Thermal Dynamics A40 User manual

A40 40
AMP
380-
400
80%
Duty
Cycle
A60 60
AMP
380-
400
80%
Duty
Cycle
Art # A-08697
AUTOMATED PLASMA
CUTTING SYSTEM
A60 CUTMASTER™
Rev. AC Date: October 20, 2009 Manual # 0-5120
Operating Features:
Operating Manual
A40

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 locate your nearest distributor or service agency call1-800-426-
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 po-
tential 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 industry.

!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster™ A40 SL100SV Torch™ Operating Manual No.: 0-5120
CutMaster™ A60 SL100SV Torch™ Operating Manual No.: 0-5120
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2008, 2009 by
Thermadyne 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.
Printed in the United States of America
Original Publication Date: December 10, 2008
Revision Date: October 20, 2009
Record the following information for Warranty purposes:
Where Purchased:_______________________________________________
Purchase Date:__________________________________________________
Power Supply Serial #:___________________________________________
Torch Serial #:___________________________________________________
i

This Page Intentionally Blank

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 Declaration of Conformity .....................................................................................1-6
1.08 Statement of Warranty ..........................................................................................1-7
SECTION 2 SYSTEM:INTRODUCTION .................................................................................2-1
2.01 How To Use This Manual ......................................................................................2-1
2.02 Equipment Identification .......................................................................................2-1
2.03 Receipt Of Equipment...........................................................................................2-1
2.04 Power Supply Specifications.................................................................................2-2
2.05 Input Wiring Specifications....................................................................................2-4
2.06 Power Supply Features.........................................................................................2-5
SECTION 2 TORCH:INTRODUCTION .................................................................................. 2T-1
2T.01 Scope of Manual................................................................................................. 2T-1
2T.02 General Description ............................................................................................ 2T-1
2T.03 Specifications ..................................................................................................... 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 Primary Input Power Connections ........................................................................3-1
3.05 Gas Connections ..................................................................................................3-3
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-2
SECTION 4 SYSTEM: OPERATION ........................................................................................4-1
4.01 Front Panel Controls / Features ............................................................................4-1
4.02 Preparations for Operation....................................................................................4-2
SECTION 4 TORCH:OPERATION ......................................................................................... 4T-1
4T.01 Machine and Automated Torch Operation........................................................... 4T-1
4T.02 Machine and Hand Torch Parts Selection ........................................................... 4T-2
4T.03 Automation Torch Parts Selection ....................................................................... 4T-3
4T.04 Cut Quality .......................................................................................................... 4T-3
4T.05 General Cutting Information................................................................................ 4T-4
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-10
4T.09 Recommended Cutting Speeds for Machine and Automated Torches With Shielded
Tip 4T-19

TABLE OF CONTENTS
PATENT INFORMATION ...................................................................................................... 4T-28
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 Circuit Fault Isolation ............................................................................................5-6
SECTION 5 TORCH:SERVICE .............................................................................................. 5T-1
5T.01 General Maintenance.......................................................................................... 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts .................................. 5T-1
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 Automation / Machine (SL100)Torch ............................6-6
6.08 Replacement Parts - for Machine Torches ............................................................6-7
6.09 Torch Consumable Parts Manual (SL60)Torch .....................................................6-8
6.10 Replacement Parts for Hand Torch ......................................................................6-9
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, 380V, 400V UNITS.................................................... A-8
APPENDIX 7: Publication History......................................................................................... A-10
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover

CUTMASTER A40, A60
Manual 0-5120 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized
as follows:
NOTE
An operation, procedure, or background information
which requires additional emphasis or is helpful in
efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause
damage to the equipment.
!
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operat-
ing area.
1.02 Important Safety Precautions
!
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of
the health equipment to determine whether a hazard
exists.
To prevent possible injury, read, understand and fol-
low all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-5711 or
your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can
be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your
head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate
to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on
the kind of metal being used, coatings on the metal, and the
different processes. 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 Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that
should be supplied with the material you are using. These
MSDSs will give you the information regarding the kind and
amount of fumes and gases that may be dangerous to your
health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications
in this manual.
• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible
or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlo-
rinated solvents and cleansers. Remove all sources of these
vapors.
• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses
and produces high voltage electrical energy. This electric energy
can cause severe or fatal shock to the operator or others in the
workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the
work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or
damp.
• Install and maintain equipment according to NEC code, refer
to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or
repairs.
• Read and follow all the instructions in the Operating Manu-
al.
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 work-
place.
• Do not cut or weld on containers that may have held com-
bustibles.

CUTMASTER A40, A60
GENERAL INFORMATION 1-2 Manual 0-5120
• Provide a fire watch when working in an area where fire
hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a
water table. DO NOT cut aluminum alloys underwater or on
a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited will cause
an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels
(sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Sub-
section 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The
plasma arc process produces very bright ultra violet and infra red
light. These arc rays will damage your eyes and burn your skin if
you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles
or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your
skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protec-
tive booths, screens or shields.
• Use the shade of lens as suggested in the following per
ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* 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.
LEAD WARNING
This product contains chemicals, including lead, or otherwise pro-
duces chemicals known to the State of California to cause cancer,
birth defects and other reproductive harm.Wash hands after han-
dling. (California Health & Safety Code § 25249.5 et seq.).
1.03 Publications
Refer to the 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, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superin-
tendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF
CUTTING AND WELDING PROCESSES, obtainable from
American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, ob-
tainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-
able from the National Welding Supply Association, 1900
Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED 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. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018

CUTMASTER A40, A60
Manual 0-5120 1-3 GENERAL INFORMATION
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général
sur lequel il importe d’insister davantage ou qui con-
tribue à l’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure en
question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans
la zone de travail en cas de non-respect de la procédure
en question.
1.05 Precautions De Securite Importantes
!
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magné-
tique qui peuvent interférer la fonction propre d’un
“pacemaker” cardiaque, les appareils auditif, ou autre
matériel de santé electronique. Ceux qui travail près
d’une application à l’arc au jet de plasma devrait con-
sulter leur membre professionel de médication et le
manufacturier de matériel de santé pour déterminer
s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertisse-
ments, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le +
603-298-5711 ou votre distributeur local si vous avez
des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent
présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
votre tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération
fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma
dépendent du genre de métal utilisé, des revêtements se trouvant
sur le métal et des différents procédés. Vous devez prendre soin
lorsque vous coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières
(sigle américain “MSDS”); celles-ci devraient être fournies avec
le matériel que vous utilisez. Les MSDS contiennent des ren-
seignements quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée et les
gaz de votre lieu de travail, consultez l’article 1 et les documents
cités à la page 5.
• Utilisez un équipement spécial tel que des tables de coupe à débit
d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
• 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.
• Ce produit, dans le procéder de soudage et de coupe, produit
de la fumée ou des gaz pouvant contenir des éléments reconnu
dans L’état de la Californie, qui peuvent causer des défauts de
naissance et le cancer. (La sécurité de santé en Californie et la
code sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au
jet de plasma requiert et produit de l’énergie électrique haute tension.
Cette énergie électrique peut produire des chocs graves, voire mor-
tels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail
ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.
• Montez et maintenez le matériel conformément au Code élec-
trique national des Etats-Unis. (Voir la page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de con-
signes.

CUTMASTER A40, A60
GENERAL INFORMATION 1-4 Manual 0-5120
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories chaudes,
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma
produit du métal, des étincelles, des scories chaudes pouvant mettre
le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable
ne se trouve sur le lieu de travail. Protégez toute telle matière
qu’il est impossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables
ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfer-
mer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone
présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces
de travail en aluminium lorsqu’elles sont coupées sous l’eau ou
sur une table d’eau. NE PAS couper les alliages en aluminium
sous l’eau ou sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.
• Maintenez votre casque et vos lunettes de protection en bon
état. Remplacez toute lentille sale ou comportant fissure ou
rognure.
• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des
écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le recom-
mendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est caché
par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des
tampons protecteurs et/ou des protections auriculaires. Pro-
tégez également les autres personnes se trouvant sur le lieu de
travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit,
consultez l’article 1, page 5.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de mal-
formations fœtales ou d’autres problèmes de reproduction.
Il faut se laver les mains après toute manipulation.
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants).

CUTMASTER A40, A60
Manual 0-5120 1-5 GENERAL INFORMATION
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 Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (Ameri-
can National Standards Institute), 1430 Broadway, New York, NY
10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO-
TECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, dis-
ponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la Ameri-
can Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre
les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTA-
TION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUD-
AGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jef-
ferson Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE
ET LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUD-
AGE, disponible auprès de l’Association Nationale de Fournitures
de Soudage (National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPA-
RATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET
TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRA-
TOIRE, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018

CUTMASTER A40, A60
GENERAL INFORMATION 1-6 Manual 0-5120
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and
to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive
89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manu-
facture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. 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 bearing the mark conform to EN50192 when used in conjunc-
tion with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to
ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigor-
ous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire ,
England PR6 7BX

CUTMASTER A40, A60
Manual 0-5120 1-7 GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser
that new Thermal Dynamics CUTMASTER™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and
workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation
shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’
specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship
within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics
Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the
date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
U.S. Non U.S.
CUTMASTER™ A40 4 Years 3 Years 1 Year
CUTMASTER™ A60 4 Years 3 Years 1 Year
CUTMASTER™ A80 4 Years 3 Years 1 Year
CUTMASTER™ A120 4 Years 3 Years 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 unauthorized party, improperly installed, improperly operated or misused based upon industry
standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product
returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such
as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the
goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,
shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal
Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective September 4, 2007

CUTMASTER A40, A60
GENERAL INFORMATION 1-8 Manual 0-5120
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CUTMASTER A40, A60
Manual 0-5120 2-1 INTRODUCTION
2.01 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 instruc-
tions and warnings. Throughout this manual, the words
WARNING, CAUTION, and NOTE may appear. Pay
particular attention to the information provided under these
headings. These special annotations are easily recognized as
follows:
!
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by
contacting Thermadyne at the address and phone number
in your area listed in the inside back cover of this manual.
Include the Owner’s Manual number and equipment
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
Dynamics and then on the Literature link:
http://www.thermal-dynamics.com
2.02 Equipment Identification
The unit’s identification number (specification or part
number), model, and serial number usually appear on a
data tag attached to the rear panel. Equipment which does
not have a data tag such as torch and cable assemblies are
identified only by the specification or part number printed on
loosely attached card or the shipping container. Record these
numbers on the bottom of page 1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against the invoice
to make sure it is complete and inspect the equipment for
possible damage due to shipping. If there is any damage,
notify the carrier immediately to file a claim. Furnish complete
information concerning damage claims or shipping errors
to the location in your area listed in the inside back cover of
this manual.
Include all equipment identification numbers as described
above along with a full description of the parts in error.
Move the equipment to the installation site before un-crating
the unit. Use care to avoid damaging the equipment when
using bars, hammers, etc., to un-crate the unit.
SECTION 2 SYSTEM:
INTRODUCTION

CUTMASTER A40, A60
INTRODUCTION 2-2 Manual 0-5120
2.04 Power Supply Specifications
CutMaster A60 Power Supply Specications
Input Power 380 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
400 VAC (360 - 480 VAC), Three Phase, 50/60 Hz
Input Power Cable Power Supply includes input cable.
CutMaster A40 Output
Current 20 - 60 Amps, Continuously Adjustable
CutMaster A60 Output
Current 20 - 80 Amps, Continuously Adjustable
Power Supply Gas
Filtering Ability Particulates to 5 Microns
CutMaster A40 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Opperating Range 0° - 50° C
IEC
Rating
IEC
Rating
IEC
Rating
All Units
Duty Cycle 40% 60% 100%
Current 60 Amps 50 Amps 30 Amps
DC Voltage 104 100 92
* NOTE: The duty cycle will be reduced if the primary input power (AC) is
low or the output voltage (DC) is higher than shown in this chart.
CutMaster A60 Power Supply Duty Cycle *
Ambient Temperature Duty Cycle Ratings @ 40° C (104° F)
Opperating 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 Voltage 112 106 100
* NOTE: The duty cycle will be reduced if the primary input power (AC) is
low or the output voltage (DC) is higher than shown in this chart.
NOTE
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.

CUTMASTER A40, A60
Manual 0-5120 2-3 INTRODUCTION
Power Supply Dimensions & Weight Ventilation Clearance Requirements
20.8"
0.528 m
43 lb / 19.5 kg
10"
254 mm
13.78"
350 mm
Art # A-08305
6"
150 mm
24"
0.6 m
6"
150 mm
6"
150 mm
Art # A-07925

CUTMASTER A40, A60
INTRODUCTION 2-4 Manual 0-5120
2.05 Input Wiring Specifications
CutMaster A40 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I1max I1 eff Fuse (amps)
Flexible Cord
(Min. mm2)
3 Phase 380 50/60 10.3 16 11 20 2.5
400 50/60 10.8 16 11 20 2.5
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
CutMaster A60 Power Supply Input Cable Wiring Requirements
Input voltage Freq Power Input Suggested Sizes
Volts Hz kVA I1max I1 eff Fuse (amps)
Flexible Cord
(Min. mm2)
3 Phase 380 50/60 11 17 11 20 2.5
400 50/60 11.5 17 11 20 2.5
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installa-
tions refer to local or national codes.
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should
be used to minimize damage to Plasma Cutting, Welding or power distribution equipment.

CUTMASTER A40, A60
Manual 0-5120 2-5 INTRODUCTION
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 Assembly
Input Power Selection
Art # A-08318

CUTMASTER A40, A60
INTRODUCTION 2-6 Manual 0-5120
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