Thermal Dynamics CUTMASTER A40 Operating Manual
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Thermal Dynamics CUTMASTER A40 Operating Manual

Automated plasma cutting system
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A40
Operating Manual
CUTMASTER
AUTOMATED PLASMA
CUTTING SYSTEM
Rev. AL
Date: Aug. 20, 2012
Operating Features:
60%
40
Duty
Cycle
™
Art # A-08838_AB
Manual # 0-4978
380-
460
400
v
600
v

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  • Page 1 CUTMASTER ™ AUTOMATED PLASMA CUTTING SYSTEM Art # A-08838_AB Operating Manual Rev. AL Date: Aug. 20, 2012 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 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 This Page Intentionally Blank...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION .................1-1 1.01 Notes, Cautions and Warnings .................1-1 1.02 Important Safety Precautions ................1-1 1.03 Publications .......................1-2 1.04 Note, Attention et Avertissement ...............1-3 1.05 Precautions De Securite Importantes ...............1-3 1.06 Documents De Reference .................1-5 1.07 Declaration of Conformity ..................1-6 1.08 Statement of Warranty ..................1-7...
  • Page 6 TABLE OF CONTENTS 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 ..................5T-1 5T.02...

  • Page 7: Section 1: General Information

    CUTMASTER A40 SECTION 1: • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. GENERAL INFORMATION • Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. • The kinds of fumes and gases from the plasma arc depend on 1.01 Notes, Cautions and Warnings the kind of metal being used, coatings on the metal, and the different processes.

  • Page 8: Publications

    CUTMASTER A40 • Ventilate all flammable or explosive vapors from the workplace. 1.03 Publications • Do not cut or weld on containers that may have held combus- Refer to the following standards or their latest revisions for more tibles. information: • Provide a fire watch when working in an area where fire hazards 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, may exist. obtainable from the Superintendent of Documents, U.S.

  • Page 9: Note, Attention Et Avertissement

    CUTMASTER A40 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. NOTE • Eloignez toute fumée et gaz de votre zone de respiration. Gardez Toute opération, procédure ou renseignement général sur...
  • Page 10 CUTMASTER A40 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

    CUTMASTER A40 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOM- MANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À Consultez les normes suivantes ou les révisions les plus récentes ayant LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT été faites à celles-ci pour de plus amples renseignements : RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION 33126 DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, 20402 disponible auprès de l’American National Standards Institute, 1430...

  • Page 12: Declaration Of Conformity

    * For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director Victor Technologies International, Inc. Europe Europa Building...

  • Page 13: Statement Of Warranty

    This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose. Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation...
  • Page 14 CUTMASTER A40 This Page Intentionally Blank 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 INTRODUCTION by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link: 2.01 How To Use This Manual This Owner’s Manual applies to just specification...

  • Page 16: Power Supply Specifications

    Input Power Cable Cable for 208/230V input power includes molded plug. 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 Operating Range 0° - 50° C IEC Rating Duty Cycle 100%...

  • Page 17: Input Wiring Specifications

    CUTMASTER A40 2.05 Input Wiring Specifications CutMaster A40 Power Supply Input Cable Wiring Requirements Input voltage Freq Power Input Suggested Sizes Flexible Cord Volts I max I1eff Fuse (amps) (Min. AWG) 10.4 1 Phase 10.8 15.2 50/60 50/60 3 Phase 50/60 Line Voltages with Suggested Circuit Protection and Wire Sizes...

  • Page 18: Power Supply Features

    CUTMASTER A40 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 0-4978...

  • Page 19: Section 2 Torch: Introduction

    CUTMASTER A40 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

    CUTMASTER A40 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 12 VDC circuit rating For options and accessories, see Section 6.
  • Page 21 CUTMASTER A40 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 CUTMASTER A40 This Page Intentionally Blank INTRODUCTION 2T-4 Manual 0-4978...

  • Page 23: Section 3 System: Installation

    CUTMASTER A40 1. First choose an appropriate location for SECTION 3 SYSTEM: mounting the power supply. Choose one INSTALLATION that allows for free movement of torch leads, complies with ventilation per section 2.04 and provides a safe firm surface where 3.01 Unpacking...

  • Page 24: Primary Input Power Connections

    CUTMASTER A40 3.05 Primary Input Power B. Cover Installation 1. Reverse previous procedures for cover Connections installation. NOTE CAUTION When installing the upper screws, attempt to Check your power source for correct voltage reuse the original threads. The easiest way before plugging in or connecting the unit.
  • Page 25 CUTMASTER A40 • Green / Yellow wire to Ground. NOTE • Remaining wires to L1 and L2 input. It There is only one jumper setting that changes does not matter what order these wires between the single and three phase settings.

  • Page 26: Gas Connections

    CUTMASTER A40 3.06 Gas Connections CAUTION Connecting Gas Supply to Unit The connection is the same for compressed air or The primary power source and power cable high pressure cylinders. Refer to the following must conform to local electrical code and the...
  • Page 27 CUTMASTER A40 NOTE NOTE For a secure seal, apply thread sealant to the Pressure should be set at 100 psi (6.9 bar) at fitting threads, according to the manufac- the high pressure cylinder regulator. turer's instructions. Do Not use Teflon tape as...
  • Page 28 CUTMASTER A40 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

    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 CUTMASTER A40 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 31: Section 4 System: Operation

    CUTMASTER A40 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

    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 33 CUTMASTER A40 Typical Cutting Speeds STANDOFF CutMaster A40 Gas Pressure Settings Cutting speeds vary according to torch output am- perage, the type of material being cut, and opera- SL100 tor skill. Refer to Section 4T.08 and following for Leads SL60/SL100 (Mechanized Torch) greater detail.
  • Page 34 CUTMASTER A40 This Page Intentionally Blank OPERATION Manual 0-4978...

  • Page 35: Section 4 Torch: Operation

    CUTMASTER A40 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

    CUTMASTER A40 4T.02 Automation Torch Parts Torch Head Art # A-04173_AB Selection Electrode Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator’s chosen amperage level. The torch parts Start Cartridge must correspond with the type of operation.

  • Page 37: 03 Machine And Hand Torch Parts Selection

    CUTMASTER A40 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

    CUTMASTER A40 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

    CUTMASTER A40 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 CUTMASTER A40 NOTE Shield Cup With Straight Edge The gas preflow and postflow are a character- The drag shield cup can be used with a non conduc- istic of the power supply and not a function tive straight edge to make straight cuts by hand.
  • Page 41 CUTMASTER A40 Piercing With Hand Torch 1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may Trigger...

  • Page 42: 07 Gouging

    CUTMASTER A40 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. NOTE WARNING The gas preflow and postflow are a character- Be sure the operator is equipped with proper...
  • Page 43 CUTMASTER A40 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

    CUTMASTER A40 4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial...
  • Page 45 CUTMASTER A40 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 CUTMASTER A40 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 47 CUTMASTER A40 Torch Initial Kerf Width Material Gas Pressure Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. Thickness (Air) Height Height Speed (mm) (torch lead Volts (mm) (mm/min) (mm) (sec) (mm) length) 1670 1140 5.2 (7.6) 5.5 (15.2) Edge Start BOLD TYPE indicates maximum piercing parameters.
  • Page 48 CUTMASTER A40 Aluminum Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8208 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 49 CUTMASTER A40 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 CUTMASTER A40 Mild Steel Air Plasma / Air Shield Standard Shield Cup Deflector Starter Cartridge Electrode Maximum Life Shield Cup 9-8218 9-8243 9-8210 9-8213 9-8232 9-8237 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 51 CUTMASTER A40 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 CUTMASTER A40 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 53 CUTMASTER A40 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 CUTMASTER A40 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 55 CUTMASTER A40 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

    CUTMASTER A40 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure...
  • Page 57 CUTMASTER A40 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 CUTMASTER A40 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 59 CUTMASTER A40 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 CUTMASTER A40 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air)
  • Page 61 CUTMASTER A40 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 CUTMASTER A40 Mild Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 63 CUTMASTER A40 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 CUTMASTER A40 Stainless Steel Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8232 Torch Initial Kerf Width Gas Pressure Material Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec.
  • Page 65 CUTMASTER A40 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 CUTMASTER A40 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 Arc Voltage Working Travel Speed Piercing Pierce Delay @ Rec. (Air)
  • Page 67 CUTMASTER A40 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

    CUTMASTER A40 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 69 CUTMASTER A40 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 70 CUTMASTER A40 This Page Intentionally Blank OPERATION 4T-36 Manual 0-4978...

  • Page 71: Section 5 System: Service

    CUTMASTER A40 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 1. Check torch consumable parts, replace if 7. Incorrect gas pressure damaged, worn or when cut performance Main Arc 1.

  • Page 73: Fault Indicator

    CUTMASTER A40 5.04 Fault Indicator Explanation of Faults " UNDER PRESSURE: Indicates that operating At initial power up, two lights will temporarily illuminate pressure is set too low and power supply out- for 2-3 seconds to show the version of software used.

  • Page 74: Basic Troubleshooting Guide

    CUTMASTER A40 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 CUTMASTER A40 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. missing parts. ON and OFF. 3. Torch start cartridge is stuck.

  • Page 76: Circuit Fault Isolation

    CUTMASTER A40 5.06 Circuit Fault Isolation B. Cover Installation 1. Reverse previous procedures for cover installation. WARNING NOTE The following procedures should not be at- When installing the upper screws, attempt to tempted by anyone who has not had proper reuse the original threads.
  • Page 77 CUTMASTER A40 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 disas- sembly. Filter Element Art # A-07989 Art # A-07990 8. Install the new or cleaned assembly by reversing these procedures.
  • Page 78 CUTMASTER A40 Optional Single-Stage Filter Element Optional Two-Stage Filter Element Replacement Replacement These instructions apply to power supplies where The Two-Stage Air Filter has two Filter Elements. the optional Single-Stage Filter has been installed. When the Filter Elements become dirty the Power...

  • Page 79: Section 5 Torch: Service

    CUTMASTER A40 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" for common and fault indicator descriptions. Threads Lower O-Ring Cleaning Torch...

  • Page 80: 02 Inspection And Replacement Of Consumable Torch Parts

    CUTMASTER A40 4. Remove the tip. Check for excessive wear 5T.02 Inspection and Replacement (indicated by an elongated or oversized ori- of Consumable Torch Parts fice). Clean or replace the tip if necessary. Worn Tip Good Tip WARNING Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 81: Section 6: Parts Lists

    CUTMASTER A40 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 fol- lows: Section "6.03 Power Supply Replacement" Section "6.04 Replacement Power Supply Parts"...

  • Page 82: Replacement Power Supply Parts

    CUTMASTER A40 6.04 Replacement Power Supply Parts Description Catalog # Regulator 9-0115 Filter Assembly Replacement Element 9-0116 Input Power Cord for 208 / 230V Power Supply 9-8596 Input Power Cord for 400 V Power Supply 9-0218 Input Power Cord for 460 and 600 V Power Supply 9-8563 6.05 Options and Accessories...
  • Page 83 CUTMASTER A40 This Page Intentionally Blank Manual 0-4978 PARTS LIST...

  • Page 84: Torch Replacement Parts Sl100Sv Torch (With Solenoid On Mounting Tube)

    CUTMASTER A40 6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O-Ring 8-3487 Small O-Ring 8-3486 PIP Switch Kit 9-7036...
  • Page 85 CUTMASTER A40 Art # A-07113 Manual 0-4978 PARTS LIST...

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

    CUTMASTER A40 6.07 Torch Consumable Parts (SL100 SV) Automation 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 9-8243...
  • Page 87 CUTMASTER A40 This Page Intentionally Blank Manual 0-4978 PARTS LIST...

  • Page 88: Torch Consumable Parts Manual (Sl60)Torch

    CUTMASTER A40 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 89: Replacement Parts For Hand Torch

    CUTMASTER A40 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 90 CUTMASTER A40 This Page Intentionally Blank PARTS LIST 6-10 Manual 0-4978...

  • Page 91: Appendix 1: Sequence Of Operation (Block Diagram

    CUTMASTER A40 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 92: Appendix 2: Data Tag Information

    CUTMASTER A40 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number M odel : and Production Code Dat e of M f r : Made in USA Type of Power...

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

    CUTMASTER A40 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 94 CUTMASTER A40 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 95: Appendix 4: Torch Connection Diagrams

    CUTMASTER A40 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 96 CUTMASTER A40 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 97 CUTMASTER A40 This Page Intentionally Blank Manual 0-4978 APPENDIX...

  • Page 98: Appendix 5: System Schematic, 208/460V Units

    CUTMASTER A40 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 99 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 100: Appendix 6: System Schematic, 400V/600V Units

    CUTMASTER A40 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 101 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 102: Appendix 7: Raw Arc Voltage

    CUTMASTER A40 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, un-shielded cable rated for 300V or greater. All work must be performed following applicable local and na- tional codes.
  • Page 103 CUTMASTER A40 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control . Manual 0-4978 A-13 APPENDIX...
  • Page 104 CUTMASTER A40 This Page Intentionally Blank APPENDIX A-14 Manual 0-4978...
  • Page 105 CUTMASTER A40 This Page Intentionally Blank Manual 0-4978 A-15 APPENDIX...

  • Page 106: Appendix 8: Publication History

    CUTMASTER A40 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) July 15, 2008 Manual released. Jan 27, 2009 Corrected art sizing in section 3 to show missing information per ECOB1248. Apr. 14, 2009 Updated system specs and input wiring specs in section 2.
  • Page 107 This Page Intentionally Blank...
  • Page 108 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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