Thermal Dynamics cutmaster A60 Service Manual Download | Manualshive

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Congratulations on your new 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.thermal-dynamics.com.

This Service Manual has been designed to instruct you on the correct
use and operation of your Thermal Dynamics product. Your satisfac-
tion with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially
the Safety Precautions. They will help you to avoid potential hazards
that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation

Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time. We

pride ourselves on technical innovation, competitive prices, excellent

delivery, superior customer service and technical support, together

with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced

products to achieve a safer working environment within the welding

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Summary of Contents for cutmaster A60

Page 1: ...Art A 08953_AB 60 Duty Cycle 60 600 v 400 460 v v Automated PLASMA CUTTING SYSTEM A60 CUTMASTER Rev AQ Date December 7 2012 Manual 0 4982 Operating Features Service Manual...

Page 2: ...please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY Th...

Page 3: ...yne Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liabi...

Page 4: ...This Page Intentionally Blank...

Page 5: ...upply Specifications 2 2 2 05 Input Wiring Specifications 2 3 2 06 Power Supply Features 2 4 SECTION 2 TORCH INTRODUCTION 2T 1 2T 01 Scope of Manual 2T 1 2T 02 General Description 2T 1 2T 03 Specifica...

Page 6: ...Fault Isolation 5 6 5 07 Main Input and Internal Power Problems 5 9 5 08 Pilot Arc Problems 5 13 5 09 Main Arc and Controls Problems 5 14 5 10 CNC Interface Problems 5 15 5 11 Test Procedures 5 15 SEC...

Page 7: ...ternal Parts Replacement 7 4 7 07 Rear Panel Parts Replacement 7 5 7 08 Right Side Internal Parts Replacement 7 7 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 DATA TAG INFORMATION A 2...

Page 8: ...TABLE OF CONTENTS...

Page 9: ...ses You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Sil...

Page 10: ...e following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washin...

Page 11: ...ne de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les...

Page 12: ...e ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v t...

Page 13: ...s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POU...

Page 14: ...irements Among them are UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of electrical shock Power Supplies bearin...

Page 15: ...1 Year This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups O rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unautho...

Page 16: ...CUTMASTER A60 GENERAL INFORMATION 16 Manual 0 4982 This Page Intentionally Blank...

Page 17: ...identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynami...

Page 18: ...60 Power Supply Duty Cycle Ambient Temperature Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C IEC Rating IEC Rating IEC Rating All Units Duty Cycle 40 60 100 Current 80 Amps 65 Amps 50 Amps DC V...

Page 19: ...72 46 100 6 460 60 20 44 28 50 10 3 Phase 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 6 16 10 20 12 Line Voltages...

Page 20: ...al 0 4982 2 06 Power Supply Features Art A 08306 Mounting Rails Torch Leads Receptacle Control Panel Work Cable and Clamp Input Power Cord Automation Interface Cable Port Gas Inlet Port Filter Assembl...

Page 21: ...s both the plasma and second ary gas The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 2T 05 Introductio...

Page 22: ...perating pressure varies with torch model op erating amperage and torch leads length Refer to gas pressure settings charts for each model H Direct Contact Hazard For standoff tip the recommended stand...

Page 23: ...tarter 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 This pilot arc crea...

Page 24: ...CUTMASTER A60 INTRODUCTION 2T 4 Manual 0 4982 This Page Intentionally Blank...

Page 25: ...mounting the power supply Choose one that allows for free movement of torch leads complies with ventilation per section 2 04 and provides a safe firm surface where the unit can be secured 2 Place the...

Page 26: ...e until you feel the threads line up then begin to turn the screw clockwise to tighten Do not over tighten C Input Power Selection Set the Input Voltage Selection Switch at the rear of the unit based...

Page 27: ...o Ground Remaining wires to L1 and L2 input It does not matter what order these wires are attached 7 With a little slack in the wires tighten the through hole protector to secure the power cable 8 Rei...

Page 28: ...r 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 Do not use Te...

Page 29: ...manufacturer s instructions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch Installing Optional Two Stage Air Filte...

Page 30: ...dust which may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm...

Page 31: ...k ing nut clockwise until it clicks DO NOT use the locking nut to pull the connection together Do not use tools to secure the connection 1 2 Art A 07885 Connecting the Torch to the Power Supply 3 The...

Page 32: ...h leads The Automation and Machine torch include a positioning tube with rack and pinch block assem bly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to...

Page 33: ...the power supply Up is ON down is OFF 4 Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock 5 AC Indica...

Page 34: ...heck connections and turn air supply ON Connect Work Cable 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 wor...

Page 35: ...aves the work piece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded metal or...

Page 36: ...CUTMASTER A60 OPERATION 4 4 Manual 0 4982 This Page Intentionally Blank...

Page 37: ...ould 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...

Page 38: ...1 If attached remove the ohmic clip then unscrew and remove the shield cup assem bly from the torch head Wipe it clean or replace if damaged 2 Remove the Electrode by pulling it straight out of the To...

Page 39: ...04Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff align ment with the workpiece cutting speed gas pressures and operator ability Cut quality requirements...

Page 40: ...e square cut Edge Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touch ing the edge of the workpiece at the point where the cut is to start W...

Page 41: ...ld the torch perpen dicular 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...

Page 42: ...cup functions best when cutting 3 16 inch 4 7 mm solid metal with relatively smooth surface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm thick or less NOTE For best parts p...

Page 43: ...te 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 per pendicular to the workpiece after the pierce is complete 4 Hold...

Page 44: ...travel speed mode of operation hand or machine torch and the amount of material to be removed Lead Angle The angle between the torch and workpiece depends on the output current setting and torch trave...

Page 45: ...CUTMASTER A60 Manual 0 4982 4T 9 OPERATION This Page Intentionally Blank...

Page 46: ...aterial Thickness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0...

Page 47: ...h Rec Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 4 8 7 6m 5 2 15 2m 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 5 112 3 6...

Page 48: ...tage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 18 0 050 75 25 80 50 110 0 19 60 0 20 0 00 0 07...

Page 49: ...torch lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 112 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 4 109 4 8 845 5 1 0 3 1 8 5 111 4 8 715 5 1 0 4 1 8 6 118...

Page 50: ...essure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 040 70 25 75 50 95 0 16...

Page 51: ...ar torch lead length Volts mm mm min mm sec mm 1 0 4 8 7 6m 5 2 15 2m 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 4 0 113 4 6 2170 4 6 0 4 1 7 5 0 118 4 6 1740 4...

Page 52: ...ial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 118 0 19 290 0 19 0 00 0 08 14 0 075 120 0 19 285 0 19 0 10 0 08 11 0...

Page 53: ...7 6m 6 2 15 2m 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 6 122 4 8 2145 4 8 0 30 2 0 8 123 4 8 1635 4 8 0...

Page 54: ...ght Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 119 0 19 350 0 20 0 00 0 05 14 0 078 116 0 19 30...

Page 55: ...sec mm 1 5 9 7 6m 6 2 15 2m 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 5 122 4 8 2195 5 1 0 20 2 1 6 123 4 8 1790 5 1 0 30 2 2 8 12...

Page 56: ...ch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 123 0 25 440 0 25 0 00 0 08 14 0 0...

Page 57: ...sec mm 1 5 9 7 6m 6 2 15 2m 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 5 132 6 4 4010 6 4 0 20 2 4 6 132 6 4 2640 6 4 0 30 2 4 8 13...

Page 58: ...ial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 110 0 19 320 0 20 0 00 0 06 11 0 120 113 0 19 230 0 20 0 10 0 07 10 0...

Page 59: ...7 6m 6 2 15 2m 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 6 114 4 8 2745 5 1 0 40 2 2 8 120 4 8 1775 5 1...

Page 60: ...Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 110 0 19 340 0 25 0 00 0 06 11...

Page 61: ...sec mm 1 5 9 7 6m 6 2 15 2m 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 5 115 4 8 3410 6 4 0 20 1 8 6 117 4 8 2765 6 4 0 30 1 9 8 119...

Page 62: ...ch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 116 0 25 350 0 25 0 00 0 10 11 0 1...

Page 63: ...m sec mm 1 5 9 7 6m 6 2 15 2m 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 5 125 6 4 4315 6 4 0 20 2 5 6 129 6 4 3190 6 4 0 30 2 4 8 13...

Page 64: ...kness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 036 75 25 80...

Page 65: ...th Rec Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 108 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 4 114 4 1 1651 4 1 0 2 1 7 5 115 4 1 1...

Page 66: ...Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 18 0 050 75 25 80 50 110 0 16 60 4 1 0 0 0 06 16 0...

Page 67: ...idth Rec Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 109 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 4 116 4 1 845 4 1 0 3 1 8 5 115 4 1 7...

Page 68: ...c Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 040 75 25 80 50 110 0 19 300 0 20 0 0...

Page 69: ...rf Width Rec Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 0 5 2 7 6 5 5 15 2 110 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 4 0 126 4 8 2170 5 1 0 4 1...

Page 70: ...Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 128 0 19 250 0 20 0 00 0 09 14 0 075 129 0 19 237 0 20 0 10 0 09 11 0 120 126 0 19...

Page 71: ...7 6m 6 2 15 2m 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 5 132 4 8 2794 5 1 0 20 2 2 6 134 4 8 2230 5 1 0 30 2 1 8 133 4 8 1425 5 1 0...

Page 72: ...eed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 110 0 13 165 0 20 0 00 0 06 14 0 078 116 0 13 155 0 20 0 10 0...

Page 73: ...m sec mm 1 5 9 7 6m 6 2 15 2m 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 5 125 3 3 1850 5 1 0 20 2 1 6 127 3 3 1605 5 1 0 30 2 1 8 13...

Page 74: ...ight Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 118 0 13 350 0 20 0 00 0 07 14 0 079 118 0 13 3...

Page 75: ...m sec mm 1 5 9 7 6m 6 2 15 2m 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 5 126 6 4 3335 6 4 0 20 2 0 6 130 6 4 2370 6 4 0 30 2 0 8 134...

Page 76: ...ght Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 115 0 13 280 0 20 0 00 0 06 11 0 120 112 0 13 190 0 20 0 10 0 06 10 0 135 110 0 13 17...

Page 77: ...7 6m 6 2 15 2m 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 5 123 4 8 3300 5 1 0 30 2 0 6 126 4 8 2735 5 1 0 40 2 2 8 131 4 8 1745 5 1...

Page 78: ...g Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 114 0 125 340 0 2 0 00 0 06 11 0 125 115 0...

Page 79: ...sec mm 1 5 9 7 6m 6 2 15 2m 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 5 115 3 2 4010 5 1 0 20 1 8 6 117 3 2 2640 5 1 0 30 2 0 8 123...

Page 80: ...ltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 115 0 13 320 0 2 0 00 0 0...

Page 81: ...m sec mm 1 5 9 7 6m 6 2 15 2m 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 5 122 3 3 3955 5 1 0 20 2 2 6 124 3 3 2905 5 1 0 30 2 3 8 13...

Page 82: ...Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8231 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip U...

Page 83: ...eld Cap US Pat No s 6914211 D505309 Other Pat s Pending 9 8245 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132...

Page 84: ...CUTMASTER A60 OPERATION 4T 48 Manual 0 4982 This Page Intentionally Blank...

Page 85: ...ck of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of pow...

Page 86: ...low air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 5 03 Common Faults Prob...

Page 87: ...voltage is outside the operating limits of the power supply as selected by the setting of INPUT VOLTAGE SELECTION SWITCH at the rear of the unit Low is 208 230 VAC and high is 460 VAC S LO HI Art A 0...

Page 88: ...components in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacement GAS indicator OFF FAULT and MIN pressure indicato...

Page 89: ...3 Worn or faulty torch parts 4 Shorted Torch 5 Temporary Short indicated by 5 blinks per second 6 Power Supply Failure Standard rate of blinking 1 Remove shield cup from torch check upper O Ring posi...

Page 90: ...st 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 C Pre Power Up Test...

Page 91: ...bar 70 psi 4 8 bar Each additional 25 7 6 m Add 5 psi 0 4 bar Add 5 psi 0 4 bar DRAG CutMaster A 60 Gas Pressure Settings Leads Length SL60 Hand Torch SL100 Mechanized Torch Up to 25 7 6 m 80 psi 5 5...

Page 92: ...ID AUTO RESTART mode 9 Close torch switch Pendant switch or activate CNC Start to establish a pilot arc Bring torch to within 1 8 3 8 of the work piece to establish main cutting arc 10 While cutting k...

Page 93: ...alled incorrectly a Check wiring of primary power cable to the contactor See illustration below 2 W1 jumpers installed incorrectly a Check jumper installation for correct phase being used Art A 07984_...

Page 94: ...fi cations If using a generator connect unit to a wall receptacle to see if problem is corrected 4 Defective Main PCB a Measure voltage on Main PCB between test point GND1 to J2 22 460 VAC input appro...

Page 95: ...e the shield cup tip start cartridge and electrode Check the lower end unit of the start cartridge for free movement Replace the cartridge if the lower end unit does not move freely Art A 08064_AC Spr...

Page 96: ...DC If voltage is present replace Main PCB 3 Defective Main PCB a Replace Main PCB N AC LED ON TEMP LED OFF GAS LED ON Gas does not flow in SET mode using a machine torch with remote solenoid Disconnec...

Page 97: ...ace Main PCB if voltage is present B SHORTED TORCH FAULT After torch switch is closed gas flows for two 2 seconds then momentarily shuts OFF then back on FAULT INDICATOR flashes and 85 PSI LED flashes...

Page 98: ...in PCB a Replace Main PCB F INTERNAL ERROR FAULT INDICATOR AND 90 PSI INDICATOR FLASHING 1 There has been a microprocessor problem a Turn ON OFF SWITCH to OFF position and then turn to ON position to...

Page 99: ...should be open no continuity L4 L3 L2 L1 T4 T3 T2 T1 Actuator Arm Cover Screws Art A 08157_AB Input Side CutMaster 52 82 W1 contactor wired for 1PH Main Contactor Jumpers Actuator Button 2 Retest con...

Page 100: ...rd Bias PRI 4 D MTH 6 Forward Bias PRI 4 D MTH 5 Reverse Bias MTH 6 PRI 4 D Reverse Bias MTH 5 PRI 4 D Forward Bias 3 If the test reveals a failed component replace Main PCB and perform main contactor...

Page 101: ...TOR PCB SIGNALS Signal Source Destination J1 1 Capacitor bank A J1 5 Capacitor bank A J2 1 Capacitor Bank B J2 5 Capacitor Bank B J3 1 12 VDC M C J3 2 460 Active low for 460VAC input M C J3 3 230 Acti...

Page 102: ...TIP VOLTS Active high when tip is installed M L J1 3 TIP_SEN Approx 100VDC while cutting with tip not in M L contact w work piece Active low when tip contact work during cut Drag Mode J1 4 460V_IN Act...

Page 103: ...17 PIP Active low PARTS IN PLACE satisfied M L J1 18 AC_ON Pulse signal M L J1 19 CSR Active high during main transfer M L J1 20 TORCH_SOL_DETECTED Active low for torch with remote solenoid M L J1 21...

Page 104: ...5 80 PSI X 4 Tip Missing D6 75 PSI X 3 Start Signal active during power up D7 70 PSI X 2 Parts In Place Fault PIP D8 65 PSI X 1 Input Power Fault D9 MIN PRESSURE X 0 Low Pressure D10 AC 1 X D11 OVERTE...

Page 105: ...CUTMASTER A60 Manual 0 4982 5 21 SERVICE This Page Intentionally Blank...

Page 106: ...J10 J9 J8 J7 J6 J5 D78 J14 D59 GND2 48V1 CHOKE1 SEC2 SEC1 TIP1 PRI_3 ELECTRODE1 V_OUT1 J4 J3 J2 TP8 TP7 J13 J12 TP2 TP1 J1 TP3 I_DMD1 GND1 12V1 12V2 48V2 TP6 PRI_2 TP5 AC3 AC1 AC2 WORK_1 PRI_1 PRI_4 T...

Page 107: ...SWITCH Start J9 4 Common J9 5 Torch solenoid 24VAC supply J9 6 Not Used J9 7 Torch solenoid 24VAC return J10 1 OK TO MOVE J10 2 Not used J10 3 OK TO MOVE J10 4 Not used J10 5 Common J10 6 Common J10...

Page 108: ...CUTMASTER A60 SERVICE 5 24 Manual 0 4982 This Page Intentionally Blank...

Page 109: ...ch and blowing it through with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head andATC Male Connec tor requires lubrication on a sched...

Page 110: ...e may be an O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Remove the tip Check for excessive wear in...

Page 111: ...m numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will...

Page 112: ...s 1 Bracket Filter Mounting not shown 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi...

Page 113: ...CUTMASTER A60 Manual 0 4982 6 3 PARTS LIST Intentionally Blank...

Page 114: ...al Replacement Parts Item Qty Description Catalog 1 1 Cover with labels 9 0128 2 1 Base Enclosure 9 0118 3 1 Power Supply Mounting Bracket 9 9386 4 1 Front Panel 9 0127 5 1 Rear Panel 9 0101 3 2 4 5 1...

Page 115: ...l Replacement Parts Item Qty Description Ref Catalog 1 1 Output Current Control and Function Control Knobs 9 8527 2 1 Toggle On Off Switch SW1 9 0109 3 1 Work Cable with Clamp 20 Ft 6 1 m 9 0184 Art A...

Page 116: ...put L1 9 0105 Not Shown 1 Power Cable Strain Relief for all units 9 0111 1 Hi Lo voltage selection switch 9 0110 NOTE 9 0107 Logic PCB If the serial number of the power supply is prior to 05078755 the...

Page 117: ...CB Input Capacitors 600V Only 9 0163 8 1 Filter Auto Drain 9 0116 Not Shown 1 CNC Harness 9 9385 NOTE 9 0115 regulator If the serial number of the power supply is prior to 05078755 then kit number 9 0...

Page 118: ...4 3060 7 1 Rack 9 9448 8 1 Mounting Tube 9 9445 9 1 End Cap Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 7 2896 13 1 Pinion Assem...

Page 119: ...CUTMASTER A60 Manual 0 4982 6 9 PARTS LIST Art A 07113 6 1 4 2 3 5 8 10 12 11 7 10 22 19 15 14 16 17 18 20 21 21 13 9 24 23...

Page 120: ...UGING Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 82...

Page 121: ...CUTMASTER A60 Manual 0 4982 6 11 PARTS LIST Intentionally Blank...

Page 122: ...dy 9 8237 70 120A 50 60A 40A Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Tip Tips Tips Tips DRAG TIP CUTTING 40 120A GOUGING CUTTING CUTTING CUTTING Art A 08065_AE DRAG SHIELD...

Page 123: ...Kit includes items No 5 6 9 8219 5 1 Large O Ring 8 3487 6 1 Small O Ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 SL60 20 foot Leads Assembly with ATC connector 4 7...

Page 124: ...CUTMASTER A60 PARTS LIST 6 14 Manual 0 4982 Intentionally Blank...

Page 125: ...wrap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil...

Page 126: ...the screws securing the tube handles to the base of the unit NOTE Some of the earliest manufactured units have Tube Handles tha are joined together under the base of the unit Later versions are not jo...

Page 127: ...Art A 08150 3 Pull the hose from the fitting 4 Replace the hose by pushing the hose back into the fitting until it fully seats Check it by pulling on the hose If done correctly it will not pull out 5...

Page 128: ...T20 Torx Driver 1 Remove the Cover per subsection 7 04 A 2 Disconnect the work cable from the WORK1 terminal on the Main PCB 3 Squeeze the top and bottom of the Work Cable Strain Relief and remove fr...

Page 129: ...rews on the Input Power Cable strain relief 10 Disengage the Rear panel from the base per sec tion 7 04 D 11 Guide the rear panel back six 6 inches away from the base 12 Guide the Center Chassis towar...

Page 130: ...y and check for leaks before reinstalling the cover B Voltage Selection Switch Replacement Tools required T20 Torx Driver 9 16 wrench 1 Remove the Cover per subsection 7 04 A 2 Disconnect J3 from the...

Page 131: ...eattach gas supply 9 Reinstall the power supply cover NOTE If unit leaks between housing and cover inspect the O ring for cuts or other damage E Optional Two Stage Filter Element Replacement The Two S...

Page 132: ...n and orientation of each wire and connector 6 Remove the four 4 mounting screws securing the PCB to the center chassis 7 Carefully guide the PCB assembly up and out of the unit 8 Install the replacem...

Page 133: ...RESULT Gas flows to set pressure ACTION RUN Rapid Auto Restart SET LATCH switch to RUN for most applications or to Rapid Auto Restart for gouging trimming or expanded metal applications or to LATCH i...

Page 134: ...acturer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 032...

Page 135: ...3 4 5 6 7 8 3 Open 2 Orange PIP 1 Black PIP 4 Open 2 PIP Circuit 1 PIP Circuit 3 Not Used 4 Not Used 6 Open Art A 07114 B Machine SL100 Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male...

Page 136: ...6 7 8 5 6 7 8 1 2 3 4 ATC Female Receptacle Front View Pilot Pilot 6 Open 7 Open 8 Open 5 Open Negative Plasma 6 Open 7 Open 5 Open 2 PIP 3 Switch 4 Switch 1 PIP 4 Green Switch 2 Orange PIP 3 White Sw...

Page 137: ...Orange Green Main PC Board Solenoid Torch Leads Torch Head Not Connected Not Connected Main PC Board Main PC Board B Machine SL100 Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine T...

Page 138: ...th ATC Connector Power Supply with ATC Receptacle Pilot Negative Plasma Power Supply PIP Switch Male ATC Leads Connector ATC Female Receptacle Pilot Negative Plasma Black Orange Torch Leads Torch Head...

Page 139: ...CUTMASTER A60 Manual 0 4982 A 7 APPENDIX Intentionally Blank...

Page 140: ...C3 C5 not installed PCB2 SOLENOID Q1 PRIMARY AC INPUT PCB1 40 PIN RIBBON CABLE SIGNALS 460_IN LATCH SET RUN RAR 40 CIRCUIT RIBBON CABLE MAX 90 85 80 75 70 65 MIN 460 230 J2 7 JUMPER D1 L1 L2 L3 GND D...

Page 141: ...SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC 42X1298 Monday March 30 2009 1 1 16052 Swingley...

Page 142: ...C INPUT PCB1 40 PIN RIBBON CABLE SIGNALS LATCH SET RUN RAR 40 CIRCUIT RIBBON CABLE MAX 90 85 80 75 70 65 MIN J2 7 D1 L1 L2 L3 GND D C AIR INLET FILTER REGULATOR SOLENOID VALVE TP1 TP2 TP3 TP4 TP5 TP6...

Page 143: ...or Distribution without Written Consent NOTE UNLESS OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Si...

Page 144: ...d 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 Route the cable through the customer supplied str...

Page 145: ...CUTMASTER A60 Manual 0 4982 A 13 APPENDIX V out Polarity Work1 Polarity Art A 10288 5 Tighten the strain relief 6 Replace the cover 7 Connect the cable to negative and positive of Torch Height Control...

Page 146: ...r per ECOB1248 Apr 24 2009 AG Added 600V system information to sections 2 6 and Appendix per ECOB1346 May 29 2009 AH Updated 400V 600V schematic in appendix per ECOB1399 and updated 230 460V schematic...

Page 147: ...This Page Intentionally Blank...

Page 148: ...ica Ph 1 954 727 8371 Fax 1 954 727 8376 Oakville Ontario Canada Canada Customer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 2...

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