Thermal Dynamics CE CutMaster 101 Operating Manual

Plasma Cutting

Power Supply

CE CutMaster™ 101

A-03661

January 6, 2004 Manual No. 0-2992

Operating Manual

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper­ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply
CE CutMaster™ 101
Operating Manual Number 0-2992

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

www.thermal-dynamics.com

Copyright 2003 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: January 6, 2004

Record the following information for W arranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference ............................................................................ 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

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

SECTION 2:

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

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

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

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

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

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

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

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

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

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

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

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

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

4.01 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 Troub leshooting Guide ........................................................................ 5-6

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

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction .................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Power Supply Replacement P arts ................................................................ 6-1

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

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

APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIA GRAM) .........................................A-1

APPENDIX 2: D ATA TAG INFORMATION ............................................................................... A-2

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

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

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

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

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high­lights are categorized as follows:

NOTE

An operation, procedure, or backgr ound informa­tion which requires additional emphasis or is help­ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may
cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may
cause injury to the operator or others in the oper­ating area.

1.02 Important Safety Precautions

WARNINGS

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

Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per­sons who work near plasma arc cutting applica­tions should consult their medical health profes­sional and the manufacturer of the health
equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and
follow all warnings, safety precautions and in­structions before using the equipment. Call 1-603­298-5711 or your local distributor if you have any
questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different pr ocesses. Y ou must
be very careful when cutting or welding any met­als which may contain one or more of the follow­ing:

Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in­formation regarding the kind and amount of fumes
and gases that may be dangerous to your health.

• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.

• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com­bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.

• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de­fects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op­erator or others in the workplace.

• Never touch any parts that are electrically “live”
or “hot.”

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

• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is
moist or damp.

• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publica­tions.

• Disconnect power source before performing any
service or repairs.

• Read and follow all the instructions in the Operat­ing Manual.

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from
the workplace.

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

• Provide a fire watch when working in an area where
fire hazards may exist.

• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under­water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis­sipated. T rapped hydrogen gas that is ignited will
cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro­cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per­manent loss of hearing.

• T o protect your hearing from loud noise, wear pr o­tective ear plugs and/or ear muffs. Protect others
in the workplace.

• Noise levels should be measured to be sure the deci­bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.

PLASMA ARC RA YS

Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.

• To protect your eyes, always wear a welding hel­met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro­tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12
400 - 800* 10 14

* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work­piece.

1.03 Publications

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

1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu­ments, U.S. Government Printing Office, Washington,
D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So­ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Govern­ment Printing Office, Washington, D.C. 20402

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

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the Ameri­can National Standards Institute, 1430 Broadway, New
York, NY 10018

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

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430
Broadway, New York, NY 10018

7. AWS Standar d A6.0, WELDING AND CUTTING CON­TAINERS WHICH HAVE HELD COMBUSTIBLES, ob­tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO­CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W1 17.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103

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

ATTENTION

Toute procédure pouvant résulter
l’endommagement du matériel en cas de non­respect de la procédur e en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.

1.05 Precautions De Securite
Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.

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

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

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

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

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.

• Eloignez toute fumée et gaz de votre zone de respira­tion. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.

• Réparez ou remplacez toute pièce usée ou
endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:

antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combus­tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

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

• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la page
5, article 9.)

• Débranchez l’alimentation électrique avant tout tra­vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de
consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com­bustibles ou provoquer l’explosion de fumées
inflammables.

• Soyez certain qu’aucune matière combustible ou in­flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.

• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper . Le gas hydrogène accumulé
explosera si enflammé.

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

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

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons

ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur . Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculair e.

• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12
400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin­tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRA­V AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na­tional Standards Institute), 1430 Broadway, New Y ork,
NY 10018

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

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. V ous dú4ez vous pr otéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.

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

7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

8. Norme 51 de l’Association Américaine pour la Pro­tection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na­tional Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269

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

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA­TIONAL, disponible auprès de la National Fire Pro­tection Association, Batterymarch Park, Quincy, MA
02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan­dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARA TION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

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

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

W est Lebanon, New Hampshire 03784
USA

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

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro­pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

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

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

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

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

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

ated accessories.

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

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

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

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

1.08 Statement of Warranty

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

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

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

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

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

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

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

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

Parts

XL Plus & Parts Parts

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

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

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

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

Torch And Leads

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

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

Effective: November 15, 2001

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

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dy­namics CE CutMaster 101 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly
trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not cov­ered in this manual, at the risk of voiding the Warranty .

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

NOTE

Refer to the Torch Manual for torch and cutting information.

2.02 Power Supply Specifications

CE CutM aster 101 Power Supply Specifications

Inpu t P o w e r
Input Power Ca ble

Output Current
Power Supply
Gas Filtering Ability

Gas S uppl y

Am bient Temperature:

40° C (104° F)

CE CutMaster 1 01

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

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

400 VA C (360 - 440 VAC), Three Phase, 50 Hz
Power Supply inc l udes Input Power Cable with Fil tering Beads

20 - 80 Amps, Conti nuous l y Adj us table
Part iculat es to 20 Microns

Power Supply us es Compressed A i r Only

CE CutM aster 101 Power Supply Duty Cycle *

IEC

Rating

Duty Cycle
Current 80A n/a 68A n/a 45A n/a
DC Volt age 112V n/a 107V n/a 98V n/ a

TDC

Rating

IEC

Rating

60% 100%35%

TDC

Rating

IEC

Rating

TDC

Rating

IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.

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

Manual 0-2992 2-1 INTRODUCTION

NOTE:

Power Supply Dimensions & Weight Ventilation Clearance Requirements

83 lb / 37.6 kg

150 mm

17.3 in /
439 mm

6"

27.5 in / 696 mm

A-03572

12.4 in /
315 mm

6"

150 mm

6"

150 mm

A-03379

2.03 Input Wiring Specifications

CE CutMaster 101 Input Wi ring S pecifications

Input Sugge sted Sizes (Se e Notes)

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

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

400 50 13.9 20 25 4

Line Vol t ages with S ugges ted Circui t P rot ecti on and Wire Si zes

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

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.

Pow er Input Current Input

Wire (mm

NOTES

6"

150 mm

2

)

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 0-2992

2.04 Power Supply Features

Handle and Leads Wrap

Art # A-03578

Control Panel

Torch Leads Receptacle

Work Cable
and Clamp

Gas Pressure Regulator /

Ports for Optional Automation
Interface Cable

Gas Pressure Gauge

Input Power Cord

Filter Assembly

Gas Inlet Port

Art # A-03738

Manual 0-2992 2-3 INTRODUCTION

2.05 Power Supply Options and Accessories

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

A. Single-Stage Air Filter Kit

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

0.85 microns. This filter increases performance and impr oves 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 ar e 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. T op 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.

INTRODUCTION 2-4 Manual 0-2992

SECTION 3: INSTALLATION

3.1 Unpacking

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

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

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

3.2 Lifting Options

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

WARNINGS

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

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

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

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

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

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

Manual 0-2992 3-1 INST ALLATION

3.3 Primary Input Power Connections

CAUTION

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

These Power Supplies are equipped with a four - conductor input power cable for three - phase input power.

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

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

CAUTION

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

- phase operation.

• Green / Yellow wire to Ground.

• Remaining wires to L1, L2, L3 input.

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

4. Connect a customer-supplied grounding cable to the grounding stud on the rear panel as required by appli­cable Local and National Codes or local authority having jurisdiction. This symbol: identifies the

grounding stud.

INST ALLATION 3-2 Manual 0-2992

3.4 Air 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 fr om high pressur e 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
T eflon tape as a thr ead sealer , as small particles of the tape may br eak off and block the small air passages in the torch.

Regulator/Filter
Assembly

Inlet Port

Bowl

1/4 NPT to 1/4"

(6mm) Fitting

Hose Clamp

Art # A-02999

Air Connection to Inlet Port

Gas Supply
Hose

Manual 0-2992 3-3 INST ALLATION

B. Installing Optional Single - Stage Air Filter

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

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

2. Attach the Filter Assembly to the filter hose.

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

NOTE

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

Regulator/Filter
Assembly

Bowl

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

Inlet Port

Optional Single - Stage Filter Installation

Art # A-03000

INST ALLATION 3-4 Manual 0-2992

C. Installing Optional Two - Stage Air Filter Kit

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

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

filter assembly.

NOTE

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

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

is shown as an example.

Regulator/Filter
Assembly

Hose

Clamp

1/4" (6 mm) Gas

Supply Hose)

Regulator Inlet Port

2-Stage Filter
Inlet Port (IN)

1/4 NPT

Hose Fitting

Optional Two - Stage Filter Installation

Outlet Port

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

Manual 0-2992 3-5 INST ALLATION

D. Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

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

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

3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100
psi (6.9 bar) maximum and flows of at least 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 pressur e cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufactur er's instructions. Do Not use

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

INST ALLATION 3-6 Manual 0-2992

3.5 Torch Connections

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

WARNING

Disconnect primary power at the source before connecting the torch.

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

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

3. The system is ready for operation.

Art # A-03573

ATC Female Receptacle
(Panel Mounted)

1

Control Cable
Connector (Mechanized
Torches Only)

2

ATC Male
Connector

Manual 0-2992 3-7 INST ALLATION

Connecting the Torch to the Power Supply

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

1

20

60

2

80

Art # A-03577

INST ALLATION 3-8 Manual 0-2992

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.

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.

Art # A

-03744

A

DRAG
CUTTING
RANGE

STANDOFF
CUTTING
RANGE

ON / OFF Switch

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

40

20

60

80

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

DC Indicator

Indicator is ON when DC output circuit is
active.

RUN / 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 air pressure and purging lines.

Manual 0-2992 4-1 OPERATION

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 tor ch and
leads assemblies.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate tor ch parts. The torch parts must correspond with the type
of operation, and with the amperage output of this Power Supply (80 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. Air Selection

Ensure compressed air source meets r equirements (r efer to Section 3.4). Check connections and turn air supply
on.

E. Connect Work Cable

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

A-03387

OPERA TION 4-2 Manual 0-2992

F. Power On

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

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

NOTE

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

A

40

20

60

80

Art # A-03580

Manual 0-2992 4-3 OPERATION

G. Set Operating Pressure

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

A

40

1

20

2. Adjust air pressure per the settings chart.

CE CutMaster 1 01

Air P r essu r e S ettings

Leads

Length

Up to 25'

(7.6 m)

Over 25'

(7.6 m)

SL100

(Hand Torc h or

Machin e Torc h)

70 psi

4.8 bar
75 psi

5.2 bar

80

70 - 75 psi /

4.5 - 5.2 bar

60

2

Art # A-03577

Pressure Control Knob /
Bouton De Contrôle
de Pression

OPERA TION 4-4 Manual 0-2992

Art #A-03793

H. Select Current Output Level

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

2. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece),
or up to 80 amps for standoff cutting. At output settings higher than 40 amps, the power supply automati­cally reduces output current to 40 amps if the tor ch tip contacts the workpiece.

2

40

A

60

1

20

Art # A-03579

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.

80

When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Air vents
through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing the
shield cup against the torch head or torch handle can damage components.

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 0-2992 4-5 OPERATION

NOTE

K. Postflow

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

L. Shutdown

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

A

40

20

60

80

Art # A-03584

OPERA TION 4-6 Manual 0-2992

SECTION 5:

SERVICE

5.01 General Maintenance

A. O-Ring Lubrication

An o-ring on the T orch ATC Male Connector requires lubrication 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 0-2992 5- 1 SERVICE

Gas Fitting

O-Ring

B. Filter Element Replacement

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

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

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

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

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

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

Regulator/Filter

Assembly

Baffle
Ring

6. Reinstall the bowl.

7. Turn on the air supply.

Filter
Element
No. 9-4414

Spring
Spool

Bowl

Art # A-02995

Regulator/Filter Element Replacement

SERVICE 5-2 Manual 0-2992

C. Optional Single-Stage Filter Element Replacement

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

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

1. Remove power from power supply .

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

3. Disconnect gas supply hose.

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

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter Element Replacement

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

6. Wipe inside of housing clean, then insert the 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 0-2992 5- 3 SERVICE

D. Optional Two-Stage Filter Element Replacement

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

1. Shut off primary input power .

2. Shut off air supply and bleed down system.

W ARNING

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

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

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

5. Slide out the old Filter Elements.

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

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

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

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

NOTE

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

SERVICE 5-4 Manual 0-2992

5.02 Common Faults

1. Insufficient Penetration

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

2. Main Arc Extinguishes

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

3. Excessive Dross Formation

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

4. Short T orch Parts Life

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

5. Difficult Piloting

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

Manual 0-2992 5- 5 SERVICE

5.03 Basic Troubleshooting Guide

W ARNING

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

A. Basic Tr oubleshooting: Overview

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

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

uct.

B. How to Use This Guide

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

This guide is set up in the following manner:

X. Symptom (Bold T ype)

Any Special Instructions

1. Cause

a. Check / Remedy

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

C. Common Symptoms

A. AC indicator OFF

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

a. Close main power switch.

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

a. Turn switch to ON (up).

3. Tor ch is not connected properly to Power Supply

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

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

4. Shield cup not fully tightened on torch head

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

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

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

SERVICE 5-6 Manual 0-2992

6. Unit internal fuse blown or loose

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

an authorized service center .

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

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

8 . Faulty components in unit

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

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

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

a. Release torch switch.

2. Faulty torch switch

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

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

1. System is in SET mode

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

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

GAS indicator OFF

1. Gas not connected

a. Check gas connections.

2. Gas pressure too low for power supply operation

a. Adjust gas pressure per torch manual.

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

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

1. Gas pressure is below power supply minimum requirement.

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

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

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

mum required for torch operation.)

a. Adjust gas pressure per torch manual.

Manual 0-2992 5- 7 SERVICE

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

1. Starter cartridge missing from torch

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

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

2. Shield cup is loose on torch

a. Check shield cup; tighten if necessary.

NOTE

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

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

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

Art # A-03640

Upper Groove
with V ent Holes
Must Remain Open

Upper O-Ring
in Correct Groove

Threads
Lower O-Ring

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

1. Air flow blocked

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

2. Unit is overheated

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

Refer to duty cycle data in Section 2.

3. Input line voltage is low

a. Check and connect to proper input power line.

4. Faulty components in unit

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

SERVICE 5-8 Manual 0-2992

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

indicator OFF

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

a. Release torch trigger.

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

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

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

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

ON; DC indicator OFF

1. T orch tip or electrode missing

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

ON (up).

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

TEMP indicator OFF

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

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

2. Faulty T orch

a. Return for repair or have qualified technician repair.

3. Faulty components in unit

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

L. T orch cuts but not adequately

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

2. Torch consumables worn

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

3. Work cable connection to work piece is poor

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

4. T orch is being moved too fast across workpiece

a. Reduce cutting speed.

5. 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 0-2992 5- 9 SERVICE

6. Excessive oil or moisture in torch

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

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

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 Tor ch manual; replace as needed.

6. Faulty components in unit

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

N. AC indicator remains ON when shield cup is removed

1. Faulty PIP switch in torch

a. Check PIP switch for continuity; replace if necessary

SERVICE 5-10 Manual 0-2992

5.04 Power Supply Basic Parts Replacement

W ARNING

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

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

A. Cover Removal

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

NOTE

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

Upper screws

Lower
screws

Lower
screws

Ground wire

Art # A-03792

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

Manual 0-2992 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 0-2992

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

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

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your distributor . Materials returned without pr oper authorization
will not be accepted.

6.02 Ordering Information

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

6.03 Power Supply Replacement

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

Qty Description Catalog #

CE CutMaster 101 Power Supply

1 400VAC,Three - Phase, 50 Hz, with input power cable 3-1320-4

6.04 Replacement Parts

Qty Description Catalog #

1 Fuse for CE CutMaster 101 Power Supply 9-8602
1 Regulator / Filter Assembly Replacement Element 9-4414

Manual 0-2852 6-1 P A RTS LISTS

6.05 Options and Accessories

Qty Description Catalog #

1 Single-Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-7500
1 Bracket, Filter Mounting (not shown) 9-7535
1 T wo-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

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second
Stage
Cartridges
(as marked)

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

Art # A-02942

PARTS LISTS 6-2 Manual 0-2852

6.06 Torch Parts

8-3487
O-Ring

8-3486

O-Ring

9-8207 (40A)

Shield

Cup

9-8218

Shield

Cup Body

9-8237

Shield Cap, Drag

9-8236 (70-100A)

Art # A-03796

Electrode

9-8215

Starter

Cartridge

9-8213

Torch Head

Starter Cartridge

9-8211 (80A)

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

Electrode

Shield

Cup

9-8218

Shield

Cup Body

9-8237

9-8243
Shield Cap, Deflector

9-8241

Shield Cap, Gouging

Manual 0-2852 6-3 P A RTS LISTS

Tip

Shield Cup

Art # A-03801

PARTS LISTS 6-4 Manual 0-2852

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

pressure is adequate

for power supply operation.

ACTION:

RESULT:

ACTION:

RESULT:

Fan(s) ON.

when input

Power circuit ready.

ACTION:

RUN /

Rapid Auto Restart /

SET switch

to SET

RESULT:

Gas flows to set pressure.

Torch moved away from work (while

ACTION:

RUN /

Rapid Auto Restart / SET

switch to RUN

(for most applications)

or to

Rapid Auto Restart

(for gouging, trimming,

or expanded metal

applications)

RESULT:

Gas flow stops.

ACTION:

still activated).

RESULT:

ACTION:

Protect eyes and activate torch.

RESULT:

Gas flows briefly, then stops.

Gas restarts.

DC indicator ON

Pilot arc established.

ACTION:

Release torch trigger.

RESULT:

Main arc stops.

Gas flow stops after post - flow.

PILOT ARC

ACTION:

ON / OFF switch

to OFF

RESULT:

All indicators off.

Power supply fan(s) shuts off.

Main arc stops.

Pilot arc automatically

restarts.

ACTION:

Torch moved within

transfer distance of workpiece.

RESULT:

Main arc transfers.

Pilot arc off.

ACTION:

Unplug input

power cord or

open external

disconnect.

RESULT:

No power to system.

Art #A-03706A

Manual 0-2992 A-1 APPENDIX

APPENDIX 2: DATA TAG INFORMATION

Type of Power
Supply (Note 1)

Plasma Cutting
Symbol

Input Power
Symbol

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

Model:

Date of Mfr:

1/3

f

1

f

2

Output Current Type

U

Rated No­Load Voltage

Degree of Protection

X

=

0

U

Conventional
Load Voltage

West Lebanon, NH USA 03784

I

2

U

1

Rated Supply
Voltage (Note 2)

S/N

Duty Cycle Factor

Rated Maximum
Supply Current

1max 1eff

I

1

1Ø

3Ø

Made in USA

I

1

3Ø1Ø

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)

Maximum Effective
Supply Current

Manufacturer's Electrical
Schematic File Number
and Revision Level

NOTES:

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

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

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

TDC duty cycle value is determined under the power supply

manufacturer's test procedures.

Second row: Rated cutting current values.
Third row: Conventional load voltage values.

4. Sections of the Data Tag may be applied to separate areas

of the power supply.

Standard Symbols

AC
DC

Phase

Ø

Art # A-03288

APPENDIX A-2 Manual 0-2992

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 0-2992 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

8 - Ground

6 - Open

8 - Ground

7 - Open

6 - Open

5 - Open

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 0-2992

5 - White /
Not Used

5 - Open

1 - PIP

Pilot

APPENDIX 5: 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

Torch
Leads

Black

Orange

White

Green

Negative / Plasma

Pilot

To Remote Control

Remote

Pendant

Connector

Black

White

Green

ATC Female

Receptacle

Power
Supply

1
2
5
6
4
3
8
7

1
2
5
6
4
3
8
7

To Power Supply

Circuitry

To Power Supply

Circuitry

Negative / Plasma

Pilot

Art # A-03798

Manual 0-2992 A-5 APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC

400/460V
1 PHASE

A

INPUT

400V
3 PHASE
INPUT

B

C

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

D

E

DRAG ON

SW ON

F

LOGIC
ASSY 19X1913 - CM101
ASSY 19X1932 - CM81

1

400/460V
3 PHASE
INPUT

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

M1
FAN1

M2
FAN2

ON/OFF SW

MODE SW

RAR OFF

CURRENT
CONTROL/
LED PCB
19X1604

IGBT
HEATSINK
TEMP

INDUCTOR
TEMP

TIP SENSE

RUN/SET

PRE SS GOOD

INV ON

OVERTEMP

D13
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

TIP VOLTS

28VAC B
28VAC A

SW1

RUN

P1

+12VDC

+12VDC
DC COM
DC COM

W1 ON

CSR

GAS ON

DC OK
AC OK

+12V

DC COM
DC COM

ISENSE3233

SW2

NTC

230V

230V

t

AC
TEMP
GAS
DC

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

SET

1
2
3
4
5
6
7
8
9

TS2

TS1

10
11
12
13
14
15
16
17
18
19

J14

P13

1
2
3
4
5
6
7
8
9

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

EXTENDER
ASSY 19X1775

CHASSIS
GND

P11 J11

(4)

(5)

(7)
(7)

(6)
(6)

P18 J18

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

P14 J27P27

(35)

1

1

(36)

2

2

(37)

3

3

(38)

4

4

(39)

5

5

(40)

6

6

(41)

7

7

(42)

8

8

J12 J43

2

W1

(1)

W1

(2)

W1

(3)

E22

1

1

2

2
3
4

1
2
3
4
5
6

1
2
3
4
5
6
7
8

1
2
3
4
5
6
7
8

P29

1
2
3
414

P32 J32

121

2

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

3

4

R29 (460/600V)
R78 (400V)
R30 (208/230V)

J15P15

1
2

K2

3
4
5
6

SEE CHART 1 FOR
F1, R29,R30 & R78

1
2
3
4
5
6
7
8

1

POT HIGH

2

POT WIPER
POT LOW

3
4

+12V

5

AC

6

GAS

7

OVERTEMP

8

DC

J29

2
3

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

MAIN BOARD

33
34
35

ASSY 19X1930 (400V)

36

ASSY 19X1929 (460V)

(FILTERING)

K1

F1

+12VDC

K1

INRUSH

K2

FAN

K5

CONTACTOR ON

K4

SOLENOID ON

T1

28VAC A
28VAC B

+18V

+18V

+18V

E3E2E1

K1

E13
E18

28VAC A28VAC B

TO B IAS SUPPLY

PRE SS GOOD

E5

K4

K5

3

INPUT DIODE

ASSY 19X1811

DC COMMON

CURRENT

SENSE

-OUT SENSE

TORCH SW RTN

F2, 0.9A,
(RESETABLE)

+12VDC

DC COM

TIP SENSE

+12VDC

I SENSE

TIP VOLTS

PIP RTN

TORCH SW

28VAC A
28VAC B

J26

1
2

J31

1
2

J30

1
22

J25

1
2

2

J33 P33

1
2
3
4

CSR

5
6
7
8

J34 P34

1

PIP

2
3
4
5
66

J23

1

GND

2
3

J24

1
2
3
4
5
6
7
8

E6
E8

E14
E16

1
2

1
2

1

1
2

11
2

1
2
3
4
5
6
7
8

1
2
3
4
5

1
2
3
4
5
6
7
8

E7

E15

E4
E20

E23
E30

P26

P31

P30

P25

P16J16

E5
E6

E10
E27

E32

TEST
CONN

P24

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

(77)

ATC CONNECTION
CONF IGURATION

(STANDARD)

(78)

1

1

(79)

2

2

(80)

4

4

(81)

3

3

8

8

(8)

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

4

MAIN TRANSFORMER

PIP

TORCH
SW

ATC MALE
CONNECTOR
ATC RECEIVER

SOL1

PS1

W1

E12A
E17A

E19A
E21A

E12B
E17B

E19B
E21B

T5

PRI

PRI

CPC CONNECTION
CONF IGURATION

(BULKHEAD)

(78)
(79)

(80)
(81)

GAS

BA

SOLENOID

PRESSURE
SWITCH

CLOSED WHEN
PRE SSURE OK

MAIN
CONTACTOR

5

GATE

12231314

24
25

IGBT BOARD

ASSY 19X1815

12231314

24
25

24567

IGBT BOARD
ASSY 19X1815

SEC

SEC

P39 J39

1
2
3
4
5
6
7
8

6

6

PIP

7

7

TORCH

8

8

SW

9

9

13

13

J3A

E52

J3B

J7B

J7A

1
2

1
2

P3A

1
2

E9A
E11A

P7A

1
2

P3B

11
22

E9B
E11B

P7B

11
22

E47

DRIVE

28

27

GATE
DRIVE

1

24567

GATE
DRIVE

28

27

GATE
DRIVE

1

1
2
3
4
5
6
7
8

Art #

A-03600

1

2

APPENDIX A-6 Manual 0-2992

3

4

5

6

7

8

CHART 1

19X1930 19X1929

ZERO-OHM

R78

115X465-2

X X X X X

R29

X X X X X X X X X X

R30

4/10, 500V

F1

400V

21X186

460V

X X X X X

ZERO-OHM
115X465-2

1/4A, 500V
21X183

9

COMP DESCRIPTION LOCATION

SEE CHART 1

F1

0.9 A, (RESETABLE)

F2
L1

OUTP UT INDUCTOR
FAN, 4.5" 220VAC

M1
M2

FAN, 4.5" 220VAC
PRE SS URE SWITCH

PS1

GAS SOLENOID

SOL1
SW1

SW ITCH, ON/OFF

SW2

SW ITCH, RUN/SET
MA IN TRANSFORMER

T5

TEMP. SE NSOR, IGBT HEATSINK

TS1

TEM P . SENSOR, INDUCTOR

TS2
W1

MAIN CONTACTOR

NOTES: UNLES S OTHERWISE SPECIFIED -

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

10

B2
F3
D7
B1
C1
F4
F4
C1
C1
D4
D1
E1
F4

A

B

PLUGS INTO J27

*

ON M AIN BOARD

(LE D PCB 19X1604)

AUTO MATION ADAPTER HARNESS
(REPLA CES CONNECTIONS
FROM J27 TO J14)

AC
TEMP
GAS
DC

J14 P14

1

1
2

2

3

3
4

4

5

5

6

6
7

7
8

8

P3

1
2
3
4
5
6
7
8

2112
3

P1

1
2
3
4
5
6
7
8

J3

3

19X2041
OPTIONAL
AUTOMATION
INTERFACE

J1

CSR

1

DC COMMON

2

+12VDC

3
4

TORCH SW -

5

TORCH SW +

6
7

Vo

8

J4

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1

P4

20
19
18
17
16
15
14
13
12
11
10

9
8
7
6
5
4
3
2
1

ALTE RNA TE 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

REM O TE CURRENT CONTROL

15
16

DC COMMON

17
18

+

19

C&G

20

-

C

E50A
E48A

E53A
E54A

OUTPUT DIODE
ASSEMBLY
19X1757

E34A

E39A

E56A
E60A

POWER OUTPUT BOARD ASSY 19X1914

6

OUTPUT INDUCTOR

L1

E49 E45

E58E37

E62

JUMPER

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E35

PILOT

E43

E34B

E32

E64

E36 E57

E39B

E61

CURRENT
SENSE

E48B
E53B

E54B

DC COMMON DC COMMON

E56B

E60B

7

E3 E1

CSR Vo

+12VDC

DC COM

ISENSE

8

P40

J40

1

1

2

2
3

3
4

4

5

5

CSR

6

6

7

7

8

8

CHASSIS GND
THRU SCREW TERMINAL

E63

E64
E64

E35

E62

14
15

17

18

RAR OFF 3

ECO 100857

AA

ECO 100864

AB

RED RAWN-NO CHGS

AC

ECO 101

AD

Last Modified:

Tuesday, October 14, 2003

(+)

4

}

TOR CH SWITCH

(-)

3

14

}

OK TO MOVE

12

(+)

6

}

SC-11

(-)

5

LOG IC COMMON

8

(+)

9

}

ARC VOLTS (C&G)

(-)

7

CPC

HOUSING

D

TORRO ID INSTALLED
ON 400V CE ONLY

T
O
R
C
H

E58

E62

E58

WORK

J28

1
2

5

8

PILOT BOARD
ASSY 19X1905

10

PCB No:
Assy No:

Date:

Tue sday, May 15, 2001

Drawn: References

D.Lilja

Chk: App:

Size

D

Art # A

DateByR evisionsRev

04/04/03DAT
04/10/03

HAS
DLL

05/07/03

In fo rma ti on Proprietary to THERMAL DYNAMICS CORPORATION.

05/07/03DLL

No t For R ele ase, Reproduction, or Distribution without Written Consent.
NOTE:

Un les s Oth erwise Specified, Resistors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF)

15:05:29

TITLE:

SCHEMATIC,

CM81/101 400/460V SYSTEM

9

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

DWG No:

42X1135

SupersedesScale

Sheet

of

11

-03600

E

F

Manual 0-2992 A-7 APPENDIX