Page 1
Plasma Cutting
Power Supply
CutMaster™ 151 (CE)
A-04517
Operating Manual
May 5, 2005 Manual No. 0-4720
Page 2
Page 3
W ARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CutMaster™ 151 (CE)
Operating Manual Number 0-4720
Covered under U.S. Patents
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2005 by
Thermadyne 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: May 5, 2005
Record the following information for W arranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
Page 4
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMA TION................................................................................................. 1-1
1.01 Notes, Cautions and Warnings ..................................................................... 1-1
1.02 Important Safety Precautions........................................................................ 1-1
1.03 Publications.................................................................................................. 1-2
1.07 Declaration of Conformity.............................................................................. 1-4
1.08 Statement of W arranty.................................................................................. 1-5
SECTION 2:
INTRODUCTION ................................................................................................................ 2-1
2.01 Scope of Manual........................................................................................... 2-1
2.02 Power Supply S pecifications......................................................................... 2-1
2.03 Input Wiring S pecifications............................................................................ 2-2
2.04 Power Supply Features................................................................................. 2-3
2.05 Power Supply Options and Accessories ....................................................... 2-4
SECTION 3: INST ALLA TION...................................................................................................... 3-1
3.1 Unpacking .................................................................................................... 3-1
3.2 Lifting Options............................................................................................... 3-1
3.3 Primary Input Power Connections ................................................................. 3-2
3.4 Gas Connections.......................................................................................... 3-3
3.5 Torch Connections ........................................................................................ 3-5
SECTION 4: OPERA TION ......................................................................................................... 4-1
4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
Page 5
T ABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance.................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-5
5.03 Basic Troubleshooting Guide ........................................................................ 5-6
5.04 Power Supply Basic Parts Replacement...................................................... 5-11
SECTION 6:
P ARTS LISTS .................................................................................................................... 6-1
6.01 Introduction................................................................................................... 6-1
6.02 Ordering Information...................................................................................... 6-1
6.03 Power Supply Replacement.......................................................................... 6-1
6.04 Replacement Parts ....................................................................................... 6-1
6.05 Options and Accessories.............................................................................. 6-2
6.06 Torch Parts ................................................................................................... 6-3
APPENDIX 1: SEQUENCE OF OPERA TION (BLOCK DIAGRAM) ........................................... A-1
APPENDIX 2: DA T A T AG INFORMA TION ................................................................................ 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
Page 6
Page 7
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.”
March 2, 2004 1- 1 GENERAL INFORMA TION
Page 8
• 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 March 2, 2004
Page 9
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. NFP A 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 AWSF4.1, 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 RESPIRA TOR Y
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
March 2, 2004 1- 3 GENERAL INFORMA TION
Page 10
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 repr esentative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
GENERAL INFORMA TION 1- 4 March 2, 2004
Page 11
1.08 Statement of Warranty
LIMITED W ARRANTY : Subject to the terms and conditions established below , Thermal Dynamics® Corporation warrants to the original
retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty
are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated
below , Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and
maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct
such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at
which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods
begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED W ARRANTY PERIOD
Product
Power Supply Com ponents
(Parts and Labor)
Torch and Leads
(Parts and Labor)
CUTMASTER™ 51 3 Years 1 Year
CUTMASTER™ 81 3 Years 1 Year
CUTMASTER™ 101 3 Years 1 Year
CUTMASTER™ 151 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party , impr operly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty , the remedies shall be, at the discr etion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMIT ATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or fr om the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective January 15, 2004
March 2, 2004 1- 5 GENERAL INFORMA TION
Page 12
GENERAL INFORMA TION 1- 6 March 2, 2004
Page 13
SECTION 2:
* NOTE: The duty c ycl e wil l be reduc ed if t he primary i nput power (AC) is l ow
CE CutM aster™ 151 Power Supply Duty Cycle *
40%
60%
100%
400 VAC (360-440 VA C), Three Phase, 50/ 60 Hz
400 VAC (360-440 VA C), Single P has e, 50/ 60 Hz
25 - 100 Amps , Cont i nuous l y A dj us table
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynamics® CE
CutMaster™ 151 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 W arranty .
Read this manual thoroughly . A complete understanding of the characteristics and capabilities of this equipment will assure the
dependable operation for which it was designed.
NOTE
Refer to the Torch Manual for torch and cutting information.
2.02 Power Supply Specifications
CE CutMaster™ 151 Power Supply Specifications
Input Power
Output Current
Power Supply
Gas Filtering Ability
Am bient Temperature
or the output voltage (DC) is higher than s hown in t hi s chart.
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications
include calculating an output voltage based upon power supply rated current. To facilitate comparison between
power supplies, all manufacturers use this output voltage to determine duty cycle.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC
torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, and actual
cutting operation.
Part iculat es to 20 Mic rons
40° C (104° F)
IEC
Rating
Dut y Cy cl e
Current 1 00A - 73A - 50A DC Volt age 120V - 109V - 100V -
Rating
NOTE:
TDC
IEC
Rating
TDC
Rating
IEC
Rating
TDC
Rating
Manual 0-4720 2- 1 INTRODUCTION
Page 14
Power Supply Dimensions & Weight Ventilation Clearance Requirements
A
/
m
g
1
Art # A-03379
83 lb / 37.6 k
150 mm
17.3 in
439 m
6"
24"
0.6 m
27.5 in / 696 mm
6"
150 mm
-03572
12.4 in /
315 mm
2.03 Input Wiring Specifications
CE CutMaster 151 Input Wiring Specifications
Input Power Input Current Input Suggested Sizes (See Notes)
Vo ltage Freq. 1-Ph 3-Ph 1-P h 3-Ph Fuse ( Amps)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph
400 50/60 19.2 48 50 10
400 50/60 10.4 26 30 4
Line Voltages with S uggest ed Cir cuit Protection an d Wire Sizes
Based on Nation al Electric Co de and Cana dian E l ectrical 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.
Wi re (mm2)
6"
50 mm
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 0-4720
Page 15
le
and Clamp
Handle and Leads Wrap
P
I
2.04 Power Supply Features
Art # A-04507
Control Panel
Torch Leads Receptacle
Work Cab
Gas Pressure Regulator /
Filter Assembly
Gas Inlet Port
orts for Optional Automation
nterface Cable
Gas Pressure Gauge
Art # A-03738
Input Power Cord
Manual 0-4720 2- 3 INTRODUCTION
Page 16
2.05 Power Supply Options and Accessories
Section 6, Parts Lists, provides catalog numbers and ordering information.
A. Single-Stage Air Filter Kit
For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns.
This filter increases performance and improves consumables parts life.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0 microns. This
filter is pre-assembled at the factory and needs only to be installed on the power supply .
C. High Pressure Regulators
High pressure regulators are available. The regulators are used to set the proper compressed air pressure.
NOTE
Regulators should not be installed with In-Line Air Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply , a 50 ft / 15.2 m work cable with clamp
is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power
supply and can also serve as a display cart. 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.
G. Power Supply Dust Cover
Nylon canvas power supply dust cover with water resistant finish, large outer pocket for storing manuals or spare consumables, and adjustable draw cord for tight fit.
INTRODUCTION 2-4 Manual 0-4720
Page 17
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, purchase 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.
F ALLING 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 0-4720 3- 1 INST ALLATION
Page 18
3.3 Primary Input Power Connections
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power
source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit
protection and wiring requirements as specified in Section 2.03.
A. Connections to 400 - Volt Three - Phase Power
These Power Supplies are equipped with a four - conductor input power cable for three - phase input power. The
460 - Volt Power Supply will accept 460 - VAC, Single - Phase input power with a change of input power cable.
1. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable.
2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (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.
system.
INST ALLATION 3-2 Manual 0-4720
Page 19
3.4 Gas Connections
1
Regulator/Filter
A. Connecting Gas Supply to Unit
Use only compressed air with this power supply .
The connection is the same for compressed air from a compressor from high pressure cylinders. Refer to subsection 3.4-B or 3.4-
C if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. Other fittings can be
used.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not use
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.
Assembly
Inlet Port
Bowl
/4 NPT to 1/4"
(6mm) Fitting
Hose Clamp
Art # A-02999
Air Connection to Inlet Port
Gas Supply
Hose
Manual 0-4720 3- 3 INST ALLATION
Page 20
B. Optional Air Filters
Inlet Port
1
1
rt
1. Connect the Filter as illustrated. Use only Synflex or equivalent grade hose. The illustrations show typical fittings as an
example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the
torch. Connect as follows:
Regulator/Filter
Assembly
Bowl
1/4 NPT Hose Fitting
Hose Clamp
/4" (6 mm) Gas Supply Hose
Art # A-03000
Optional Single-Stage Filter Installation Optional Two-Stage Filter Installation
D. Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
Regulator/Filter
Assembly
Hose
Clamp
/4" (6 mm) Gas
Supply Hose)
Regulator Inlet Port
1/4 NPT
Hose Fitting
2-Stage Filter
Inlet Port (IN)
Outlet Po
(OUT)
Two Stage
Filter
Assembly
Art # A-03004
1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regulators.
2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder
valve to blow out any dust which may be present.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi (6.9 bar)
maximum and flows of at least 500 scfh (236 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the
torch.
INST ALLATION 3-4 Manual 0-4720
Page 21
3.5 Torch Connections
If necessary , connect the torch to the Power Supply . Connect only the Thermal Dynamics model SL60 or SL100 T orch (with ATC
connector) to this power supply . Maximum torch leads length is 100 feet / 30.5 m, including extensions.
W ARNING
Disconnect primary power at the source before connecting the torch.
1. Align the ATC male connector (on the tor ch 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
Connecting the Torch to the Power Supply
Manual 0-4720 3- 5 INST ALLATION
Page 22
B. Check Air Quality
Art # A-04254
To test the quality of air:
1. Put the ON / OFF switch in the ON (up) position.
2. Put the RUN / RAPID AUTO REST ART / 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
75
50
1
25
100
2
INST ALLATION 3-6 Manual 0-4720
Page 23
SECTION 4: OPERATION
Art # A-04253
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.
DRAG
CUTTING
RANGE
50
A
75
AC Indicator
Steady light indicates power supply is ready
for operation. Blinking light indicates unit is
in protective interlock mode. Shut unit off,
shut off or disconnect input power, correct
the fault, and restart the unit. Refer to Section
5 for details.
TEMP Indicator
Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
limits. Shut unit OFF; let the unit cool before
continuing operation.
25
STANDOFF
CUTTING
RANGE
ON
Controls input power to the power supply.
Up is ON, down is OFF .
/ OFF Switch
100
RUN / RAPID AUTO RESTART / SET Switch
RUN (up) position is for general torch operation.
RAPID AUT O REST ART (middle) position is for an uninterr upted restart,
GAS Indicator
Indicator is ON when minimum input gas
pressure for power supply operation is
present. Minimum pressure for power supply operation is not sufficient for torch operation.
DC Indicator
Indicator is ON when DC output circuit is
active.
when cutting expanded metal or in gouging or trimming operations.
SET (down) position is for setting gas pressure and purging lines.
Manual 0-4720 4- 1 OPERA TION
Page 24
4.02 Preparations For Operating
Art # A-04509
Perform the following steps at the start of each operating session:
W ARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and
leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type of
operation, and with the amperage output of this Power Supply (100 amps maximum). Refer to the T orch Manual.
B. Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics model SL60™ or SL100™ Torches may be
connected to this Power Supply.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure compressed air source meets r equirements (refer to Section 3.4). Check connections and turn gas supply
on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free 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.
OPERATION 4-2 Manual 0-4720
Page 25
F. Power On
5
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator
turns on if there is sufficient gas pressure for power supply operation.
NOTE
Minimum pressure for power supply operation is lower than minimum for torch operation.
A
75
50
25
100
Art # A-0425
Manual 0-4720 4- 3 OPERA TION
Page 26
G. Set Operating Pressure
Art # A-04254
7
4
/
1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow .
A
75
50
1
25
2. Adjust gas pressure per the settings chart.
CutMaster ™ 151
G a s Pressu re Settings
Leads
Length
Up to 25'
(7.6 m)
Over 25'
(7.6 m)
SL100™
(Hand Torch or
Machine Torch)
70 psi
4.8 bar
75 psi
5.2 bar
100
0 - 75 psi /
.5 - 5.2 bar
2
Pressure Control Knob
Bouton De Contrôle
de Pression
Art #A-03793
OPERATION 4-4 Manual 0-4720
Page 27
H. Select Current Output Level
1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops.
2. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece), or
up to 100 amps for standoff cutting. At output settings higher than 40 amps, the power supply automatically
reduces output current to 40 amps if the torch tip contacts the workpiece.
2
50
A
75
1
25
Art # A-04256
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. W ith 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.
100
NOTE
When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas
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 0-4720 4- 5 OPERA TION
Page 28
K. Postflow
7
Release the trigger to stop the cutting arc. Gas continues to flow for approximately 20 seconds. During post - flow ,
if the user moves the trigger release to the rear and pr esses 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
75
50
25
100
Art # A-0425
OPERATION 4-6 Manual 0-4720
Page 29
SECTION 5:
A
SERVICE
5.01 General Maintenance
A. O-Ring Lubrication
An O-ring on the T orch A TC Male Connector requires lubrication on a r egular 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
Gas Fitting
rt #A-03791
Manual 0-4720 5- 1 SERVICE
O-Ring
Page 30
B. Filter Element Replacement
5
R
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.
egulator/Filter
Assembly
Baffle
Ring
Filter
Element
No. 9-4414
Spring
Spool
Bowl
Art # A-0299
Regulator/Filter Element Replacement
6. Reinstall the bowl.
7. Turn on the air supply.
SERVICE 5- 2 Manual 0-4720
Page 31
C. Optional Single-Stage Filter Element Replacement
er
(
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 fr om the Filter Housing. The Filter Element is located inside the
Housing.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filt
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 0-4720 5- 3 SERVICE
Page 32
D. Optional Two-Stage Filter Element Replacement
d
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 & Secon
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 0-4720
Page 33
5.02 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
g. Incorrect gas pressure
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f. Non - Genuine Thermal Dynamics parts used
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non - Genuine Thermal Dynamics parts used
f. Incorrect gas pressure
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Gas pressure too low
e. Improperly assembled torch
f. Non - Genuine Thermal Dynamics parts used
5. Difficult Piloting
a. Worn torch parts
b. Non - Genuine Thermal Dynamics parts used
c. Incorrect gas pressure
Manual 0-4720 5- 5 SERVICE
Page 34
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 Troubleshooting: Overview
This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this
system. If major complex subassemblies are faulty , the unit must be 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 0-4720
Page 35
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. Torch will not pilot; gas flows; AC and Gas indicators ON; DC and TEMP indicators OFF
1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower than mini-
mum required for torch operation.)
a. Adjust gas pressure per torch manual.
Manual 0-4720 5- 7 SERVICE
Page 36
G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON
g
U
w
M
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
pper Groove
ith V ent Holes
ust Remain Open
Upper O-Ring
in Correct Groove
Threads
Lower O-Rin
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 0-4720
Page 37
I. T orch cannot be activated; AC indicator flashing; Gas indicator ON; T emp 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 0-4720 5- 9 SERVICE
Page 38
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 0-4720
Page 39
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-04510
2. Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit.
Manual 0-4720 5-11 SERVICE
Page 40
B. Cover Installation
n
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 per steps in paragraph "B" above.
Internal Fuse Location
This completes the parts replacement procedures.
Fuse Locatio
Art # A-03002
SERVICE 5-12 Manual 0-4720
Page 41
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.
Qt y Description Catalog #
1 CutMaster 151 Power Supply , 400V, Three Phase, CE 3-1720-4
6.04 Replacement Parts
Qt y Description Catalog #
1 Fuse 9-8602
1 Regulator / Filter Assembly Replacement Element 9-4414
Manual 0-4720 6- 1 PAR TS LISTS
Page 42
6.05 Options and Accessories
er
(
d
Qt y 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 T wo-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 Multi-Purpose Cart 7-8888
1 Automation Interface Kit 9-8310
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313
1 Power Supply Dust Cover 9-7072
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filt
Art # A-02476
First & Secon
Stage
Cartridges
(as marked)
Optional Single-Stage Filter Kit Optional Two-Stage Filter Kit
Art # A-02942
P ARTS LISTS 6- 2 Manual 0-4720
Page 43
6.06 Torch Parts
A)
J
A
8-3487
O-Ring
oint torique
8-3486
O-Ring
Joint torique
9-8215
9-8213
9-8207 (40A)
9-8212 (100A)
9-8225 - A (40A)
9-8226 - B
9-8227 - C
9-8228 - D (100A)
9-8218
9-8237
9-8218
9-8237
9-8236 (70-100
9-8243
9-8281
9-8241
Art # A-04516
Good Tip
Worn Tip
New Electrode
A-03406
rt # A-03284
Worn Electrode
Manual 0-4720 6- 3 PAR TS LISTS
Page 44
P ARTS LISTS 6- 4 Manual 0-4720
Page 45
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION:
Close external
disconnect switch.
RESULT:
Power to system.
Connect work cable to workpiece.
Set output amperage.
System is ready
for operation.
ON / OFF switch to ON
AC indicator ON.
GAS indicator ON
for power supply operation.
ACTION:
RESULT:
ACTION:
RESULT:
Fan(s) ON.
when input
pressure is adequate
Power circuit ready.
ACTION:
RUN /
Rapid Auto Restart /
SET switch
to SET
RESULT:
Gas flows to set pressure.
Torch moved away from work (while
ACTION:
RUN /
Rapid Auto Restart / SET
switch to RUN
(for most applications)
or to
Rapid Auto Restart
(for gouging, trimming,
or expanded metal
applications)
RESULT:
Gas flow stops.
ACTION:
still activated).
RESULT:
ACTION:
Protect eyes and activate torch.
RESULT:
Gas flows briefly, then stops.
Gas restarts.
DC indicator ON
Pilot arc established.
ACTION:
Release torch trigger.
RESULT:
Main arc stops.
Gas flow stops after post - flow.
PILOT ARC
ACTION:
ON / OFF switch
to OFF
RESULT:
All indicators off.
Power supply fan(s) shuts off.
Main arc stops.
Pilot arc automatically
restarts.
ACTION:
Torch moved within
transfer distance of workpiece.
RESULT:
Main arc transfers.
Pilot arc off.
ACTION:
Unplug input
power cord or
open external
disconnect.
RESULT:
No power to system.
Art #A-03706
Manual 0-4720 A-1 APPENDIX
Page 46
APPENDIX 2: DATA TAG INFORMATION
r
g
I
S
(
H
Type of Power
Supply (Note 1)
Plasma Cutting
Symbol
Input Power
Symbol
nput Power
pecifications
Phase, AC or DC
ertz Rating)
Model:
Date of Mfr:
1/3
Rated NoLoad V oltage
Degree of Protection
f
1
f
2
Output Current Type
U
0
X
I
=
U
2
Conventional
Load V oltage
U
1
Rated Supply
Voltage (Note 2)
West Lebanon, NH USA 03784
S/N
Made in USA
Duty Cycle Factor
Rated Maximum
Supply Current
1max 1eff
1
1Ø
I
3Ø
1
Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Numbe
and Production Code
Regulatory Standard Coverin
This Type of Power Supply
Output Range (Amperage/
Voltage)
Duty Cycle Data (Note 3)
I
3Ø1Ø
Maximum Effective
Supply Current
Manufacturer's Electrical
Schematic File Number
and Revision Level
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission.
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.
Standard Symbols
AC
DC
Phase
Ø
Art # A-03288
APPENDIX A-2 Manual 0-4720
Page 47
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, 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.
Manual 0-4720 A-3 APPENDIX
Page 48
APPENDIX 4: TORCH PIN - OUT DIAGRAMS
h
h
2
P
2
P
h
h
Art # A-03799
A. Hand Torch Pin - Out Diagram
ATC Male Connector
Negative /
Plasma
4 - Green /
Switch
3 - White /
Switch
- Orange /
IP
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
- Orange /
IP
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 - Switc
3 - Switc
4
3
2 - PIP
1 - PIP
A-03701
Negative / Plasma
4 - Switc
3 - Switc
2 - PIP
1 - Black /
PIP
Pilot
5 - White /
Not Used
5 - Open
Pilot
1 - PIP
APPENDIX A-4 Manual 0-4720
Page 49
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
Pilot Lead
Torch
Leads
Black
Orange
White
Green
Negative / Plasma Lead
To Remote Control
Remote
Pendant
Connector
Black
White
Green
ATC Female
Receptacle
Power
Supply
1
2
5
6
4
3
8
7
1
2
5
6
4
3
8
7
To Power Supply
Circuitry
To Power Supply
Circuitry
Negative / Plasma
Pilot
Art # A-03798
Manual 0-4720 A-5 APPENDIX
Page 50
APPENDIX 6: SYSTEM SCHEMATIC
400/460V
1 PHASE
A
INPUT
400V
3 PHASE
INPUT
B
C
CURRENT ADJUST:
25 - 100 AMP
D
E
DRAG ON
F
400/460V
3 PHASE
INPUT
400V 'CE' VERSION
INCLUDES IN-LINE
EMC FILTER
M1
FAN1
M2
FAN2
ON/OFF SW
MODE SW
RAR OFF
(PILOT PCB)
(F9)
CURRENT
CONTROL/
LED PCB
19X1604
IGBT
HEATSINK
TEMP
INDUCTOR
TEMP
PRESS GOOD
INV ON
D13
D25
SW ON
D33
TORCH SW RTN
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
LOGIC
ASSY 19X2189
1
RUN
(46)
+12VDC
+12VDC
DC COM
DC COM
W1 ON
TIP SENSE
RUN/SET
OVERTEMP
GAS ON
DC OK
OVTEMP
AC OK
TORCH SW
+12V
POT HIGH
POT WIPER
POT LOW
DC COM
DC COM
ISENSE3233
TIP VOLTS
L1
L2
L3
230V
230V
28VAC B
28VAC A
SW1
SW2
NTC
P1
CSR
tt
SET
AC
TEMP
GAS
DC
TS2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
34
35
36
J14
TS1
P13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
EXTENDER
ASSY 19X1775
CHASSIS
GND
(4)
(5)
(7)
(7)
(6)
(6)
(21)
(22)
(23)
(24)
(25)
(26)
P14 J27P27
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
W1
(1)
W1
(2)
W1
(3)
E22
P11 J11
P18 J18
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
P29
P32 J32
J12 J43
E33
1
1
2
2
3
3
4
4
R29 (460/600V)
R78 (400V)
R30 (208/230V)
J15P15
1
1
2
2
K2
3
3
4
4
5
5
6
6
SEE TABLE 1 FOR
F1, R29,R30 & R78
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
1
1
POT HIGH
2
2
POT WIPER
3
POT LOW
3
4
4
+12V
5
5
AC
6
6
GAS
7
7
OVERTEMP
8
8
DC
J29
1
2
2
3
3
414
121
2
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
27
28
28
29
29
30
30
31
31
32
32
33
33
MAIN BOARD
34
34
35
35
ASSY 19X2198 (400V)
36
36
ASSY 19X2197 (460V)
2
F1
CONTACTOR ON
SOLENOID ON
K1
K1
INRUSH
K2
FAN
K5
K4
+12VDC
(FILTERING)
T1
28VAC A
28VAC B
+18V
+18V
+18V
E3E2E1
K1
28VAC A28VAC B
TO BIAS SUPPLY
PRESS GOOD
K4
K5
3
AC
AC
AC
INPUT DIODE
CURRENT
SENSE
TORCH SW RTN
F2, 0.9A,
(RESETABLE)
J26
J31
J30
J25
-OUT SENSE
DC COM
TIP SENSE
+12VDC
CSR
I SENSE
TIP VOLTS
PIP RTN
TORCH SW
28VAC A
GND
28VAC B
1
2
1
2
1
22
1
2
J33 P33
1
2
3
4
5
6
7
8
J34 P34
1
2
PIP
3
4
5
66
J23
1
2
3
J24
1
2
3
4
5
6
7
8
E7
E15
E4
E20
E23
E30
1
2
1
2
1
1
2
E5
E6
E10
E27
E32
1
2
3
4
5
6
7
8
1
2
3
4
5
TEST
CONN
P24
1
2
3
4
5
6
7
8
P26
P31
P30
P25
(70)
(71)
(72)
(73)
(74)
(75)
(77)
(78)
(79)
(80)
(81)
(10)
(11)
(12)
(13)
(TS2)
(TS1)
ATC CONNECTION
CONFIGURATION
(STANDARD)
1
1
2
2
4
4
3
3
8
8
(8)
(9)
4
MAIN TRANSFORMER
PIP
TORCH
SW
ATC MALE
CONNECTOR
ATC RECEIVER
SOL1
PS1
W1
BA
E12A
E17A
E19A
E21A
E12B
E17B
E19B
E21B
T5
PRI
PRI
GAS
SOLENOID
PRESSURE
SWITCH
CLOSED WHEN
PRESSURE OK
MAIN
CONTACTOR
SEC
SEC
24
25
24
25
ASSY 19X1787
12231314
24567
IGBT BOARD
ASSY 19X1787
12231314
24567
IGBT BOARD
P39 J39
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
GATE
DRIVE
28
27
GATE
DRIVE
1
GATE
DRIVE
28
27
GATE
DRIVE
1
5
E52
J3B
J7B
J3A
J7A
P3A
1
1
2
2
E9A
E11A
P7A
1
1
2
2
P3B
11
22
E9B
E11B
P7B
11
22
E47
Art # A-04540
1
2
3
4
5
APPENDIX A-6 Manual 0-4720
Page 51
6
7
8
TABLE 1
19X1930 19X1929
ZERO-OHM
R78
115X465-2
R29
R30
4/10, 500V
F1
460V
400V
X X X X X
X X X X X
ZERO-OHM
115X465-2
X X X X X X X X X X
1/4A, 500V
21X186
21X183
9
COMP DESCRIPTION LOCATION
F1
SEE CHART 1
0.9A, (RESETABLE)
F2
OUTPUT INDUCTOR
L1
FAN, 4.5" 220VAC
M1
M2
FAN, 4.5" 220VAC
PS1
PRESSURE SWITCH
SOL1
GAS SOLENOID
SWITCH, ON/OFF
SW1
SWITCH, RUN/SET/RAR
SW2
T5
MAIN TRANSFORMER
TS1
TEMP. SENSOR, IGBT HEATSINK
TS2
TEMP. SENSOR, INDUCTOR
W1
MAIN CONTACTOR
NOTES: UNLESS OTHERWISE SPECIFIED -
1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY
10
B2
F3
D7
B1
C1
F4
F4
C1
C1
D4
D1
E1
F4
A
E37
E34A
E50A
E39A
E48A
E53A
E56A
E54A
OUTPUT DIODE
ASSEMBLY 19X2213
OUTPUT DIODE
ASSEMBLY 19X2213
E60A
E34A
E50A
E39A
E48A
E53A
E56A
E54A
E60A
DC COMMON DC COMMON
POWER OUTPUT BOARD ASSY 19X2191
6
E49
E58
PLUGS INTO J27
*
ON MAIN BOARD
(LED PCB 19X1604)
ADAPTER HARNESS USED
WHEN REMOTE CURRENT
CONTROL IS USED WITH
AUTOMATION
(REPLACES CONNECTIONS
FROM J27 TO J14)
OUTPUT INDUCTOR
E35
E45
E62
E43
PILOT
JUMPER
E50B
E48B
E53B
E54B
OUTPUT DIODE
ASSEMBLY 19X2213
E50B
E48B
E53B
E54B
OUTPUT DIODE
ASSEMBLY 19X2213
7
E34B
E39B
E56B
E60B
E34B
E39B
E56B
E60B
OPTIONAL AUTOMATION INTERFACE CONNECTIONS
P3
J14 P14
AC
TEMP
GAS
DC
L1
E32
E64
E36 E57
1
2
3
4
5
6
7
8
(47)
(48)
(49)
(CSR) (NEG)
E3 E1
CSR Vo
J40
+12VDC
DC COM
CSR
ISENSE
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
E61
CURRENT
SENSE
E63
8
J3
2112
3
3
19X2041
OPTIONAL
AUTOMATION
INTERFACE
J1
P1
(CSR)
1
CSR
1
(51)
2
2
DC COMMON
(52)
3
3
+12VDC
4
4
(TS2)
5
5
TORCH SW -
(TS1)
6
6
TORCH SW +
7
7
(NEG)
Vo
8
8
(E64)
(E64)
(E35)
(E62)
(C1)
(MODE SW)
RAR OFF
P40
(14)
1
1
(15)
2
2
3
3
4
4
(17)
5
5
6
6
7
7
(18)
8
8
CHASSIS GND
THRU SCREW TERMINAL
AA
Last Modified:
Last Modified:
Last Modified:
P4
J4
20
20
19
19
18
18
17
17
16
16
15
15
14
14
13
13
12
12
11
11
10
10
9
8
7
6
5
4
3
2
1
(E58)
E58
(52)
(51)
(46)
J28
Monday, March 21, 2005
Monday, March 21, 2005
Monday, March 21, 2005
9
8
7
6
5
4
3
2
1
J1
1
2
1
2
3
5
8
PILOT BOARD
ASSY 19X2157
03/21/05HASECO 101593 (REL)
11:05:29
11:05:29
11:05:29
9
ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
J2
1
+
2
TORCH SWITCH
3
-
4
5
6
OK TO MOVE
7
8
9
+
10
DIVIDED OUTPUT
11
-
12
13
14
REMOTE CURRENT CONTROL
15
16
DC COMMON
17
18
+
19
C&G
20
-
(57)
(59)
(61)
(63)
CPC
HOUSING
(56)
4
3
(58)
14
12
(60)
6
5
(62)
8
9
(64)
7
ATC RECEIVER
ATC MALE CONNECTOR
WORK
E62
DateByRevisionsRev
DateByRevisionsRev
DateByRevisionsRev
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
NOTE:
NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
TITLE:
TITLE:
TITLE:
SCHEMATIC,
SCHEMATIC,
SCHEMATIC,
CM151 400/460V SYSTEM
CM151 400/460V SYSTEM
CM151 400/460V SYSTEM
(+)
TORCH SWITCH
}
(-)
}
OK TO MOVE
(+)
SC-11
}
(-)
LOGIC COMMON
(+)
ARC VOLTS (C&G)
}
(-)
T
O
R
C
H
THERMAL DYNAMICS
THERMAL DYNAMICS
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2
INDUSTRIAL PARK No. 2
INDUSTRIAL PARK No. 2
WEST LEBANON, NH 03784
WEST LEBANON, NH 03784
WEST LEBANON, NH 03784
603-298-5711
603-298-5711
603-298-5711
10
PCB No:
PCB No:
PCB No:
Assy No:
Assy No:
Assy No:
SupersedesScale
SupersedesScale
SupersedesScale
Date:
Date:
Date:
03/03/05
Drawn: References
Drawn: References
Drawn: References
HAS
Sheet
Sheet
Sheet
Chk: App:
Chk: App:
Chk: App:
11
11
11
DWG No:
Size
DWG No:
Size
DWG No:
Size
42X1188
42X1188
42X1188
D
D
D
Art # A-04540
B
C
D
E
F
of
of
of
Manual 0-4720 A-7 APPENDIX
Page 52
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