand or steadied with two hands. Position teristic of the power supply and not a func- tion of the torch.

  • Page 44: 07 Gouging

    4T.07 Gouging 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 WARNING greater than 45° the molten metal will not be blown...
  • Page 45 This Page Intentionally Blank Manual 0-4981 4T-9 OPERATION...

  • Page 46: 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 Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208...
  • 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) 3990 2920 1810 1470 4.8 (7.6m) 1345 5.2 (15.2m)
  • Page 48 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • 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) 1670 1140 5.2 (7.6m) 5.5 (15.2m) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 50 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8208 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • 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) 7620 3500 2350 4.8 (7.6m) 2170 1740 5.2 (15.2m)
  • Page 52 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • 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) 7540 7015 0.10 4570 0.10 3650 0.20...
  • Page 54 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • 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) 10890 0.00 7560 0.10 4365 0.10 2865 0.20...
  • Page 56 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8210 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • 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) 17010 0.00 7680 0.10 6410 0.10 5230 0.20...
  • Page 58 Mild Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • 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) 8915 0.00 7415 0.10 5915 0.10 4095 0.30...
  • Page 60 Stainless Steel Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-821 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage...
  • 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) 9020 0.00 8380 0.00 7730 0.10 5865 0.20...
  • Page 62 Aluminum Air Plasma / Air Shield Starter Cartridge Standard Shield Cup Deflector Heavy Duty Starter Electrode Maximum Life Shield Cup Cartridge 9-8218 9-8213 9-8243 9-8211 9-8232 9-8237 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working...
  • 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) 0.00 8890 8420 0.00 0.10 7170 5710 0.20...

  • Page 64: 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 Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277...
  • Page 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) 3266 2239 1794 1651 5.2 (7.6m) 1578 5.5 (15.2m)
  • Page 66 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • 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) 1670 1140 5.2 (7.6m) 5.5 (15.2m) BOLD TYPE indicates maximum piercing parameters.
  • Page 68 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8245 9-8237 9-8208 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 69 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 (7.6m) 2170 1630 5.5 (15.2m)
  • Page 70 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 71 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 72 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed...
  • Page 73 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 74 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8238 9-8237 9-8210 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 75 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 8890 0.00 8890 0.10 7070 0.10 5095 0.20...
  • Page 76 Mild Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 77 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 7895 6395 0.10 4895 0.10 4025 0.30...
  • Page 78 Stainless Steel Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Kerf Width Gas Pressure Material Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec.
  • Page 79 Torch Kerf Width Material Gas Pressure Initial Piercing Arc Voltage Working Travel Speed Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 0.00 9410 8120 0.00 6830 0.10 5635 0.20...
  • Page 80 Aluminum Air Plasma / Air Shield Starter Cartridge Shield Cap Maximum Life Shield Cup Heavy Duty Starter Electrode Cartridge 9-8213 9-8239 9-8237 9-8211 9-8232 9-8277 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 81 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...

  • Page 82: 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 9-8232 Electrode US Pat No(s) 6163008; 6987238...
  • Page 83 Catalog # Description Patent(s) 9-8239 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending 9-8244 Shield Cap US Pat No(s) 6914211; D505309 Other Pat(s) Pending 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No. 5,120,930 and 5,132,512:...
  • Page 84 This Page Intentionally Blank OPERATION 4T-48 Manual 0-4981...

  • Page 85: Section 5 System

    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 86: Maintenance Schedule

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

  • Page 87: Fault Indicator

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

  • Page 88: 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 89 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 Gas flow is cycling cartridge missing.

  • Page 90: Circuit Fault Isolation

    5.06 Circuit Fault Isolation C. Filter Element Assembly 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), WARNING and either cleaned or replaced.
  • Page 91 Optional Single-Stage Filter Element 6. Disconnect the input line from the filter element assembly. Replacement 7. Remove the filter element assembly through the These instructions apply to power supplies where the rear opening. optional Single-Stage Filter has been installed.
  • Page 92 Optional Two-Stage Filter Element NOTE Replacement A small amount of air leakage from the bottom fitting is normal. The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will This completes the parts replacement procedures.

  • Page 93: Section 5 Torch

    SECTION 5 TORCH: SERVICE Upper Groove 5T.01 General Maintenance with Vent Holes Must Remain Open NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System: Service" for common and fault indicator descriptions. Threads Cleaning Torch Lower O-Ring...

  • Page 94: 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 WARNING Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 95: 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 A60 Power Supply 208/230 - 460VAC, Single or 3 Phase, 60Hz, with input power cable and plug 3-1134-1...

  • Page 96: 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 9-0218 Input Power Cord for 460/600 V Power Supply...
  • Page 97 Intentionally Blank Manual 0-4981 PARTS LIST...

  • Page 98: Torch Replacement Parts Sl100Sv Torch (W/Solenoid On Mounting Tube)

    6.06 Torch Replacement Parts SL100SV Torch (w/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 99 Art # A-07113 Manual 0-4981 PARTS LIST...

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

    6.07 Torch Consumable Parts Automation / Machine (SL100)Torch Ohmic Clip Automation Torch Ohmic Clip 9-8224 Manual Torch 9-8259 20-40A Shield Tip: Shield Cap, Machine Cup Body, STANDOFF 40A 9-8245 9-8237 CUTTING 9-8205 Shield Cap, Deflector Shield Cup 9-8206...
  • Page 101 Intentionally Blank Manual 0-4981 PARTS LIST...

  • Page 102: Torch Consumable Parts Manual (Sl60)Torch

    6.08 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 103: Replacement Parts For Hand Torch

    6.09 Replacement Parts for Hand Torch Item # Description Catalog # Torch Handle Replacement Kit (includes items No. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.
  • Page 104 Intentionally Blank PARTS LIST 6-10 Manual 0-4981...

  • Page 105: Appendix 1: Sequence Of Operation

    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 106: 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 107 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 108 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 109 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 Connector Receptacle Power Torch Torch Supply Head Leads Black To Power Supply...
  • Page 110 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS K1-K4 K1-K4 K5, K6 K5, K6 PRI 2 PRI 2 PRI 1 PRI 1 PRI 4 PRI 4 PRI 3 PRI 3 +12VDC BIAS SUPPLY MTH2 MTH2 MTH1 MTH1 C1-C4* C1-C4* /INRUSH...
  • Page 111 05/09/08 Date: Date: Date: ECO B1159 10/03/08 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 112 APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS PRI 1 PRI 1 PRI 2 PRI 2 PRI 4 PRI 4 PRI 3 PRI 3 BIAS SUPPLY MTH1 MTH1 MTH2 MTH2 +12VDC + C1-C4* + C1-C4* CHOKE /INRUSH CE UNITS ONLY...
  • Page 113 St Louis, MO 63017 USA St Louis, MO 63017 USA 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 114 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 mm ), single pair, unshielded cable rated for 300V or greater. All work must be performed following applicable local and national codes.
  • Page 115 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control . Manual 0-4981 A-11 APPENDIX...
  • Page 116 Dec. 7, 2012 ECOB2305 Dec. 17, 2012 Changed logo on Front Cover and Inside Front Cover from "Thermal Dynamics" to "Victor Thermal Dynamics", modified Prop 65 Text Section 1, added information regarding Automation Interface Kit to 3T.02 pg. 3T-1, deleted information regarding Automation Interface Kit from 6.05 pg.
  • Page 117 This Page Intentionally Blank...
  • Page 118 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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