40 208230V 380400V 460V 600V CUTMASTER® A40 AUTOMATED PLASMA CUTTING SYSTEM Operating Manual Art # A-08838_AD Revision: AP Issue Date: February 12, 2014 Manual No.: 0-4978 VictorThermalDynamics.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.VictorThermalDynamics.com.
! 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® A40 SL100 ™ SV Automated Torch Operating Manual Number 0-4978 Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 www.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION.................................................................... 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings......................................................................... 1-1 Important Safety Precautions.......................................................................... 1-1 Publications.....................................................................................................
TABLE OF CONTENTS SECTION 4 TORCH: OPERATION......................................................................... 4T-1 4T.01 4T.02 4T.03 4T.04 4T.05 4T.06 4T.07 4T.08 Machine and Automated Torch Operation.......................................................4T-1 Automation Torch Parts Selection...................................................................4T-1 Machine and Hand Torch Parts Selection........................................................4T-2 Cut Quality.............................
TABLE OF CONTENTS APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)................................................................................... A-1 APPENDIX 2: DATA TAG INFORMATION.................................................................. A-2 APPENDIX 3: TORCH PIN - OUT DIAGRAMS............................................................ A-3 APPENDIX 4: TORCH CONNECTION DIAGRAMS........................................................ A-4 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS...........
CUTMASTER A40 SECTION 1: GENERAL INFORMATION 1.01 NOTES, CAUTIONS AND WARNINGS Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.
CUTMASTER A40 • Disconnect power source before performing any service or repairs. • Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. • Read and follow all the instructions in the Operating Manual. • Protect others in the work area from the arc rays. Use protective booths, screens or shields. • Use the shade of lens as suggested in the following per ANSI/ASC Z49.1: FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
CUTMASTER A40 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 ! Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question. 8.
CUTMASTER A40 • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés.
CUTMASTER A40 • Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure. • Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection. • Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1: Nuance Minimum 1.
CUTMASTER A40 2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126 3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. Norme ANSI Z87.
CUTMASTER A40 1.07 DECLARATION OF CONFORMITY Declaration of Conformity Application of Council Directive(s): The equipment described in this document conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 2006/95/EC) and to the National legislation for the enforcement of this Directive.
CUTMASTER A40 Classification: The equipment described in this manual is Class A and intended for industrial use. ! WARNING This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
CUTMASTER A40 1.08 STATEMENT OF WARRANTY LIMITED WARRANTY: Subject to the terms and conditions established below, Victor Thermal Dynamics® Corporation warrants to the original retail purchaser that new Victor Thermal Dynamics CUTMASTER® plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
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CUTMASTER A40 SECTION 2 SYSTEM: INTRODUCTION 2.02 EQUIPMENT IDENTIFICATION This Owner’s Manual applies to just specification or part numbers listed on page i. The unit’s identification number (specification or part number), model, and serial number usually appear on a data tag attached to the rear panel. Equipment which does not have a data tag such as torch and cable assemblies are identified only by the specification or part number printed on loosely attached card or the shipping container.
CUTMASTER A40 2.04 POWER SUPPLY SPECIFICATIONS CutMaster A40 Power Supply Specifications 208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz 230 VAC (187 - 253 VAC), Three Phase, 50/60 Hz 380 VAC (360 - 440 VAC), Three Phase, 50/60 Hz Input Power 400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (540 - 630 VAC), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable.
CUTMASTER A40 2.05 INPUT WIRING SPECIFICATIONS CutMaster A40 Power Supply Input Cable Wiring Requirements 1 Phase 3 Phase Input voltage Freq Power Input Suggested Sizes Volts Hz kVA I max I1eff Fuse (amps) Flexible Cord (Min. AWG) 208 60 10.4 47 30 50 10 230 60 10.8 45 29 50 10 460 60 15.2 31 20 35 12 208 60 5.4 26 17 30 12 230 50/60 5.8 24 16 30 12 380 50/60 6.1 16 11 20 14 400 50/60 6.4 16 11 20 14 460 60 7.4 16 10 20 12 600 60 7.
CUTMASTER A40 2.
CUTMASTER A40 SECTION 2 TORCH: INTRODUCTION 2. Machine /Mechanized Torch, Model The standard machine torch has a positioning tube with rack & pinch block assembly. 15.875" / 403 mm 9.285" / 236 mm 2T.01 SCOPE OF MANUAL This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60/Manual, SL100/Mechanized and SL100 SV Automated Plasma Cutting Torches.
CUTMASTER A40 2T.05 INTRODUCTION TO PLASMA Manual Torch Ratings Ambient Temperature 104° F 40° C Duty Cycle 100% @ 60 Amps @ 400 scfh Maximum Current 60 Amps Voltage (Vpeak) 500V Arc Striking Voltage 7kV A. Plasma Gas Flow G. Gas Requirements While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
CUTMASTER A40 B. Gas Distribution Remote Pendant The single gas used is internally split into plasma and secondary gases. The plasma gas flows into the torch through the negative lead, through the starter cartridge, around the electrode, and out through the tip orifice. To ATC The secondary gas flows down around the outside of the torch starter cartridge, and out between the tip and shield cup around the plasma arc. PIP Switch Shield Cup CNC Start C.
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CUTMASTER A40 SECTION 3 SYSTEM: INSTALLATION 3.01 2. Place the unit in the desired position and mark where the four keyway holes rails touch. UNPACKING 1. Use the packing lists to identify and account for each item. 2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation. 3.
CUTMASTER A40 Most units are shipped from the factory with a 230Volt input power cable wired to the input contactor in the single - phase configuration. The following illustrations and directions are for changing that configuration to a different voltage and or to three - phase operation or back again if a change had already been made. C. Input Power Selection Set the Input Voltage Selection Switch at the rear of the unit based on the primary input voltage it is connected to.
CUTMASTER A40 E. Connections to Single Phase Input Power F. Connections to Three Phase Input Power WARNING WARNING Disconnect input power from the power supply and input cable before attempting this procedure. Disconnect input power from the power supply and input cable before attempting this procedure. These instructions are for changing the input power and or cable on the 208/230, 400, 460 VAC Power Supply to Single Phase input power.
CUTMASTER A40 3.06 GAS CONNECTIONS Filter Assembly Connecting Gas Supply to Unit Inlet Port The connection is the same for compressed air or high pressure cylinders. Refer to the following subsections if an optional air line filter is to be installed. 1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions.
CUTMASTER A40 Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. Connect the air supply as follows: 1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly. NOTE For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions.
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CUTMASTER A40 SECTION 3 TORCH: INSTALLATION 3T.02 CNC CONNECTION 1. Locate the interface connection port on the rear of the power supply. Automation Interface Cable Port 3T.01 TORCH CONNECTIONS If necessary, connect the torch to the Power Supply. Connect only the Victor Thermal Dynamics model SL100SV / Automation, SL100 / Mechanical or SL60 / Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
CUTMASTER A40 FULL FEATURED AUTOMATION INTERFACE PCB OPTION * J3 No jumper installed for ARC VOLTS /16.
CUTMASTER A40 WARNING Disconnect primary power at the source before disassembling the torch or torch leads. The Automation and Machine torch include a positioning tube with rack and pinch block assembly. 1. Mount the torch assembly on the cutting table. 2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece. Pinch Block Assembly Square Workpiece A-02585 Automated and Machine Torch Set - Up 3.
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CUTMASTER A40 SECTION 4 SYSTEM: OPERATION 4.01 1 2 3 4 FRONT PANEL CONTROLS / FEATURES MIN A MAX See Illustration for numbering Identification PSI BAR MAX MAX MIN MIN + 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. ! 2. Function Control Function Control Knob, Used to select between the different operating modes.
CUTMASTER A40 4.02 Connect Work Cable PREPARATIONS FOR OPERATION Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off. At the start of each operating session: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
CUTMASTER A40 Select Current Output Level 2 1 1. Place the Function Control Knob in one of the three operating positions available: RUN MIN A MAX PSI BAR MAX MAX MIN MIN , RAPID AUTO RESTART + or LATCH . Gas flow stops. 2. Set the output current to desired amperage with the Output Current Control Knob. ! Cutting Operation When the torch leaves the workpiece during cutting operations with the Function Control Knob in the RUN position, there is a brief delay in restarting the pilot arc.
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CUTMASTER A40 SECTION 4 TORCH: OPERATION 4T.01 Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required.
CUTMASTER A40 4T.03 WARNING MACHINE AND HAND TORCH PARTS SELECTION Depending on the type of operation to be done determines the torch parts to be used. Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies. Type of operation: Drag cutting, standoff cutting or gouging NOTE Torch parts: Shield Cup, Cutting Tip, Electrode and Starter Cartridge The shield cup holds the tip and starter cartridge in place.
CUTMASTER A40 3. Install the replacement Electrode by pushing it straight into the torch head until it clicks. Bottom Dross Buildup Molten material which is not blown out of the cut area and resolidifies on the plate. Excessive dross may require secondary cleanup operations after cutting. 4. Install the starter cartridge and desired tip for the operation into the torch head. 5. Hand tighten the shield cup assembly until it is seated on the torch head.
CUTMASTER A40 life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally result in a more square cut. 4T.06 HAND TORCH OPERATION Standoff Cutting With Hand Torch Edge Starting For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal.
CUTMASTER A40 8. For a consistent standoff height from the workpiece, install the standoff guide by sliding it onto the torch shield cup. Install the guide with the legs at the sides of the shield cup body to maintain good visibility of the cutting arc. During operation, position the legs of the standoff guide against the workpiece. Trigger Trigger Release A-02986 5. Bring the torch within transfer distance to the work. The main arc will transfer to the work, and the pilot arc will shut OFF.
CUTMASTER A40 1. Install the drag cutting tip and set the output current. NOTE 2. 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 be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows good control and movement.
CUTMASTER A40 Gouging Parameters NOTE Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff). The gas preflow and postflow are a characteristic of the power supply and not a function of the torch. When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle.
CUTMASTER A40 Torch Head 35° Standoff Height Workpiece A-00941_AB Gouging Angle and Standoff Distance Standoff Distance The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.
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CUTMASTER A40 4T.08 RECOMMENDED CUTTING SPEEDS FOR MACHINE AND AUTOMATED TORCHES WITH EXPOSED TIP Mild Steel 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 101 3.6 3990 4.6 0.0 1.1 2 105 3.6 2920 4.6 0.1 1.4 3 109 3.6 1810 4.6 0.3 1.5 110 3.6 1470 4.6 0.3 1.6 112 3.6 1345 4.6 0.4 1.6 116 3.6 1100 4.6 0.5 1.7 8 118 3.6 815 4.6 1.0 1.7 10 119 3.6 595 4.6 1.5 1.8 12 120 3.
CUTMASTER A40 Stainless Steel 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 18 0.050 110 0.19 60 0.20 0.00 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 112 4.8 1670 4.8 0.0 1.7 2 105 4.8 1140 5.1 0.1 1.8 3 109 4.8 980 5.1 0.2 1.8 109 4.8 845 5.1 0.3 1.8 111 4.8 715 5.1 0.4 1.8 118 4.8 525 5.1 0.5 2.0 8 123 4.8 350 5.1 1.5 2.0 10 125 4.8 245 5.1 2.0 2.0 12 120 4.
CUTMASTER A40 Aluminum 40A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Kerf Width Travel Speed Pierce Delay Height Height @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 95 0.16 300 0.16 0.0 0.06 20 0.040 16 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Kerf Width Travel Speed Pierce Delay Height Height @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1.0 95 4.1 7620 4.1 0.0 1.5 2.0 104 4.1 3500 4.1 0.2 1.6 3.0 115 4.1 2350 4.6 0.3 1.7 113 4.6 2170 4.6 0.4 1.7 118 4.6 1740 4.6 0.5 1.8 125 4.6 1015 4.6 0.8 1.9 8.0 139 4.6 500 Edge Start 2.0 10.0 153 4.6 180 Edge Start 2.2 4.
CUTMASTER A40 Mild Steel 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Travel Speed Height Height PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.060 118 0.19 290 0.19 0.00 0.08 14 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 115 4.8 7540 4.8 0 2.1 2 120 4.8 7015 4.0 0.10 1.9 3 118 4.8 4570 4.8 0.10 0.1 4 120 4.8 3650 4.8 0.20 1.9 5 121 4.8 2465 4.8 0.20 2.1 122 4.8 2145 4.8 0.30 2.0 123 4.8 1635 4.8 0.40 2.2 125 4.8 1180 4.8 0.60 2.
CUTMASTER A40 Stainless Steel 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8243 9-8218 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) Torch Working Initial Piercing Travel Speed Height Height 16 0.063 119 0.19 350 0.20 0.00 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 124 4.8 10890 5.1 0.00 0.8 2 116 4.8 7560 5.1 0.10 1.7 3 122 4.8 4365 5.1 0.10 1.7 4 119 4.8 2865 5.1 0.20 2.1 122 4.8 2195 5.1 0.20 2.1 123 4.8 1790 5.1 0.30 2.2 127 4.8 1190 5.1 0.40 2.2 10 130 4.8 725 5.1 0.50 2.
CUTMASTER A40 Aluminum 60A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup 9-8243 9-8218 9-8237 Material Thickness (GA) (in) inch Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8210 9-8213 9-8277 9-8232 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) Torch Working Initial Piercing Travel Speed Height Height 16 0.064 123 0.25 440 0.25 0.00 0.08 14 0.
CUTMASTER A40 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 118 6.4 17010 6.4 0.00 1.8 2 126 6.4 7680 6.4 0.10 2.3 3 128 6.4 6410 6.4 0.10 2.3 4 130 6.4 5230 6.4 0.20 2.3 132 6.4 4010 6.4 0.20 2.4 132 6.4 2640 6.4 0.30 2.4 137 6.4 1630 6.4 0.40 2.4 10 142 6.4 1085 6.4 0.60 2.
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CUTMASTER A40 4T.09 RECOMMENDED CUTTING SPEEDS FOR MACHINE AND AUTOMATED TORCHES WITH SHIELDED TIP Mild Steel 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip 9-8245 9-8237 9-8208 Material Thickness (GA) (in) inch Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8213 9-8277 9-8232 Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 108 4.1 3266 4.1 0.0 1.4 2 108 4.1 2239 4.1 0.0 1.5 3 112 4.1 1794 4.1 0.1 1.7 114 4.1 1651 4.1 0.2 1.7 115 4.1 1578 4.1 0.3 1.7 117 4.1 1256 4.1 0.4 1.7 8 121 4.1 853 4.1 0.5 1.7 10 124 4.1 565 4.1 1.2 1.8 127 4.
CUTMASTER A40 Stainless Steel 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 18 0.050 110 0.16 60 4.1 0.0 0.06 16 0.063 108 0.16 50 4.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 109 4.1 1670 4.1 0.0 1.7 2 114 4.1 1140 4.1 0.1 1.8 3 114 4.1 980 4.1 0.2 1.8 116 4.1 845 4.1 0.3 1.8 115 4.1 725 4.1 0.4 1.8 117 4.1 565 4.1 0.5 2.0 4 5 6 5.2 (7.6) 5.5 (15.2) 8 122 4.1 440 4.1 1.5 2.0 10 125 4.1 360 4.
CUTMASTER A40 Aluminum 40A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8245 9-8237 9-8208 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Kerf Width Travel Speed Pierce Delay Height Height @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 20 0.040 110 0.19 300 0.20 0.0 0.06 16 0.063 113 0.19 170 0.20 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Kerf Width Travel Speed Pierce Delay Height Height @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1.0 110 4.8 7660 5.1 0.0 1.6 2.0 116 4.8 3490 5.1 0.2 1.8 124 4.8 2350 5.1 0.3 1.8 126 4.8 2170 5.1 0.4 1.8 129 4.8 1630 5.1 0.6 1.8 6.0 135 4.8 990 5.1 1.0 1.9 8.0 141 4.8 500 5.1 1.6 2.0 146 4.8 180 5.1 2.1 2.3 3.0 4.0 5.
CUTMASTER A40 Mild Steel 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Travel Speed Height Height PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.060 128 0.19 250 0.20 0.00 0.09 14 0.075 129 0.19 237 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 127 4.8 6804 5.1 0 2.2 2 129 4.8 5942 5.1 0.10 2.2 3 126 4.8 5080 5.1 0.10 0.1 4 130 4.8 3316 5.1 0.20 2.3 132 4.8 2794 5.1 0.20 2.2 134 4.8 2230 5.1 0.30 2.1 133 4.8 1425 5.1 0.40 2.3 10 134 4.8 822 5.1 0.60 2.
CUTMASTER A40 Stainless Steel 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Travel Speed Height Height PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.063 110 0.13 165 0.20 0.00 0.06 14 0.078 116 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 101 3.3 4590 5.1 0.00 1.2 2 116 3.3 3925 5.1 0.10 1.7 3 118 3.3 3285 5.1 0.10 1.7 4 126 3.3 1985 5.1 0.20 2.2 125 3.3 1850 5.1 0.20 2.1 127 3.3 1605 5.1 0.30 2.1 131 3.3 1100 5.1 0.40 2.1 10 134 3.3 670 5.1 0.50 2.
CUTMASTER A40 Aluminum 60A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8238 9-8237 9-8210 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Initial Piercing Travel Speed Height Height PSI (torch lead length) Volts (in) (ipm) Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.064 118 0.13 350 0.20 0.00 0.07 14 0.079 118 0.13 350 0.20 0.
CUTMASTER A40 Material Thickness (mm) Gas Pressure (Air) Arc Voltage Bar (torch lead length) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed Volts (mm) (mm/min) (mm) (sec) (mm) 1 118 6.4 8890 6.4 0.00 2 2 118 6.4 8890 6.4 0.10 2.0 3 123 6.4 7070 6.4 0.10 2.1 4 124 6.4 5095 6.4 0.20 2.0 126 6.4 3335 6.4 0.20 2.0 130 6.4 2370 6.4 0.30 2.0 134 6.4 1570 6.4 0.40 2.0 10 136 6.4 1070 6.4 0.60 2.
CUTMASTER A40 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER A40 Catalog # Description Patent(s) 9-8239 Shield Cap 9-8244 Shield Cap 9-8245 Shield Cap US Pat No(s) 6914211; D496951 Other Pat(s) Pending US Pat No(s) 6914211; D505309 Other Pat(s) Pending US Pat No(s) 6914211; D496951 Other Pat(s) Pending The following parts are also licensed under U.S. Patent No.
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CUTMASTER A40 SECTION 5 SYSTEM: SERVICE 5.01 GENERAL MAINTENANCE Warning! Disconnect input power before maintaining. Maintain more often if used under severe conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip, electrode, start cartridge and shield cup Visually inspect the cables and leads.
CUTMASTER A40 5.02 MAINTENANCE SCHEDULE 5.03 COMMON FAULTS NOTE Problem - Symptom The actual frequency of maintenance may need to be adjusted according to the operating environment. Insufficient Penetration 1. Cutting speed too fast. 2. Torch tilted too much. 3. Metal too thick. 4. Worn torch parts 5. Cutting current too low. 6. Non - Genuine Victor Thermal Dynamics parts used 7. Incorrect gas pressure Main Arc Extinguishes 1. Cutting speed too slow. 2. Torch standoff too high from workpiece. 3.
CUTMASTER A40 5.04 Explanation of Faults FAULT INDICATOR At initial power up, two lights will temporarily illuminate for 2-3 seconds to show the version of software used. To determine the first digit, count the function indicators left to right, 1 through 5. To determine the second digit count the pressure indicators, reading from bottom to top, 0 through 7. In the example below the Temp indicator and 75 psi indicators are ON indicating the version would be 2.3.
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 Recommended Action ON / OFF Switch is ON but the A/C Indicator does not light 1. Primary power disconnect is in 1. Turn primary power disconnect switch to ON position. OFF position. 2.
CUTMASTER A40 Problem - Symptom FAULT & 80 PSI indicators flashing. Gas flow is cycling ON and OFF. Possible Cause 1. Torch shield cup is loose. 2. Torch tip, electrode or starter cartridge missing. 3. Torch start cartridge is stuck. 4. Open conductor in torch leads. Recommended Action 1. Tighten shield cup by hand. Do not overtighten. 2. Turn OFF power supply. Remove shield cup. Install missing parts. 3. Turn OFF power supply. Bleed down system pressure. Remove shield cup, tip and start cartridge.
CUTMASTER A40 5.06 B. Cover Installation CIRCUIT FAULT ISOLATION 1. Reverse previous procedures for cover installation. NOTE WARNING When installing the upper screws, attempt to reuse the original threads. The easiest way to do this is by turning the screw counter-clockwise until you feel the threads line up, then begin to turn the screw clockwise to tighten to 15-18 in. lbs. Do not over tighten.
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 disassembly. 1 Filter Element Art # A-07989 2 Art # A-07990 8. Install the new or cleaned assembly by reversing these procedures. 3 4 9. Turn ON the air supply and check for leaks before reinstalling the cover. 5 6mm 5.
CUTMASTER A40 Optional Single-Stage Filter Element Replacement Optional Two-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.
CUTMASTER A40 SECTION 5 TORCH: SERVICE Upper Groove with Vent Holes Must Remain Open 5T.01 GENERAL MAINTENANCE NOTE Upper O-Ring in Correct Groove Refer to Previous "Section 5 System" for common and fault indicator descriptions. Threads Cleaning Torch Lower O-Ring Art # A-03725 Torch Head O-Ring Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue.
CUTMASTER A40 Worn Tip Good Tip 5T.02 INSPECTION AND REPLACEMENT OF CONSUMABLE TORCH PARTS A-03406 WARNING Example of Tip Wear Disconnect primary power to the system before disassembling the torch or torch leads. 5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion. Replace if necessary. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
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 follows: Section "6.03 Power Supply Replacement" Section "6.04 Replacement Power Supply Parts" Section "6.05 Options and Accessories" Section "6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)" Section "6.07 Torch Consumable Parts (SL100 SV) Automation" Section "6.
CUTMASTER A40 6.04 REPLACEMENT POWER SUPPLY PARTS Qty Description 1 Regulator 1 Filter Assembly Replacement Element 1 Input Power Cord for 208 / 230V Power Supply 1 Input Power Cord for 400 V Power Supply 1 Input Power Cord for 460 and 600 V Power Supply 6.
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CUTMASTER A40 6.06 TORCH REPLACEMENT PARTS SL100SV TORCH (WITH SOLENOID ON MOUNTING TUBE) Item No. Qty Description 1 1 Torch Head Assembly without leads (includes items 2, 3, and 14) 2 1 Large O-Ring 3 1 Small O-Ring 4 1 PIP Switch Kit 5 1 PIP Plunger and Return Spring Kit 6 Automated Leads Assemblies with ATC connectors 1 25 - foot / 7.6 m Leads Assembly with ATC connector 1 35 - foot / 10.6 m Leads Assembly with ATC connector 1 50 - foot / 15.
CUTMASTER A40 23 24 9 10 7 8 13 19 21 16 10 1 21 20 11 2 3 4 12 17 5 15 22 18 14 6 Art # A-07113 Manual 0-4978 PARTS LIST 6-5
CUTMASTER A40 6.
CUTMASTER A40 6.08 TORCH CONSUMABLE PARTS MANUAL (SL60)TORCH Tips: Shield Cup Body, 9-8237 DRAG TIP CUTTING 20A 30A 40A 60A 40A 9-8205 9-8206 9-8207 9-8252 DRAG SHIELD CUTTING Tip: CUTTING 40A 9-8208 STANDOFF CUTTING 50-60A DRAG SHIELD CUTTING Tips: CUTTING Start Cartridge 9-8213 50-55A 9-8209 60A 9-8210 STANDOFF CUTTING Electrode 9-8215 70-120A DRAG SHIELD CUTTING CUTTING 70A 80A 90/100A 120A Shield Cap, Deflector 9-8243 Shield Cup 9-8218 O-Ring No.
CUTMASTER A40 6.09 REPLACEMENT PARTS FOR HAND TORCH Item # Qty Description 1 1 Torch Handle Replacement Kit (includes items No. 2 & 3) 2 1 Trigger Assembly Replacement Kit 3 1 Handle Screw Kit (5 each, 6-32 x 1/2” cap screw, and wrench) 4 1 Torch Head Assembly Replacement Kit (includes items No.
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CUTMASTER A40 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: Close external disconnect switch. RESULT: Power to system. ACTION: ON / OFF switch to ON RESULT: AC indicator ON. GAS indicator ON when input pressure is adequate for power supply operation. Power circuit ready. RUN / Rapid Auto Restart / SET / LATCH switch to SET RESULT: Gas flows to set pressure.
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CUTMASTER A40 APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Model : Dat e of Mf r : Type of Power Supply (Note 1) 1/ 3 f1 S/N Made in USA Regulatory Standard Covering This Type of Power Supply f2 Output Current Type Duty Cycle Factor Output Range (Amperage/ Voltage) Plasma Cutting Symbol X U0 = Rated NoLoad Voltage Duty Cycle Data (Note 3) I U2 Conventional Load Voltage Rated Maximum Supply Current Input Power Symbol U1 I 1max 3Ø 1 1Ø 1 1Ø I 1eff 3Ø Input Power Specif
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CUTMASTER A40 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A.
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 Male Torch Leads Connector Torch Head Torch Leads Pin No.s 1 Black PIP Switch ATC Female Torch Receptacle Main PC Board Main PC Board Orange 2 2 White 5 5 Green 4 3 7 6 8 4 3 7 6 8 Solenoid Power Supply Socket No.
CUTMASTER A40 C.
CUTMASTER A40 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS 5 4 3 2 J3 1 2 3 T1 K1-K4 J12 D 1 /460 /230 1 2 3 4 5 4 PRI 4 A D PRI 3 C MTH2 MTH1 Q1 K1 INRUSH RESISTORS 2 B J1 3 PRI 1 PRI 2 +12VDC BIAS SUPPLY SW1 1 2 3 K5, K6 C1-C4* /INRUSH + D1 MTH3 W1 L1 * PRIMARY AC INPUT L2 L3 JUMPER GND L1 T1 L2 T2 L3 T3 L4 T4 MTH4 AC1 7 AC2 8 K1 K2 K5 K3 K6 K4 AC3 9 7A MTH6 MTH8 Q2 C *PRIMARY POWER CONNECTIONS: 3PH USE L1,L2,L3 & GND REMOVE JUMPER BETWEEN
CUTMASTER A40 1 CM82 / A60 ONLY TS1 1TORCH L1 PIP SWITCH 1 2 J11 SEC1 CHOKE1 SEC2 D +12VDC TORCH SWITCH TEMP CIRCUIT /OVERTEMP ATC CONNECTOR J1 1 2 3 4 5 6 7 8 NTC -V OUT 1 1 2 3 4 5 6 7 8 E64 - E35 + ELECTRODE1 D3 TIP1 Q5 AUTOMATION TORCH SOLENOID PILOT IGBT WORK1 WORK J9 /PIP 78 79 80 81 82 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY C 83 CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE +12VDC 1
CUTMASTER A40 APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS 5 4 PRI 1 PRI 2 D SW1 1 EMI *CHOKE UNITS * CEONLY EMI *FILTER 1 1 L2 2 2 L3 PRI 3 C Q1 K1 + C1-C4* /INRUSH D1 L1 GND D +12VDC 1 2 3 4 5 4 PRI 4 A MTH2 MTH1 J1 3 INRUSH RESISTORS 2 C B BIAS SUPPLY 3 3 4 4 MTH4 W1 L1 T1 L2 T2 L3 T3 L4 T4 MTH3 AC1 7 AC2 8 AC3 9 7A MTH8 MTH6 Q2 380/400/415V OR 600V 3 PH AC INPUT + C5-C8* PRIMARY POWER CONNECTIONS: USE L1, L2, L3 & GND MTH7 MTH5 PCB2 INPUT CA
CUTMASTER A40 3 2 1 TS1 T1 1TORCH L1 PIP SWITCH 1 2 J11 SEC1 CHOKE1 SEC2 D +12VDC TORCH SWITCH TEMP CIRCUIT /OVERTEMP ATC CONNECTOR J1 1 2 3 4 5 6 7 8 NTC -V OUT 1 E64 - E35 + ELECTRODE1 D3 TIP1 Q5 1 2 3 4 5 6 7 8 AUTOMATION TORCH SOLENOID PILOT IGBT WORK1 WORK J9 /PIP 78 79 80 81 82 1 2 3 4 5 6 7 /START 24VAC RETURN 24VAC SUPPLY C 83 CNC INTERFACE STANDARD ON A40 & A60 UNITS CNC INTERFACE OPTIONAL ON CM52 & CM82 UNITS J2 J10 1 2 3 4 5 6 7 8 OK-TO-MOVE +12VDC 1 2 3 4
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 mm2), single pair, un-shielded cable rated for 300V or greater. All work must be performed following applicable local and national codes. 1. Disconnect the power from the power supply. 2. Remove the screws that attach the power supply cover to the chassis. Remove the cover. 3.
CUTMASTER A40 Art # A-10288 Work1 (+) Polarity -V out (-) Polarity 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control .
CUTMASTER A40 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) July 15, 2008 AA Manual released. Jan 27, 2009 AB Corrected art sizing in section 3 to show missing information per ECOB1248. Apr. 14, 2009 AC Updated system specs and input wiring specs in section 2. May 28, 2009 AD Updated 400V/600V schematic in appendix per ECOB1399 and updated 230/460V schematic per ECOB1357. Oct. 20, 2009 AE Updated electrode part number per ECOB1494 by changing 9-8215 to 9-8232. Jan.
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THE AMERICAS Denton, TX USA U.S.
