Thermal Dynamics A120 User Manual

380-
400
AUTOMATED PLASMA
CUTTING SYSTEM
A120
CUTMASTER
™
Rev. AB Date: September 19, 2008 Manual # 0-4989
Operating Features:
Operating Manual

Thermal Dynamics A120 Specifications

General

Open Circuit Voltage (OCV)	300 VDC
Input Phase	3-Phase
Output Current	120 A
Duty Cycle	60% @ 120 A
Gas Type	Air, Nitrogen

Summary

SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions, and Warnings

Defines types of annotations (Note, Caution, Warning) used for emphasis or potential hazards.

1.02 Important Safety Precautions

Covers electrical hazards, gases, fumes, noise, arc rays, and lead warnings for safe operation.

1.07 Declaration of Conformity

States the product's conformity to applicable EU directives and national legislation.

1.08 Statement of Warranty

Outlines the limited warranty terms, conditions, and exclusions for the product.

SECTION 2 SYSTEM: INTRODUCTION

2.01 How To Use This Manual

Guides users on how to effectively read and understand the manual for safe operation.

2.04 Power Supply Specifications

Details technical specifications for the power supply, including input power, output, and duty cycle.

2.05 Input Wiring Specifications

Specifies requirements for input power connections, including voltage, frequency, and wire sizing.

SECTION 2 TORCH: INTRODUCTION

2T.01 Scope of Manual

Defines the scope of this section regarding the 1Torch models and service restrictions.

2T.03 Specifications

Lists specifications for torch configurations, lead lengths, and other technical details.

2T.05 Introduction to Plasma

Explains the principles of plasma, plasma cutting, and gouging processes.

SECTION 3 SYSTEM: INSTALLATION

3.01 Unpacking

Instructions for unpacking the equipment, checking contents, and inspecting for damage.

3.03 Power Supply location and Mounting

Guidance on selecting a suitable location and mounting the power supply securely.

3.04 Primary Input Power Connections

Instructions for making primary input power connections, including voltage and phase configurations.

SECTION 3 TORCH: INSTALLATION

3T.01 Torch Connections

Explains how to connect the Thermal Dynamics torch to the power supply.

3T.03 Setting Up Automation or Machine Torch

Guides on setting up automation or machine torches for cutting operations.

SECTION 4 SYSTEM: OPERATION

4.01 Front Panel Controls / Features

Identifies and explains the functions of the front panel controls and indicators.

4.02 Preparations for Operation

Outlines essential steps for preparing the system before starting operation.

SECTION 4 TORCH: OPERATION

4T.01 Machine and Automated Torch Operation

Details operation procedures for machine and automated torches, including cutting and piercing.

4T.04 Cut Quality

Discusses factors influencing cut quality and characteristics like kerf width and bevel angle.

4T.06 Hand Torch Operation

Details how to perform standoff and drag cutting using the hand torch.

4T.08 Recommended Cutting Speeds for Machine and Automated Torches With Exposed Tip

Provides cutting speed recommendations for mild steel with exposed tips for automated torches.

SECTION 5 SYSTEM: SERVICE

5.02 Maintenance Schedule

Details routine maintenance tasks for the power supply unit based on frequency of use.

5.03 Common Faults

Lists common operational problems, their possible causes, and recommended solutions.

5.05 Basic Troubleshooting Guide

Provides a guide to diagnose and resolve specific operational issues and error indicators.

SECTION 5 TORCH: SERVICE

5T.02 Inspection and Replacement of Consumable Torch Parts

Instructions for inspecting and replacing consumable parts like tips, electrodes, and shield cups.

SECTION 6: PARTS LISTS

6.02 Ordering Information

Explains how to order replacement parts by catalog number, description, model, and serial number.

6.06 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube)

Provides a detailed parts list for the SL100SV torch assembly and its components.

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM)

Sequence of Operation

Illustrates the operational sequence of the system using a block diagram.

APPENDIX 2: DATA TAG INFORMATION

Data Tag Information

Explains the various sections and symbols found on the equipment's data tag.

APPENDIX 3: TORCH PIN - OUT DIAGRAMS

Hand Torch Pin - Out Diagram

Shows the pin-out configuration for the hand torch's ATC male and female connectors.

Mechanized (Machine) Torch Pin - Out Diagram

Details the pin-out configuration for mechanized torch connectors, including CNC interface.

APPENDIX 4: TORCH CONNECTION DIAGRAMS

Hand Torch Connection Diagram

Illustrates the electrical connections for a hand torch to the power supply.

Mechanized Torch Connection Diagram

Shows the electrical connections for a mechanized torch to the power supply and CNC.

APPENDIX 5: SYSTEM SCHEMATIC, 208/460V UNITS

System Schematic

Presents the electrical schematic for 208/460V units of the plasma cutting system.

APPENDIX 6: SYSTEM SCHEMATIC, 400V UNITS

System Schematic

Displays the electrical schematic for 400V units of the plasma cutting system.