Thermadyne CE CutMaster™ 51 Operating Manual

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Plasma Cutting

Power Supply

CE CutMaster™ 51

A-03688

January 12, 2004 Manual No. 0-2989

Operating Manual

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 CE CutMaster™ 51 Operating Manual Number 0-2989

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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

Publication Date: January 12, 2004

Record the following information for W arranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and W arnings ..................................................................... 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 ............................................................................. 1-7

1.08 Statement of Warranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION .............................................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 Power Supply Specifications ........................................................................ 2-1

2.03 Input Wiring Specifications ........................................................................... 2-2

2.04 Power Supply F eatures ................................................................................ 2-3

2.05 Power Supply Options and Accessories....................................................... 2-4

SECTION 3: INSTALLATION .................................................................................................... 3-1

3.1 Unpacking .................................................................................................... 3-1

3.2 Lifting Options .............................................................................................. 3-1

3.3 Primary Input Power Connections................................................................ 3-2

3.4 Air Connections............................................................................................ 3-3

3.5 Torch Connections ....................................................................................... 3-7

SECTION 4: OPERATION ........................................................................................................ 4-1

4.01 Front Panel Controls and Indicators ............................................................. 4-1

4.02 Preparations for Operation ........................................................................... 4-2

SECTION 5:

SERVICE .......................................................................................................................... 5-1

5.01 General Maintenance................................................................................... 5-1

5.02 Common Faults ............................................................................................ 5-5

5.03 Basic Troub leshooting Guide ........................................................................ 5-6

5.04 Power Supply Basic Parts Replacement .................................................... 5-11

TABLE OF CONTENTS (continued)

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 Parts....................................................................................... 6-1

6.05 Options and Accessories ............................................................................. 6-2

6.06 T orch Parts................................................................................................... 6-3

APPENDIX 1: SEQ UENCE OF OPERATION (BLOCK DIAGRAM) ..........................................A-1

APPENDIX 2: DATA T AG INFORMATION.................................................................................A-2

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................ A-3

APPENDIX 4: TORCH PIN - OUT DIAGRAMS.........................................................................A-4

APPENDIX 5: TORCH CONNECTION DIAGRAMS .................................................................A-5

APPENDIX 6: SYSTEM SCHEMATIC.......................................................................................A-6

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 backgr ound 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 operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEAL TH.

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 follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 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 pr ocesses. Y ou 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 chlorinated 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.”

Date: No v ember 15, 2001 1-1 GENERAL INFORMATION

• 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 Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

• 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. T rapped 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.

• T o protect your hearing from loud noise, wear pr otective 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 Subsection 1.03, Publications, in this manual.

PLASMA ARC RA YS

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 pr otected.

• 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 protective 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.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEAL TH 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 Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND FACE PROTECTION, obtainable 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 Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001

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 Standar d A6.0, WELDING AND CUTTING CONTAINERS 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, obtainable 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 W1 17.2, 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 obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédur e 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 magnétique 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 consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

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 contribue à l’efficacité de fonctionnement du système.

Date: No v ember 15, 2001 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votr e 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.

• 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.

• 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 différ ents 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 renseignements 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

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (V oir 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 consignes.

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 renfermer 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.

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Date: Nov ember 15, 2001

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 oculair e.

• 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 recommendation 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.

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 TRA VAIL 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 TRAV AIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

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. V ous dú4ez vous pr otéger 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. Protégez 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.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS A YANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American 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 ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park, Quincy, MA 02269

Date: No v ember 15, 2001 1-5 GENERAL INFORMATION

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 SOUDAGE, 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 Jefferson 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 SOUDAGE, 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 PRÉPARA TION 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 RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) 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 manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements. Among them ar e:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* CENELEC EN50199 EMC Product Standard for Ar c W elding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192

when used in conjunction 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 manufac-

turing 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. Rigorous 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: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal 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 customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year Control PC Board 3 Y ears 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year

But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year SureLok T orches 1 Y ear 1 Y ear 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation char ges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynamics CutMaster 51 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty .

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

NOTE

Refer to the Torch Manual for torch and cutting information.

2.02 Power Supply Specifications

CE CutMaster 51 Power S upply Specifications

400 VA C (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power Ca ble

Output Current

Power Supply Gas

Filtering Ability

Am bient Temperature

CE CutMaster 5 1

* NOTE: The duty cycle will be reduc ed i f the prim ary i nput power (AC) is l ow

Power Supply inc l udes i nput cable wit h filtering beads 20 - 40 Amps, Conti nuous l y Adj us table

Part iculat es to 20 Microns

CE CutM aster 51 Power Supply Duty Cycle *

40° C (104° F)

IEC

Rating Duty Cycle Current DC Volt age

or the output voltage (DC) is higher t han s hown in this chart.

40 Am ps n/a 25 Amps n/a n/ a n/ a

96 vdc n/a 90 vdc n/a n/a n/ a

TDC

Rating

40% 60% 100%

IEC

Rating

TDC

Rating

IEC

Rating

TDC

Rating

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.

TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of tor ch, consumables, and actual cutting operation.

Manual 0-2989 2-1 INTRODUCTION

NOTE:

Power Supply Dimensions & Weight Ventilation Clearance Requirements

10.75"

273 mm

A-03700

16.375"

416 mm

150 mm

22.5"

0.57 m

58 lb / 26 kg

150 mm

A-03379

2.03 Input Wiring Specifications

CE CutM aster 51 Input W i ri ng Specifications

Input Sugge sted Sizes (Se e Notes)

Voltage Frequency 3-Ph 3-Ph Fuse (Amps)

(Volts) (Hz) (kVA) (Amps ) 3-Ph 3-Ph

CE CutM as t er 51 400 50 7.9 11.5 15 4

Line Vol t ages with S uggested Circ ui t Protec t i on and Wire Si zes

Bas ed on Nat i onal E l ec tric Code and Canadian Electri c Code

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Pow er Input Current Input

NOTES

150 mm

Wire (mm

)

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 installations

refer to local or national codes. Cable conductor temperature used is 167° F (75° C). 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. NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

INTRODUCTION 2-2 Manual 0-2989

2.04 Power Supply Features

Handle and Leads Wrap

Art # A-03578

Control Panel

Torch Leads Receptacle

Gas Pressure Regulator /

Ports for Optional Automation Interface Cable

Gas Pressure Gauge

Work Cable and Clamp

Filter Assembly

Gas Inlet Port

Manual 0-2989 2-3 INTRODUCTION

Art # A-03738

Input Power Cord

2.05 Power Supply Options and Accessories

Section 6, Parts Lists, provides catalog numbers and ordering information.

A. Single-Stage Air Filter Kit

For use with compressed air shop systems. Filters moisture and particulate matter from the air str eam to at least

0.85 microns.

B. Two Stage Air Filter Kit

For use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at least

5.0 microns.

C. High Pressure Regulators

High pressure regulators ar e available. The regulators ar e used to set the proper pr essure for the type gas being used.

NOTE

Regulators should not be installed with In-Line Air Filters.

D. Extended Work Cable with Clamp

As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work cable with clamp is available.

E. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. T op shelf is 12" / 305 mm x 20" / 508 mm. Steel handle is 30" / 762 mm high.

F. Wheel Kit

A kit with easy - r olling wheels, for maximum portability for the power supply.

F. Automation Interface Kit

This kit allows the user to convert a non automated power supply for use as part of a fully automated system. The kit includes an automation interface board, wiring harness, mounting hardware and instructions. The automation interface provides the basic start / stop and OK to move functions, and a switch selectable voltage divider output. An external connector simplifies the connection to a CNC type cutting machine. CNC cables are available in 25' / 7.6 m and 50' / 15.m lengths for use with this kit.

INTRODUCTION 2-4 Manual 0-2989

SECTION 3: INSTALLATION

3.1 Unpacking

1. Use the packing lists to identify and account for each item.

2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.

3. Record Power Supply and Torch model and serial numbers, pur chase date and vendor name, in the information block at the front of this manual.

3.2 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNINGS

Do not touch live electrical parts. Disconnect input power cord before moving unit.

FALLING EQUIPMENT can cause serious personal injury and can damage equipment. HANDLE is not for mechanical lifting.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handle, using two hands. Do not use straps for lifting.

• Use optional cart or similar device of adequate capacity to move unit.

• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Manual 0-2989 3-1 INST ALLATION

3.3 Primary Input Power Connections

CAUTION

Check your power source for correct voltage before plugging in or connecting the unit. The primary power sour ce, fuse, and any extension cords used must conform to local electrical code and the recommended circuit pr otection and wiring requirements as specified in Section 2.03.

A. Connections to Primary Input Power

These Power Supplies are equipped with a four - conductor input power cable weith filtering beads for 400-Volt three - phase input power.

1. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable.

2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (r efer to table in Section 2 ). All the input cable wires must be connected for three

- phase operation.

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2, L3 input.

3. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

INST ALLATION 3-2 Manual 0-2989

3.4 Air Connections

A. Connecting Air Supply to Unit

The connection is the same for compressed air or high pressure cylinders. Refer to subsection 3.4-B or 3.4-C if an optional air line filter is to be installed.

1. Connect the air 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 T eflon tape as a thr ead sealer , as small particles of the tape may br eak off and block the small air passages in the torch.

Regulator/Filter Assembly

Inlet Port

Bowl

1/4 NPT to 1/4"

(6mm) Fitting

Hose Clamp

Art # A-02999

Air Connection to Inlet Port

Gas Supply Hose

Manual 0-2989 3-3 INST ALLATION

B. Installing Optional Single - Stage Air Filter

An optional filter kit is recommended for improved filtering with compr essed air , to keep moisture and debris out of the torch.

1. Attach the Single - Stage Filter Hose to the Inlet Port.

2. Attach the Filter Assembly to the filter hose.

3. Connect the air line to the Filter. The illustration shows typical fittings as an example.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use T eflon tape as a thr ead sealer , as small particles of the tape may br eak off and block the small air passages in the torch. Connect as follows:

Regulator/Filter Assembly

Bowl

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

Inlet Port

Optional Single - Stage Filter Installation

Art # A-03000

INST ALLATION 3-4 Manual 0-2989

C. Installing Optional Two - Stage Air Filter Kit

This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns.

Connect the air supply as follows: a. Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the

filter assembly.

NOTE

For a secure seal, apply thread sealant to the fitting threads according to manufactur er's instructions. Do Not use T eflon tape as a thr ead sealer as small particles of the tape may break off and block the small air passages in the tor ch.

b. Connect the two stage filter outlet hose to the inlet port of the Regulator / Filter Assembly. c. Use customer - supplied fittings to connect the air line to the Filter. A 1/4 NPT to 1/4" hose barbed fitting

is shown as an example.

Regulator/Filter Assembly

Hose

Clamp

1/4" (6 mm) Gas

Supply Hose)

Regulator Inlet Port

2-Stage Filter Inlet Port (IN)

1/4 NPT

Hose Fitting

Optional Two - Stage Filter Installation

Outlet Port

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

Manual 0-2989 3-5 INST ALLATION

D. Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure r egulators.

2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any 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).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressur e cylinder regulator. Supply hose must be at least 1/4 inch (6 mm) I.D. For a secure seal, apply thread sealant to the fitting threads, according to manufactur er's instructions. Do Not use

T eflon tape as a thr ead sealer , as small particles of the tape may br eak off and block the small air passages in the torch.

INST ALLATION 3-6 Manual 0-2989

3.5 Torch Connections

If necessary , connect the tor ch to the Power Supply . Connect only the Thermal Dynamics model SL60 or SL100 Torch (with ATC connector) to this power supply . Maximum torch leads length is 100 feet / 30.5 m, including extensions.

WARNING

Disconnect primary power at the source before connecting the torch.

1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.

2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together . Do not use tools to secure the connection.

3. The system is ready for operation.

ATC Female Receptacle (Panel Mounted)

Control Cable Connector (Mechanized Torches Only)

A-03689

Connecting the Torch to the Power Supply

ATC Male Connector

Manual 0-2989 3-7 INST ALLATION

B. Check Air Quality

To test the quality of air:

1. Put the ON / OFF switch in the ON (up) position.

2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position.

3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible on the lens. Do not start an arc!

A-03690

INST ALLATION 3-8 Manual 0-2989

SECTION 4: OPERATION

4.01 Front Panel Controls and Indicators

(A) Output Current Control

Sets the desired output current. Output settings up to 40 Amps may be used for drag cutting (with the torch tip contacting the workpiece) or standoff cutting.

AC Indicator

Steady light indicates power supply is ready for

operation. Blinking light indicates unit is in protective interlock mode. Shut unit off, shut off or disconnect input power, correct the fault, and restart the unit. Refer to Section 5 for details.

TEMP Indicator

ON / OFF Switch

Controls input power to the power supply. Up is ON, down is OFF.

A-03742

RUN / RAPID AUTO RESTART / SET Switch

Indicator is normally OFF . Indicator is ON when internal temperature exceeds normal limits. Shut unit OFF; let the unit cool before continuing operation.

GAS Indicator

Indicator is ON when minimum input air pressure for power supply operation is present. Minimum pressure for power supply operation is not sufficient for torch operation.

DC Indicator

Indicator is ON when DC output circuit is active.

RUN (up) position is for general torch operation. RAPID AUTO RESTART (middle) position is for an uninterrupted restart,

when cutting expanded metal or in gouging or trimming operations. SET (down) position is for setting air pressure and purging lines.

Manual 0-2989 4-1 OPERATION

4.02 Preparations for Operation

At the start of each operating session:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply , torch parts, or tor ch and leads assemblies.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate tor ch parts. The torch parts must correspond with the type of operation, and with the amperage output of this Power Supply (40 amps maximum). Refer to Section 6.06 for torch parts selection.

B. Torch Connection

Check that the torch is properly connected. Only Thermal Dynamics model SL60 or SL100 Torches may be connected to this Power Supply.

C. Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications.

2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

D. Air Source

Ensure source meets requirements (refer to Section 2). Check connections and turn air supply on.

E. Connect Work Cable

Clamp the work cable to the workpiece or cutting table. The area must be free fr om oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.

A-03387

OPERA TION 4-2 Manual 0-2989

F. Power On

Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator

turns on if there is sufficient air pressure for power supply operation.

NOTE

Minimum pressure for power supply operation is lower than minimum for torch operation.

A-03746

Manual 0-2989 4-3 OPERATION

G. Set Operating Pressure

1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Air will flow.

A-03690

2. Adjust air pressure to 65 - 85 psi / 4.5 - 5.9 bar. Refer to the chart for pressure setting details.

65 - 85 psi /

4.5- 5.9 bar

Pressure Control Knob / Bouton De Contrôle de Pression

CE CutMaster 51 Ai r Pressur e S ettings Leads

Length

Up to 25'

(7.6 m)

Over 25'

(7.6 m)

SL60

(Hand Torch)

75 psi

5.2 bar 85 psi

5.9 bar

SL100

(Machine Torc h)

65 psi

4.5 bar 70 psi

4.8 bar

OPERA TION 4-4 Manual 0-2989

Art # A-03831

H. Select Current Output Level

1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Air flow stops.

2. Set the output current output level.

A-03747

I. Cutting Operation

Refer to the manual supplied with the torch for details on cutting operation, cutting speeds, parts selection and replacement, etc.

When the torch leaves the workpiece during cutting operations with the RUN / Rapid Auto Restart / SET switch in the RUN (up) position, there is a brief delay in restarting the pilot arc. With the switch in the 'Rapid Auto Restart' (middle) position, when the torch leaves the workpiece 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 gratings, or in gouging or trimming operations when an uninterrupted restart is desired.

J. Typical Cutting Speeds

Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer to the Torch Manual for details.

Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using a template or cutting guide while still producing cuts of excellent quality.

Manual 0-2989 4-5 OPERATION

K. Postflow

Release the trigger to stop the cutting arc. Air continues to flow for appr oximately 6 seconds. During post - flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

L. Shutdown

T urn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.

A-03748

OPERA TION 4-6 Manual 0-2989

SECTION 5:

SERVICE

5.01 General Maintenance

A. O-Ring Lubrication

An o-ring on the T orch A TC Male Connector requires lubrication on a scheduled basis. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential performance problems.

It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.

NOTE

DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain

“unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

ATC Male Connector

Art #A-03791

Manual 0-2989 5- 1 SERVICE

Gas Fitting

O-Ring

B. Filter Element Replacement

The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter element should be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced.

1. Remove power from the power supply; turn off the gas supply and bleed down the system.

2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly . The filter element will be visible and still attached to the main body of the Regulator/Filter .

3. Grasp the filter element and unscrew it from the Regulator/Filter body. The filter element will come off with a spool and some additional pieces.

4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace it.

5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. T ighten firmly by hand.

Regulator/Filter

Assembly

Baffle Ring

6. Reinstall the bowl.

7. Turn on the air supply.

Filter Element No. 9-4414

Spring Spool

Bowl

Art # A-02995

Regulator/Filter Element Replacement

SERVICE 5-2 Manual 0-2989

C. Optional Single-Stage Filter Element Replacement

These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter

Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry . Refer to Section 6, Parts List, for replacement filter element catalog number .

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

4. T urn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is located inside the Housing.

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.

6. Wipe inside of housing clean, then insert the r eplacement Filter Element open side first.

7. Replace Housing on Cover .

8. Reattach gas supply.

NOTE

If unit leaks between housing and cover , inspect the "O" Ring for cuts or other damage.

Manual 0-2989 5- 3 SERVICE

D. Optional Two-Stage Filter Element Replacement

The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number .

1. Shut off primary input power .

2. Shut off air supply and bleed down system.

W ARNING

Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

First & Second Stage Cartridges (as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then tor que each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper tor que may damage the gasket.

8. Slowly apply air pressure to the assembly , checking for leaks.

NOTE

A small amount of air leakage from the bottom fitting is normal.

SERVICE 5-4 Manual 0-2989

5.02 Common Faults

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting current too low f. Non - Genuine Thermal Dynamics parts used g. Incorrect gas pressure

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non - Genuine Thermal Dynamics parts used

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Non - Genuine Thermal Dynamics parts used f. Incorrect gas pressure

4. Short T orch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Gas pressure too low e. Improperly assembled torch f. Non - Genuine Thermal Dynamics parts used

5. Difficult Starting

a. Worn torch parts b. Non - Genuine Thermal Dynamics parts used c. Incorrect gas pressure

Manual 0-2989 5- 5 SERVICE

5.03 Basic Troubleshooting Guide

W ARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

A. Basic Tr oubleshooting: Overview

This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this system. If major complex subassemblies are faulty , the unit must be r eturned to an authorized service center for repair .

Follow all instructions as listed and complete each section in the order presented. For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for this prod-

uct.

B. How to Use This Guide

The following information will help the Customer / Operator determine the most likely causes for various symptoms. Follow all instructions as listed and complete each section in the order presented.

This guide is set up in the following manner:

X. Symptom (Bold T ype)

Any Special Instructions

1. Cause

a. Check / Remedy

Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that unit operates properly after any repairs.

C. Common Symptoms

A. AC indicator OFF

1. Switch at main power panel in OFF (open) position.

a. Close main power switch.

2. Power Supply ON / OFF switch in OFF (down) position.

a. Turn switch to ON (up).

3. Tor ch is not connected properly to Power Supply

a. Turn power supply ON / OFF switch to OFF (down). Check tor ch connection to Power Supply . T ighten or

adjust as required. Do not use tools. Turn power supply ON / OFF switch to ON (up).

4. Shield cup not fully tightened on torch head

a. Check shield cup for proper installation. Do not overtighten. Do not use tools to tighten.

5. Main power line fuse(s) or circuit breaker(s) blown

a. Check main power panel fuse(s). Replace as required.

SERVICE 5-6 Manual 0-2989

6. Unit internal fuse blown or loose

a. If blown, double-check input voltage and replace fuse per Section 5.04-C. If fuse blows again, return unit to

an authorized service center .

7. Actual input voltage does not correspond to voltage of unit

a. Verify that the input line voltage is corr ect. Refer to Section 2, Input Wiring Requir ements.

8 . Faulty components in unit

a. Return for repair or have qualified technician repair per Service Manual.

B. Gas flows continuously when power is turned on, AC indicator flashes

1. Tor ch switch is activated (closed) before user turns power on.

a. Release torch switch.

2. Faulty torch switch

a. Check torch switch for continuity . Replace if necessary.

C. Gas flows continuously; T orch will not pilot when torch switch is activated; AC indicator ON

1. System is in SET mode

a. Change RUN / Rapid Auto Restart / SET switch to RUN (up).

D. No gas flow; RUN / Rapid Auto Restart / SET switch in SET position; Fans operate; AC indicator ON;

GAS indicator OFF

1. Gas not connected

a. Check gas connections.

2. Gas pressure too low for power supply operation

a. Adjust gas pressure per torch manual.

3. Faulty components in unit a. Return for repair or have qualified technician repair.

E. T orch will not pilot; gas flows; AC indicator ON, GAS , TEMP , and DC indicators OFF

1. Gas pressure is below power supply minimum requirement.

a. Adjust pressure to 60 - 75 psi / 4.1 - 5.2 bar.

F. T orch will not pilot; gas flows; AC and Gas indicators ON; DC and TEMP indicators OFF

1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower than mini-

mum required for torch operation.)

a. Adjust gas pressure according to torch model and leads length per Section 4.02G.

Manual 0-2989 5- 7 SERVICE

G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON

1. Starter cartridge missing from torch

a. Shut off power supply . Remove shield cup, install starter cartridge. Reinstall torch tip and shield cup. T urn

power supply ON / OFF switch to ON (up).

2. Shield cup is loose on torch

a. Check shield cup; tighten if necessary.

NOTE

When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.

3. Upper O-ring on torch head is in wrong position.

a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary .

Art # A-03640

Upper Groove with V ent Holes Must Remain Open

Upper O-Ring in Correct Groove

Threads Lower O-Ring

H. Torch will not pilot; AC , GAS , and TEMP indicators ON, DC indicator OFF

1. Air flow blocked

a. Check for blocked air flow around the unit and correct condition.

2. Unit is overheated

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.

Refer to duty cycle data in Section 2.

3. Input line voltage is low

a. Check and connect to proper input power line.

4. Faulty components in unit

a. Return for repair or have qualified technician repair per Service Manual.

SERVICE 5-8 Manual 0-2989

I. T orch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC

indicator OFF

1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.)

a. Release torch trigger.

2. System is in protective interlock mode. (T orch parts are missing or loose.)

a. Release torch trigger, and set power supply ON / OFF switch to OFF (down). Open main disconnect switch.

Check torch parts. Replace parts as needed. Reinstall shield cup; hand - tighten it securely against the torch head. Do not overtighten. Do not use tools. Close main disconnect switch. Set ON / OFF switch to ON (up) position.

J. Gas cycles on and off without torch switch being activated; AC indicator Flashing; Gas indicator

ON; DC indicator OFF

1. T orch tip or electrode missing

a. Shut off power supply . Remove shield cup, install missing part(s). T urn power supply ON / OFF switch to

ON (up).

K. No cutting output; T orch pilots; Gas flows; Fans operate; AC ,Gas , and DC indicator ON;

TEMP indicator OFF

1. Work cable not connected to work piece, or connection is poor

a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.

2. Faulty T orch

a. Return for repair or have qualified technician repair.

3. Faulty components in unit

a. Return for repair or have qualified technician repair per Service Manual.

L. T orch cuts but not adequately

1. Incorrect setting of output current (A) control a. Check and adjust to proper setting.

2. Torch consumables worn

a. Check torch consumables per Tor ch manual; replace as needed.

3. Work cable connection to work piece is poor

a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.

4. T orch is being moved too fast across workpiece

a. Reduce cutting speed.

5. Excessive oil or moisture in torch

a. Put RUN / RAPID AUTO REST ART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from

clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contaminants in the gas, additional filtering may be needed.

Manual 0-2989 5- 9 SERVICE

6. Fluctuations in input power

a. Have electrician check input line voltage.

7. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual.

M. Arc shuts off during operation; arc will not restart when torch switch is activated.

1. Power Supply is overheated (TEMP indicator ON)

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.

Refer to Section 2 for duty cycle specifications.

2. Fan blades blocked (TEMP indicator ON)

a. Check and clear blades.

3. Air flow obstructed (TEMP indicator ON)

a. Check for obstructed air flow around the unit and correct condition.

4. Gas pressure too low (GAS indicator OFF when torch switch is activated)

a. Check source for at least 60 psi / 4.1 bar; adjust as needed. (Minimum pressure for power supply operation

is lower than minimum required for torch operation.)

5. Torch consumables worn

a. Check torch consumables per Tor ch manual; replace as needed.

6. Faulty components in unit

a. Return for repair or have qualified technician repair per Service Manual.

N. AC indicator remains ON when shield cup is removed

1. Faulty PIP switch in torch

a. Check PIP switch for continuity; replace if necessary

SERVICE 5-10 Manual 0-2989

5.04 Power Supply Basic Parts Replacement

W ARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.

A. Cover Removal

1. Remove the upper screws which secure the cover to the main assembly.

NOTE

There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there is a need for more room to work.

Upper screws

Lower screws

Ground wire

Art # A-03792

2. Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit.

Manual 0-2989 5-11 SERVICE

B. Cover Installation

1. Reconnect the ground wire, if necessary .

2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.

3. Tighten lower scr ews.

4. Reinstall and tighten the upper screws.

C. Fuse Replacement

1. Remove the unit cover per paragraph "A" above.

2. Locate the internal fuse on the left side of the center chassis.

3. Replace the fuse. A replacement fuse is located inside the power supply. Refer to Section 6, Parts Lists, for replacement fuse catalog number .

4. Reinstall the cover by reversing the steps in paragraph "B" above.

Internal Fuse Location

This completes the parts replacement procedures.

Fuse Location

Art # A-03002

SERVICE 5-12 Manual 0-2989

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Complete Power Supply Replacement Section 6.04 Replacement Parts Section 6.05 Options and Accessories

NOTE

Parts listed without item 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 pr oper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized distributor .

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual.

Qty Description Catalog #

1 CE CutMaster 51 Power Supply, 400VAC, Three - Phase, 50 / 60Hz, 3-5120-4

with input power cable

6.04 Replacement Parts

Qty Description Catalog #

1 Fuse for CE CutMaster 51 Power Supply 9-8583 1 Regulator / Filter Assembly Replacement Element 9-4414

Manual 0-2989 6-1 P A RTS LISTS

6.05 Options and Accessories

Qty Description Catalog #

1 Single - Stage Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741 1 Two - Stage Filter Kit (includes Hose & Mounting Screws) 7-7500 1 Bracket, Filter Mounting (not shown) 9-7535 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 - Purpose Cart 7-8888 1 High - Pr essur e Air Regulator 9-3022 1 Wheel Kit 9-8510 1 Automation Interface Kit 9-8310 1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312 1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second Stage Cartridges (as marked)

Optional Single - Stage Filter Kit Optional Two - Stage Filter Kit

Art # A-02942

PARTS LISTS 6-2 Manual 0-2989

6.06 Torch Parts

8-3487 O-Ring

Art # A-03816

8-3486 O-Ring

Electrode

9-8215

Starter

Cartridge

9-8213

Torch Head

Starter Cartridge

9-8207 (40A)

9-8225 - A (40A)

Electrode

Shield

Cup

9-8218

Shield

Cup Body

9-8237

9-8241

Shield Cap, Gouging

A-03417

Tip

Shield Cup Assembly

Manual 0-2989 6-3 P A RTS LISTS

PARTS LISTS 6-4 Manual 0-2989

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION:

Close external

disconnect switch.

RESULT:

Power to system.

Connect work cable to workpiece.

Set output amperage.

System is ready

for operation.

ON / OFF switch to ON

AC indicator ON.

GAS indicator ON

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

Fan(s) ON.

when input

pressure is adequate

Power circuit ready.

ACTION:

RUN /

Rapid Auto Restart /

SET switch

to SET

RESULT:

Gas flows to set pressure.

Torch moved away from work (while

ACTION:

RUN /

Rapid Auto Restart / SET

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

RESULT:

Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate torch.

RESULT:

Gas flows briefly, then stops.

Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release torch trigger.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fan(s) shuts off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-03706A

Manual 0-2989 A-1 APPENDIX

APPENDIX 2: DATA TAG INFORMATION

Type of Power Supply (Note 1)

Plasma Cutting Symbol

Input Power Symbol

Input Power Specifications (Phase, AC or DC Hertz Rating)

Model:

Date of Mfr:

1/3

Output Current Type

Rated NoLoad Voltage

Degree of Protection

Conventional Load Voltage

Rated Supply Voltage (Note 2)

West Lebanon, NH USA 03784

S/N

Made in USA

Duty Cycle Factor

Rated Maximum Supply Current

1max 1eff

1Ø

3Ø

Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code

Regulatory Standard Covering This Type of Power Supply

Output Range (Amperage/ Voltage)

Duty Cycle Data (Note 3)

3Ø1Ø

Maximum Effective Supply Current

Manufacturer's Electrical Schematic File Number and Revision Level

NOTES:

1. Symbol shown indicates single- or three-phase AC input, static frequency converter-transformer-rectifier, DC output.

2. Indicates input voltages for this power supply. Most power supplies carry a label at the input power cord showing input voltage requirements for the power supply as built.

3. Top row: Duty cycle values. IEC duty cycle value is calculated as specified by the International ElectroTechnical Commission.

TDC duty cycle value is determined under the power supply

manufacturer'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.

Standard Symbols

AC DC

Phase

Art # A-03288

APPENDIX A-2 Manual 0-2989

APPENDIX 3: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary .

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary .

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow .

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow 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.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary .

3. Check all contactor points for severe arcing or pits, replace if necessary .

Manual 0-2989 A-3 APPENDIX

APPENDIX 4: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram

ATC Male Connector

Negative / Plasma

4 - Green / Switch

3 - White / Switch

2- Orange / PIP

1 - Black / PIP

4 3

Pilot

Front View

8 - Open

7 - Open

8 7

6 - Open

5 - Open

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector

4- Black Pendant Connector

3 - White Pendant Connector

2 - Orange / PIP

Front View

4 3

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green Pendant Connector Ground

8 7

7 - Green / Not Used

6 - Open

8 - Ground

6 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

7 - Open

ATC Female Receptacle

Front View

8 7

Pilot

ATC Female Receptacle

8 7

6 5

2 1

Front View

2 1

Negative / Plasma

4 - Switch

3 - Switch

2 - PIP

1 - PIP

A-03701

Negative / Plasma

4 - Switch

3 - Switch

2 - PIP

1 - Black / PIP

Pilot

Art # A-03799

APPENDIX A-4 Manual 0-2989

5 - White / Not Used

5 - Open

1 - PIP

Pilot

APPENDIX 5: TORCH CONNECTION DIAGRAMS

A. hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Po wer Supply: with ATC Receptacle

Torch

Head

PIP

Switch

Torch

Switch

Torch Leads

Black

Orange

Green

White

Negative / Plasma

Pilot

Male

ATC Leads

Connector

ATC Female

Receptacle

1 2 5 6 4 3 8 7

Power Supply

1 2 5 6 4 3 8 7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03797

B. Mechanized Torch Connection Diagram

Torch: Unshielded Mechanized SL100 Machine Torch Leads: Leads with ATC Connector and

Remote Pendant Connector

Po wer Supply: with ATC Female Receptacle

Male

ATC Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Torch Leads

Black

Orange

White

Green

Negative / Plasma

Pilot

To Remote Control

Remote Pendant

Connector

Black

White

Green

ATC Female

Receptacle

Power Supply

1 2 5 6 4 3 8 7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

Manual 0-2989 A-5 APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC

400/460V 1 PHASE

INPUT

400V 3 PHASE INPUT

400/460V

...OR...

3 PHASE INPUT

400V ’CE’ VERSION INCLUDES IN-LINE EMC FILTER

M1 FAN1

ON/OFF SW

MODE SW

RAR OFF

CURRENT ADJUST: 20 - 40 AMPS

CURRENT CONTROL/ LED PCB 19X1604

IGBT HEATSINK TEMP

INDUCTOR TEMP

230V

28VAC B 28VAC A

SW1

RUN

SW2

INV ON (RED)

LOGIC ASSY 19X2000

CHASSIS GND

SET

J14

TEMP

GAS DC

NTC

TS1

TS2

PRE SS GOOD INRUSH DONE

TORCH SWITCH

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

CURRENT SENSE A CURRENT SENSE A CURRENT SENSE B CURRENT SENSE B

(4)

(3)

(6)

(5)

(21) (22) (23) (24) (25) (26)

P14

(35)

(36)

(37)

(38)

(39)

(40)

(41)

(42)

(15) (16)

(17) (18)

+12VDC +12VDC

AGND AGND

W1 ON

SPARE

RUN/SET

OVERTEMP

28VAC A

GAS ON

CSR

PILOT ON

DC OK

OVTEMP

AC OK

+12V

POT HIGH

POT WIPER

POT LOW

- OUT

ISENSE

(1)

(2)

(3)

E14

P8 J8

1 2 3 4

1 2 343 4

1 2 3 4 5 6 7 8

P22

1 2 3 4 5 6 7 8

P2 J2

1 2 3 4

P23

121

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19

RTN

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

TIP

1 2 3 4

J26P26

1 2

1 2 3 4 5 6 7 8

J22

1 2 3 4 5 6 7 8

1 2 3 4

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

F1 (1/4A 500V)

R94 (460V) R93 (400V)

F1 (1/4A 500V) R93 (19X2033 400V) R94 (19X2060 460V)

INRUSH

FAN

POT HIGH POT WIPER POT LOW +12V AC GAS OVERTEMP DC

J23

CONTACTOR ON

SOL ENOID ON

MAIN BOARD ASSY 19X2033 (400V) ASSY 19X2060 (460V)

CHASSIS GND

THRU SCREW TERMINAL

E16 E28

E2 E1

(FILTERING)

28VAC B 28VAC A

28VAC A 28VAC B

+12V

+18V

TO BIAS SUPPLY

DC COMMON

PRE SS GOOD

E5 E13 E18

GATE DRIVE A RTN

GATE DRIVE B RTN

F2, 0.9A, (RESETABLE)

INPUT DIODE

ASSY 19X1811

GATE DRIVE A

GATE DRIVE B

TORCH SWITCH TORCH SWITCH +

PIP RTN

TORCH SW RTN

TORCH SW

28VAC A

28VAC B

ISENSE

J21 P21

121

J20 P20

121

+12V

GND CSR

J9 P9

PIP

2 3 4 5 6

GND

2 3

J4 P4

1 2 3 4 5 6

+12V

7 8

CSR

E6 E8

E14 E16

E22

1 2

1 2 3 4 5 6

1 2 3 4 5 6 7 8 9

E11

E12

E13

E15

E35

E9 E8

E21

E20

E26 E25 E23 E24

E19

E18 E5 E10

E6 E7 E17 E34

TEST CONN

MAIN TRANSFORMER

PRI

SEC

(33) (34)

(78)

ATC M A LE CONNECTOR ATC RECEIVER

PIP

TORCH SW

SOL1

PS1

ATC CONNECTION CONF IGURATION

GAS

SOLENOID

PRESSURE SWITCH

CLOSED WHEN PRE SSURE OK

MAIN CONTACTOR

(79)

(80) (81)

(7) (8)

(9) (10) (11) (12) (13) (14) (19) (20)

Art # A

-03692

APPENDIX A-6 Manual 0-2989

E28 E29

E32 E33

E38 E39

E40 E41

TOROID (INSTALLED ON 400CE ONLY)

24 25

OUTPUT DIODE ASSEMBLY 19X1720

12231314

24567

IGBT BOARD ASSY 19X1721

DC COMMON

GATE DRIVE

J18

GATE DRIVE

J19 P19

OUTPUT INDUCTOR

E36 E37

E42 E43

2 1

P18

2 1

E30 E31

WORK

COMP DESCRIPTION

FUS E, 1/4A 500V FNQ

F1 W1 MAIN CONTACTOR SW1

SW ITCH, ON/OFF

SW2

SW ITCH, RUN/SET M1 FAN , 4.5" 220VAC SOL1 GAS SOLENOID PS1 PRESS URE SWITCH

TEM P . S E NSOR, IGBT HEATSINK

TS1

TEM P . SENSOR, INDUCTOR

TS2 T1 AU X TRANSFORMER

MA IN TRANSFORMER

T5 C5 L1 OUTPUT INDUCTOR

NOTES: UNLESS OTHERWISE SPECIFIED

1. D EPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FO R REFERENCE ONLY

LOCATION

B3 F5 C2 C2 B2 F5 F5 D2 E2 B3

ALTE RNA TE 20-PIN HEADER

CSR

DC COMMON

+12VDC

TORCH SW -

TORCH SW +

2112 3

19X2041 OPTIONAL

AUTOMATION INTERFACE

PLUGS INTO J22

ON M AIN BOARD

(LE D PCB 19X1604)

J14 P14

AC TEMP

GAS

T O R C H

7 8

AUTO MATION ADAPTER HARNESS (REPLA CES CONNECTIONS FROM J22 TO J14)

20-P OSITION TERMINAL STRIP

TORCH SWITCH

3 4 5 6

OK TO MOVE 7 8 9

DIVIDED OUTPUT

12 13 14

REM O TE CURRENT CONTROL

15 16 17

DC COMMON

C&G

3 14 12

CPC

HOUSING

(+)

}

TOR CH SWITCH

(-)

}

OK TO MOVE

(+)

}

SC-11

(-)

LOG IC COMMON

(+)

}

ARC VOLTS (C&G)

(-)

E62

PILOT BOARD

ASSY 19X1905

E58

12 85

J28

+12V

GND

CSR

ISENSE

RAR OFF

Manual 0-2989 A-7 APPENDIX

PCB No: Assy No:

SupersedesScale

Date:

Tue sday, May 15, 2001

Drawn: R eferences

D.Lilja

Chk: App:

DWG No:

Size

42X1151

Art # A

-03692

Sheet

DateByR evisionsRev

(REL)

ECO 101

Last Modified:

Fr iday, October 10, 2003

DLL 05/27/03

In fo rma tio n Proprietary to THERMAL DYNAMICS CORPORATION.

No t F or Re lease, Reproduction, or Distribution without Written Consent. NOTE:

Un les s Oth erwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF)

15:05:29

TITLE:

SCHEMATIC,

CM51 400/460V SYSTEM 1O/3O

TH ERMAL DYNAMICS IN DUSTRIAL PARK No. 2 WE ST LEBANON, NH 03784 603-298-5711

Thermadyne CE CutMaster™ 51 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual