Thermal Dynamics CUTMASTER 81, 101 CUTMASTER Operating Manual

81

™

CUTMASTER

PLASMA CUTTING SYSTEM

Operating Manual

A-04517

Rev. AB.01 Date: March 14, 2007 Manual # 0-2956
Operating Features:

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 call 1-800­426-1888, or visit us on the web at www.thermal-dynamics.com.

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market­leading, 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.

W ARNINGS

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™ 81
Operating Manual Number 0-2956

Covered under U.S. Patents.

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

© Copyright 2003, 2004, 2005, 2006, 2007 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: March 14, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

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 Declaration of Conformity ............................................................................. 1-4

1.05 Statement of Warranty .................................................................................. 1-5

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 Features ................................................................................. 2-3

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

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

3.01 Unpacking .................................................................................................... 3-1

3.02 Lifting Options .............................................................................................. 3-1

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

3.04 Gas Connections .......................................................................................... 3-4

3.05 Torch Connections ........................................................................................ 3-8

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

4.01 Product Features .......................................................................................... 4-1

4.02 Preparations For Operating ........................................................................... 4-2

SECTION 5:

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

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

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

5.03 Basic Troubleshooting Guide ......................................................................... 5-6

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

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 ....................................................................................... 6-2

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

6.06 Torch Parts ................................................................................................... 6-3

TABLE OF CONTENTS (continued)

PATENT INFORMATION ............................................................................................................ 6-4

APPENDIX 1: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .......................................................................................................... A-1

APPENDIX 2: DATA TAG 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, 208/230 VOLT UNITS ................................................. A-6

APPENDIX 7: SYSTEM SCHEMATIC, 400 / 460- VOLT UNITS ............................................... A-8

APPENDIX 8: SYSTEM SCHEMATIC, 600 VOLT UNITS ....................................................... A-10

APPENDIX 9: Publication History ........................................................................................... A-12

Global Customer Service Contact Information ..................................................... Inside Rear Cover

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 oper­ating 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
follow all warnings, safety precautions and instruc­tions before using the equipment. Call 1-603-298­5711 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 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.”

Manual 0-2956 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 alu-
minum 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 Subsection 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 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 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 Superintendent 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, 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 Manual 0-2956

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
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 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
obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM­MENDED 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
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018

Manual 0-2956 1-3 GENERAL INFORMATION

1.04 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’
(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.

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 requirements. Among them are:

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

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

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

ated accessories.

* 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

GENERAL INFORMATION 1-4 Manual 0-2956

1.05 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™ 1Series 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)
CUTMASTER™ 51 3 Years 1 Year
CUTMASTER™ 81 3 Years 1 Year
CUTMASTER™ 101 3 Years 1 Year
CUTMASTER™ 151 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 January 15, 2004

Manual 0-2956 1-5 GENERAL INFORMATION

This Page Intentionally Blank

GENERAL INFORMATION 1-6 Manual 0-2956

SECTION 2:

%

%

%

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dy­namics CutMaster 81 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

CutMaster 81 Power Supply Specifications

208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz

Input Power

Input Power Cable
Output Current
Power Supply Gas Filtering Ability

Ambient Temperature

208/230V

and 460V Units

400V Units

600V Units

* 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.

460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (517 - 632 VAC), Three Phase, 60 hz
Cable for 208/230 VAC unit includes plug.
20 - 60 Amps, Continuously Adjustable
Particulates to 20 Microns

CutMaster 81 Power Supply Duty Cycle*

40° C (104° F)

IEC

Rating
Duty Cyc le
Current 60A 60A 60A 60A 45A 45A
DC Voltage 104V 109V 104V 109V 98V 98V
Duty Cyc le
Current 60A n/a 60A n/a 45A n/a
DC Voltage 104V n/a 104V n/a 98V n/a
Duty Cyc le
Current 60A 60A 60A 60A 43A 43A
DC Voltage 104V 109V 104V 109V 97V 97V

TDC

Rating

50% 60

50% 60

50% 60

IEC

Rating

TDC

Rating

IEC

Rating

100%

100%

100%

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 torch, consumables, and
actual cutting operation.

Manual 0-2956 2-1 INTRODUCTION

NOTE:

Power Supply Dimensions & Weight Ventilation Clearance Requirements

Art # A-03379

83 lb / 37.6 kg

150 mm

17.3 in /
439 mm

6"

24"

0.6 m

27.5 in / 696 mm

6"

150 mm

6"

150 mm

A-03572

12.4 in /
315 mm

2.03 Input Wiring Specifications

CutMaster 81 Input Wiring Requireme nts

Input Power Input Current Input Suggested Sizes (See Notes)

Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)

(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph

208 50/60 11.8 57 60 6 6
230 50/60 11.8 52 60 6 6
400 50/60 11.1 16 20 10 10
460 60 11.7 27 30 10 10
460 60 10.8 16 20 12 12

600 60 10.5 10 15 12 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

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 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 0-2956

NOTES

2.04 Power Supply Features

Handle and Leads Wrap

Art # A-04507

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 0-2956 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 stream to at least

0.85 microns. This filter increases performance and improves consumables parts life.

B. Two Stage Air Filter Kit

For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0
microns. This filter is pre-assembled at the factory and needs only to be installed on the power supply.

C. High Pressure Regulators

High pressure regulators are available. The regulators are used to set the proper compressed air pressure.

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. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle
is 30" / 762 mm high.

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.

G. Vinyl Cover

Nylon canvas power supply dust cover with water resistant finish, large outer pocket for storing manuals or spare
consumables, and adjustable draw cord for tight fit.

INTRODUCTION 2-4 Manual 0-2956

SECTION 3: INSTALLATION

3.01 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, purchase date and vendor name, in the information
block at the front of this manual.

3.02 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 0-2956 3-1 INSTALLATION

3.03 Primary Input Power Connections

CAUTION

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

A. Connections to 208 / 230 - Volt Power

The 208 / 230 - Volt power supply includes a factory - installed input power cable and plug.

1. Check your power source for correct voltage before plugging in the unit.

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

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2.03.).

B. Connections to 400 - Volt, 460 - Volt, or 600 - Volt Three - Phase Power

These Power Supplies are equipped with a four - conductor input power cable for three - phase input power. The
460 - Volt Power Supply will accept 460 - VAC, Single - Phase input power with a change of input power cable.

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 (refer 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.

INSTALLATION 3-2 Manual 0-2956

C. Connections to 460 - Volt Single- Phase Power

The 460 - Volt Power Supply will accept 460 - VAC, Single - Phase input power with a change of input power cable.

1. Remove the Power Supply cover per section 5.04.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out
of the power supply.

4. Pass a customer - supplied, three - conductor input power cable through the access opening in the back panel
of the power supply. Refer to Section 2 for power cable specifications. Tighten the through - hole protector to
secure the power cable.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2.03.).

5. Strip back the insulation on the individual wires.

6. Connect to main input contactor as follows:

• Line 1 wire to terminal L1.

• Line 3 wire to terminal L3.

7. Connect the ground wire to Ground (Earth). The Ground wire connection requires a ring terminal.

Input Power Connections, 460 VAC, Single - Phase

8. Replace the Power Supply cover.

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

Manual 0-2956 3-3 INSTALLATION

Ground Wire
with Ring
Terminal

Input Cable

A-03041

L1

L3

L1 L2 L3

Main Input
Contactor

3.04 Gas Connections

A. Connecting Air Supply to Unit

Use only compressed air with this power supply.

The connection is the same for compressed air from a compressor from 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. Other fittings can be
used.

NOTE

For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

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

INSTALLATION 3-4 Manual 0-2956

B. Installing Optional Single - Stage Air Filter

An optional filter kit is recommended for improved filtering with compressed 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
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
Connect as follows:

Inlet Port

Regulator/Filter
Assembly

Bowl

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

Art # A-03000

Optional Single - Stage Filter Installation

Manual 0-2956 3-5 INSTALLATION

C. Installing Optional Two - Stage Air Filter Kit

t

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 manufacturer's instructions. Do Not use
Teflon tape as a thread sealer as small particles of the tape may break off and block the small air passages in the torch.

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 Por

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

INSTALLATION 3-6 Manual 0-2956

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 regula­tors.

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 500 scfh (236 lpm).

4. Connect supply hose to the cylinder.

NOTE

Pressure should be set at 100 psi (6.9 bar) at the high pressure 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 manufacturer's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Manual 0-2956 3-7 INSTALLATION

3.05 Torch Connections

If necessary, connect the torch 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.

Art # A-05556

ATC Female Receptacle
(Panel Mounted)

Control Cable
Connector (Mechanized
Torches Only)

1

2

ATC Male
Connector

Connecting the Torch to the Power Supply

INSTALLATION 3-8 Manual 0-2956

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

40

20

1

60

Art # A-03592

2

Manual 0-2956 3-9 INSTALLATION

This Page Intentionally Blank

INSTALLATION 3-10 Manual 0-2956

SECTION 4: OPERATION

4.01 Product Features

A. 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). At output set­tings over 40 Amps, the power supply automati­cally reduces output current to 40 Amps if the tip
touches the workpiece.

A

DRAG

CUTTING

RANGE

STANDOFF

CUTTING

RANGE

20

40

60

Art # A-03743

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

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 gas
pressure for power supply operation is
present. Minimum pressure for power sup­ply operation is not sufficient for torch op­eration.

ON / OFF Switch

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

RUN / RAPID AUTO RESTART / SET Switch

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 gas pressure and purging lines.

Manual 0-2956 4-1 OPERATION

DC Indicator

Indicator is ON when DC output circuit is
active.

4.02 Preparations For Operating

Perform the following steps at the start of each operating session:

WARNING

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

A. Torch Parts Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type
of operation, and with the amperage output of this Power Supply (60 amps maximum). Refer to the Torch
Manual.

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. Gas Selection

Ensure compressed air source meets requirements (refer to Section 3.4). Check connections and turn gas supply
on.

E. Connect Work Cable

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

Art # A-04509

OPERATION 4-2 Manual 0-2956

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 gas pressure for power supply operation.

NOTE

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

A

40

20

60

Art # A-03594

Manual 0-2956 4-3 OPERATION

G. Set Operating Pressure

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

A

40

20

1

2. Adjust gas pressure per the gas settings chart.

CutMa ster 81 Ga s Pre ssure Settings

Leads

Length

Up to 25'

(7.6 m)

Over 25'

(7.6 m)

SL60

(Hand Torch)

70 psi

4.8 bar
80 psi

5.5 bar

SL100

(Machine Torch)

65 psi

4.5 bar
70 psi

4.8 bar

60

Art # A-03592

65 - 80 psi /

4.5- 5.5 bar

2

Pressure Control Knob /
Bouton De Contrôle
de Pression

OPERATION 4-4 Manual 0-2956

Art # A-03581

H. Select Current Output Level

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

2. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece),
or up to 60 amps for standoff cutting. At output settings higher than 40 amps, the power supply automati­cally reduces output current to 40 amps if the torch tip contacts the workpiece.

A

2

20

Art # A-03593

40

1

60

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 0-2956 4-5 OPERATION

K. Postflow

Release the trigger to stop the cutting arc. Gas continues to flow for approximately 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

Turn 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

40

20

60

Art # A-03595

OPERATION 4-6 Manual 0-2956

SECTION 5:

SERVICE

5.01 General Maintenance

A. O-Ring Lubrication

An o-ring on the Torch ATC Male Connector requires lubrication on on a regular basis, depending on how fre­quently the torch is disconnected and re-connected. 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 0-2956 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. Tighten 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 0-2956

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. Turn 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

(Cat. No. 9-7743)

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 replacement 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 0-2956 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.

WARNING

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 torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque 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 0-2956

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 Torch 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 Piloting

a. Worn torch parts

b. Non - Genuine Thermal Dynamics parts used

c. Incorrect gas pressure

Manual 0-2956 5-5 SERVICE

5.03 Basic Troubleshooting Guide

WARNING

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 Troubleshooting: 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 returned 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 prod­uct.

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 Type)

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. Torch is not connected properly to Power Supply

a. Turn power supply ON / OFF switch to OFF (down). Check torch connection to Power Supply. Tighten 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 0-2956

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 correct. Refer to Section 2, Input Wiring Requirements.

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. Torch 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; Torch 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. Torch 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. Torch 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 mini­mum required for torch operation.)

a. Adjust gas pressure per torch manual.

Manual 0-2956 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. Turn

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 Vent 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 0-2956

I. Torch 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. (Torch 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. Torch tip or electrode missing

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

ON (up).

K. No cutting output; Torch 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 Torch

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. Torch 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 Torch 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. Torch is being moved too fast across workpiece

a. Reduce cutting speed.

5. Torch being dragged on work. ('Tip saver' circuit active) At output current settings greater than 40 amps, the power
supply automatically reduces current to 40 amps if the torch tip contacts the workpiece.

a. Lift torch off work.

Manual 0-2956 5-9 SERVICE

6. Excessive oil or moisture in torch

a. Put RUN / RAPID AUTO RESTART / 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.

7. Fluctuations in input power

a. Have electrician check input line voltage.

8. 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 Torch 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 0-2956

5.04 Power Supply Basic Parts Replacement

WARNING

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

Art # A-04510

Lower
screws

Ground wire

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

Manual 0-2956 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 screws.

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 0-2956

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 proper 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 #

CutMaster 81 Power Supply

1 208 / 230 VAC, Single-Phase, 50 / 60 Hz, with input power cable 3-1120-1

and plug
1 400 VAC, Three - Phase, 50/60 Hz, with input power cable 3-1120-3
1 460 VAC, Three - Phase, 60 Hz, with input power cable 3-1120-2
1 600 VAC, Three - Phase, 60 Hz, with input power cable 3-1120-5

Manual 0-2956 6-1 PARTS LISTS

6.04 Replacement Parts

Qty Description Catalog #

Fuse
1 for 208 / 230VAC Power Supply 9-8588
1 for 400 VAC Power Supply 9-8602
1 for 460 VAC Power Supply 9-8583
1 for 600 VAC Power Supply 9-8638
1 Regulator / Filter Assembly Replacement Element 9-4414

Input Power Cord
1 for 208 / 230VAC Power Supply 9-8596
1 for 400 VAC Power Supply 9-8562
1 for 460 VAC Power Supply 9-8593
1 for 600 VAC Power Supply 9-8593

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 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
1 Nylon Dust Cover 9-7072

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

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

PARTS LISTS 6-2 Manual 0-2956

Assembled Filter

Art # A-02476

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

6.06 Torch Parts

8-3487
O-Ring
(Black)

Electrode

9-8215

8-3486
O-Ring

(Red)

Start

Cartridge

9-8213

9-8207 (40A)

9-8210 (60A)

Shield

Cup

9-8218

Shield

Cup Body

9-8237

Shield

Cup

9-8218

Shield Cap, Drag

9-8235 (50-60A)

Shield Cap, Deflector

9-8243

Standoff

Cutting Guide

9-8281

Art # A-03795

9-8225 - A (40A)
9-8226 - B
9-8227 - C
9-8228 - D

Torch Head

Electrode

Start Cartridge

Shield Cup

Tip

Shield

Cup Body

9-8237

9-8241

Shield Cap, Gouging

Manual 0-2956 6-3 PARTS LISTS

Standoff Cutting Guide

Art # A-04070

PATENT INFORMATION

The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512

Catalog Number Description

9-8235 Shield Cap, Drag 50-60A
9-8236 Sheild Cap, Drag 70-100A
9-8237 Shield Cup, Body
9-8238 Shield Cap, Machine 50-60A
9-8239 Shield Cap, Machine 70-100A
9-8244 Shield Cap, Drag 40A
9-8245 Shield Cap, Machine 40A

PARTS LISTS 6-4 Manual 0-2956

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-03706

Manual 0-2956 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:

f

1/3

Rated No­Load Voltage

Degree of Protection

1

f

2

Output Current Type

U

0

X

I

=

U

2

Conventional
Load Voltage

U

1

Rated Supply
Voltage (Note 2)

West Lebanon, NH USA 03784

S/N

Made in USA

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1eff

1

1Ø

I

3Ø

1

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)

I

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.

APPENDIX A-2 Manual 0-2956

Standard Symbols

AC

DC

Phase

Ø

Art # A-03288

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 0-2956 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

2

1

Pilot

Front View

6

5

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

2
1

UNSHIELDED MACHINE TORCH

Negative / Plasma

8 - Green ­Pendant
Connector
Ground

8

7

6

5

7 - Green /
Not Used

6 - Open

6 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

8 - Ground

7 - Open

ATC Female Receptacle

Front View

8
7

6
5

Pilot

ATC Female Receptacle

8

7

6
5

2
1

Front View

4
3

2
1

Negative /
Plasma

4 - Switch

3 - Switch

4
3

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 0-2956

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
Power 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

Power Supply: with ATC Female Receptacle

Male

ATC Leads

Connector

Torch

Head

PIP

Switch

Not

Used

Pilot Lead

Torch
Leads

Black

Orange

White

Green

Negative / Plasma Lead

To Remote Control

Remote

Pendant

Connector

Black

White

Green

ATC Female

Receptacle

Power
Supply

1

2

5

6

4

3

8

7

1

2

5

6

4

3

8

7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

Manual 0-2956 A-5 APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC, 208/230 VOLT UNITS

208/230V
1 PHASE
INPUT

A

B

ON/OFF SW

C

MODE SW

CURRENT ADJUST:
20 - 80 FOR CM101
20 - 60 FOR CM81

CURRENT
CONTROL/
LED PCB
19X1604

D

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

LOGIC
ASSY 19X1913 - CM101
ASSY 19X2285 - CM101
ASSY 19X1932 - CM81
ASSY 19X2284 - CM81

E

INV ON

DRAG ON

SW ON

F

Art # A-07153

1

M1
FAN1

M2
FAN2

(46)

RAR OFF

(PILOT PCB)

(F9)

DC COM
DC COM

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

D13

GAS ON

D25

OVTEMP

D33

TORCH SW

TORCH SW RTN

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

- OUT SENSE
CURRENT SENSE
CURRENT SENSE

CURRENT SENSE RTN
CURRENT SENSE RTN

DC COM
DC COM

TIP VOLTS

1

L1

L2

L3

L4

28VAC B
28VAC A

SW1

RUN

SW2

NTC

P1

+12VDC
+12VDC

W1 ON

CSR

DC OK

AC OK

+12V

ISENSE3233

230V

230V

tt

SET

AC

TEMP

GAS

DC

TS2

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

34
35
36

J14

TS1

P13

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

EXTENDER
ASSY 19X1775

W1

(1)

W1

(2)

W1

(3)

W1

(78)

E22

CHASSIS
GND

(4)

P11

(5)

P15 J15

(7)
(7)

(6)
(6)

P18 J18

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

P14 P27 J27

(35)

1

1

(36)

2

2

(37)

3

3

(38)

4

4

(39)

5

5

(40)

6

6

(41)

7

7

(42)

8

8

P29

P32 J32

J12

J11

1

1

2

2

3

3

4

4

1

1

2

2

3

3

4

4

5

5

6

6

1

1
2

2
3

3
4

4

5

5
6

6

7

7
8

8

1

1

POT HIGH

2

POT WIPER

2

3

POT LOW

3

4

+12V

4

5

AC

5

6

6

GAS

7

7

OVERTEMP

8

8

DC

J29

1

2

2
3

3

414

121
2

J43

1

1

2

2

3

3

4

4

5

5

6

6
7

7
8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

19

19

20

20

21

21

22

22

23

23

24

24

25

25

26

26

27

27

28

28

29

29

30

30

31

31

32

32

33

33

34

34

35

35

MAIN BOARD

36

36

ASSY 19X1912

2

(6/10A 600V)

K2

2

E1E1

E33E33

K1

R30

(0 ohm)

F1

K1

INRUSH

K2

FAN

K5

CONTACTOR ON

K4

SOLENOID ON

E2E2

(FILTERING)

T1

28VAC A
28VAC B

+12VDC

+18V

+18V

+18V

(33)

E3E3

K1

28VAC A28VAC B

3

E5

E13

E18

INPUT DIODE

ASSY 19X2073

COPPER STRAP

TO BIAS SUPPLY

CURRENT
SENSE

K4

F2, 0.9A,
(RESETABLE)

PRESS GOOD

K5

3

J26

J31

J30

J25

-OUT SENSE
DC COM

TIP SENSE

+12VDC

CSR

I SENSE

TIP VOLTS

PIP RTN

TORCH SW RTN

TORCH SW

28VAC A

GND

28VAC B

E6
E8

E14
E16

1
2

1
2

1

22

1
2

1
2
3
4

5
6
7

8

J34 P34

1

2

PIP

3

4

5

66

J23

1
2
3

J24

1

2

3

4

5

6

7

8

E7

E15

E4

E20

E23

E30

P26

1
2

P31

1
2

P30

1

P25

1
2

(TS2)

E5

(TS1)

E6

E10

E27

E32

P33J33

(70)

1

(71)

2

(72)

3

(73)

4

(74)

5

(75)

6
7

(77)

8

ATC CONNECTION
CONFIGURATION

(STANDARD)

(78)

1

(79)

2
3
4

(80)

5

(81)

TEST
CONN

P24

(8)

1

(9)

2

(10)

3

(11)

4

(12)

5

(13)

6
7
8

MAIN

4

MAIN TRANSFORMER

T5

PRI

PRI

1

1

PIP

2

2

575
7
4

4

TORCH

3

3

SW

8

8

ATC MALE
CONNECTOR

ATC RECEIVER

SOL1

BA

GAS
SOLENOID

PS1

CLOSED WHEN

PRESSURE OK

W1

CONTACTOR

4

5

E12A

E17A

24
25

E19A

E21A

E12B

E17B

24
25

E19B

E21B

ASSY 19X1756

SEC

SEC

P39

SOL2

BA

T6

11 15

PRI

SEC

6

10

FACTORY INSTALLED OPTIONAL
TORCH MOUNTED GAS SOLENOID

PRESSURE
SWITCH

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

12231314

7

IGBT BOARD

ASSY 19X1756

12231314

IGBT BOARD

J39

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

GATE
DRIVE

28

27

GATE
DRIVE

1

2456

GATE
DRIVE

28

27

GATE
DRIVE

1

24567

E52 E47

5

J7B

J3A

J7A

J3B

1

2

1

2

121

2

1

2

P3A

1

2

E9A

E11A

P7A

1

2

P3B

E9B

E11B

P7B

1

2

APPENDIX A-6 Manual 0-2956

6

7

8

9

10

COMP DESCRIPTION LOCATION

F1

FUSE, 6/10A 600V KTK

FUSE, 0.9A, RESETABLE

F2

OUTPUT INDUCTOR

L1

FAN, 4.5" 220VAC

M1

FAN, 4.5" 220VAC

M2

PRESSURE SWITCH

PS1

GAS SOLENOID

SOL1

SW1

SWITCH, ON/OFF

SWITCH, RUN/SET/RAR

SW2

MAIN TRANSFORMER

T5

TEMP. SENSOR, IGBT HEATSINK

TS1

TEMP. SENSOR, INDUCTOR

TS2

MAIN CONTACTOR

W1

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

B2

F3

D7

B1

C1

F4

F4

C1

C1

D4

D1

E1

F4

A

ADAPTER HARNESS USED

WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION
(REPLACES CONNECTIONS
FROM J27 TO J14)

E49 E45 E35

E62

JUMPER

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E48B

E53B
E54B

OUTPUT DIODE
ASSEMBLY
19X1757

E50A

E48A

E53A
E54A

E34A

E37 E58

E39A

E56A
E60A

POWER OUTPUT BOARD ASSY 19X1914

6

PLUGS INTO J27

*

ON MAIN BOARD

(LED PCB 19X1604)

AC

TEMP

GAS

DC

OUTPUT INDUCTOR

E43

PILOT

E34B

7

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

P3

J14 P14

1
2
3
4
5
6
7
8

L1

E32

E64

E36 E57

E39B

E56B
E60B

1
2
3
4
5
6
7
8

CURRENT
SENSE

(47)
(48)
(49)

(CSR) (NEG)

CSR Vo

CHASSIS
GND

NOMMOC CDNOMMOC CD

E3 E1

+12VDC
DC COM

CSR

ISENSE

1
2
3
4
5
6
7
8

E61

8

2112
3

P1

(CSR)

1

(51)

2

(52)

3
4

(TS2)

5

(TS1)

6
7

(NEG)

8

(E64)

(E64)

(E35)

(E62)

(MODE SW)

J40

P40

1

1

2

2

3

3

4

4
5

5
6

6

7

7

8

8

E63

THRU SCREW TERMINAL

J3

3

19X2041

OPTIONAL
AUTOMATION
INTERFACE

J1

1
2
3
4
5
6
7
8

RAR OFF

(14)
(15)

(17)

(18)

J4

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6

CSR

5

DC COMMON

4

+12VDC

3
2

TORCH SW ­TORCH SW +

Vo

(C1)

1

(E58)

(52)
(51)

(46)

ECO 101136

AA

ECO 101314

AB

ECO 101429 HAS 06/09/04

AC

ECO 101614

AD

ECO B028 RS

AE

ECO B016 RWH 01/27/06

AF

Friday, January 27, 2006

Friday, January 27, 2006

Friday, January 27, 2006

Last Modified:

Last Modified:

Last Modified:

P4

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1

E58

J1

1
2

1
2

3

5

8

J28

(REL) DLL 05/07/03

ALTERNATE 20-PIN HEADER

20-POSITION TERMINAL STRIP

J2

1

+

2

TORCH SWITCH

3

-

4
5
6

OK TO MOVE
7
8
9

+

10

DIVIDED OUTPUT

11

-

12
13
14

REMOTE CURRENT CONTROL

15
16

DC COMMON

17
18

+

19

C&G

20

-

(57)

(59)

(61)

(63)

E62

PILOT BOARD
ASSY 19X2157

DateByRevisionsRev

DateByRevisionsRev

DateByRevisionsRev

HAS 02/11/04

HAS 03/22/05

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

01/09/06

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

11:05:29

11:05:29

11:05:29

CM81/101 208/230V SYSTEM

CM81/101 208/230V SYSTEM

CM81/101 208/230V SYSTEM

9

CPC

HOUSING

(56)

4
3

(58)

14
12

(60)

6
5

(62)

8
9

(64)

7

ATC RECEIVER
ATC MALE CONNECTOR

WORK

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

(+)

TORCH SWITCH

}

(-)

}

OK TO MOVE

(+)

}

SC-11

(-)

LOGIC COMMON

(+)

}

ARC VOLTS (C&G)

(-)

T
O
R
C
H

THERMAL DYNAMICS

THERMAL DYNAMICS

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784

WEST LEBANON, NH 03784

WEST LEBANON, NH 03784
603-298-5711

603-298-5711

603-298-5711

10

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:
Scale

Scale

Scale

Date:

Date:

Date:

Drawn: References

Drawn: References

Drawn: References

Chk: App:

Chk: App:

Chk: App:

Size

Size

Size

Supersedes

Supersedes

Supersedes

05/07/03

D.Lilja

Sheet

Sheet

Sheet

11

11

11

of

of

of

DWG No:

DWG No:

DWG No:

42X1136

42X1136

42X1136

D

D

D

Art # A-07153

B

C

D

E

F

Manual 0-2956 A-7 APPENDIX

APPENDIX 7: SYSTEM SCHEMATIC, 400 / 460- VOLT UNITS

208/230V
1 PHASE

A

INPUT

400V
3 PHASE
INPUT

400V 'CE' VERSION
INCLUDES IN-LINE

B

EMC FILTER

ON/OFF SW

C

MODE SW

CURRENT ADJUST:
20 - 80 FOR CM101
20 - 60 FOR CM81

CURRENT
CONTROL/
LED PCB
19X1604

D

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

LOGIC
ASSY 19X1913 - CM101
ASSY 19X2285 - CM101
ASSY 19X1932 - CM81
ASSY 19X2284 - CM81

E

INV ON

DRAG ON

SW ON

F

Art # A-07152

1

415/400V

/460V
3 PHASE
INPUT

M1
FAN1

M2
FAN2

(46)

RAR OFF

(PILOT PCB)

(F9)

+12VDC

+12VDC
DC COM
DC COM

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

D13

GAS ON

D25

OVTEMP

D33

TORCH SW

TORCH SW RTN

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

- OUT SENSE
CURRENT SENSE
CURRENT SENSE

CURRENT SENSE RTN
CURRENT SENSE RTN

DC COM
DC COM

ARC HOLD

ISENSE3233

TIP VOLTS

1

RUN

W1 ON

DC OK

AC OK

+12V

L1

L2

L3

230V

230V

28VAC B
28VAC A

SW1

SW2

NTC

tt

P1

CSR

SET

AC

TEMP

GAS

DC

TS2

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

34
35
36

TS1

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

J14

1
2
3
4
5
6
7
8

P13

1
2
3
4
5
6
7
8
9

EXTENDER
ASSY 19X1775

W1

W1

W1

CHASSIS GND

E22

P11 J11

(4)

(5)

(7)
(7)

(6)
(6)

P18

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

P14 J27P27

(35)

1

(36)

2

(37)

3

(38)

4

(39)

5

(40)

6

(41)

7

(42)

8

P29

P32 J32

J12 J43

2

(1)

(2)

(3)

E33

1

1

2

2

3

3

4

4

R29 (415/460/600V)

R78 (400V)

R30 (208/230V)

F1

J15P15

1

1

2

2

K2

3

3

4

4

5

5

6

6

SEE TABLE 1 FOR
F1, R29,R30 & R78

J18

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

1

1

POT HIGH

2

POT WIPER

2
3

3

POT LOW

4

+12V

4

AC

5

5

6

6

GAS

7

7

OVERTEMP

8

8

DC

J29

1

2

2
3

3

414

121
2

1

1

2

2

3

3

4

4

5

5

6

6
7

7
8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

19

19

20

20

21

21

22

22

23

23

24

24

25

25

26

26

27

27

28

28

29

29

30

30

31

31

32

32

33

33

34

34

35

35

36

36

CONTACTOR ON

SOLENOID ON

MAIN BOARD
ASSY 19X1930 (400V)
ASSY 19X2228 (415V)
ASSY 19X1929 (460V)

2

E1

K1

+12VDC

K1

INRUSH

K2

FAN

K5

K4

E2

(FILTERING)

T1

28VAC A
28VAC B

+18V

+18V

+18V

E3

K1

E5

E13

E18

28VAC A28VAC B

TO BIAS SUPPLY

K4

PRESS GOOD

K5

3

INPUT DIODE

ASSY 19X2073

ARC HOLD

CURRENT

SENSE

TORCH SW RTN

F2, 0.9A,
(RESETABLE)

3

J26

J31

J30

J25

28VAC A

28VAC B

-OUT SENSE
DC COM

TIP SENSE

+12VDC

CSR

I SENSE

TIP VOLTS

PIP RTN

TORCH SW

28VAC A

GND

28VAC B

E6
E8

E14
E16

1
2

1
2

1
22

1
2

J33 P33

1
2
3
4
5
6
7
8

J34

1

PIP

2
3
4
5
66

J23

1
2
3

J24

1
2
3
4
5
6
7
8

E7

E15

E4

E20

E23

E30

1
2

1
2

1

1
2

E34
E36
E35
E5
E6

E10

E27

E32

1
2
3
4
5
6
7
8

P34

(78)

1

(79)

2
3
4
5

TEST
CONN

P24

1
2

(10)

3

(11)

4

(12)

5

(13)

6
7
8

P26

P31

P30

P25

(80)
(81)

(8)
(9)

(TS2)

(TS1)

(70)
(71)
(72)
(73)
(74)
(75)

(77)

MAIN TRANSFORMER

ATC CONNECTION
CONFIGURATION

(STANDARD)

1

1

2

2

575
7
4

4
3

3
8

8

ATC MALE
CONNECTOR

ATC RECEIVER

A

GAS
SOLENOID

PS1

MAIN

CONTACTOR

PRI

PRI

PIP

TORCH
SW

SOL1

W1

4

E12A

E17A

12231314

24
25

E19A

E21A

24567

IGBT BOARD

ASSY 19X1756

E12B

E17B

E19B

E21B

24
25

IGBT BOARD
ASSY 19X1756

12231314

28

27

1

24567

T5

SEC

SEC

P39

J39

1

1

2

2
3

3
4

4

5

5

6

6
7

7
8

8

SOL2

BA

T6

11 15

PRI

SEC

6

10

FACTORY INSTALLED OPTIONAL
TORCH MOUNTED GAS SOLENOID

B

PRESSURE
SWITCH

CLOSED WHEN
PRESSURE OK

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

4

GATE
DRIVE

28

27

GATE
DRIVE

1

GATE
DRIVE

GATE
DRIVE

5

E52

5

J3B

J7B

J3A

J7A

1

2

1

2

P3A

1

2

E9A

E11A

P7A

1

2

P3B

11

22

E9B

E11B

P7B

11

22

E47

APPENDIX A-8 Manual 0-2956

6

7

8

TABLE 1

19X1930 19X1929

19X2228

415V

400V 460V

R78

R29

R30

F1

ZERO-OHM

115X465-2

4/10, 500V

X X X X X

21X186

X X X X X

ZERO-OHM
115X465-2

X X X X X

4/10, 500V

21X186

X X X X X

ZERO-OHM

115X465-2

1/4A, 500V

21X183

9

10

COMP DESCRIPTION LOCATION

SEE CHART 1

F1

0.9A, (RESETABLE)

F2

OUTPUT INDUCTOR

L1

FAN, 4.5" 220VAC

M1

FAN, 4.5" 220VAC

M2

PRESSURE SWITCH

PS1

GAS SOLENOID

X X X X XX X X X X

SOL1

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET/RAR

SW2

MAIN TRANSFORMER

T5

TEMP. SENSOR, IGBT HEATSINK

TS1

TEMP. SENSOR, INDUCTOR

TS2

MAIN CONTACTOR

W1

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

B2

F3

D7

B1

C1

F4

F4

C1

C1

D4

D1

E1

F4

A

E65E65

E50A
E48A

E53A
E54A

OUTPUT DIODE
ASSEMBLY
19X1757

E34A

E39A

E56A
E60A

POWER OUTPUT BOARD ASSY 19X1914

6

E49 E45

TIP

E58E37

MOC CD

ADAPTER HARNESS USED

WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION

(REPLACES CONNECTIONS

FROM J27 TO J14)

E62

JUMPER

E48B

E53B
E54B

NOM

*

(LED PCB 19X1604)

E35

PILOT

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

7

PLUGS INTO J27
ON MAIN BOARD

J14 P14

1
2
3

AC

4
5
6

TEMP

7
8

GAS

DC

OUTPUT INDUCTOR

L1

E32

E43

E64

E36 E57

E34B

E39B

E56B

E60B

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

ALTERNATE 20-PIN HEADER

J3

1
2
3
4
5
6
7
8

E61

CURRENT

SENSE

MOC CD

1
2
3
4
5
6
7
8

NOM

(47)
(48)

(49)

(CSR) (NEG)

E3 E1

CSR Vo

J40

+12VDC
DC COM

CSR

ISENSE

E63

8

P3

2112
3

3

19X2041

OPTIONAL
AUTOMATION
INTERFACE

J1

P1

(CSR)

CSR

1

1

(51)

2

2

DC COMMON

(52)

+12VDC

3

3

(TIP)

TIP

4

4

(TS2)

5

5

TORCH SW -

(TS1)

6

TORCH SW +

6

7

7

(NEG)

8

8

Vo

99

ARC HOLD

(E64)

(E64)

(E35)

(E62)

(C1)

(MODE SW)

RAR OFF

P40

(14)

1

1

(15)

2

2

3

3
4

4

(17)

5

5
6

6

7

7

(18)

8

8

CHASSIS GND
THRU SCREW TERMINAL

Rev

Rev

Rev

ECO B028

AJ

ECO B016

AK

Last Modified:

Last Modified:

Last Modified:

P4

J4

20

20

19

19
18

18
17

17
16

16

15

15

14

14

13

13

12

12

11

11
10

10

9

9
8

8

7

7
6

6
5

5

4

4

3

3

2

2

1

1

(E58)

E58

(52)

1

(51)

2

1
2

(46)

3

5

8

J28

Friday, January 27, 2006

Friday, January 27, 2006

Friday, January 27, 2006

J1

J2

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

E62

PILOT BOARD
ASSY 19X2157

DateByRevisions

DateByRevisions

DateByRevisions

01/09/06

RS

01/27/06

RWH

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

CM81/101 400/415/460V SYSTEM

CM81/101 400/415/460V SYSTEM

9

CM81/101 400/415/460V SYSTEM

20-POSITION TERMINAL STRIP

+

TORCH SWITCH

-

OK TO MOVE

+

DIVIDED OUTPUT

-

REMOTE CURRENT CONTROL

DC COMMON

+

C&G

-

}

OHMIC SENSE RELAY

ARC HOLD
ARC HOLD RETURN

CPC
HOUSING

(56)

(+)

4

(57)

3

(58)

14

(59)

12

(60)

(+)

6

(61)

5

(62)

8

(63)

9

(64)

7

ATC RECEIVER
ATC MALE CONNECTOR

T
O
R
C
H

(+)

WORK

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

TORCH SWITCH

}

(-)

}

OK TO MOVE

SC-11

}

(-)

LOGIC COMMON
ARC VOLTS (C&G)

}

(-)

THERMAL DYNAMICS

THERMAL DYNAMICS

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2

INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784

WEST LEBANON, NH 03784

WEST LEBANON, NH 03784
603-298-5711

603-298-5711

603-298-5711

10

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:
Scale

Scale

Scale

Supersedes

Supersedes

Supersedes

Date:

Date:

Date:

05/07/03

Drawn: References

Drawn: References

Drawn: References

D.Lilja

Sheet

Sheet

Sheet

Chk: App:

Chk: App:

Chk: App:

11

11

11

of

of

of

DWG No:

Size

DWG No:

Size

DWG No:

Size

42X1135

42X1135

42X1135

D

D

D

Art # A-07152

B

C

D

E

F

Manual 0-2956 A-9 APPENDIX

APPENDIX 8: SYSTEM SCHEMATIC, 600 VOLT UNITS

600VAC
3 PHASE

A

INPUT

B

C

CURRENT ADJUST:
20 - 80 FOR CM101
20 - 60 FOR CM81

D

LOGIC
ASSY 19X1913 - CM101
ASSY 19X2285 - CM101
ASSY 19X1932 - CM81
ASSY 19X2284 - CM81

E

DRAG ON

F

Art # A-07151

M1
FAN1

M2
FAN2

ON/OFF SW

MODE SW

RAR OFF

(PILOT PCB)

(F9)

CURRENT

CONTROL/

LED PCB
19X1604

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

INV ON

D25

SW ON

D33

GATE DRIVE B RTN

GATE DRIVE A RTN

CURRENT SENSE

CURRENT SENSE
CURRENT SENSE RTN
CURRENT SENSE RTN

1

L1

L2

L3

(46)

+12VDC

+12VDC
DC COM
DC COM

W1 ON

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

D13

GAS ON

DC OK

OVTEMP

AC OK

TORCH SW

TORCH SW RTN

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B

GATE DRIVE A

- OUT SENSE

DC COM
DC COM

ISENSE3233

TIP VOLTS

1

28VAC B
28VAC A

RUN

CSR

+12V

SW1

P1

SW2

NTC

230V

230V

tt

SET

AC

TEMP

GAS

DC

TS2

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

34
35
36

J14

TS1

P13

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

EXTENDER
ASSY 19X1775

W1

W1

W1

(4)

(5)

(7)
(7)

(6)
(6)

1
2
3
4
5
6
7
8

(1)

(2)

(3)

E22

CHASSIS
GND

P11

P18 J18

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

P14 P27

(35)

1

(36)

2

(37)

3

(38)

4

(39)

5

(40)

6

(41)

7

(42)

8

P29 J29

P32

J12 J43

141
2
3

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

1
2
3
414

11

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

2
3
4

1
2
3
4
5
6

1
2
3
4
5
6
7
8

J27

1
2
3
4
5
6
7
8

2
3

22

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

J11

J15P15

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

J32

2

E33

(FILTERING)

K1

R29

(0 ohm)

F1

(3/10A 600V)

K2

+12VDC

K1

INRUSH

K2

FAN

K5

CONTACTOR ON

K4

SOLENOID ON

MAIN BOARD
ASSY 19X1931

2

T1

28VAC A
28VAC B

+18V

+18V

+18V

E3E2E1

K1

28VAC A28VAC B

TO BIAS SUPPLY

PRESS GOOD

E5

E13

E18

K4

K5

3

INPUT DIODE

ASSY 19X2073

CURRENT
SENSE

TORCH SW RTN

F2, 0.9A,
(RESETABLE)

3

-OUT SENSE
DC COM

TIP SENSE

+12VDC

I SENSE

TIP VOLTS

PIP RTN

TORCH SW

28VAC A

28VAC B

E6
E8

E14
E16

E7

E15

E4

E20

E23

E30

J26 P26

1

1

2

2

J31 P31

11
2

2

J30

P30

11

22

J25 P25

1

1
2

2

E5
E6

E10

E27

E32

J33 P33

1

1
2

2
3

3

4

4

CSR

5

5
686
7

7
8

J34 P34

1

1

PIP

2

2
3

3
4

4
5

5
66

J23

1

TEST

GND

2

CONN

3

J24 P24

1

1

2

2

3

3

4

4

5

5

6

6

7

7
8

8

(TS2)

(TS1)

(70)
(71)
(72)
(73)
(74)
(75)

(77)

ATC CONNECTION
CONFIGURATION

(STANDARD)

(78)
(79)

(80)
(81)

(8)

(9)
(10)
(11)
(12)
(13)

MAIN

CONTACTOR

4

MAIN TRANSFORMER

T5

PRI

PRI

1

1
2

2

575
7
4

4
3

3

8

8

PIP

TORCH
SW

ATC MALE
CONNECTOR

ATC RECEIVER

SOL1

GAS
SOLENOID

SOL2

BA

PS1

W1

4

5

E12A

E17A

24
25

E19A

E21A

E12B

E17B

24
25

E19B

E21B

SEC

SEC

BA

T6

11 15

PRI

SEC

6

FACTORY INSTALLED OPTIONAL
TORCH MOUNTED GAS SOLENOID

PRESSURE
SWITCH

CLOSED WHEN
PRESSURE OK

WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

12231314

6

7

IGBT BOARD

ASSY 19X1815

12231314

24567

IGBT BOARD

ASSY 19X1815

P39

1

1

2

2

3

3

4

4

5

5
686
7

7
8

10

GATE

J3A

DRIVE

28

27

GATE
DRIVE

J7A

1

245

GATE

J3B

DRIVE

28

27

GATE
DRIVE

J7B

1

J39

5

2112

2112

2112

2112

P3A

E9A

E11A

P7A

P3B

E9B

E11B

P7B

74E25E

APPENDIX A-10 Manual 0-2956

6

7

8

9

10

COMP DESCRIPTION LOCATION

F1

FUSE, 3/10A 600V FNQ-R

F2

FUSE, 0.9A, RESETABLE

OUTPUT INDUCTOR

L1

M1M2FAN, 4.5" 220VAC

FAN, 4.5" 220VAC

PS1 PRESSURE SWITCH

SOL1 GAS SOLENOID

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET/RAR

SW2

MAIN TRANSFORMER

TS1

TEMP. SENSOR, IGBT HEATSINK

TEMP. SENSOR, INDUCTOR

W1

MAIN CONTACTOR

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

B2

F3

D7

B1

C1
F4

F4

C1

C1

4D5T

D1

1E2ST

F4

A

OUTPUT DIODE
ASSEMBLY
19X1757

E34A

E39A

E50A

E48A

E53A
E54A

E56A
E60A

DC COMMON

POWER OUTPUT BOARD ASSY 19X1914

6

E58E37

PLUGS INTO J27

*

ON MAIN BOARD

(LED PCB 19X1604)

ADAPTER HARNESS USED

WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION

(REPLACES CONNECTIONS

FROM J27 TO J14)

OUTPUT INDUCTOR

54E94E

E35

E62

PILOT

E43

JUMPER

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E48B

E53B
E54B

7

AC

TEMP

GAS

DC

E34B

OPTIONAL AUTOMATION INTERFACE CONNECTIONS

P3

J14 P14

1

1

2

2

3

3

4

4

5

5
6

6
7

7

8

8

L1

E32

E64

E36 E57

E39B

E56B
E60B

DC COMMON

(47)

1

(48)

2

(49)

3
4
5
6
7
8

E61 E3 E1

CSR

CURRENT
SENSE

J40 P40

+12VDC
DC COM

CSR

ISENSE

E63

8

2112
3

P1

(CSR)

1

(51)

2

(52)

3
4

(TS2)

5

(TS1)

6
7

(NEG)

8

(NEG)(CSR)

Vo

(MODE SW)

RAR OFF

(14)

1

1

(15)

2

2

3

3

4

4

(17)

5

5

6

6

7

7

(18)

8

8

CHASSIS GND
THRU SCREW TERMINAL

J3

3

19X2041

OPTIONAL
AUTOMATION
INTERFACE

J1

1
2
3
4
5
6
7
8

(E64)

(E64)

(E35)

(E62)

(C1)

J4

20
19
18
17
16
15
14
13
12
11
10

9

CSR

8

DC COMMON

7

+12VDC

6
5

TORCH SW -

4

TORCH SW +

3
2

Vo

1

(E58)

(52)
(51)

(46)

ECO 101136

AA
AB
AC

ECO 101614 HASAD03/22/05

ECO 101664 HAS 03/24/05

AE
AF

ECO B028

AG

ECO B016 RWH 01/27/06

ECO B077

AH

Friday, January 27, 2006

Friday, January 27, 2006

Friday, January 27, 2006

Last Modified:

Last Modified:

Last Modified:

P4

E58 E62

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1

J1

1
2

1
2

3

5

8

J28

PILOT BOARD
ASSY 19X2157

(REL) DLL

HASECO 101314

HASECO 101429

RS

RWH

ALTERNATE 20-PIN HEADER

DateByRevisionsRev

DateByRevisionsRev

DateByRevisionsRev

05/07/03

02/11/04

06/09/04

01/09/06

07/31/06

9

20-POSITION TERMINAL STRIP

J2

1

+

2

TORCH SWITCH

3

-

4
5
6

OK TO MOVE
7
8
9

+

10

DIVIDED OUTPUT

11

-

12
13
14

REMOTE CURRENT CONTROL

15
16

DC COMMON

17
18

+

19

C&G

20

-

HOUSING

(56)

(57)

(58)

(59)

(60)

(61)

(62)

(63)

(64)

ATC RECEIVER
ATC MALE CONNECTOR

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

NOTE:

NOTE:

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

Capacitors are in Microfarads (UF)

TITLE:

TITLE:

TITLE:

SCHEMATIC,

SCHEMATIC,

SCHEMATIC,

CM81/101 600V 3PH SYSTEM 42X1134D

CPC

4

3
14
12

6

5

8

9

7

WORK

(+)
(-)

(+)
(-)

(+)
(-)

T
O
R
C
H

TORCH SWITCH

}
}

OK TO MOVE

SC-11

}

LOGIC COMMON

ARC VOLTS (C&G)

}

THERMAL DYNAMICS
INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784
603-298-5711

10

PCB No:

PCB No:

PCB No:

Assy No:

Assy No:

Assy No:

SupersedesScale

SupersedesScale

SupersedesScale

Date:

Date:

Date:

05/07/03

Drawn: References

Drawn: References

Drawn: References

D.Lilja

Sheet

Sheet

Sheet

Chk: App:

Chk: App:

Chk: App:

11

11

11

DWG No:

DWG No:

DWG No:

Size

Size

Size

Art # A-07151

B

C

D

E

F

of

of

of

Manual 0-2956 A-11 APPENDIX

APPENDIX 9: Publication History

Cover Date Revision Comments

6/3/2003 -- Manual released.

7/18/03 -- Added 600V units per ECO 100979.

12/5/03 -- Updated w/ new schematics & input from Sales/Tech Service

1/5/04 -- Updated gas pressures & flows.

1/16/04 -- Updated warranty statement & system schematics, misc minor edits.

2/9/04 -- Deleted system schematics.

2/12/04 -- Added updated schematics, ECO 101314.

6/23/04 -- Updated system schematics per ECO 101429.

9/21/05 -- Updated system schematics and art work for new work-lead clamp

2/17/06 -- Updated system schematics per ECO B033.

10/20/06 AA.01 Added patent information, new rev. standard and cover graphic standard.

3/14/07 AB.01 Updated 600 volt schematic to show new fuse.

NOTE

Thermal Dynamics uses the manual cover date to indicate revision level.

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