60 208230V 400V 460V 600V CUTMASTER® A60 AUTOMATED PLASMA CUTTING SYSTEM Operating Manual Art # A-08952_AD Revision: AT Issue Date: February 13, 2014 Manual No.: 0-4981 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® A60 SL100 ™ SV Automated Torch Operating Manual Number 0-4981 Published by: Victor Technologies International, Inc.
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 4T.09 Machine and Automated Torch Operation.......................................................4T-1 Automation Torch Parts Selection...................................................................4T-2 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 A60 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 GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
CUTMASTER A60 • Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. • Ventilate all flammable or explosive vapors from the workplace. • Do not cut or weld on containers that may have held combustibles. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.
CUTMASTER A60 WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé. 15. ANSI Standard Z88.
CUTMASTER A60 • Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage. • Réparez ou remplacez toute pièce usée ou endommagée. • Prenez des soins particuliers lorsque la zone de travail est humide ou moite. • Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.
CUTMASTER A60 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 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.
CUTMASTER A60 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 A60 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 A60 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. Should any failure to conform to this warranty appear within the applicable period stated below, Victor Technologies, Inc.
CUTMASTER A60 SECTION 2 SYSTEM: INTRODUCTION 2.01 2.02 How To Use This Manual This Owner’s Manual applies to just specification or part numbers listed on page i. To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings. Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
CUTMASTER A60 2.04 Power Supply Specifications CutMaster A60 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), Three Phase, 60 Hz Input Power Cable Power Supply includes input cable.
CUTMASTER A60 2.05 Input Wiring Specifications CutMaster A60 Power Supply Input Cable Wiring Requirements 1 Phase 3 Phase Input voltage Freq Power Input Suggested Sizes Volts Hz kVA I max I eff Fuse (amps) Flexible Cord (Min. AWG) 208 60 16 75 48 100 6 230 60 17 72 46 100 6 460 60 20 44 28 50 10 208 60 16 40 26 50 8 230 50/60 16 39 25 50 10 380 50/60 11.8 17 11 20 12 400 50/60 11.8 17 11 20 12 460 60 17 21 14 25 12 600 60 9.
CUTMASTER A60 2.
CUTMASTER A60 SECTION 2 TORCH: INTRODUCTION 2. Machine Torch, Model The standard machine torch has a positioning tube with rack & pinch block assembly. 2T.01 Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the 1Torch Models SL60/Manual and SL100/Mechanized Plasma Cutting Torches.
CUTMASTER A60 F. Torch Ratings 2T.05 Introduction to Plasma Automated / Machine Torch Ratings A. Plasma Gas Flow Ambient Temperature 104° F 40° C Duty Cycle 100% @ 100 Amps @ 400 scfh Maximum Current 120 Amps Voltage (Vpeak) 500V Arc Striking Voltage 7kV Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece.
CUTMASTER A60 B. Gas Distribution 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. 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. C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip.
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CUTMASTER A60 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 A60 Most units are shipped from the factory with a 230 Volt 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 A60 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 A60 3.06 Gas Connections Connecting Gas Supply to Unit 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 A60 1. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly. NOTE NOTE Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator. Supply hose must be at least 1/4 inch (6 mm) I.D. For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions.
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CUTMASTER A60 SECTION 3 TORCH: INSTALLATION Check Air Quality To test the quality of air: 1. Put the ON / OFF tion. 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. switch in the ON (up) posi- 2. Put the Function Control switch in the SET position. 3.
CUTMASTER A60 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 & 3 3. Connect CNC to the power supply.
CUTMASTER A60 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. 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.
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CUTMASTER A60 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. 2. Function Control Function Control Knob, Used to select between the different operating modes. SET Used to purge the air through the unit and torch and leads and to adjust gas pressure.
CUTMASTER A60 4.02 Power ON Preparations for Operation Place the Power Supply ON / OFF switch to the ON (up) At the start of each operating session: position. AC indicator turns ON. Gas indicator turns ON if there is sufficient gas pressure for power supply operation and the cooling fans turn ON. WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
CUTMASTER A60 Typical Cutting Speeds STANDOFF Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to Sections "4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip" and following for greater details. CutMaster A60 Gas Pressure Settings Leads Length SL60 (Hand Torch) SL100 (Mechanized Torch) SL 100 SV (Automation Torch) Up to 25' (7.6 m) 75 psi 5.2 bar 75 psi 5.2 bar Each additional 25' (7.6 m) Add 5 psi 0.
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CUTMASTER A60 SECTION 4 TORCH: OPERATION For optimum smooth surface quality, the travel speed should be adjusted so that only the leading 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 for transfer. 4T.01 Machine and Automated Torch Operation Travel speed also affects the bevel angle of a cut.
CUTMASTER A60 1. If attached, remove the ohmic clip then unscrew and remove the shield cup assembly from the torch head. Wipe it clean or replace if damaged Change the torch parts for a different operation as follows: WARNING 2. Remove the Electrode by pulling it straight out of the Torch Head. Disconnect primary power at the source before assembling or disassembling torch parts, or torch and leads assemblies. NOTE The shield cup holds the tip and starter cartridge in place.
CUTMASTER A60 Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting. Dross - free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in the following figure: 4T.
CUTMASTER A60 2. Depending on the cutting operation, do one of the following: a. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start. b. For standoff cutting, hold the torch 1/8 - 3/8 in (3-9 mm) from the workpiece as shown below. Side Characteristics Of Cut To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle.
CUTMASTER A60 Shield Cup With Straight Edge The drag shield cup can be used with a non conductive straight edge to make straight cuts by hand. WARNING The straight edge must be non - conductive. 6. Cut as usual. Simply release the trigger assembly to stop cutting. 7. Follow normal recommended cutting practices as provided in the power supply operator's manual. Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3/16 inch (4.
CUTMASTER A60 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 be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and allows good control and movement. NOTE 7. Bring the torch within transfer distance to the work.
CUTMASTER A60 7. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti spatter compound will minimize the amount of scale which adheres to it. Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance: CAUTION Touching the torch tip or shield cup to the work surface will cause excessive parts wear.
CUTMASTER A60 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 A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec.
CUTMASTER A60 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) 1 101 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.
CUTMASTER A60 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 Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 18 0.050 110 0.19 60 0.20 0.00 0.
CUTMASTER A60 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) 1 112 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 A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 20 0.040 95 0.16 300 0.16 0.0 0.06 16 0.
CUTMASTER A60 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) 1.0 95 4.1 7620 4.1 0.0 1.5 2.0 104 4.1 3500 4.1 0.2 1.6 115 4.1 2350 4.6 0.3 1.7 4.0 4.8 (7.6m) 113 4.6 2170 4.6 0.4 1.7 5.0 5.2 (15.2m) 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.
CUTMASTER A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.060 118 0.19 290 0.19 0.00 0.
CUTMASTER A60 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) 1 115 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 5.9 (7.6m) 122 4.8 2145 4.8 0.30 2.0 6.2 (15.2m) 123 4.8 1635 4.8 0.40 2.2 125 4.
CUTMASTER A60 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 Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 119 0.19 350 0.20 0.00 0.
CUTMASTER A60 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) 1 124 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 A60 Aluminum 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 123 0.25 440 0.25 0.00 0.08 14 0.
CUTMASTER A60 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.
CUTMASTER A60 Mild Steel 80A 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 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.060 110 0.19 320 0.20 0.00 0.
CUTMASTER A60 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) 1 109 4.8 8915 5.1 0.00 1.5 2 111 4.8 7415 5.1 0.10 1.7 3 113 4.8 5915 5.1 0.10 1.8 4 110 4.8 4095 5.1 0.30 1.7 5 111 4.8 3325 5.1 0.30 1.8 114 4.8 2745 5.1 0.40 2.2 120 4.8 1775 5.1 0.50 2.3 125 4.8 1060 5.1 0.50 2.
CUTMASTER A60 Stainless Steel 80A 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 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 110 0.19 340 0.25 0.00 0.
CUTMASTER A60 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) 1 108 4.8 9020 6.4 0.00 1.5 2 111 4.8 8380 6.4 0.00 1.5 3 114 4.8 7730 6.4 0.10 1.5 4 115 4.8 5865 6.4 0.20 1.6 115 4.8 3410 6.4 0.20 1.8 117 4.8 2765 6.4 0.30 1.9 119 4.8 1815 6.4 0.40 2.0 10 120 4.8 1070 6.4 0.60 2.
CUTMASTER A60 Aluminum 80A 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 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 116 0.25 350 0.25 0.00 0.10 11 0.
CUTMASTER A60 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) 1 114 6.4 8890 6.4 0.00 2.4 2 117 6.4 8420 6.4 0.00 2.5 3 120 6.4 7170 6.4 0.10 2.5 4 122 6.4 5710 6.4 0.20 2.5 125 6.4 4315 6.4 0.20 2.5 129 6.4 3190 6.4 0.30 2.4 5 6 8 5.9 (7.6m) 6.2 (15.2m) 133 6.4 2070 6.4 0.40 2.
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CUTMASTER A60 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 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec.
CUTMASTER A60 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) 1 108 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 4 5 6 5.2 (7.6m) 5.5 (15.2m) 117 4.1 1256 4.1 0.4 1.7 8 121 4.1 853 4.1 0.5 1.7 10 124 4.
CUTMASTER A60 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 Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed 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 A60 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) 1 109 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 4 5 6 5.2 (7.6m) 5.5 (15.2m) 117 4.1 565 4.1 0.5 2.0 8 122 4.1 440 4.1 1.5 2.0 10 125 4.
CUTMASTER A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ 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.
CUTMASTER A60 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) 1.0 110 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 4.0 5.2 (7.6m) 126 4.8 2170 5.1 0.4 1.8 5.0 5.5 (15.2m) 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.
CUTMASTER A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (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 A60 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) 1 127 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 5 6 8 5.9 (7.6m) 6.2 (15.2m) 133 4.8 1425 5.1 0.40 2.
CUTMASTER A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 110 0.13 165 0.20 0.00 0.06 14 0.078 116 0.
CUTMASTER A60 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) 1 101 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 A60 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 Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 118 0.13 350 0.20 0.00 0.07 14 0.079 118 0.13 350 0.
CUTMASTER A60 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 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 A60 Mild Steel 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 16 0.060 115 0.13 280 0.20 0.00 0.06 11 0.120 112 0.13 190 0.
CUTMASTER A60 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 116 3.3 7895 5.1 0.00 1.6 2 114 3.3 6395 5.1 0.10 1.6 3 112 3.3 4895 5.1 0.10 1.5 4 115 4.8 4025 5.1 0.30 1.7 123 4.8 3300 5.1 0.30 2.0 126 4.8 2735 5.1 0.40 2.2 131 4.8 1745 5.1 0.50 2.5 10 134 4.8 1000 5.1 0.50 2.6 12 136 4.8 935 5.1 0.60 2.6 15 143 4.8 580 5.1 0.
CUTMASTER A60 Stainless Steel 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 16 0.063 114 0.125 340 0.2 0.00 0.06 11 0.125 115 0.
CUTMASTER A60 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 114 3.2 9410 5.1 0.00 1.5 2 114 3.2 8120 5.1 0.00 1.4 3 115 3.2 6830 5.1 0.10 1.4 4 116 3.2 5635 5.1 0.20 1.5 115 3.2 4010 5.1 0.20 1.8 117 3.2 2640 5.1 0.30 2.0 123 4.8 1630 6.4 0.40 2.1 10 128 4.8 1030 6.4 0.60 2.2 12 134 4.8 565 6.4 0.75 2.6 15 141 4.
CUTMASTER A60 Aluminum 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8211 9-8213 9-8277 9-8232 Material Thickness (GA) (in) inch Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.064 115 0.13 320 0.2 0.00 0.09 11 0.120 120 0.13 240 0.
CUTMASTER A60 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) 1 113 3.3 9020 5.1 0.00 2.4 2 116 3.3 7595 5.1 0.00 2.2 3 120 3.3 6165 5.1 0.10 2.0 4 121 3.3 5045 5.1 0.20 2.1 122 3.3 3955 5.1 0.20 2.2 124 3.3 2905 5.1 0.30 2.3 132 4.8 2010 5.1 0.40 2.3 10 140 4.8 1430 5.1 0.50 2.
CUTMASTER A60 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER A60 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 A60 SECTION 5 SYSTEM: SERVICE 5.
CUTMASTER A60 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 A60 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 A60 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 A60 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 A60 5.06 C. Filter Element Assembly Replacement Circuit Fault Isolation The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced. WARNING The following procedures should not be attempted by anyone who has not had proper training or authorized to do so. 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system. 2.
CUTMASTER A60 NOTE If replacing or cleaning just the filter element refer to the following illustration for disassembly. Optional Single-Stage Filter Element Replacement 5. Remove the Filter Element from the Housing and set Element aside to dry. 8. Install the new or cleaned assembly by reversing these procedures. 6. Wipe inside of housing clean, then insert the replacement Filter Element open side first. 9. Turn ON the air supply and check for leaks before reinstalling the cover. 7.
CUTMASTER A60 Optional Two-Stage Filter Replacement 6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above. 7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket. 8. Slowly apply air pressure to the assembly, checking for leaks. NOTE A small amount of air leakage from the bottom fitting is normal. This completes the parts replacement procedures.
CUTMASTER A60 SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE Refer to Previous "Section 5 System: Service" for common and fault indicator descriptions. Cleaning Torch Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch. Torch Head O-Ring WARNING Disconnect primary power to the system before disassembling the torch or torch leads.
CUTMASTER A60 4. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. 5T.02 Inspection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. Example of Tip Wear 5. Remove the starter cartridge. Check for excessive wear, plugged gas holes, or discoloration.
CUTMASTER A60 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 (w/Solenoid on Mounting Tube)" Section "6.07 Torch Consumable Parts Automation / Machine (SL100)Torch" Section "6.
CUTMASTER A60 6.
CUTMASTER A60 6.06 Torch Replacement Parts SL100SV Torch (w/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 A60 6-4 PARTS LIST Manual 0-4981
CUTMASTER A60 6.
CUTMASTER A60 6.
CUTMASTER A60 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 A60 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) Manual 0-4981 APPENDIX A-1
CUTMASTER A60 APPENDIX 2: DATA TAG INFORMATION A-2 APPENDIX Manual 0-4981
CUTMASTER A60 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Automation SL100SV Torch Pin - Out Diagram B. Machine SL100 Torch Pin - Out Diagram C.
CUTMASTER A60 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Automation (SL100SV) Torch Connection Diagram B.
CUTMASTER A60 C.
CUTMASTER A60 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS A-6 APPENDIX Manual 0-4981
CUTMASTER A60 Manual 0-4981 APPENDIX A-7
CUTMASTER A60 APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS A-8 APPENDIX Manual 0-4981
CUTMASTER A60 Manual 0-4981 APPENDIX A-9
CUTMASTER A60 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, unshielded 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 A60 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control .
CUTMASTER A60 APPENDIX 8: PUBLICATION HISTORY Cover Date Rev. Change(s) Dec. 20, 2007 AA Manual released. Apr. 15, 2008 AB Per ECOB752 updated firmware changes to pgs. 4-1 and 5-5. Per ECOB845 corrected drag cutting statement to ¼” pg. 4T-5. Per ECOB803 releasing 400 – 460V systems. May 7, 2008 AC Per ECOB890 updated system schematic. Per ECOB880 updated section 2 spec chart and input wiring chart for CSA approval.
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THE AMERICAS Denton, TX USA U.S.
