Thermal Dynamics A80 CUTMASTER User manual

Thermal-Dynamics.com
100 208-
230V 460V
Art # A-08954_AD
600V
380-
400V
®
Operating
Manual
Revision: AS Issue Date: 10/03/2020 Manual No.: 0-4985
A80
AUTOMATED PLASMA CUTTING SYSTEM

WE APPRECIATE YOUR BUSINESS!
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 lo-
cate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at
www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the correct use and operation of
your Thermal Dynamics product. Your satisfaction with this product and its safe operation is
our ultimate concern. 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
Thermal Dynamics Corporation.
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 industry.
®

!!
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
judgment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
A80
SL100 1Torch™
Operating Manual Number 0-4985
Published by:
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207
Phone: [phone], FAX [phone]
www.thermal-dynamics.com
Copyright 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2017, 2018 by
Thermal Dynamics 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 liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error results
from negligence, accident, or any other cause.
For Printing Material Specification refer to document 47x1909
Original Publication Date: June 30, 2008
Revision Date: March 10, 2020
Record the following information for Warranty purposes:
WherePurchased:_______________________________ __________________
PurchaseDate:__________________________________ _________________
Power Supply Serial #:___________________________ __________________
Torch Serial #:___________________________________ _________________
i

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding and cutting equipment,
we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install,
operate, or maintain this equipment. Do NOT attempt to install or operate this equip-
ment until you have read and fully understand these instructions. If you do not fully
understand these instructions, contact your supplier for further information. Be sure
to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual
and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance
with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly
maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contami-
nated should be replaced immediately. Should such repair or replacement become necessary, the manu-
facturer recommends that a telephone or written request for service advice be made to the Authorized
Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the
manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which re-
sults from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than
the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AND OTHERS!

ASSUREZ-VOUS QUE CE DOCUMENT D’INFORMATION EST DISTRIBUÉ À L’OPÉRATEUR.
DES COPIES SUPPLÉMENTAIRES SONT DISPONIBLES CHEZ VOTRE FOURNISSEUR.
MISE EN GARDE
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement. Si
vous n’avez pas une connaissance approfondie des principes de fonctionnement et
des règles de sécurité applicables au soudage à l’arc et à l’équipement de coupage,
nous vous suggérons de lire notre brochure « Précautions et pratiques de sécurité
pour le soudage à l’arc, le coupage et le gougeage », Formulaire 52-529. Ne permettez
PAS aux personnes non qualiées d’installer, d’utiliser ou d’e󰀨ectuer des opérations
de maintenance sur cet équipement cet équipement. Ne tentez PAS d’installer ou
d’utiliser cet équipement avant d’avoir lu et bien compris ces instructions. Si vous ne
comprenez pas bien les instructions, renseignez-vous auprès de votre fournisseur.
Assurez-vous de lire les Règles de Sécurité avant d’installer ou d’utiliser cet
équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement fonctionnera conformément à la description contenue dans ce manuel, les étiquettes
d’accompagnement et/ou les feuillets d’information à condition d’être installé, utilisé, entretenu et réparé selon
les instructions fournies. L’équipement doit être contrôlé de manière périodique. Ne jamais utiliser un équi-
pement qui ne fonctionne correctement bien ou n’est pas bien entretenu. Les pièces qui sont brisées, usées,
déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un
remplacement est nécessaire, e fabricant recommande de faire une demande de conseil de service écrite ou
par téléphone auprès du distributeur agréé où l’équipement a été acheté.
Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite du fabricant.
L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant de toute utilisation, mainte-
nance, réparation incorrectes, de dommages ou encore de modication apportées par une personne autre que
le fabricant ou un centre de service désigné par ce dernier.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’UTILISER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

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EU DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EU, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING POWER SUPPLY
Type designation etc.
A80 w SL100 SV Torch, from serial number 845-XXX-XXXX
Brand name or trade mark
Thermal Dynamics
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No:
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Phone: [phone], FAX [phone]
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2017/AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 + AMD 1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic
compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
Date Signature Position
20 August, 2019
John Boisvert Vice President,
Global Cutting
Mechanized Cutting
2019

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION...................................................................................................................1-1
1.01 Notes, Cautions and Warnings........................................................................................................................ 1-1
1.02 Important Safety Precautions ......................................................................................................................... 1-1
1.03 Publications........................................................................................................................................................... 1-2
1.04 Note, Attention et Avertissement.................................................................................................................. 1-3
1.05 Precautions De Securite Importantes .......................................................................................................... 1-3
1.06 Documents De Reference................................................................................................................................. 1-5
1.07 Statement of Warranty....................................................................................................................................... 1-6
SECTION 2 SYSTEM:
INTRODUCTION .................................................................................................................................2-1
2.01 How To Use This Manual ................................................................................................................................... 2-1
2.02 Equipment Identication.................................................................................................................................. 2-1
2.03 Receipt Of Equipment ....................................................................................................................................... 2-1
2.04 Power Supply Specications ........................................................................................................................... 2-2
2.05 Input Wiring Specications.............................................................................................................................. 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 Specications ..................................................................................................................................................... 2T-1
2T.04 Options And Accessories ................................................................................................................................ 2T-2
2T.05 Introduction to Plasma.................................................................................................................................... 2T-2
SECTION 3 SYSTEM:
INSTALLATION ...................................................................................................................................3-1
3.01 Unpacking ............................................................................................................................................................ 3-1
3.02 Lifting Options...................................................................................................................................................... 3-1
3.03 Power Supply location and Mounting......................................................................................................... 3-1
3.04 Opening the Contactor Cover......................................................................................................................... 3-1
3.05 Primary Input Power Connections ................................................................................................................ 3-1
3.06 Gas Connections.................................................................................................................................................. 3-4
SECTION 3 TORCH:
INSTALLATION.................................................................................................................................. 3T-1
3T.01 Torch Connections ............................................................................................................................................ 3T-1
3T.02 CNC Connection ................................................................................................................................................ 3T-1
3T.03 Setting Up Automation or Machine Torch................................................................................................ 3T-3
SECTION 4 SYSTEM:
OPERATION........................................................................................................................................4-1
4.01 Front Panel Controls / Features ...................................................................................................................... 4-1
4.02 Preparations for Operation .............................................................................................................................. 4-2

TABLE OF CONTENTS
SECTION 4 TORCH:
OPERATION....................................................................................................................................... 4T-1
4T.01 Machine and Automated Torch Operation .............................................................................................. 4T-1
4T.02 Automation Torch Parts Selection............................................................................................................... 4T-1
4T.03 Machine and Hand Torch Parts Selection ................................................................................................. 4T-2
4T.04 Cut Quality .......................................................................................................................................................... 4T-3
4T.05 General Cutting Information......................................................................................................................... 4T-3
4T.06 Hand Torch Operation...................................................................................................................................... 4T-4
4T.07 Gouging .......................................................................................................................................................... 4T-7
4T.08 Recommended Cutting Speeds for Machine and
Automated Torches With Exposed Tip ....................................................................................................... 4T-8
4T.09 Recommended Cutting Speeds for Machine and
Automated Torches With Shielded Tip.....................................................................................................4T-32
PATENT INFORMATION ...........................................................................................................................4T-56
SECTION 5 SYSTEM:
SERVICE ..............................................................................................................................................5-1
5.01 General Maintenance......................................................................................................................................... 5-1
5.02 Maintenance Schedule...................................................................................................................................... 5-2
5.03 Common Faults .................................................................................................................................................... 5-2
5.04 Fault Indicator....................................................................................................................................................... 5-3
5.05 Basic Troubleshooting Guide .......................................................................................................................... 5-4
5.06 Power Supply Basic Parts Replacement ...................................................................................................... 5-6
SECTION 5 TORCH:
SERVICE ............................................................................................................................................ 5T-1
5T.01 General Maintenance....................................................................................................................................... 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts.................................................................. 5T-2
SECTION 6:
PARTS LISTS........................................................................................................................................6-1
6.01 Introduction .......................................................................................................................................................... 6-1
6.02 Ordering Information......................................................................................................................................... 6-1
6.03 Power Supply Replacement............................................................................................................................. 6-1
6.04 Replacement Power Supply Parts.................................................................................................................. 6-2
6.05 Options and Accessories................................................................................................................................... 6-2
6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) .............................. 6-4
6.07 Torch Consumable Parts (SL100 SV)............................................................................................................. 6-6
6.08 Replacement Parts for Hand Torch ............................................................................................................... 6-7
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 ...............................................................................A-6
APPENDIX 6: SYSTEM SCHEMATIC, 400V/600V UNITS.............................................................................A-8
APPENDIX 7: RAW ARC VOLTAGE ........................................................................................................... A-10

TABLE OF CONTENTS
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