Thermal Dynamics CutMaster 100 Operating Manual

Plasma Cutting

Power Supply

CutMaster™ 100

March 22, 2004 Manual No. 0-2859

A-02991

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
CutMaster™ 100
Operating Manual Number 0-2859

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

www.thermal-dynamics.com

Copyright 2001 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 22, 2004

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMA TION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.0 2 Important Safety Precautions ....................................................................... 1-1

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

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

1.08 Statement of Warranty .................................................................................. 1-5

SECTION 2:

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

2.0 1 Scope of Manual .......................................................................................... 2-1

2.02 General Description ...................................................................................... 2-1

2.03 Specifications/Design Features .................................................................... 2-1

2.0 4 Power Supply Options and Accessories ....................................................... 2-2

SECTION 3:

INST ALLA TION PR OCEDURES ........................................................................................ 3-1

3.01 Introduction................................................................................................... 3-1

3.02 Site Selection ............................................................................................... 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Lifting Options .............................................................................................. 3-1

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

3.06 Gas Connections .......................................................................................... 3-3

3.07 T orch Connections ........................................................................................ 3-5

3.08 Ground Connections For Mechanized Applications ....................................... 3-8

SECTION 4:

OPERATION...................................................................................................................... 4-1

4.01 Introduction................................................................................................... 4-1

4.02 Product Features .......................................................................................... 4-1

4.03 Preparations For Operating ........................................................................... 4-2

4.04 Sequence of Operation ................................................................................. 4-3

SECTION 5:

CUSTOMER & OPERATOR SER VICE .............................................................................. 5-1

5.01 Introduction................................................................................................... 5-1

5.02 General Maintenance.................................................................................... 5-1

5.03 Common F aults ............................................................................................ 5-2

5.04 Basic T roubleshooting Guide......................................................................... 5-3

5.0 5 Power Supply Basic P arts Replacement....................................................... 5-5

TABLE OF CONTENTS (continued)

SECTION 6:

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

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

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

6.03 P ower Supply Replacement .......................................................................... 6-2

6.04 Replacement P arts ....................................................................................... 6-2

6.0 5 Options and Accessories.............................................................................. 6-2

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... A-2

APPENDIX 3: TORCH CONTR OL CABLE WIRING DIA GRAM.................................................. A-3

APPENDIX 4: MAINTENANCE SCHEDULE ............................................................................. A-4

APPENDIX 5: SYSTEM SCHEMATIC, 208/230 VOL T UNITS .................................................. A-6

APPENDIX 6: SYSTEM SCHEMATIC, 400 and 460 V UNITS.................................................. A-8

APPENDIX 7: SYSTEM SCHEMATIC, 600 VOL T UNITS....................................................... A-10

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. 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.”

January 27, 2004 1- 1 GENERAL INFORMA TION

• 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 wher e
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.

• T o protect your hearing fr om 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 OCCU­P A TION 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 INFORMA TION 1- 2 January 27, 2004

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

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

January 27, 2004 1- 3 GENERAL INFORMA TION

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.

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 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 boar ds 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: Steve Ward

Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

GENERAL INFORMA TION 1- 4 January 27, 2004

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
PARTICULAR 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 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

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

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

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year
SureLok Torches 1 Year 1 Year 1 Year
All Other To rches 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
charges 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 August 6, 2001

January 27, 2004 1- 5 GENERAL INFORMA TION

GENERAL INFORMA TION 1- 6 January 27, 2004

SECTION 2:

p

pply

p

p

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions
and basic maintenance procedures for the Thermal Dy­namics CutMaster 100 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 General Description

The power supply provides 80 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, primary input power cable, and
work cable & clamp.

3. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary input
voltage (AC) is low or the DC voltage is higher
than shown in the chart.

CutMaster 100, 208/230-Volt and 460-Volt Duty Cycle:

CutMaster 100 208/230-Volt

an d 46 0 - Volt Pow er Su

Ambient

erature

Tem

Duty Cy cle

Current

DC Voltage

Cutmaster 100, 400-Volt Power Supply Duty Cycle:

Ambient

Tem

erature

Duty Cy cle

Current

DC Vol ta g e

104° F

(40° C)

40% 60% 100%

78 Amps 68 Amps 45 Amps

120 vdc 111 vdc 98 vdc

CutMaster 100 400-Volt

Power Suppl y Duty Cycle

104° F

(40° C)

35% 60% 100%

80 Amps 68 Amps 45 Amps

112 vdc 111 vd c 98 vdc

Duty Cycle

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

Section 2.04 lists power supply options and accessories.

2.03 Specifications/Design Features

1. Input Power (See Note)

Available for the following input power:

• 208 / 230VAC (±10%), Single-Phase, 50/60 Hz

• 400VAC (±10%), Three-Phase, 50/60 Hz

• 460VAC (±10%), Three-Phase, 60 Hz

• 460VAC (±10%), Single-Phase, 60 Hz

• 600VAC, (517-632 VAC), Three-Phase, 60 Hz

NOTE

Refer to Appendix 1 for input wiring requirements.
Units ordered as 208/230V, single-phase, have an

input cable and plug factory installed.

2. Output Power

Continuously variable from 20 to 80 amps maximum.

Cutmaster 100, 600-Volt Power Supply Duty Cycle:

CutMaster 100 600-Volt

Power Suppl y Duty Cycle

Ambient

Tem

erature

Duty Cy cle

Current

DC Vol ta g e

4. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

5. Weight

83 lbs (37.6 kg)
W eight includes Power Supply w/Input Cable, W ork

Lead, and Torch & Leads.

104° F

(40° C)

35% 60% 100%

78 Amps 68 Amps 43 Amps

120 vdc 111 vd c 97 vdc

104° F

(40° C)

104° F

(40° C)

Manual 0-2859 2-1 INTRODUCTION

6. Overall Dimensions (including handles)

• Length: 27.5 inches (696 mm)

• Width: 12.4 inches (315 mm)

• Height: 17.3 inches (439 mm)

7. Gas Regulator/Filter Assembly Specifications

• Operating Pressure (Output): 70 psi (4.8 bar)

• Maximum input gas pressure: 125 psi (8.6 bar)

• Filter: Coalescent type filter

2.04 Power Supply Options and
Accessories

Refer to Section 6, Parts Lists, for 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.

B. Two Stage Air Filter Kit

For use on compressed air shop systems. Filters mois­ture and particulate matter from the air stream to at
least 5.0 microns.

C. High Pressure Regulators

High pressure regulators are available. The regula­tors are used to set the proper pressure for the type gas
being used.

NOTE

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

D. Extended Work Cable with Clamp

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

E. Multi-Purpose Cart

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

INTRODUCTION 2-2 Manual 0-2859

SECTION 3:

3.03 Unpacking

INSTALLATION

PROCEDURES

3.01 Introduction

This Section describes installation of the Power Supply
and connecting the Torch.

These instructions apply to the Power Supply only; in­stallation procedures for the Torch, Options, and Acces­sories are given in Manuals specifically provided for those
units.

Depending on how the system was ordered, some Power
Supply Options may already be installed.

If option(s) have been factory installed some of the in­structions may not apply . It is r ecommended that all sub­sections be read for general information.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply
a. Input power
b. Gas
c. T o r ch Leads
d. Work cable

4. Grounding

5. Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and ad­equate working space around all components.

The product is packaged and protected to prevent dam­age during shipping.

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list(s) to iden­tify and account for each item.

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

3.04 Lifting Options

This unit is equipped with a handle designed for hand
lifting only. Be sure unit is lifted and transported safely

and securely.

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

• Lift unit by the handle, using two hands.

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

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

WARNINGS

Do not touch live electrical parts.
Disconnect input power conductors from de-ener-

gized supply line before moving unit.
F ALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.
HANDLE is not for mechanical lifting.

Review Important Safety Precautions (Section 1) to be sure
that the selected location meets all safety requirements.

The power supply is fan cooled by air flow through the
side panel to the front and rear panels. Air flow must not
be obstructed. Provide at least 2 feet (61 cm) in the rear
and at least 6 inches (152 mm) on each side for clearance.
Provide a minimum of 6 inches (or 152 mm) clearance in
front of the unit to allow access to the front panel con­trols.

CAUTION

Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.

Manual 0-2859 3-1 INST ALLATION PROCEDURES

3.05 Primary Input Power
Connections

Check the power source for correct voltage before con­necting the unit.

4. Pass a customer-supplied, three-conductor input
power cable through the access opening in the
back panel of the power supply. Refer to Appen­dix 1 for power cable specifications. Tighten the
strain relief to secure the power cable.

A. 400-Volt, 460-Volt, or 600-Volt Power Supply

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

For 400-Volt 460-Volt, or 600-Volt Three-Phase op-

eration:

1. Remove the Power Supply cover per section 5.05.

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

3. 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 requir ements
(refer to table in Appendix 1). All the input cable
wires must be connected for three-phase operation.

CAUTION

The primary power source and power cable must
conform to local electrical code and the recom­mended circuit protection and wiring requir ements
(refer to table in Appendix 1).

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 wir e to Ground (Earth). The
Ground wire connection requir es a ring terminal.

• L1 wire to Line 1.

• L2 wire to Line 2.

• L3 wire to Line 3, refer to Caution above.

• Ground wire to Ground.

4. Replace the Power Supply cover.

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

For 460-VAC, Single-Phase operation:

1. Remove the Power Supply cover per section 5.05

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

3. Loosen the strain relief on the back panel of the
power supply. Pull the original power cable out
of the power supply.

L1

L3

L1 L2 L3

Ground Wire
with Ring
Terminal

Input Cable

A-03041

Main Input
Contactor

Input Power Connections, 460VAC, 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.

INSTALLA TION PROCEDURES 3-2 Manual 0-2859

B. 208/230-Volt Power Supply

C. Connecting Gas to Power Supply

This 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 requir ements
(refer to table in Appendix 1).

3.06 Gas Connections

A. Gas Requirements

WARNING

This unit is not to be used with oxygen (O2).

The gas supply is connected to the Regulator/Filter As­sembly located on the rear of the unit. The connection is
the same for compressed air or high pressure gas cylin­ders. If an optional air line filter is to be installed, refer to
procedures in subsection 3.06-D.

Connect the gas supply as follows:

1. Use customer-supplied fittings to connect the gas line
to the Regulator/Filter. Typical fittings are shown;
other fittings may be used.

Regulator/Filter
Assembly

Inlet Port

Bowl

1/4 NPT to 1/4"

(6mm) Fitting

Gases: Single Gas - Plasma/Secondary

Compressed Air Only

Pressure: 70 psi (4.8 bar)

CAUTION

Maximum pressure at inlet must not exceed 125 psi
(8.6 bar)

Flow: Cutting - 400 scfh (190 lpm)

Gouging - 400 scfh (190 lpm)

scfh = standard cubic feet per hour .

B. Checking Air Quality

To test the quality of air, place the RUN/SET switch to
SET position, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moistur e in the air
will be visible on the lens. Do not initiate an arc!

CAUTION

Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even com­plete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.

Hose Clamp

Gas Supply

Art # A-02999

Hose

Gas Connection to Regulator/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 gas passages in the torch.

D. Installing Optional Air Filter Kits

Additional filtering is recommended when using air from
a compressor to insure that moisture and debris fr om the
supply hose does not enter the torch. Although the Regu­lator/Filter Assembly has its own filter, the optional fil­ter kits are recommended for improved filtering.

1. Optional Single-Stage Air Filter Kit

This optional in-line air filter for use on compressed
air shop systems is highly effective at removing mois­ture and particulate matter from the air stream to at
least 0.85 microns.

Manual 0-2859 3-3 INST ALLATION PROCEDURES

Regulator/Filter
Assembly

Inlet Port

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

gas line to the Filter . A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.

Bowl

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

Art # A-03000

Optional Single-Stage Filter Installation

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 gas passages in the torch. Connect the gas
supply as follows:

a. Attach the Single-Stage Filter Hose to the Regu-

lator/Filter Assembly inlet port as shown.

b. Attach the Single-Stage Filter Assembly to the

filter hose.

c. Use customer-supplied fittings to connect the

gas line to the Filter . A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.

2. 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 gas supply as follows:
a. Attach the T wo 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 gas passages in the torch.

Regulator/Filter
Assembly

Hose

Clamp

1/4" (6 mm) Gas

Supply Hose)

Regulator Inlet Port

1/4 NPT

Hose Fitting

2-Stage Filter
Inlet Port (IN)

Outlet Port

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

Optional Two-Stage Filter Installation

E. Using High Pressure Gas Cylinders

Refer to the following when using high pressure gas cyl­inders as the gas supply:

CAUTION

Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.

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

2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate­rial. Momentarily 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 up to 400 scfh (190 lpm).

4. Use customer-supplied fittings to connect the gas
line to the cylinder .

NOTE

Supply hose must be at least 1/4 inch (6 mm) I.D.

INSTALLA TION PROCEDURES 3-4 Manual 0-2859

3.07 Torch Connections

NOTE

5. Connect the Negative/Plasma Lead to the bulk­head connection inside the Power Supply.

Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.

The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub-section covers connecting the Torch for
the following applications:

A. Hand Systems
B. Machine Systems (Unshielded Leads)
C. Machine Systems (Shielded Leads)
D. Remote Pendant Control (Optional)

The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.

A. Hand Systems

WARNING

Disconnect primary power at the source before dis­assembling the torch or torch leads.

1. Remove the Cover of the Power Supply for ac­cess to the T orch Bulkhead Panel. See Section 5.05.

2. Remove the retaining nut from the Strain Relief.

3. Feed the torch lead ends and the Strain Relief into
the hole in the front of the unit.

Strain Relief

Torch Leads

Assembly

Note: Actual Bulkhead
configuration may
differ from that shown.

Adapter

Adapter

Control Circuit

Connectors

Negative/Plasma
Lead Connection

Torch Lead

Assembly

Pilot Lead

Negative/Plasma

Lead

Connector

Pilot Lead Stud

A-03608

Torch Lead Connections To Bulkhead

6. Connect the Control Circuit Connectors to the
mating connectors on the Power Supply Adapter .

7. Remove the top nut and washer from the Pilot
Stud.

8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in Step 7.

9. Tighten the Strain Relief onto the Torch Leads.

10. Check the torch for proper parts assembly.

CAUTION

The torch parts must correspond with the type of
operation. Refer to the appropriate torch manual
for proper parts selection.

Negative /
Plasma Lead

A-03607

Pilot Lead

Strain Relief

Retaining Nut Removal

4. Secure the Strain Relief with the retaining nut r e­moved earlier .

Manual 0-2859 3-5 INST ALLATION PROCEDURES

11. Reinstall the Power Supply Cover on the Power
Supply.

Nut

B. Machine Systems (Unshielded Leads)

1. Remove the Cover of the Power Supply for access
to the T orch Bulkhead Panel. See Section 5.05.

2. Remove the strain relief nut from the Strain Relief.

Torch Leads

Assembly

Remove Tie Wrap ,
Remove Insulator,
Disconnect Wires

A-03609

Strain Relief

Strain Relief

Nut

Strain Relief Nut Removal

3. Install the Torch Adapter as follows:
a. Inside the Power Supply Bulkhead area, route

the connector on the free end of the Adapter
through the Strain Relief Nut.

b. Continue routing the connector out the hole

in the front of the Power Supply.

c. Feed the end of the torch lead and the Strain

Relief into the hole in the unit while routing
the single black wire into the notch of the Strain
Relief.

Negative/Plasma
Lead Connection

Power Supply Adapter

Control Circuit

Remote
Pendant
Adapter

Torch Lead

Assembly

Connectors

Open

Open

Pilot Lead

Negative/Plasma

Lead

Torch Lead Connections To Bulkhead

Power Supply Adapter

Control Circuit

Connectors

Open

Torch Lead

Assembly

Adapter

Connector

Pilot Lead

Stud

A-03610

Open

d. Tighten the Strain Relief Nut to secure the

Strain Relief to the Power Supply.

4. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.

5. If not previously done, r emove the tie wrap from
the two mated and joined wires on the torch leads.
Disconnect the joined wires. Connect the Con­trol Circuit Connectors to the mating connectors
on the Adapter supplied on the Power Supply.
Two wires on the Tor ch Leads remain unused.

6. Remove the top nut and washer from the Pilot
Stud.

7. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.

INSTALLA TION PROCEDURES 3-6 Manual 0-2859

Pilot Lead

Negative/Plasma

Lead

A-03611

Wiring Connection Detail

8. T ighten the Strain Relief onto the T orch Leads.

9. Check the torch for proper parts assembly per the
torch manual.

CAUTION

The torch parts must correspond with the type of
operation. Refer to Section 4.04-A, Torch Parts

Selection.

10. Reinstall the Power Supply Cover .

C. Machine Systems (Shielded Leads)

1. Remove the Strain Relief Nut from the Strain Re­lief.

Torch Leads

Strain Relief

Assembly

A-02826

Strain Relief
Nut

Strain Relief Nut Removal

2. Install the Adapter supplied with the Power Sup­ply as follows:

a. Inside the Power Supply Bulkhead area, route

the connector on the free end of the Adapter
through the Strain Relief Nut.

b. Continue routing the connector out the hole

in the front of the Power Supply.

c. Feed the end of the torch lead and the Strain Relief

into the hole in the unit while routing the single
black wire into the notch of the Strain Relief.

Adapter Connector

Adapter
(Supplied With
Power Supply)

Control (PIP) Circuit

Connectors

Shield Connectors

Negative/Plasma

Torch Lead

Assembly

Negative/Plasma
Lead Connection

Lead

Pilot Lead

Stud

Pilot Lead

A-02829

Torch Lead Connections

D. Remote Pendant Control (Optional)

In machine type operations the Power Supply has an
Adapter that has a cable connector . The r emote pen­dant lead connector allows connection to a remote
pendant or CNC cable while using Control Circuit
connections in the Torch Assembly.

Connect the remote pendant control cable to the connec­tor provided on the Adapter fr om the Power Supply.

d. Tighten the Strain Relief Nut to secure the

Strain Relief to the Power Supply.

3. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.

4. Connect the PIP and Shield Cables to the mating
connectors on the Adapter supplied on the Power
Supply.

5. Remove the top nut and washer from the Pilot
Stud.

6. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.

7. Tighten the Strain Relief onto the Torch Leads.

8. Check the torch for proper parts assembly.

CAUTION

The torch parts must correspond with the type of
operation. Refer to Section 4.04-A, Torch Parts

Selection.

NOTE

Refer to Appendix 3, Torch Control Cable Wiring
Diagram For Mechanized Systems, for detailed
schematic of the Adapter.

Remote Pendant
Cable Connector

Control

12
14
13

3
4

PIP

Circuit

Torch Control

Cable Connector

2
3

4
12
14
13

A-03102

Remote Pendant Connector Diagram

Manual 0-2859 3-7 INST ALLATION PROCEDURES

3.08 Ground Connections For
Mechanized Applications

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electro­magnetic interference (EMI), commonly called RF noise.
This RF noise may interfere with other electronic equip­ment such as CNC controllers, remote controls, height con­trollers, etc. To minimize RF interference, follow these
grounding procedures when installing mechanized sys­tems:

B. Grounding

1. The preferred grounding arrangement is a single point

or “Star” ground. The single point, usually on the
cutting table, is connected with 1/0 AWG (European
50 mm2) or larger wire to a good earth ground (refer to
paragraph ‘C’, Creating An Earth Ground). The
ground rod must be placed as close as possible to the
cutting table, ideally less than 10 ft (3.0 m), but no more
than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible.
Long wires will have increased resistance to RF fre­quencies. Smaller diameter wire has increased re­sistance to RF frequencies, so using a larger diam­eter wire is better .

2. Grounding for components mounted on the cutting

table (CNC controllers, height controllers, plasma re­mote controls, etc.) should follow the manufacturer’s
recommendations for wire size, type, and connection
point locations.

For Thermal Dynamics components it is recommended
to use a minimum of 10 A WG (Eur opean 6 mm2) wire
or flat copper braid with cross section equal to or greater
than 10 A WG connected to the cutting table frame. The
connection point must be clean bare metal; rust and
paint make poor connections. For all components,
wires larger than the recommended minimum can be
used and may improve noise protection.

3. The cutting machine frame is then connected to the

“Star” point using 1/0 AWG (European 50 mm2) or
larger wire.

4. The plasma power supply work cable (see NOTE) is

connected to the cutting table at the single point “Star”
ground.

5. Make sure work cable and ground cables are properly
connected. The work cable must have a solid connec­tion to the cutting table. The work and ground connec­tions must be free from rust, dirt, grease, oil and paint.
If necessary grind or sand down to bare metal. Use
lock washers to keep the connections tight. Using elec­trical joint compound to prevent corrosion is also rec­ommended.

6. The plasma power supply chassis is connected to the
power distribution system ground as required by elec­trical codes. If the plasma supply is close to the cutting
table (see NOTE) a second ground rod is not usually
needed, in fact it could be detrimental as it can set up
ground loop currents that cause interference.

When the plasma power supply is far away from the
ground rod and interference is experienced, it may
help to install a second earth ground rod next to the
plasma power supply . The plasma power supply chas­sis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supply be
within 20 - 30 ft (6.1 – 9.1 m) of the cutting table, if
possible.

7. The plasma control cable should be shielded with the
shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground
loop currents which may cause more interference than
with no shield at all.

C. Creating An Earth Ground

1. T o create a solid, low r esistance, earth ground, drive a
1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the
rod contacts moist soil over most of its length. Depend­ing on location, a greater depth may be required to
obtain a low resistance ground (see NOTE). Ground
rods, typically 10 ft (3.0 m) long, may be welded end to
end for greater lengths. Locate the rod as close as pos­sible to the work table. Install a ground wire, 1/0
AWG (European 50 mm2) or greater, between the
ground rod and the star ground point on the cutting
table.

NOTE

Ideally, a properly installed ground rod will have a
resistance of three ohms or less.

NOTE

Do Not connect the work cable directly to the ground
rod.

INSTALLA TION PROCEDURES 3-8 Manual 0-2859

T o test for a proper earth ground, refer to the following
diagram. Ideally , the reading on the multimeter should
be as follows:

• For 115V AC: 3.0 VAC

• For 230V AC: 1.5 VAC

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as
far as possible from any CNC components, drive mo­tors, control cables, or primary power lines. If cables
have to pass over torch leads, do so at an angle. Do not
run the plasma control or other control cables in paral­lel with the torch leads in power tracts.

115VAC: 3.0 VAC
230VAC: 1.5 VAC

Meter set to
VAC setting

WARNING

Use extreme caution. This

test uses live voltage.

Neutral

115 or 230VAC

Line (Hot)

Art # A-02971

~

V

100W

Light Bulb

~

V

VR COM A

_

+

2. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and increased
chance of RF interference.

Ground

Rod

Ground Testing

CAUTION

No other connections should be made at the ground
rod being tested. This test assumes that the 1 15 or
230-VAC source neutral is connected to the utility
earth ground.

2. Increasing the ground rod length beyond 20 - 30 ft (6.1
– 9.1 m) does not generally increase the effectiveness of
the ground rod. A larger diameter rod which has more
surface area may help. Sometimes keeping the soil
around the ground rod moist by continuously running
a small amount of water into it will work. Adding salt
to the soil by soaking it in salt water may also reduce
its resistance. When these methods are used, periodic
checking of the ground resistance is required to make
sure the ground is still good.

Manual 0-2859 3-9 INST ALLATION PROCEDURES

INSTALLA TION PROCEDURES 3-10 Manual 0-2859

SECTION 4:

B. Control Panel Features

OPERATION

4.01 Introduction

This section describes the power supply operating con­trols and procedures, identifies the front and rear com­ponents, and describes the operating procedures.

4.02 Product Features

A. General Features

1. Control Panel

All operator controls, except gas pressure adjustment,
are located on this panel.

4

1

2

A

40

3

20

1

Operating Controls and Indicators

1. ON/OFF Power Switch

ON (up) position supplies AC power to activate all
control circuits. OFF (down) position deactivates con­trol circuits.

2. RUN/SET Switch

RUN (up) position is for general torch operation.
T orch switch must be held. SET (down) position used
for setting gas pressure and purging lines.

60

80

A-02989

4
5
6

7

2

3

A-02992

2. Torch Leads Input

Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.

3. Work Cable and Clamp

20 ft (6.1 m) work cable with clamp.

4. Roll Handle/Torch Leads Wrap

The torch leads and work cable wrap around the
handle.

3. Current Control (A)

Adjustment to set the output current between 20-80
amps (for standoff cutting) or 20-40 amps (for drag
cutting). At settings over 40 amps, circuitry in the
power supply automatically reduces output current
to 40 amps if the torch tip contacts the workpiece.

4. AC Power Indicator

Indicates operating power is present in the unit.

5. TEMP Indicator

Normally OFF . Yellow indicator is ON when internal
sensors detect temperatures above normal limits. The
unit should be allowed to cool before continuing op­eration.

6. GAS Indicator

Green indicator is ON when the input gas pressure is
set to 35 psi (2.4 bar) or higher . Indicator is OFF when
the pressure falls below 35 psi (2.4 bar).

7. DC Indicator

Manual 0-2859 4-1 OPERATION

Green indicator will come ON while the torch switch
is pressed. Indicates DC output circuit is active.

C. Rear Panel Features

A. Torch Par ts Selection

1. Gas Input Port

Input connection for compressed air .

W ARNING

This unit is not to be used with oxygen (O2).

3

Check the torch for proper assembly and appropriate
front end torch parts. The torch parts must corr espond
with the type of operation (cutting or gouging). Re­fer to the torch manual for proper parts selection.

B. 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 subsection 2.03-A,
Specifications/Design Features.

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

1

C. Gas Selection

Select single gas supply. Make sure gas source meets
requirements (refer to subsection 3.06, Gas Require­ments). Check connections and turn gas supply on.

D. Work Cable Connection

Check for a solid work cable connection to the work­piece.

2

A-02996

Rear Panel Features

2. Primary Input Power Cable

Primary input power cable (400-V , 460-V and 600-Volt
units); input power cable with plug on 208/230-Volt
units.

3. Gas Pressure Regulator / Filter Assembly

Pressure regulator to adjust the input gas pr essure to
the Power Supply . The pr essure regulator includes a
built-in filter. For improved filtering, other filtering
packages are available as options.

4.03 Preparations For Operating

Follow this procedure at the beginning of each shift:

WARNING

Make a solid work cable
connection to the work­piece or cutting table

A-00925

E. Torch Connection

Check that the torch is properly connected.

F. Power On

Place the ON/OFF switch to the ON (up) position.

G. Select Current Output Level

Set the current output level between 20-80 amps for
cutting or gouging.

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

OPERA TION 4-2 Manual 0-2859

H. Set Operating Pressure

7. After gas pre-flow:

Place the RUN/SET switch to the SET (down) posi­tion. Gas will flow . Adjust gas pr essur e to 70 psi (4.8
bar).

I. Prepare to Cut

Return the RUN/SET switch to RUN (up) position.
Gas will not flow until the Torch is activated.

The system is now ready for operation. Activate the
torch (press torch switch on the handle, send START
signal from CNC or press the tor ch switch on the Re­mote Pendant). There is a 2 second pre-flow before
the arc starts.

4.04 Sequence of Operation

The following is a typical sequence of operation for this
power supply. Refer to Appendix 2 for block diagram.

1. Close main power source disconnect switch.
a. AC power is available at the Power Supply.

2. Place RUN/SET switch to RUN (up) position.

3. Place the ON/OFF power switch on the front panel
of the Power Supply to ON (up) position.

a. AC Power Indicator blinks ON and OFF

for eight seconds then stays ON. Fans turn on.

a. Power Supply enabled. DC indicator turns

ON.

8. Pilot arc is established.

9. Move T orch within transfer distance of workpiece.
a. Main arc transfers to work piece. Pilot arc OFF.

10. Complete cutting operation.

NOTES

If the torch is lifted from the workpiece while the
torch switch is activated, the main arc will stop
and the pilot arc will automatically restart.

At output settings over 40 amps, control circuitry
in the power supply automatically reduces output
current to 40 amps if the torch tip contacts the
workpiece.

11. Release or deactivate the tor ch switch.
a. Main arc stops. Pilot arc stops.

If torch is activated during post-flow, the pilot
arc will immediately restart. If tor ch is within
1/4 inch (6.4 mm) transfer distance to work­piece, the main arc will transfer.

12. Gas will flow for 10 seconds (post-flow).

NOTE

Gas comes on if T or ch Trigger is pressed (although
unit will not pilot until switch is released and re­closed after the light stops blinking).

4. Place RUN/SET switch to SET (down) position.
a. Gas solenoid opens and gas flows to set pres-

sure. Set gas pressure to 70 psi (4.8 bar).

b. GAS indicator turns ON.

NOTE

GAS Indicator will not come ON if the gas pres­sure is set below 35 psi (2.4 bar) at the Gas Pres­sure Regulator/Filter Assembly.

5. Place RUN/SET switch to RUN (up) position.

a. Gas flow stops. GAS Indicator turns OFF.

6. Protect eyes and activate torch.
a. Gas pre-flow starts (approximately 2 seconds).

a. Gas flow stops. GAS indicator turns OFF .

13. Place the ON/OFF power switch to OFF (down).
a. AC Power indicator turns OFF . Fans turn

OFF .

14. Place the main power disconnect to open.
a. Main AC power is removed from the system.

For information on cutting techniques, cutting problems,
cutting speeds, cut quality, etc., refer to the torch manual
supplied with the torch.

GAS Indicator turns ON.

Manual 0-2859 4-3 OPERATION

OPERA TION 4-4 Manual 0-2859

SECTION 5:

CUSTOMER & OPERATOR

SERVICE

5.01 Introduction

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.

This section describes basic maintenance procedures per­formable by operating personnel. No other adjustments
or repairs are to be attempted other than by properly trained
personnel.

5.02 General Maintenance

A. Maintenance Schedule

W ARNING

Disconnect primary power and bleed down the sys­tem before disassembling the torch, leads, or power
supply.

To clean the unit, open the enclosure per procedure in
section 5.05-A, Cover Removal, and use a vacuum cleaner
to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, use solvents for clean­ing electrical apparatus.

Refer to Appendix 4 for maintenance schedule and proce­dures.

Regulator/Filter

Assembly

Baffle
Ring

Filter
Element
No. 9-4414

Spring

Spool

Bowl

Art # A-02995

Regulator/Filter Element Replacement

6. Reinstall the bowl.

7. T urn on the air supply.

B. Regulator/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, and either cleaned or replaced. Refer to Section
6, Parts List, for replacement filter element catalog num­ber .

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. Re­move the filter from the spool and clean it or re­place it.

C. Optional Single-Stage Filter Element

Replacement

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.

Manual 0-2859 5- 1 CUSTOMER/OPERATOR SERVICE

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

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)

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 hose.

NOTE

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

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

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).

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

5.03 Common Faults

1. Insufficient Penetration

a. Cutting speed too fast
b. T or ch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Thermal Dynamics parts used

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

CUSTOMER/OPERA T OR SERVICE 5- 2 Manual 0-2859

2. Main Arc Extinguishes

B. How to Use This Guide

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

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

The following information is a guide to 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 (T ext T ype)

1. Cause (Italic Type)

a. Check/Remedy (T ext T ype)

Locate your symptom, check the causes (easiest listed
first), then remedies. Repair as needed. Be sure to
verify that unit is fully operational after any repairs.

C. Common Symptoms

A. AC Power indicator OFF

1. Switch at customer's main power panel in OFF posi­tion.

a. Close main power panel switch.

2. Customer's main power line fuse(s) blown

d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
f. Non-Genuine Thermal Dynamics parts used

5.04 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 Troubleshooting: Overview

This guide covers a basic level of troubleshooting that re-
quires limited disassembly and measurements. 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.

a. Check main power panel fuse(s) and replace as

required.

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

a. Verify that the input line voltage is corr ect. Re-

fer to Appendix 1, Input W iring Requirements.

4. Unit internal fuse blown or loose

a. If blown, double check input voltage and replace

fuse per subsection 5.05-B. If fuse blows again,
return unit to an authorized service center .

6. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

B. AC Power indicator ON; TEMP indicator

ON

1. Airflow obstructed

a. Check for obstructed air flow around the unit

and correct condition.

2. Fan(s) blocked

a. Check and correct condition.

For major troubleshooting and parts replacement proce­dures refer to Power Supply Service Manual 0-2860.

Manual 0-2859 5- 3 CUSTOMER/OPERATOR SERVICE

3. Unit is overheated

F . Limited output with no control

a. Allow unit to cool down for at least 5 minutes.

Make sure the unit has not been operated be­yond Duty Cycle limit. Refer to Section 2.03.

4. Input line voltage is below 75% of rated level

a. Check and connect to proper input power line.

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

C. T orch will not pilot when torch switch is activated

1. RUN/SET switch in SET position

a. Move switch to RUN position.

2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-

fer to Instruction Manual supplied with torch).

3. Gas pressure too high or too low

a. Set pressure to 70 psi (4.8 bar).

4. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

D. No cutting output; T orch activated; AC Power

indicator

ON; Gas flows; Fans operate

1. Tor ch not properly connected to power supply

a. Check that torch leads are properly attached to

power supply .

2. Shield cup not properly installed on torch

1. Poor input or output connections

a. Check all input and output connections.

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

repair per Service Manual.

G. Erratic or improper cutting output

1. Poor input or output connections

a. Check all input and output connections.

2. Poor ground or work connection is poor.

a. Check connection.

H. Arc shuts off during operation; Arc will not restart

when torch switch is activated.

1. Unit is overheated (TEMP indicator ON)

a. Allow unit to cool down for at least 5 minutes.

Make sure the unit has not been operated be­yond Duty Cycle limit. See 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.

a. Check that shield cup is fully seated against torch

head. Refer to the torch manual for details.

3. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

4. Faulty T orch

a. Return for repair or have qualified technician

repair per T or ch Manual.

E. Low cutting output

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

2. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

CUSTOMER/OPERA T OR SERVICE 5- 4 Manual 0-2859

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

a. Check source for at 70 psi (4.8 bar); adjust as

needed.

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

I. No gas flow; AC POWER indicator ON; Fan

operates

1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 bar).

2. Gas supply pressure too high

A-03001

Lower
screws

Upper screws

Ground wire

Lower
screws

Upper
screws

a. Maximum 125 psi (8.6 bar) inlet pressure

3. Shield Cup not properly installed.

5.05 Power Supply Basic Parts
Replacement

a. Check to see that Control Circuit (PIP) pins are

installed. Refer to the torch manual for details.

4. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

J. Torch cuts but not adequately

1. Current set too low

a. Increase current setting.

2. T orch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Torch Instr uction

Manual supplied with torch).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

while purging and observe oil or moisture
buildup (do not activate torch).

4. Tor ch tip being dragged on work.

a. Lift torch tip off work. At output settings over

40 amps, control circuitry automatically reduces
output current to 40 amps if the torch tip con­tacts the workpiece.

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.

Manual 0-2859 5- 5 CUSTOMER/OPERATOR SERVICE

Cover Removal

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

3. Reinstall the cover as follows:
a. Reconnect the ground wire, if necessary.
b. Place the cover onto the frame so that it rests on

the lower screws.
c. Reinstall and tighten the upper screws.
d. Tighten lower screws.

B. 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 "A" above.

Fuse Location

Art # A-03002

Internal Fuse Location

This completes the parts replacement procedures.

CUSTOMER/OPERA T OR SERVICE 5- 6 Manual 0-2859

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all r eplaceable 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 .

Manual 0-2859 6-1 P A RTS LISTS

6.03 Power Supply Replacement

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

Qty Description Catalog #

CutMaster 100 Power Supply
1 208/230VAC, Single-Phase, 60Hz, with input power cable and plug 3-1250-1
1 400V AC, Thr ee-Phase, 50/60 Hz, with input power cable 3-1250-3
1 460V AC, Thr ee-Phase, 60Hz, with input power cable 3-1250-2
1 600V AC, Thr ee-Phase, 60Hz, with input power cable 3-1250-5

6.04 Replacement Parts

Qty Description Catalog #

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

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

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second
Stage
Cartridges
(as marked)

Art # A-02942

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

PARTS LISTS 6-2 Manual 0-2859

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input C urrent Input Suggested Sizes (See N otes )

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 14.4 69 90 6 6
208 60 15.6 75 90 6 6
230 50 15 65 80 6 6
230 60 15.5 67 80 6 6
400 50/60 13.9 20 30 10 10
460 60 18 39 50 10 10
460 60 16 20 30 12 12
600 60 13.5 13 20 12 12

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Can adian Electrical Code

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired 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.

Manual 0-2859 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed)

post-flow, pilot arc will immediately restart.

(1/4 in/6.4mm) of workpiece, main arc

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (10 seconds)

NOTE - If torch is activated during

If torch is within transfer distance

will transfer.

After post-flow:

GAS indicator off.

APPENDIX A-2 Manual 0-2859

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-02778

APPENDIX 3: TORCH CONTROL CABLE WIRING

DIAGRAM

This diagram applies to mechanized systems only.

T o Torch

Control Device

Torch Control

Cable

Torch Control

Connectors

Control Connector

Plug with Connectors

To Power Supply

Control Connector

Control Shield

Connector

Shield

Return

Power Supply

Control

OK-To-Move

Relay

A-02821

12
14

Torch Lead

Assembly

Mate & Lock

2
1
3
4

Connectors

Lead Shield

Connector

Torch Leads

Connectors only on

Shielded Leads

Mate & Lock

Connectors

Torch Head

PIP Pin

Shield Cup

PIP Pin

3
4

12

OK-To-Move

14

A-02801

Control

13

Torch Control

Cable Connector

Manual 0-2859 A-3 APPENDIX

13

Pendant Ground

Remote Pendant/CNC

Cable Connector

APPENDIX 4: 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, r eplace 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, r eplace 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 ar cing or pits, replace if necessary.

APPENDIX A-4 Manual 0-2859

Notes:

Manual 0-2859 A-5 APPENDIX

APPENDIX 5: SYSTEM SCHEMATIC, 208/230 VOLT UNITS

A

B

C

D

E

F

208/230V
SINGLE PHASE
INPUT

M2

FAN2

M1

FAN1

PILOT RELAY

28VAC B
28VAC A

ON/OFF SW

R

RUN/SET SW

SW2

CURRENT
CONTROL

LED PCB
19X1604

CURRENT ADJUST
20 - 80

IGBT HEATSINK

INDUCTOR TEMP

SW1

PCR

TEMP

1

W1

L1

W1

L2

(2)

W1

L3

(3)

W1

L4

230V

S

AC

TEMP

GAS

DC

NTC

t

TS1

TS2

J14

P15

J15

(6)

6

6

(6)

5

5

(7)

2

2

(7)

1

1

J18

P18

(19)

1

1

(20)

2

2

(21)

3

3

(22)

4

4

(23)

5

5

(24)

6

6

(25)

7

7

(26)

8

8

J27

P27

(35)

1

1

1

(36)

2

2

2

(37)

3

3

3

(38)

4

4

4

(39)

5

5

5

(40)

6

6

6

(41)

7

7

7

(42)

8

8

8

J29

P29

1

1
2

2
3

3
4

4

J32

P32

1

1

2

2

(1)

COPPER
STRAP

(78)

CHASSIS
GND

(4)

(5)

E1

E2

E3

(33)

E33

P11

1

4

K2

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

2

E22

J11

1

4

+18V

TEST CONNECTOR

FILTERING

R30
ZERO

FOR 230V
ONLY

600V, 6/10A, KTK

PILOT ON

3

2

1

J23

K4

(8)

SOL1

A

GAS SOLENOID

F1

FUSE

0.9A

J24
P24

B

INPUT DIODE
ASSEMBLY 19X1755

E13

E18

1 2

LT1

460V

400V

230V

F2

RESETABLE

1

2

4

3

1

2

4

3

(9)

(10)

(11)

PRESSURE SW

3

6

5

3

1

K5

7

5

6

6

7

5

(12)

PS1

K1

T1

7

9
10

12

PRESS GOOD

8
8

(13)

W1

MAIN CONTACTOR

E6

E8

E14

E16

INRUSH

K1

28VAC A

TO BIAS SUPPLY

28VAC B

4

E7

E15

+12VDC

K1

+18V

FAN

K2

+18VDC

+18VDC

MAIN BOARD ASSEMBLY 19X1777

CD ON

INV ON

DRAG ON

SW ON

LOGIC BOARD
ASSEMBLY 19X1759

E4

E5

E20

E23

E30

GAS SOLENOID

MAIN CONTACTOR

D20

D21

D37

D32

IGBT PCB ASSEMBLY 19X1756

E12A

E17A

24
25

E19A

E21A

IGBT PCB ASSEMBLY 19X1756

E12B

E17B

24
25

E19B

E21B

K4

K5

P1

J13
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

GATE DRIVE B RTN

26

26
27

27

GATE DRIVE A RTN

28

28
29

29

30

30
31
32
33
34
35
36

CURRENT SENSE

31

CURRENT SENSE

32

CURRENT SENSE RTN

33

CURRENT SENSE RTN

34
35
36

EXTENDER BOARD
ASSEMBLY 19X1775

+12VDC

+12VDC
DC COM
DC COM

MC1ON

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

INRUSH DONE

CD ENABLE
CD ENABLE

GAS ON

PILOT ON

DC OK

OVTEMP

AC OK

TORCH SW RTN

TORCH SW

+12VDC

POT HIGH

POT WIPER

POT LOW
GATE DRIVE B
GATE DRIVE A

DC COM
DC COM

-OUT

5

GATE

12231314

DRIVE

28

27

GATE
DRIVE

1

24567

GATE

12231314

DRIVE

28

27

GATE
DRIVE

1

24567

J43

J12

1

1

2

2

3

3
4

4
5

5

6

6

7

7

8

8
9

9

1010

11

11
12

12

13

13
14

14
15

15

CSR

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

A-03186

1

APPENDIX A-6 Manual 0-2859

2

3

4

5

E11A

E11B

6

P25J25

1

212

P3A

J3A

1

1

2

2

E32

E9A

P7A

J7A

E10

1

1

2

J3B

E9B

J7B

2

P3B

1

1

2

2

P7B

1

1

2

2

1

J30 P30

212

1

J31 P31

212

E27

P26J26

1

212

DC COM

TIP SENSE

+12VDC

TORCH SW

TORCH SW RTN

CD ENABLE

-OUT

CSR

MAIN

T5

PRI

PRI

J33

P33

(70)

1

1

(71)

2

2

(72)

3

3

(73)

4

4

(74)

5

5

(75)

6

6

(76)

7

7

(77)

8

88

SEC

SEC

P39

7

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E45

E48B

E49

E53B
E54B

OUTPUT DIODE
ASSEMBLY
19X1757

E50A

E47

E48A

E52

E53A
E54A

J39

1

1
2

2
3

3

4

4

5

5
6

6
7

7

8

8

E34B

POWER OUTPUT BOARD
ASSEMBLY 19X1754

E39B

E56B
E60B

E34A
E39A

E56A
E60A

E36

E57

E37

E58

+12VDC

CD ENABLE

E47

E45

CURRENT SENSE

DC COM

9

E32

E62

E35

PILOT

E43

E64

E63

THRU SCREW TERMINAL

CHASSIS GND

J40

P40

1

1

2

2

3

3

4

4
5

5

6

6
7

7
8

8

E61

J41

P41

3

3
2

2
1

1

OUTPUT INDUCTOR

L1

E(62)

E(35)

CD ASSEMBLY
19X1751

J28

1

2

14

15

17

18

E(58)

J42

(30)

3

(31)

4

13

10

A

B

PCR

T10

CD

8

5

T
O
R
C
H

WORK

C

D

(30)

TORCH
SWITCH

(31)

6

7

Manual 0-2859 A-7 APPENDIX

COMP DESCRIPTION LOCATION

F1

FUSE, 6/10A 600V, KTK
FUSE, 0.9A, RESETABLE

F2
L1

OUTPUT INDUCTOR A10

M1

FAN, 4.5" 220VAC

M2

FAN, 4.5" 220VAC
PILOT RELAY

PR
PS1 PRESSURE SWITCH
SOL1 GAS SOLENOID

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET

SW2
T5

MAIN TRANSFORMER
T1 CD TRANSFORMER C10
TS1

TEMP. SENSOR, IGBT HEATSINK
TS2

TEMP. SENSOR, INDUCTOR

MAIN CONTACTOR F3

W1

DateByRevisionsRev

RELEASE ECO 38AE

AA

Last Modified:

Thursday, July 12, 2001

GCW 07/11/01

15:05:29

Information Proprietary to THERMAL DYNAMICS CORPORATION.

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

NOTE:

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

Capacitors are in Microfarads (UF)

TITLE:

CM100 208/230V SINGLE PHASE 50/60 Hz

8

B2
E3

C1
B1
C1
F3
F2
C1
D1
B7

E1
F1

SCHEMATIC,

9

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

PCB No:
Assy No:

SupersedesScale

Date:

Tuesday, May 15, 2001

Drawn: References

GCW

DWG No:

10

Sheet

11

42X1086

A-03186

Chk: App:

Size

C

E

F

of

APPENDIX 6: SYSTEM SCHEMATIC, 400 and 460 V UNITS

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18VDC

+18VDC

+18V

3

GATE DRIVE A

(22)

460VAC
3 PHASE
INPUT

SOL1

J32

19

32

(38)

33

28

2

AC

PILOT ON

27

20

3

K1

FOR 460V ONLY

34

TIP SENSE

P1

4

22

MAIN CONTACTOR

4

18

35

30

23

14

(37)

AC

21

17

7

(23)

230V

K5

29

3

3

P32

3

19

INRUSH DONE

+12VDC

26

29

4

CURRENT
CONTROL

24

460V

W1 ON

(40)

6

4

1

35

OVERTEMP

+12V

POT LOW

8

11

OVTEMP

K2

LOGIC BOARD

34

24

3

J14

26

GATE
DRIVE

FILTERING

30

22

1

(5)

1010

CURRENT SENSE

8

7

1

4

(36)

(19)

1

30

OVERTEMP

24

GATE DRIVE A RTN

7

25

30

6

31

18

1

4

18

CURRENT SENSE RTN

(39)

J18

(3)

J29

11

1

(35)

2

6

13

CURRENT SENSE

17

+12VDC

(42)

1

11

17

6

CSR

230V

14

35

21

3

2

4

1

34

DC OK

(41)

P18

(20)

(26)

20

8

5

P29

1

6

CD ENABLE

IGB T PCB ASSEMBLY 19X1756

7

GAS ON

15
16

POT WIPER

3

GAS

POT HIGH

1

29

36

1

2

1

TO BIAS SUPPLY

28

(7)

GATE
DRIVE

36

32

+12VDC

6

6

3

33

AC OK

4

13

DC

22

32

GAS

1

CD ENABLE

J13

5

W1

24

33

DC

5

1

7

MAIN BOARD ASSEMBLY
400-VOLT: 19X1778
460-VOLT: 19X1753

GATE
DRIVE

P24

17

PILOT ON

11

2

4

4

TORCH SW

28

15

ON/OFF SW

CHASSIS
GND

J43

19

J27

5

8

5

P11

FAN1

14

8

16

15

5

(25)

1

1

PRESS GOOD

23

22

9

(24)

RUN/SET SW

20

GATE DRIVE B

35

LED PCB
19X1604

27

J11

2

2

32

5

12

M2

7

4

8

W1

A

33

GATE DRIVE B RTN

GAS SOLENOID

1

13

(12)

34

3

28VAC B

31

2

28VAC B

S

3

27

D21

9

6

8

8

8

7

K4

21

2

12

20

(8)

25

D32

27

12

5

J12

26

16

P15

(6)

36

TEMP

FAN2

15

PRESS GOOD

W1

(9)

5

31

IGB T PCB ASSEMBLY 19X1756

(1)

21

PILOT RELAY

FOR 400V ONLY

GATE
DRIVE

J24

7

2

25

29

14

6

B

4

23

POT WIPER

7

P27

5

(13)

5

3

28

(21)

D37

36

10

4

31

6

1

W1

16

19

10

R

J15

9

2

(4)

26

-OUT

6

2

PRESSURE SW

RUN/SET

(2)

2

2

2

25

M1

9

18

POT HIGH

12

J23

23

13

28VAC A

K1

400V

POT LOW

2

CURRENT SENSE RTN

CURRENT ADJUST
20 - 80

D20

INV ON

DRAG ON

CD ON

SW ON

(6)

(7)

1

7

3
4
5

2

8

6

1

7

3
4
5

2

8

6

K1

INPUT DIODE

ASS EMBLY 19X1811

PCR

INRUSH

0.9A

EXTENDER BOARD
ASSEMBLY 19X1775

TEST CONNECTOR

28VAC A

K5

K4

MAIN CONTACTOR

GAS SOLENOID

SW1

SW2

TS1

F2

PS1

(11)(10)

IGBT HEATSINK

TEMP

TS2

INDUCTOR TEMP

ASSEMBLY 19X1759

K2

FAN

NTC

DC COM
DC COM

DC COM

DC COM

TORCH SW RTN

460VAC
1 PHASE
INPUT

EMC

FILTER

ONLY

400V CE

400VAC
3 PHASE
INPUT

CHASSIS
GND

(SEE NOTES)

E13

E30

E22

E3

E12B

E16

E17B

E6

E17A

E19A

E21A

E5

R78

24

12231314

25

27

24567

1

28

E1

E23

F1

FUSE

E8

24

12231314

25

27

24567

1

28

E12A

E4

RESETABLE

T1

6

1

3

5

7

9
10

12

E20

E15

E14

E2

E19B

t

E7

E18

R29

LT1

1 2

E21B

Art # A-03093

APPENDIX A-8 Manual 0-2859

E9A

E11A

E11B

6

P25J25

1

J3A

212

P3A

1

1

2

2

E32

MAIN

T5

E10

P7A

J7A

1

1

2

2

J3B

P3B

1

1

2

2

E9B

J7B

P7B

1

1

2

2

1

J30 P30

212

1

J31 P31

212

E27

P26J26

1

212

TIP SENSE

TORCH SW

TORCH SW RTN

CD ENABLE

-OUT

DC COM

+12VDC

CSR

PRI

PRI

J33

P33

1

1
2

2
3

3

4

4

5

5
6

6
7

7
8

8

6

(74)

(70)
(71)
(72)
(73)

(75)
(76)
(77)

7

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E45

E48B

E49

E53B

SEC

SEC

E54B

OUTPUT DIODE
ASSEMBLY
19X1757

E50A

E47

E48A

E52

E53A
E54A

P39

J39

1

1
2

2

3

3
4

4
5

5

6

6

7

7

8

8

COMP DESCRIPTION LOCATION

F1

FOR 460-VOLT UNITS; 1/4A 500V
SLO-BLO, FNQ

FOR 400-VOLT UNITS; 0.4A 500V
SLO-BLO, FNQ

F2

FUSE, 0.9A, RESETABLE
L1E3OUTPUT INDUCTOR A10
M1

FAN, 4.5" 220VAC
M2

FAN, 4.5" 220VAC
PR

PILOT RELAY
PS1 PRESSURE SWITCH
SOL1 GAS SOLENOID
SW1

SWITCH, ON/OFF
SW2

SWITCH, RUN/SET

MAIN TRANSFORMER

T5
T10 CD TRANSFORMER C10

TEMP. SENSOR, IGBT HEATSINK

TS1

TEMP. SENSOR, INDUCTOR

TS2

MAIN CONTACTOR F3

W1

AA

ECO 38FA HAS 07/16/01

AB
AC
AD

EC O 1 00038 HAS 0 2 /26/02

AE
AF

Last Modified:

Tu es d ay , Ma rch 16, 2004

7

8

E34B

E36

POWER OUTPUT BOARD

ASSEMBLY 19X1754

E39B

E56B

E57

E60B

E34A

E37

E39A

E56A

E58

E60A

DateByRe vi sionsRev

06 /08/01

HASEC O 3 7E2

11 /13/01GCWECO 3CE2

11 /05/02HASE C O 1 00397
03 /12/04HASE C O 1 01341

15:05:29

8

9

OUTPUT INDUCTOR

E32

L1

E62

E35

E43

E64

E63

+12VDC

J40

1

CD ENABLE

E47

E45

CURRENT SENSE

DC COM

2
3
4
5
6
7
8

E61

J41

3

2

1

B2

C1
B1
C1
F3
F2
C1
D1
B7

E1
F1

Information Proprietary to THERMAL DYNAMICS CORPORATION.

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

NOTE:

Un les s O th er wi s e Sp ecifie d , R esi s tors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)

TITLE:

SCHEMATIC,

CM100 400V 3PH/460V 3PH/1PH

E(62)

E(35)

PILOT

THRU SCREW TERMINAL

CHASSIS GND

CD ASSEMBLY
19X1751

J28

1

2

P40

14

1

15

2
3
4

17

5
6
7

18

8

E(58)

J42

P41

(30)

3

2

(31)

1

THERMAL DYNAMICS
IN D USTRIAL PARK No. 2
WE S T L EBANON, NH 03784
603-298-5711

8

5

(30)

3

(31)

4

13

9

10

T10

CD

T
O
R
C
H

WORK

TORCH
SWITCH

114X301

PCB No:

19X1753

Ass y No:

19X1778

Su persedesScale

Date:

Tuesday, May 15, 2001

Dr awn: Re fe re nces

GCW

Chk: App:

DWG No:

Size

42X1080

C

Art # A-03093

10

PCR

Sh eet

11

of

A

B

C

D

E

F

Manual 0-2859 A-9 APPENDIX

APPENDIX 7: SYSTEM SCHEMATIC, 600 VOLT UNITS

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

+12VDC

+18V

+18VDC

+18VDC

+18V

3

GATE DRIVE A

(22)

600VAC
3 PHASE
INPUT

SOL1

J32

19

32

(38)

33

28

2

AC

PILOT ON

27

20

3

K1

34

TIP SENSE

P1

4

22

MAIN CONTACTOR

4

18

35

30

23

14

(37)

AC

21

17

7

(23)

230V

K5

29

3

3

P32

3

19

INRUSH DONE

+12VDC

26

29

4

CURRENT
CONTROL

24

575V

W1 ON

(40)

6

4

1

35

OVERTEMP

+12V

POT LOW

8

11

OVTEMP

K2

LOGIC BOARD

34

24

3

J14

26

GATE
DRIVE

FILTERING

30

22

1

(5)

1010

CURRENT SENSE

8

7

1

4

(36)

(19)

1

30

OVERTEMP

(SEE NOTES)

24

GATE DRIVE A RTN

7

25

30

6

31

18

1

4

18

CURRENT SENSE RTN

(39)

J18

(3)

J29

11

1

(35)

2

6

13

CURRENT SENSE

17

+12VDC

(42)

1

11

17

6

CSR

230V

14

35

21

3

2

4

1

34

DC OK

(41)

P18

(20)

(26)

20

8

5

P29

1

6

CD ENABLE

IGBT PCB ASSEMBLY 19X1815

7

GAS ON

15
16

POT WIPER

3

GAS

POT HIGH

1

29

36

1

2

1

TO BIAS SUPPLY

28

(7)

GATE
DRIVE

36

32

+12VDC

6

6

3

33

AC OK

4

13

DC

22

32

GAS

1

CD ENABLE

J13

5

W1

24

33

DC

5

1

7

MAIN BOARD ASSEMBLY 19X1806

GATE
DRIVE

P24

17

PILOT ON

11

2

4

4

TORCH SW

28

15

ON/OFF SW

CHASSIS
GND

J43

19

J27

5

8

5

P11

FAN1

14

8

16

15

5

(25)

1

1

PRESS GOOD

23

22

9

(24)

RUN/SET SW

20

GATE DRIVE B

35

LED PCB
19X1604

27

J11

2

2

32

5

12

M2

7

4

8

W1

A

33

GATE DRIVE B RTN

GAS SOLENOID

1

13

(12)

34

3

28VAC B

31

2

28VAC B

S

3

27

D21

9

6

8

8

8

7

K4

21

2

12

20

(8)

25

D32

27

12

5

J12

26

16

P15

(6)

36

TEMP

FAN2

15

PRESS GOOD

W1

(9)

5

31

(1)

21

PILOT RELAY

GATE
DRIVE

J24

7

2

25

29

14

6

B

4

23

POT WIPER

7

P27

5

(13)

5

3

28

(21)

D37

36

10

4

31

6

1

W1

16

19

10

R

J15

9

2

(4)

26

-OUT

6

2

PRESSURE SW

RUN/SET

(2)

2

2

2

25

M1

9

18

POT HIGH

12

J23

23

13

28VAC A

K1

POT LOW

2

CURRENT SENSE RTN

CURRENT ADJUST
20 - 80

D20

INV ON

DRAG ON

CD ON

SW ON

(6)

(7)

1

7

3
4
5

2

8

6

1

7

3
4
5

2

8

6

K1

INPUT DIODE
ASS EMBLY 19X1811

PCR

INRUSH

0.9A

EXTENDER BOARD

ASSEMBLY 19X1775

TEST CONNECTOR

28VAC A

K5

K4

MAIN CONTACTOR

GAS SOLENOID

SW1

SW2

TS1

F2

PS1

(11)(10)

IGBT HEATSINK

TEMP

TS2

INDUCTOR TEMP

ASSEMBLY 19X1759

K2

FAN

NTC

DC COM
DC COM

DC COM

DC COM

TORCH SW RTN

IGBT PCB ASSEMBLY 19X1815

E13

E30

E22

E3

E12B

E16

E17B

E6

E17A

E19A

E21A

E5

24

12231314

25

27

24567

1

28

E1

E23

F1

FUSE

E8

24

12231314

25

27

24567

1

28

E12A

E4

RESETABLE

T1

6

1

3

7

9
10

12

E20

E15

E14

E2

E19B

t

E7

E18

R29

LT1

1 2

E21B

Art # A-03327

APPENDIX A-10 Manual 0-2859

J3A

E9A

E11A

J7A

J3B

E9B

E11B

J7B

6

P25J25

1

212

P3A

1

1

2

2

E32

E10

P7A

1

1

2

2

P3B

1

2

P7B

1

2

1

2

1

2

1

J30 P30

212

1

J31 P31

212

E27

P26J26

1

212

DC COM

TIP SENSE

+12VDC

TORCH SW

TORCH SW RTN

CD ENABLE

-OUT

CSR

MAIN

T5

PRI

PRI

J33

P33

1

1
2

2
3

3

4

4

5

5
6

6
7

7

8

8

(70)
(71)
(72)
(73)
(74)
(75)
(76)
(77)

7

OUTPUT DIODE
ASSEMBLY
19X1757

E50B

E45

E48B

E49

E53B

SEC

SEC

E54B

OUTPUT DIODE
ASSEMBLY
19X1757

E50A

E47

E48A

E52

E53A
E54A

P39

J39

1

1

2

2

3

3
4

4

5

5

6

6

7

7

8

8

8

E34B

E36

POWER OUTPUT BOARD
ASSEMBLY 19X1754

E39B

E56B

E57

E60B

E34A

E37

E39A

E56A

E58

E60A

+12VDC

CD ENABLE

E47

E45

CURRENT SENSE

DC COM

9

E32

E62

E35

E43

E64

E63

J40

1
2
3
4
5
6
7
8

E61

P41

J41

3

2

1

OUTPUT INDUCTOR

L1

E(62)

E(35)

PILOT

THRU SCREW TERMINAL

CHASSIS GND

CD ASSEMBLY
19X1751

J28

1

2

P40

14

1

15

2
3
4

17

5
6
7

18

8

E(58)

J42

(30)

3

3

2

(31)

1

4

13

10

A

B

PCR

T10

CD

8

5

C

T
O
R
C
H

WORK

D

(30)

TORCH
SWITCH

(31)

6

Manual 0-2859 A-11 APPENDIX

COMP DESCRIPTION LOCATION

F1

FUSE, 1/4A 600V KTK-R
FUSE, 0.9A, RESETABLE

F2
L1E3OUTPUT INDUCTOR A10
M1

FAN, 4.5" 220VAC

M2

FAN, 4.5" 220VAC
PILOT RELAY

PR
PS1 PRESSURE SWITCH
SOL1 GAS SOLENOID

SWITCH, ON/OFF

SW1

SWITCH, RUN/SET

SW2

MAIN TRANSFORMER

T5
T10

CD TRANSFORMER C10

TS1

TEMP. SENSOR, IGBT HEATSINK

TS2

TEMP. SENSOR, INDUCTOR
MAIN CONTACTOR F3

W1

DateByRe vi sionsRev

8

04 /16/02GCWE C O 1 00032

In f o rm a ti o n P ro p r i e t a ry t o TH ER MAL D Y N AMI C S C OR PO R AT ION.

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

NOTE:

TITLE:

15 :0 5:29

AA

AB

Last Modified:

7

EC O 1 01341 03 /12/04HAS

Monday, March 15, 2004

B2

C1
B1
C1
F3
F2
C1
D1
B7

E1
F1

THERMAL DYNAMICS
IN D USTRIAL PARK No. 2
WE S T L EBANON, NH 03784
603-298-5711

Un les s O ther wi s e Sp ec if ie d, R es i s tors are in Ohms 1/4W 5%.

Capacitors are in Microfarads (UF) Chk: App:

SCHEMATIC,

CM100 600V 3PH

9

PCB No:
Ass y No:

Date:

Tuesday, May 15, 2001

Dr awn: Re fe re nces

GCW

Size

C

10

Su persedesS cale

Sh eet

11

of

DWG No:

42X1107

Art # A-03327

E

F