00 208230V 380400V 460V 600V CUTMASTER® A80 AUTOMATED PLASMA CUTTING SYSTEM Operating Manual Art # A-08954_AC Revision: AO Issue Date: December 3, 2013 Manual No.: 0-4985 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® A80 SL100 1Torch™ Operating Manual Number 0-4985 Published by: Victor Technologies International, Inc. 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
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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 4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded Tip......................................................................................................4T-32 PATENT INFORMATION................................................................................................................4T-51 SECTION 5 SYSTEM: SERVICE.......................................................................................................5-1 5.01 5.02 5.03 5.04 5.05 5.
CUTMASTER A80 SECTION 1: GENERAL INFORMATION 1.01 GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
CUTMASTER A80 * These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc. • 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.
CUTMASTER A80 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 1.05 ! 14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W.
CUTMASTER A80 • • Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée. AVERTISSEMENT: Ce produit contient des produits chimiques, notamment du plomb, reconnu par l'État de la Californie pour causer des malformations congénitales et d'autres dommages touchant le système reproductif. Se laver les mains après manipulation.
CUTMASTER A80 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 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.
CUTMASTER A80 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 A80 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 A80 1.08 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conaditions 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.
CUTMASTER A80 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 W A R N I N G , CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings.
CUTMASTER A80 2.04 Power Supply Specifications CutMaster A80 Power Supply Specifications Input Power 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 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 A80 2.05 Input Wiring Specifications CutMaster A80 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) Flexible Cord (Min. mm2) 208 60 20.6 99 76 100 4 Type W 25 Type W 230 60 21.9 95 74 100 4 Type W 25 Type W 460 60 27.6 60 46 60 6 15 208 60 17.7 49 38 60 6 15 230 60 17.9 45 36 60 6 15 380 50 18.
CUTMASTER A80 2.
CUTMASTER A80 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 SL100/Manual and SL100/Mechanized Plasma Cutting Torches.
CUTMASTER A80 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 80% @ 120 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.
CUTMASTER A80 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 A80 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 A80 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 A80 4. If the power cable being used is not the factory - supplied cable, use a three - conductor input power cable for the voltage desired and strip back the insulation on the individual wires. 5. Pass the cable being used through the access opening in the back panel of the power supply. Refer to Section 2 for power cable specifications. 5. Pass the cable being used through the access opening in the back panel of the power supply. Refer to Section 2 for power cable specifications.
CUTMASTER A80 Air Connection to Inlet Port Optional Single - Stage Filter Installation Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port. 2. Attach the Filter Assembly to the filter hose. 3. Connect the air line to the Filter. The illustration shows typical fittings as an example.
CUTMASTER A80 Installing Optional Two - Stage Air Filter Kit Using High Pressure Air Cylinders 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. When using high pressure air cylinders as the air supply: 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 1.
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CUTMASTER A80 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 tion. posi- 3.
CUTMASTER A80 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.
CUTMASTER A80 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 A80 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 A80 Cutting Operation STANDOFF CutMaster A80 Gas Pressure Settings Leads Length SL100 (Hand Torch) SL100 (Mechanized Torch) SL 100 SV (Automated Torch) Up to 50' (7.6 m) 75 psi 5.2 bar 75 psi 5.2 bar Each additional 25' (7.6 m) Add 5 psi 0.4 bar Add 5 psi 0.4 bar 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 A80 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 A80 NOTE Type of operation: The shield cup holds the tip and starter cartridge in place. Position the torch with the shield cup facing upward to keep these parts from falling out when the cup is removed. Drag cutting, standoff cutting or gouging Torch parts: Shield Cup, Cutting Tip, Electrode and Starter Cartridge 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 NOTE Refer to Section 4T.
CUTMASTER A80 Kerf Width 4T.04 Cut Quality The width of the cut (or the width of material removed during the cut). NOTE Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability. Top Spatter (Dross) 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.
CUTMASTER A80 NOTE Direction of Cut In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left. The tip should never come in contact with the workpiece except during drag cutting operations. 2. Depending on the cutting operation, do one of the following: a.
CUTMASTER A80 WARNING The straight edge must be non - conductive. Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3/16 inch (4.7 mm) solid metal with relatively smooth surface. 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. Drag Cutting With a Hand Torch Drag cutting works best on metal 1/4" (6 mm) thick or less.
CUTMASTER A80 NOTE The tip should never come in contact with the workpiece except during drag cutting operations. 2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete. 3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete. 7.
CUTMASTER A80 Lead Angle 4T.07 Gouging 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. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.
CUTMASTER A80 4T.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 101 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 4 110 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 1.8 120 3.6 435 5.1 2.0 1.8 5 6 12 4.8 (7.6m) 5.2 (15.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed 18 0.050 110 0.19 60 0.20 0.00 0.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 112 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 4.8 215 4 5 6 5.2 (7.6) 5.5 (15.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed 20 0.040 95 0.16 300 0.16 0.0 0.06 16 0.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1.0 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 Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 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.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height 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 A80 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 2.1 122 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 A80 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) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.063 119 0.19 350 0.20 0.00 0.
CUTMASTER A80 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 A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.064 123 0.25 440 0.25 0.00 0.08 14 0.
CUTMASTER A80 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 A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.060 110 0.19 320 0.20 0.00 0.06 11 0.
CUTMASTER A80 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 A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.063 110 0.19 340 0.25 0.00 0.
CUTMASTER A80 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 A80 Aluminum 80A Air Plasma / Air Shield Deflector Standard Shield Cup Maximum Life Shield Cup Tip 9-8243 9-8218 9-8237 9-8211 Material Thickness (GA) (in) inch Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8213 9-8232 9-8277 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 16 0.064 116 0.25 350 0.25 0.00 0.10 11 0.
CUTMASTER A80 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 2.5 5 6 5.9 (7.6m) 6.2 (15.2m) 133 6.4 2070 6.4 0.
CUTMASTER A80 Mild Steel 100A 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 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) 4T-26 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) (in) inch 1/4 0.250 110 0.18 85 0.20 0.10 0.
CUTMASTER A80 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) 6 110 4.6 2200 5.1 0.10 2.3 8 111 4.6 2030 5.1 0.10 2.3 112 4.6 1790 5.1 0.20 2.3 114 4.6 1310 5.1 0.40 2.5 117 4.6 870 5.1 0.60 2.7 20 120 4.6 490 5.0 1.20 3.0 25 123 4.6 390 Edge Start 3.0 30 127 4.6 250 Edge Start 3.
CUTMASTER A80 Stainless Steel 100A 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 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) 4T-28 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) (in) inch 1/4 0.250 102 0.16 100 0.18 0.
CUTMASTER A80 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) 6 102 4.1 2630 4.6 0.00 2.3 8 104 4.1 2080 4.6 0.10 2.4 106 4.1 1575 4.6 0.20 2.4 108 4.1 1255 4.6 0.30 2.4 119 4.6 685 5.7 2.00 2.7 20 129 4.8 360 Edge Start 3.1 25 135 4.8 260 Edge Start 3.2 10 12 15 5.2 (7.6m) 5.2 (15.
CUTMASTER A80 Aluminum 100A 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 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) 4T-30 (in) inch 1/4 0.250 3/8 0.375 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) 110 0.19 Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) 100 0.
CUTMASTER A80 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) 6 109 4.8 2630 5.1 0.00 2.3 8 117 4.8 2080 5.1 0.10 2.5 125 4.8 1575 5.1 0.20 2.7 127 4.8 1255 5.1 0.30 2.7 131 4.8 960 5.1 0.50 2.8 20 136 4.8 470 6.0 2.00 3.3 25 140 4.8 270 10 12 15 5.2 (7.6m) 5.2 (15.2m) Edge Start 3.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 108 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 (7.6) 5.5 (15.2) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 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 A80 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 PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed 18 0.050 110 0.16 60 4.1 0.0 0.06 16 0.063 108 0.16 50 4.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1 109 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) Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 8 122 4.1 440 4.1 1.5 2.0 10 125 4.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) Torch Working Initial Piercing Travel Speed Pierce Delay Height Height Kerf Width @ Rec. Speed 20 0.040 110 0.19 300 0.20 0.0 0.06 16 0.063 113 0.19 170 0.20 0.
CUTMASTER A80 Material Thickness Gas Pressure (Air) Arc Voltage Torch Working Height Travel Speed (mm) Bar (torch lead length) Volts (mm) (mm/min) (mm) (sec) (mm) 1.0 110 4.8 7660 5.1 0.0 1.6 2.0 116 4.8 3490 5.1 0.2 1.8 3.0 124 4.8 2350 5.1 0.3 1.8 Initial Piercing Pierce Delay Height Kerf Width @ Rec. Speed 4.0 5.2 (7.6) 126 4.8 2170 5.1 0.4 1.8 5.0 5.5 (15.2) 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 A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height 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 A80 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 A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height 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 A80 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 5 6 8 5.9 (7.6m) 6.2 (15.2m) 131 3.3 1100 5.1 0.40 2.
CUTMASTER A80 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 PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height 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 A80 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 A80 Mild Steel 80A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip 9-8239 9-8237 9-8211 Material Thickness (GA) (in) inch Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8213 9-8232 9-8277 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 0.060 115 0.13 280 0.20 0.00 0.06 11 0.120 112 0.13 190 0.
CUTMASTER A80 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) 1 116 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 5 6 8 5.9 (7.6m) 6.2 (15.2m) 131 4.8 1745 5.1 0.50 2.
CUTMASTER A80 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 Initial Piercing Height Pierce Delay Kerf Width @ Rec. Speed PSI (torch lead length) Volts (in) (ipm) (in) (sec) (in) 16 0.063 114 0.125 340 0.2 0.00 0.06 11 0.125 115 0.
CUTMASTER A80 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 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 5 6 8 5.9 (7.6m) 6.2 (15.2m) 123 4.8 1630 6.4 0.40 2.
CUTMASTER A80 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 A80 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 A80 Mild Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8233 9-8213 9-8277 9-8232 Material Thickness (GA) 4T-50 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) (in) inch 1/4 0.250 114 0.16 85 0.18 0.00 0.08 3/8 0.375 112 0.
CUTMASTER A80 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) 6 114 4.1 2210 4.6 0.00 2.0 8 113 4.1 1960 4.6 0.10 2.2 10 112 4.1 1665 4.6 0.20 2.3 12 114 4.1 1185 4.6 0.30 2.4 15 121 4.1 830 4.6 0.40 2.5 20 128 4.1 475 5.0 0.80 2.8 25 133 4.1 315 Edge Start 2.9 30 134 4.
CUTMASTER A80 Stainless Steel 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip 9-8239 9-8237 9-8212 Material Thickness (GA) 4T-52 Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8213 9-8232 9-8277 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) (in) inch 1/4 0.250 114 0.16 110 0.18 0.00 0.08 3/8 0.
CUTMASTER A80 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) 6 114 4.1 2900 4.6 0.00 2.0 8 115 4.1 2265 4.6 0.10 2.2 5.2 (7.6m) 116 4.1 1685 4.6 0.20 2.4 5.2 (15.2m) 118 4.1 1285 4.6 0.30 2.4 127 4.6 685 5.7 2.00 2.7 136 4.8 360 5.7 2.80 2.8 140 4.8 260 10 12 15 20 25 Edge Start 2.
CUTMASTER A80 Aluminum 100A Air Plasma / Air Shield Shield Cap Maximum Life Shield Cup Tip Starter Cartridge Heavy Duty Starter Cartridge Electrode 9-8239 9-8237 9-8212 9-8213 9-8277 9-8232 Material Thickness (GA) 4T-54 Gas Pressure (Air) Arc Voltage PSI (torch lead length) Volts (in) (ipm) Torch Working Initial Piercing Travel Speed Height Height Pierce Delay Kerf Width @ Rec. Speed (in) (sec) (in) (in) inch 1/4 0.250 121 0.18 110 0.19 0.00 0.10 3/8 0.375 129 0.
CUTMASTER A80 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) 6 120 4.6 2920 4.8 0.00 2.5 8 125 4.6 2135 4.8 0.10 2.5 5.2 (7.6m) 130 4.6 1470 4.8 0.20 2.6 5.2 (15.2m) 134 4.6 1230 4.8 0.30 2.7 134 4.6 905 4.8 0.60 2.9 139 4.6 595 6.0 2.00 3.0 143 4.6 395 Edge Start 10 12 15 20 25 3.
CUTMASTER A80 PATENT INFORMATION Plasma Cutting Torch Patents The following parts are covered under U.S.
CUTMASTER A80 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 A80 SECTION 5 SYSTEM: SERVICE 5.
CUTMASTER A80 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 A80 5.04 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 76 psi indicators are ON indicating the version would be 2.3.
CUTMASTER A80 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 A80 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 A80 5.06 C. Filter Element Assembly Replacement Power Supply Basic Parts Replacement The Filter Element Assembly is in the rear panel. For better system performance, the filter element should be checked per the Maintenance Schedule (Subsection 5.02), and either cleaned or replaced. WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. 1. Remove power from the power supply; turn OFF the gas supply and bleed down the system.
CUTMASTER A80 5. Remove the fitting from the filter element assembly by inserting a 6 mm hex wrench into the internal hex fitting and turning it counter clock-wise (left). Numbers 4 and 5 in the previous illustration. Optional Single-Stage Filter Element Replacement 6. Disconnect the input line from the filter element assembly. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused.
CUTMASTER A80 Optional Two-Stage Filter Element Replacement 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. 1. Shut OFF primary input power. 2. Shut OFF air supply and bleed down system.
CUTMASTER A80 SECTION 5 TORCH: SERVICE 5T.01 General Maintenance NOTE Refer to Previous "Section 5 System" 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 A80 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 A80 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)" Section "6.
CUTMASTER A80 6.04 Replacement Power Supply Parts Qty Description 1 Regulator 1 Filter Assembly Replacement Element 1 Input Power Cord for 208 / 230 V Power Supply 1 Input Power Cord for 400 V Power Supply 6.
CUTMASTER A80 This Page Intentionally Blank Manual 0-4985 PARTS LIST 6-3
CUTMASTER A80 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 A80 Manual 0-4985 PARTS LIST 6-5
CUTMASTER A80 6.
CUTMASTER A80 6.08 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 A80 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) Manual 0-4985 APPENDIX A-1
CUTMASTER A80 APPENDIX 2: DATA TAG INFORMATION A-2 APPENDIX Manual 0-4985
CUTMASTER A80 APPENDIX 3: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram B.
CUTMASTER A80 APPENDIX 4: TORCH CONNECTION DIAGRAMS A. Hand Torch Connection Diagram B.
CUTMASTER A80 This Page Intentionally Blank Manual 0-4985 APPENDIX A-5
CUTMASTER A80 APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS A-6 APPENDIX Manual 0-4985
CUTMASTER A80 Manual 0-4985 APPENDIX A-7
CUTMASTER A80 APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS A-8 APPENDIX Manual 0-4985
CUTMASTER A80 Manual 0-4985 APPENDIX A-9
CUTMASTER A80 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 A80 5. Tighten the strain relief. 6. Replace the cover. 7. Connect the cable to negative and positive of Torch Height Control.
CUTMASTER A80 APPENDIX 8: PUBLICATION HISTORY Cover Date June 30, 2008 Rev. AA Change(s) Manual released. Sept. 19, 2008 AB Added CE information per ECOB. Jan. 27, 2009 AC Updated art in section 3 to show all the information for the two stage filter per ECOB1248. Updated power supply and input wiring specs per ECOB1197. Apr.
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THE AMERICAS Denton, TX USA U.S.
