Tweco 151 User Manual

151
CUTMASTER
PLASMA CUTTING SYSTEM
Art # A-06754
Operating Manual
Rev. AC.01 Date: March 14, 2007 Manual # 0-4668 Operating Features:
Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800­426-1888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market­leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.
W ARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operat­ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply CutMaster™ 151 Operating Manual Number 0-4668
Covered under U.S. Patents
Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711
www.thermal-dynamics.com
© Copyright 2005, 2006, 2007 by Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub­lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: March 14, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Declaration of Conformity ............................................................................. 1-4
1.05 Statement of Warranty .................................................................................. 1-5
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 Power Supply Specifications......................................................................... 2-1
2.03 Input Wiring Specifications ........................................................................... 2-2
2.04 Power Supply Features ................................................................................. 2-3
2.05 Power Supply Options and Accessories ....................................................... 2-4
SECTION 3:
INSTALLATION .................................................................................................................. 3-1
3.01 Unpacking .................................................................................................... 3-1
3.02 Lifting Options .............................................................................................. 3-1
3.03 Primary Input Power Connections ................................................................. 3-2
3.04 Gas Connections .......................................................................................... 3-4
3.05 Torch Connections ........................................................................................ 3-6
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-5
5.03 Basic Troubleshooting Guide ......................................................................... 5-6
5.04 Power Supply Basic Parts Replacement ...................................................... 5-11
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Power Supply Replacement .......................................................................... 6-1
6.04 Replacement Parts ....................................................................................... 6-1
6.05 Options and Accessories .............................................................................. 6-2
6.06 Torch Parts ................................................................................................... 6-3
TABLE OF CONTENTS (continued)
PATENT INFORMATION ............................................................................................................ 6-4
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM) .......................................................................................................... A-1
APPENDIX 2: DATA TAG INFORMATION ................................................................................ A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................. A-3
APPENDIX 4: TORCH PIN - OUT DIAGRAMS .......................................................................... A-4
APPENDIX 5: CONNECTION DIAGRAMS................................................................................ A-5
APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS .......................................................... A-6
APPENDIX 7: SYSTEM SCHEMATIC, 400/460V UNITS .......................................................... A-8
APPENDIX 8: SYSTEM SCHEMATIC, 600V UNITS .............................................................. A-10
APPENDIX 9: Publication History ........................................................................................... A-12
Global Customer Service Contact Information ..................................................... Inside Rear Cover
SECTION 1:
GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high­lights are categorized as follows:
NOTE
An operation, procedure, or background informa­tion which requires additional emphasis or is help­ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the oper­ating area.

1.02 Important Safety Precautions

WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN­GEROUS AND HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instruc­tions before using the equipment. Call 1-603-298­5711 or your local distributor if you have any ques­tions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any met­als which may contain one or more of the follow­ing:
Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the in­formation regarding the kind and amount of fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com­bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
• This product, when used for welding or cutting, pro­duces fumes or gases which contain chemicals known to the State of California to cause birth de­fects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the op­erator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
October 5, 2006 1-1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any ser­vice or repairs.
• Read and follow all the instructions in the Operat­ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable mate­rial in the workplace. Any material that cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwa­ter or while using a water table. DO NOT cut alu- minum alloys underwater or on a water table un­less the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc pro­cesses can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent per­manent loss of hearing.
• To protect your hearing from loud noise, wear pro­tective ear plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the deci­bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding hel­met or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro­tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding So­ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU­PATION AND EDUCATIONAL EYE AND FACE PRO­TECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the Ameri­can National Standards Institute, 1430 Broadway, New York, NY 10018
GENERAL INFORMATION 1-2 October 5, 2006
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS­TIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO­CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Associa­tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO­CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM­PRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa­tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONTAIN­ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
October 5, 2006 1-3 GENERAL INFORMATION

1.04 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street
West Lebanon, New Hampshire 03784 USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy
GENERAL INFORMATION 1-4 October 5, 2006

1.05 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor) CUTMASTER™ 51 3 Years 1 Year CUTMASTER™ 81 3 Years 1 Year CUTMASTER™ 101 3 Years 1 Year CUTMASTER™ 151 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective January 15, 2004
October 5, 2006 1-5 GENERAL INFORMATION
This Page Left Blank
GENERAL INFORMATION 1-6 October 5, 2006
SECTION 2:
INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynamics® 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 Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.
NOTE
Refer to the Torch Manual for torch and cutting information.

2.02 Power Supply Specifications

CutMaster™ 151 Power Supply Specifications
208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz 400 VAC (360-440 VAC), Single Phase, 50/60 Hz
Input Power
Output Current Power Supply Gas Filtering Ability
Ambient Temperature
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.
400 VAC (360-440 VAC), Three Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Single Phase, 50/60 Hz 460 VAC (414 - 506 VAC), Three Phase, 50/60 Hz 600 VAC (517 - 632 VAC), Three Phase, 60 Hz 25 - 100 Amps, Continuously Adjustable
Particulates to 20 Microns
CutMaster™ 151 Power Supply Duty Cycle *
40° C (104° F)
IEC
Rating Duty Cyc le Current 100A - 73A - 50A -
DC Voltage 120V - 110V - 100V -
TDC
Rating
40% 60% 100%
IEC
Rating
TDC
Rating
IEC
Rating
TDC
Rating
NOTE:
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications include calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.
TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, and actual cutting operation.
Manual 0-4668 2-1 INTRODUCTION
Power Supply Dimensions & Weight Ventilation Clearance Requirements
Art # A-03379
83 lb / 37.6 kg
150 mm
17.3 in / 439 mm
6"
24"
0.6 m
27.5 in / 696 mm
6"
150 mm
A-03572
12.4 in / 315 mm

2.03 Input Wiring Specifications

CutMaster™ 151 Input Wiring Specifications
Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (Non CSA) Wire (CSA)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50 na na 4 4 208 60 20.8 na 100 na 100 4 4 230 50 na na 6 4
2306021.2na92 na100 6 4 400 50/60 19.2 48 50 8 8 400 50/60 18 26 30 10 10 460 50/60 21.1 58 60 10 10 460 50/60 19 24 30 12 12 600 60 15.6 18 20 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
6"
150 mm
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.
INTRODUCTION 2-2 Manual 0-4668

2.04 Power Supply Features

Handle and Leads Wrap
Art # A-04507
Control Panel
Torch Leads Receptacle
Work Cable and Clamp
Gas Pressure Regulator /
Ports for Optional Automation Interface Cable
Gas Pressure Gauge
Input Power Cord
Filter Assembly
Gas Inlet Port
Art # A-03738
Manual 0-4668 2-3 INTRODUCTION

2.05 Power Supply Options and Accessories

Section 6, Parts Lists, provides catalog numbers and ordering information.
A. Single-Stage Air Filter Kit
For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least
0.85 microns. This filter increases performance and improves consumables parts life.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0 microns. This filter is pre-assembled at the factory and needs only to be installed on the power supply.
C. High Pressure Regulators
High pressure regulators are available. The regulators are used to set the proper compressed air pressure.
NOTE
Regulators should not be installed with In-Line Air Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work cable with clamp is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle is 30" / 762 mm high.
F. Automation Interface Kit
This kit allows the user to convert a non automated power supply for use as part of a fully automated system. The kit includes an automation interface board, wiring harness, mounting hardware and instructions. The automa­tion interface provides the basic start / stop and OK to move functions, and a switch selectable voltage divider output. An external connector simplifies the connection to a CNC type cutting machine. CNC cables are available in 25' / 7.6 m and 50' / 15 m lengths for use with this kit.
G. 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 0-4668
SECTION 3:
INSTALLATION

3.01 Unpacking

1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation.
3. Record Power Supply and Torch model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.

3.02 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.
WARNINGS
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.
• Only persons of adequate physical strength should lift the unit.
• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
Manual 0-4668 3-1 INSTALLATION

3.03 Primary Input Power Connections

CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.03.
A. Connections to 208 / 230 - Volt Power
The 208 / 230 - Volt power supply includes a factory - installed input power cable for single - phase input power.
1. Check your power source for correct voltage before connecting the unit.
2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2 ).
• Green / Yellow wire to Ground.
• Remaining wires to L1, L2 input.
3. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
B. Connections to 400 - Volt, 460 - Volt, or 600 - Volt Three - Phase Power
These Power Supplies are equipped with a four - conductor input power cable for three - phase input power. The 400 - Volt and 460 - Volt Power Supplies will accept Single - Phase input power with a change of input power cable.
1. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable.
2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2 ). All the input cable wires must be connected for three
- phase operation.
• Green / Yellow wire to Ground.
• Remaining wires to L1, L2, L3 input.
3. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
INSTALLATION 3-2 Manual 0-4668
C. Connections to 400 - Volt, and 460 - Volt Single- Phase Power
The 400 - Volt or 460 - Volt Power Supplies will accept Single - Phase input power with a change of input power cable.
1. Remove the Power Supply cover per section 5.04.
2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.
3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out of the power supply.
4. Pass a customer - supplied, three - conductor input power cable through the access opening in the back panel of the power supply. Refer to Section 2 for power cable specifications. Tighten the through - hole protector to secure the power cable.
CAUTION
The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Section 2.03).
5. Strip back the insulation on the individual wires.
6. Connect to main input contactor as follows:
• Line 1 wire to terminal L1.
• Line 3 wire to terminal L3.
7. Connect the ground wire to Ground (Earth). The Ground wire connection requires a ring terminal.
L1
L3
L1 L2 L3
Ground Wire with Ring Terminal
Input Cable
A-03041
Main Input Contactor
Input Power Connections, 400 - Volt or 460 VAC, Single - Phase
8. Replace the Power Supply cover.
9. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Manual 0-4668 3-3 INSTALLATION

3.04 Gas Connections

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 Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
Regulator/Filter Assembly
Inlet Port
Bowl
1/4 NPT to 1/4"
(6mm) Fitting
Hose Clamp
Art # A-02999
Air Connection to Inlet Port
Gas Supply Hose
INSTALLATION 3-4 Manual 0-4668
B. Optional Air Filters
t
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 Inlet Port
2-Stage Filter Inlet Port (IN)
Regulator/Filter Assembly
Bowl
Inlet Port
Regulator/Filter Assembly
Hose
Clamp
1/4 NPT Hose Fitting
Hose Clamp
1/4" (6 mm) Gas Supply Hose
Art # A-03000
1/4" (6 mm) Gas
Supply Hose)
1/4 NPT
Hose Fitting
Optional Single-Stage Filter Installation Optional Two-Stage Filter Installation
C. Using High Pressure Air Cylinders
When using high pressure air cylinders as the air supply:
Outlet Por
(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.
Manual 0-4668 3-5 INSTALLATION

3.05 Torch Connections

If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 or SL100 Torch (with ATC connector) to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
WARNING
If an SL60 Torch is used on this unit, do not exceed an output setting (dial on front of unit) higher than 60.
WARNING
Disconnect primary power at the source before connecting the torch.
1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together. Do not use tools to secure the connection.
3. The system is ready for operation.
Art # A-04508
ATC Female Receptacle (Panel Mounted)
Control Cable Connector (Mechanized Torches Only)
1
2
ATC Male Connector
Connecting the Torch to the Power Supply
INSTALLATION 3-6 Manual 0-4668
B. Check Air Quality
To test the quality of air:
1. Put the ON / OFF switch in the ON (up) position.
2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position.
3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible on the lens. Do not start an arc!
1
Art # A-04254
2
Manual 0-4668 3-7 INSTALLATION
INSTALLATION 3-8 Manual 0-4668
SECTION 4:
OPERATION

4.01 Product Features

A. Front Panel Controls and Indicators
A) Output Current Control
(
Sets the desired output current. Output settings up to 40 Amps may be used for drag cutting (with the torch tip contacting the workpiece). At output set­tings over 40 Amps, the power supply automatically reduces output current to 40 Amps if the tip touches the workpiece.
DRAG
CUTTING
RANGE
A
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.
STANDOFF
CUTTING
RANGE
Art # A-04253
ON / OFF Switch
Controls input power to the power supply. Up is ON, down is OFF.
RUN / RAPID AUTO RESTART / SET Switch
RUN (up) position is for general torch operation.
RAPID AUTO RESTART (middle) position is for an uninterrupted restart,
when cutting expanded metal or in gouging or trimming operations.
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.
SET (down) position is for setting gas pressure and purging lines.
Manual 0-4668 4-1 OPERATION

4.02 Preparations For Operating

Perform the following steps at the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or 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 Torch Manual.
B. Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics model SL60™ or SL100™ Torches may be connected to this Power Supply.
WARNING
If an SL60 Torch is used on this unit, do not exceed an output setting (dial on front of unit) higher than 60.
C. Check Primary Input Power Source
1. Check the power source for proper input voltage. Make sure the input power source meets the power require­ments for the unit per Section 2, Specifications.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
D. Gas Selection
Ensure compressed air source meets requirements (refer to Section 3.4). Check connections and turn gas supply on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect only to the main part of the workpiece; do not connect to the part to be cut off.
Art # A-04509
OPERATION 4-2 Manual 0-4668
F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator
turns on if there is sufficient gas pressure for power supply operation.
NOTE
Minimum pressure for power supply operation is lower than minimum for torch operation.
1
Art # 04255
Manual 0-4668 4-3 OPERATION
G. Set Operating Pressure
1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow.
1
2. Adjust gas pressure per the settings chart.
CutMaster™ 151
Gas Pressure 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
70 - 75 psi /
4.5 - 5.2 bar
2
Art # A-04254
Pressure Control Knob / Bouton De Contrôle de Pression
Art #A-03793
OPERATION 4-4 Manual 0-4668
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
1
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. With the switch in the 'Rapid Auto Restart' (middle) position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece. Use the 'Rapid Auto Restart' position when cutting expanded metal or gratings, or in gouging or trimming operations when an uninterrupted restart is desired.
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 0-4668 4-5 OPERATION
K. Postflow
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 presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.
L. Shutdown
Turn the ON / OFF switch to OFF (down). All Power Supply indicators shut off. Unplug the input power cord or disconnect input power. Power is removed from the system.
Art # A-04257
OPERATION 4-6 Manual 0-4668
SECTION 5:
SERVICE

5.01 General Maintenance

A. O-Ring Lubrication
An O-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected. This will allow the O-ring to remain pliable and provide a proper seal. The O-ring will dry out, becoming hard and cracked, if the O-ring lubricant is not used on a regular basis. This can lead to potential performance problems.
It is recommended to apply a very light film of O-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.
NOTE
DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain
“unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.
ATC Male Connector
Gas Fitting
Art #A-03791
Manual 0-4668 5-1 SERVICE
O-Ring
B. Filter Element Replacement
The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter element should be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced.
1. Remove power from the power supply; turn off the gas supply and bleed down the system.
2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly. The filter element will be visible and still attached to the main body of the Regulator/Filter.
3. Grasp the filter element and unscrew it from the Regulator/Filter body. The filter element will come off with a spool and some additional pieces.
4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace it.
5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand.
Regulator/Filter
Assembly
Baffle Ring
6. Reinstall the bowl.
7. Turn on the air supply.
Filter Element No. 9-4414
Spring
Spool
Bowl
Art # A-02995
Regulator/Filter Element Replacement
SERVICE 5-2 Manual 0-4668
C. Optional Single-Stage Filter Element Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement filter element catalog number.
1. Remove power from power supply.
2. Shut off air supply and bleed down system before disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is located inside the Housing.
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single-Stage Filter Element Replacement
5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect the "O" Ring for cuts or other damage.
Manual 0-4668 5-3 SERVICE
D. Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.
1. Shut off primary input power.
2. Shut off air supply and bleed down system.
WARNING
Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.
4. Note the location and orientation of the old Filter Elements.
5. Slide out the old Filter Elements.
First & Second Stage Cartridges (as marked)
Art # A-02942
Optional Two-Stage Filter Replacement
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom fitting is normal.
SERVICE 5-4 Manual 0-4668

5.02 Common Faults

1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non - Genuine Thermal Dynamics parts used
g. Incorrect gas pressure
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f. Non - Genuine Thermal Dynamics parts used
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non - Genuine Thermal Dynamics parts used
f. Incorrect gas pressure
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Gas pressure too low
e. Improperly assembled torch
f. Non - Genuine Thermal Dynamics parts used
5. Difficult Piloting
a. Worn torch parts
b. Non - Genuine Thermal Dynamics parts used
c. Incorrect gas pressure
Manual 0-4668 5-5 SERVICE

5.03 Basic Troubleshooting Guide

WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.
A. Basic Troubleshooting: Overview
This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this system. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for this prod­uct.
B. How to Use This Guide
The following information will help the Customer / Operator determine the most likely causes for various symptoms. Follow all instructions as listed and complete each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions
1. Cause
a. Check / Remedy
Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that unit operates properly after any repairs.
C. Common Symptoms
A. AC indicator OFF
1. Switch at main power panel in OFF (open) position.
a. Close main power switch.
2. Power Supply ON / OFF switch in OFF (down) position.
a. Turn switch to ON (up).
3. Torch is not connected properly to Power Supply
a. Turn power supply ON / OFF switch to OFF (down). Check torch connection to Power Supply. Tighten or
adjust as required. Do not use tools. Turn power supply ON / OFF switch to ON (up).
4. Shield cup not fully tightened on torch head
a. Check shield cup for proper installation. Do not overtighten. Do not use tools to tighten.
5. Main power line fuse(s) or circuit breaker(s) blown
a. Check main power panel fuse(s). Replace as required.
SERVICE 5-6 Manual 0-4668
6. Unit internal fuse blown or loose
a. If blown, double-check input voltage and replace fuse per Section 5.04-C. If fuse blows again, return unit to
an authorized service center.
7. Actual input voltage does not correspond to voltage of unit
a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.
8 . Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
B. Gas flows continuously when power is turned on, AC indicator flashes
1. Torch switch is activated (closed) before user turns power on.
a. Release torch switch.
2. Faulty torch switch
a. Check torch switch for continuity. Replace if necessary.
C. Gas flows continuously; Torch will not pilot when torch switch is activated; AC indicator ON
1. System is in SET mode
a. Change RUN / Rapid Auto Restart / SET switch to RUN (up).
D. No gas flow; RUN / Rapid Auto Restart / SET switch in SET position; Fans operate; AC indicator ON;
GAS indicator OFF
1. Gas not connected
a. Check gas connections.
2. Gas pressure too low for power supply operation
a. Adjust gas pressure per torch manual.
3. Faulty components in unit
a. Return for repair or have qualified technician repair.
E. Torch will not pilot; gas flows; AC indicator ON, GAS , TEMP , and DC indicators OFF
1. Gas pressure is below power supply minimum requirement.
a. Adjust pressure to 60 - 75 psi / 4.1 - 5.2 bar.
F. Torch will not pilot; gas flows; AC and Gas indicators ON; DC and TEMP indicators OFF
1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower than mini­mum required for torch operation.)
a. Adjust gas pressure per torch manual.
Manual 0-4668 5-7 SERVICE
G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON
1. Starter cartridge missing from torch
a. Shut off power supply. Remove shield cup, install starter cartridge. Reinstall torch tip and shield cup. Turn
power supply ON / OFF switch to ON (up).
2. Shield cup is loose on torch
a. Check shield cup; tighten if necessary.
NOTE
When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
3. Upper O-ring on torch head is in wrong position.
a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.
Art # A-03640
Upper Groove with Vent Holes Must Remain Open
Upper O-Ring in Correct Groove
Threads Lower O-Ring
H. Torch will not pilot; AC , GAS , and TEMP indicators ON, DC indicator OFF
1. Air flow blocked
a. Check for blocked air flow around the unit and correct condition.
2. Unit is overheated
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to duty cycle data in Section 2.
3. Input line voltage is low
a. Check and connect to proper input power line.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
SERVICE 5-8 Manual 0-4668
I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC
indicator OFF
1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.)
a. Release torch trigger.
2. System is in protective interlock mode. (Torch parts are missing or loose.)
a. Release torch trigger, and set power supply ON / OFF switch to OFF (down). Open main disconnect switch.
Check torch parts. Replace parts as needed. Reinstall shield cup; hand - tighten it securely against the torch head. Do not overtighten. Do not use tools. Close main disconnect switch. Set ON / OFF switch to ON (up) position.
J. Gas cycles on and off without torch switch being activated; AC indicator Flashing; Gas indicator
ON; DC indicator OFF
1. Torch tip or electrode missing
a. Shut off power supply. Remove shield cup, install missing part(s). Turn power supply ON / OFF switch to
ON (up).
K. No cutting output; Torch pilots; Gas flows; Fans operate; AC , Gas , and DC indicator ON;
TEMP indicator OFF
1. Work cable not connected to work piece, or connection is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
2. Faulty Torch
a. Return for repair or have qualified technician repair.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
L. Torch cuts but not adequately
1. Incorrect setting of output current (A) control
a. Check and adjust to proper setting.
2. Torch consumables worn
a. Check torch consumables per Torch manual; replace as needed.
3. Work cable connection to work piece is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
4. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
5. Torch being dragged on work. ('Tip saver' circuit active) At output current settings greater than 40 amps, the power supply automatically reduces current to 40 amps if the torch tip contacts the workpiece.
a. Lift torch off work.
Manual 0-4668 5-9 SERVICE
6. Excessive oil or moisture in torch
a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from
clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contami­nants in the gas, additional filtering may be needed.
7. Fluctuations in input power
a. Have electrician check input line voltage.
8. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
M. Arc shuts off during operation; arc will not restart when torch switch is activated.
1. Power Supply is overheated (TEMP indicator ON)
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to Section 2 for duty cycle specifications.
2. Fan blades blocked (TEMP indicator ON)
a. Check and clear blades.
3. Air flow obstructed (TEMP indicator ON)
a. Check for obstructed air flow around the unit and correct condition.
4. Gas pressure too low (GAS indicator OFF when torch switch is activated)
a. Check source for at least 60 psi / 4.1 bar; adjust as needed. (Minimum pressure for power supply operation
is lower than minimum required for torch operation.)
5. Torch consumables worn
a. Check torch consumables per Torch manual; replace as needed.
6. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
N. AC indicator remains ON when shield cup is removed
1. Faulty PIP switch in torch
a. Check PIP switch for continuity; replace if necessary
SERVICE 5-10 Manual 0-4668

5.04 Power Supply Basic Parts Replacement

WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.
A. Cover Removal
1. Remove the upper screws which secure the cover to the main assembly.
NOTE
There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there is a need for more room to work.
Upper screws
Lower screws
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 0-4668 5-11 SERVICE
B. Cover Installation
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.
C. Fuse Replacement
1. Remove the unit cover per paragraph "A" above.
2. Locate the internal fuse on the left side of the center chassis.
3. Replace the fuse. A replacement fuse is located inside the power supply. Refer to Section 6, Parts Lists, for replacement fuse catalog number.
4. Reinstall the cover per steps in paragraph "B" above.
Internal Fuse Location
This completes the parts replacement procedures.
Fuse Location
Art # A-03002
SERVICE 5-12 Manual 0-4668
SECTION 6:
PARTS LISTS

6.01 Introduction

A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual.
Qty Description Catalog #
1 CutMaster™ 151 Power Supply, 208 - 230V Single Phase Non CSA 3-1720-1 1 CutMaster™ 151 Power Supply, 208 - 230V Single Phase CSA 3-1720-7 1 CutMaster™ 151 Power Supply, 460V Three Phase 3-1720-2 1 CutMaster™ 151 Power Supply, 400V Three Phase 3-1720-3 1 CutMaster™ 151 Power Supply, 600V Three Phase 3-1720-5

6.04 Replacement Parts

Qty Description Catalog #
1 Fuse for 208/230V Power Supply 9-8588 1 Fuse for 460V Power Supply 9-8583 1 Fuse for 400V Power Supply 9-8602 1 Fuse for 600V Power Supply 9-8638 1 Regulator / Filter Assembly Replacement Element 9-4414
Manual 0-4668 6-1 PARTS LISTS

6.05 Options and Accessories

Qty Description Catalog #
1 Single-Stage Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741 1 Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-7500 1 Bracket, Filter Mounting (not shown) 9-7535 1 Two-Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022 1 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 Filter
Art # A-02476
First & Second Stage Cartridges (as marked)
Optional Single-Stage Filter Kit Optional Two-Stage Filter Kit
Art # A-02942
PARTS LISTS 6-2 Manual 0-4668

6.06 Torch Parts

8-3487 O-Ring
Joint 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 (70-100A)
9-8243
9-8281
9-8241
Art # A-04516
Art # A-03284
New Electrode
Worn Electrode
Good Tip
Worn Tip
A-03406
Manual 0-4668 6-3 PARTS LISTS

PATENT INFORMATION

The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512
Catalog Number Description
9-8235 Shield Cap, Drag 50-60A 9-8236 Sheild Cap, Drag 70-100A 9-8237 Shield Cup, Body 9-8238 Shield Cap, Machine 50-60A 9-8239 Shield Cap, Machine 70-100A 9-8244 Shield Cap, Drag 40A 9-8245 Shield Cap, Machine 40A
PARTS LISTS 6-4 Manual 0-4668
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 0-4668 A-1 APPENDIX

APPENDIX 2: DATA TAG INFORMATION

Type of Power Supply (Note 1)
Plasma Cutting Symbol
Input Power Symbol
Input Power Specifications (Phase, AC or DC Hertz Rating)
Model:
Date of Mfr:
1/3
Rated No­Load Voltage
Degree of Protection
f
1
f
2
Output Current Type
U
0
X
I
=
U
2
Conventional Load Voltage
U
1
Rated Supply Voltage (Note 2)
West Lebanon, NH USA 03784
S/N
Made in USA
Duty Cycle Factor
Rated Maximum Supply Current
1max 1eff
1
I
1
Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number and Production Code
Regulatory Standard Covering This Type of Power Supply
Output Range (Amperage/ Voltage)
Duty Cycle Data (Note 3)
I
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 0-4668

APPENDIX 3: MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air flow.
2. Blow or vacuum dust and dirt out of the entire machine.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.
Manual 0-4668 A-3 APPENDIX

APPENDIX 4: TORCH PIN - OUT DIAGRAMS

A. Hand Torch Pin - Out Diagram
ATC Male Connector
Negative / Plasma
4 - Green / Switch
3 - White / Switch
2- Orange / PIP
1 - Black / PIP
4 3
2 1
Pilot
Front View
6
5
8 - Open
7 - Open
8 7
6 - Open
5 - Open
B. Mechanized (Machine) Torch Pin - Out Diagram
ATC Male Connector
4- Black ­Pendant Connector
3 - White ­Pendant Connector
2 - Orange / PIP
Front View
4 3
2
1
UNSHIELDED MACHINE TORCH
Negative / Plasma
8 - Green ­Pendant Connector Ground
8 7
6
5
7 - Green / Not Used
6 - Open
6 - Open
8 - Ground
7 - Open
6 - Open
5 - Open
8 - Ground
7 - Open
ATC Female Receptacle
Front View
8 7
6
5
Pilot
ATC Female Receptacle
8 7
6 5
2 1
Front View
4 3
2 1
Negative / Plasma
4 - Switch
3 - Switch
4 3
2 - PIP
1 - PIP
A-03701
Negative / Plasma
4 - Switch
3 - Switch
2 - PIP
1 - Black / PIP
Art # A-03799
Pilot
5 - White / Not Used
5 - Open
Pilot
1 - PIP
APPENDIX A-4 Manual 0-4668

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 0-4668 A-5 APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS

208/230V 1 PHASE INPUT
A
B
ON/OFF SW
C
MODE SW
CURRENT ADJUST: 25 - 100 AMP
CURRENT CONTROL/ LED PCB 19X1604
D
IGBT HEATSINK TEMP
INDUCTOR TEMP
E
INV ON
DRAG ON
SW ON
F
LOGIC ASSY 19X2189 ASSY 19X2286
Art # A-07156
1
M1 FAN1
M2 FAN2
(46)
RAR OFF
(PILOT PCB)
(F9)
TIP SENSE
PRESS GOOD
OVERTEMP
D13
D25
D33
TORCH SW
TORCH SW RTN
POT HIGH
POT WIPER
POT LOW
GATE DRIVE B RTN
GATE DRIVE B
GATE DRIVE A RTN
GATE DRIVE A
- OUT SENSE CURRENT SENSE CURRENT SENSE
CURRENT SENSE RTN CURRENT SENSE RTN
TIP VOLTS
1
L1
L2
L3
L4
28VAC B 28VAC A
RUN
P1
+12VDC
+12VDC DC COM DC COM
W1 ON
RUN/SET
CSR
GAS ON
DC OK
OVTEMP
AC OK
+12V
DC COM DC COM
ISENSE3233
SW1
SW2
230V
230V
NTC
tt
SET
AC
TEMP
GAS
DC
TS2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
34 35 36
J14
TS1
P13
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
EXTENDER ASSY 19X1775
W1
(1)
W1
(2)
W1
(3)
W1
(78)
E22
CHASSIS GND
(4)
P11
(5)
P15 J15
(7) (7)
(6) (6)
P18 J18
(21) (22) (23) (24) (25) (26)
P14 P27 J27
(35)
1
1
(36)
2
2
(37)
3
3
(38)
4
4
(39)
5
5
(40)
6
6
(41)
7
7
(42)
8
8
P29
P32 J32
J12
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
1 2 3 4
1 2 3 4 5 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 414
121 2
1 2 3 4 5 6 7 8 9
1 2 3 4
1 2 3 4 5 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
J29
2 3
J43
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
J11
POT HIGH POT WIPER POT LOW +12V AC GAS OVERTEMP DC
2
E1E1
E33E33
(FILTERING)
K1
R30
(0 ohm)
F1
(6/10A 600V)
K2
+12VDC
K1
INRUSH
K2
FAN
K5
CONTACTOR ON
K4
SOLENOID ON
MAIN BOARD ASSY 19X2190
2
E2E2
T1
28VAC A 28VAC B
+18V
+18V
+18V
(33)
E3E3
K1
28VAC A28VAC B
3
AC
AC
AC
INPUT DIODE
COPPER STRAP
TO BIAS SUPPLY
K4
F2, 0.9A, (RESETABLE)
PRESS GOOD
K5
3
CURRENT SENSE
-OUT SENSE DC COM
TIP SENSE
+12VDC
I SENSE
TIP VOLTS
PIP RTN
TORCH SW RTN
TORCH SW
28VAC A
28VAC B
(+)
(-)
J26
J31
J30
J25
CSR
J34 P34
PIP
J23
GND
J24
1 2
1 2
1
22
1 2
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
1
1 2
2
3
3
4
4 5
5 66
1 2 3
1
1
2
2 3
3 4
4
5
5
6
6
7
7 8
8
E7
E15
E4
E20
E23
E30
P26
1 2
P31
1 2
P30
1
P25
1 2
(TS2)
E5
(TS1)
E6
E10
E27
E32
P33J33
(70) (71) (72) (73) (74) (75)
(77)
ATC CONNECTION CONFIGURATION
(78) (79)
(80) (81)
TEST CONN
P24
(8)
(9) (10) (11) (12) (13)
MAIN
(STANDARD)
1
1
2
2
575 7 4
4 3
3 8
8
W1
CONTACTOR
PS1
4
MAIN TRANSFORMER
T5
PRI
SEC
PRI
SEC
PIP
TORCH SW
ATC MALE CONNECTOR
ATC RECEIVER
FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID
SOL1
A
B GAS SOLENOID
PRESSURE SWITCH
CLOSED WHEN PRESSURE OK
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
4
BA
E12A
E17A
E19A
E21A
E12B
E17B
E19B
E21B
T6
11 15
PRI
SEC
6
P39
24 25
24 25
10
12231314
7
IGBT BOARD
ASSY 19X1787
12231314
IGBT BOARD
ASSY 19X1787
J39
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
5
GATE DRIVE
28
27
GATE DRIVE
1
2456
GATE DRIVE
28
27
GATE DRIVE
1
24567
E52 E47
5
J7B
J3A
J7A
J3B
1
2
1
2
121
2
1
2
P3A
1
2
E9A
E11A
P7A
1
2
P3B
E9B
E11B
P7B
1
2
APPENDIX A-6 Manual 0-4668
6
7
8
9
10
COMP DESCRIPTION LOCATION
F1
FUSE, 6/10A 600V KTK
FUSE, 0.9A, RESETABLE
F2
OUTPUT INDUCTOR
L1
FAN, 4.5" 220VAC
M1
FAN, 4.5" 220VAC
M2
PRESSURE SWITCH
PS1
GAS SOLENOID
SOL1
SW1
SWITCH, ON/OFF
SWITCH, RUN/SET/RAR
SW2
MAIN TRANSFORMER
T5
TEMP. SENSOR, IGBT HEATSINK
TS1
TEMP. SENSOR, INDUCTOR
TS2
MAIN CONTACTOR
W1
NOTES: UNLESS OTHERWISE SPECIFIED -
1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY
B2
F3
D7
B1
C1
F4
F4
C1
C1
D4
D1
E1
F4
A
E50A
E48A
E53A
E54A
OUTPUT DIODE ASSEMBLY 19X2213
E50A
E48A
E53A
E54A
OUTPUT DIODE ASSEMBLY 19X2213
ADAPTER HARNESS USED
WHEN REMOTE CURRENT
CONTROL IS USED WITH AUTOMATION (REPLACES CONNECTIONS FROM J27 TO J14)
E49 E45 E35
E62
E37
E58
E34A
E39A
E56A
E60A
E34A
E39A
E56A
E60A
OMMOC CD
JUMPER
E50B
E48B
E53B
E54B
OUTPUT DIODE ASSEMBLY 19X2213
E50B
E48B
E53B
E54B
OUTPUT DIODE ASSEMBLY 19X2213
POWER OUTPUT BOARD ASSY 19X2191
6
PLUGS INTO J27
*
ON MAIN BOARD
(LED PCB 19X1604)
AC
TEMP
GAS
DC
OUTPUT INDUCTOR
E43
PILOT
E34B
E39B
E56B
E60B
E34B
E39B
E56B
E60B
7
OPTIONAL AUTOMATION INTERFACE CONNECTIONS
P3
J14 P14
1 2 3 4 5 6 7 8
L1
E32
E64
E36 E57
DN
1 2 3 4 5 6 7 8
CURRENT SENSE
(47) (48) (49)
(CSR) (NEG)
E3 E1
CSR Vo
+12VDC DC COM
CSR
ISENSE
CHASSIS GND
1 2 3 4 5 6 7 8
E61
NOMMOC C
8
2112 3
P1
(CSR)
1
(51)
2
(52)
3 4
(TS2)
5
(TS1)
6 7
(NEG)
8
(E64)
(E64)
(E35)
(E62)
(MODE SW)
J40
P40
1
1
2
2
3
3
4
4 5
5 6
6
7
7
8
8
E63
THRU SCREW TERMINAL
J3
3
19X2041
OPTIONAL AUTOMATION INTERFACE
J1
1 2 3 4 5 6 7 8
RAR OFF
(14) (15)
(17)
(18)
J4
20 19 18 17 16 15 14 13 12 11 10
9
CSR
8
DC COMMON
7
+12VDC
6 5
TORCH SW -
4
TORCH SW +
3 2
Vo
(C1)
1
(E58)
(52) (51)
(46)
ECO 101593 (REL)
AA
ECO B028 RS 12/27/05
AB
ECO B016 RWH 01/27/06
AC
Friday, January 27, 2006
Friday, January 27, 2006
Friday, January 27, 2006
Last Modified:
Last Modified:
Last Modified:
P4
20 19 18 17 16 15 14 13 12 11 10
9 8 7 6 5 4 3 2 1
E58
J28
1 2
1 2
3
5
8
J1
PILOT BOARD ASSY 19X2157
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 17
DC COMMON
18
+
19
C&G
20
-
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
E62
DateByRevisionsRev
DateByRevisionsRev
DateByRevisionsRev
HAS 03/21/05
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
NOTE:
NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
TITLE:
TITLE:
TITLE:
11:05:29
11:05:29
11:05:29
9
SCHEMATIC,
SCHEMATIC,
SCHEMATIC,
CM151 208/230V SYSTEM
CM151 208/230V SYSTEM
CM151 208/230V SYSTEM
CPC
HOUSING
(+)
4
TORCH SWITCH
}
(-)
3
14
}
OK TO MOVE
12
(+)
6
SC-11
}
(-)
5
LOGIC COMMON
8
(+)
9
ARC VOLTS (C&G)
}
(-)
7
ATC RECEIVER ATC MALE CONNECTOR
T O R C H
WORK
THERMAL DYNAMICS
THERMAL DYNAMICS
THERMAL DYNAMICS INDUSTRIAL PARK No. 2
INDUSTRIAL PARK No. 2
INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784
WEST LEBANON, NH 03784
WEST LEBANON, NH 03784 603-298-5711
603-298-5711
603-298-5711
10
PCB No:
PCB No:
PCB No:
Assy No:
Assy No:
Assy No: Scale
Scale
Scale
Supersedes
Supersedes
Supersedes
Date:
Date:
Date:
03/03/05
Drawn: References
Drawn: References
Drawn: References
HAS
Chk: App:
Chk: App:
Chk: App:
Sheet
Sheet
Sheet
11
11
11
of
of
of
DWG No:
Size
DWG No:
Size
DWG No:
Size
42X1176
42X1176
42X1176
D
D
D
Art # A-07156
B
C
D
E
F
Manual 0-4668 A-7 APPENDIX

APPENDIX 7: SYSTEM SCHEMATIC, 400/460V UNITS

208/230V 1 PHASE
INPUT
A
400V 3 PHASE INPUT
400V 'CE' VERSION INCLUDES IN-LINE
B
EMC FILTER
ON/OFF SW
C
MODE SW
CURRENT ADJUST: 25 - 100 AMP
CURRENT CONTROL/ LED PCB
D
IGBT HEATSINK TEMP
INDUCTOR TEMP
E
INV ON
DRAG ON
SW ON
F
LOGIC
Art # A-07641
1
400/415V
/460V
3 PHASE
INPUT
M1 FAN1
M2 FAN2
(46)
RAR OFF
(PILOT PCB)
(F9)
+12VDC
+12VDC DC COM DC COM
W1 ON
TIP SENSE
RUN/SET
PRESS GOOD
OVERTEMP
D13
GAS ON
DC OK
D25
OVTEMP
AC OK
D33
TORCH SW
TORCH SW RTN
POT HIGH
POT WIPER
POT LOW
GATE DRIVE B RTN
GATE DRIVE B
GATE DRIVE A RTN
GATE DRIVE A
- OUT SENSE CURRENT SENSE CURRENT SENSE
CURRENT SENSE RTN CURRENT SENSE RTN
DC COM DC COM
ISENSE
TIP VOLTS
1
L1
L2
L3
28VAC B 28VAC A
SW1
RUN
SW2
NTC
P1
CSR
+12V
230V
230V
AC
TEMP
GAS
DC
tt
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
SET
1 2 3 4 5 6 7 8 9
TS2
TS1
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 2 3 4 5 6 7 8 9
J14
1 2 3 4 5 6 7 8
P13
EXTENDER
W1
W1
W1
CHASSIS GND
(4)
P11
(5)
P15
(7) (7)
(6) (6)
P18 J18
(21) (22) (23) (24) (25) (26)
P14 J27P27
(35)
1
(36)
2
(37)
3
(38)
4
(39)
5
(40)
6
(41)
7
(42)
8
J12 J43
(1)
(2)
(3)
E22
1 2 3 4
1 2 3 4 5 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
P29
1 2 3 4
P32 J32
121
2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
2
E33
1 2
J11
3 4
R29 (415/460/600V)
R78 (400V)
R30 (208/230V)
J15
1 2
K2
3 4 5 6
SEE TABLE 1 FOR F1, R29,R30 & R78
1 2 3 4 5 6 7 8
1
POT HIGH POT WIPER
2
POT LOW
3
+12V
4
AC
5 6
GAS
7
OVERTEMP
8
DC
J29
1 2 3 4
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
MAIN BOARD
2
E1
(FILTERING)
K1
F1
+12VDC
K1
INRUSH
K2
FAN
K5
CONTACTOR ON
K4
SOLENOID ON
T1
28VAC A 28VAC B
+18V
+18V
+18V
E3E2
K1
28VAC A28VAC B
TO BIAS SUPPLY
PRESS GOOD
K4
F2, 0.9A, (RESETABLE)
K5
3
AC
AC
AC
INPUT DIODE
CURRENT SENSE
-OUT SENSE
TIP SENSE
TIP VOLTS
TORCH SW RTN
TORCH SW
3
J26
J31
J30
J25
DC COM
+12VDC
CSR
I SENSE
PIP RTN
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
P26
1 2
P31
1 2
P30
1
P25
1 2
(TS2)
E5
(TS1)
E6
E10
E27
E32
(70)
1
(71)
2
(72)
3
(73)
4
(74)
5
(75)
6 7
(77)
8
ATC CONNECTION CONFIGURATION
(78)
1
(79)
2 3 4
(80)
5
(81)
TEST CONN
P24
(8)
1
(9)
2
(10)
3
(11)
4
(12)
5
(13)
6 7 8
MAIN TRANSFORMER
PRI
PRI
(STANDARD)
1
1
PIP
2
2 575
7
4
4
TORCH
3
SW
8
8
ATC MALE CONNECTOR
ATC RECEIVER
SOL1
GAS SOLENOID
PS1
W1
CONTACTOR
MAIN
4
E12A
E17A
E19A
E21A
E12B
E17B
E19B
E21B
T5
SEC
SEC
A
B
FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID
BA
PRESSURE SWITCH
CLOSED WHEN PRESSURE OK
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
4
24 25
24 25
T6
11 15
PRI
SEC
6
IGBT BOARD
3
IGBT BOARD
P39 J39
1 2 3 4 5 6 7 8
10
5
GATE
12231314
12231314
J3A
DRIVE
28
27
GATE DRIVE
1
24567
GATE DRIVE
28
27
GATE DRIVE
1
24567
1 2 3 4 5 6 7 8
E52
J3B
J7B
J7A
1
2
1
2
P3A
1
2
E9A
E11A
P7A
1
2
P3B
11
22
E9B
E11B
P7B
11
22
E47
5
APPENDIX A-8 Manual 0-4668
Manual 0-4668 A-9 APPENDIX

APPENDIX 8: SYSTEM SCHEMATIC, 600V UNITS

600VAC 3 PHASE
A
INPUT
B
C
CURRENT ADJUST: 20 - 80 FOR CM101 20 - 60 FOR CM81
D
LOGIC ASSY 19X1913 - CM101 ASSY 19X2285 - CM101 ASSY 19X1932 - CM81 ASSY 19X2284 - CM81
E
DRAG ON
F
Art # A-07151
M1 FAN1
M2 FAN2
ON/OFF SW
MODE SW
RAR OFF
(PILOT PCB)
(F9)
CURRENT
CONTROL/
LED PCB 19X1604
IGBT HEATSINK TEMP
INDUCTOR TEMP
INV ON
SW ON
GATE DRIVE B RTN
GATE DRIVE A RTN
CURRENT SENSE RTN CURRENT SENSE RTN
1
L1
L2
L3
RUN
(46)
+12VDC
+12VDC DC COM DC COM
W1 ON
TIP SENSE
RUN/SET
PRESS GOOD
OVERTEMP
D13
GAS ON
D25
DC OK
OVTEMP
AC OK
D33
TORCH SW
TORCH SW RTN
+12V
POT HIGH
POT WIPER
POT LOW
GATE DRIVE B
GATE DRIVE A
- OUT SENSE CURRENT SENSE CURRENT SENSE
DC COM DC COM
ISENSE3233
TIP VOLTS
1
230V
230V
28VAC B 28VAC A
SW1
SW2
NTC
tt
P1
CSR
SET
AC
TEMP
GAS
DC
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
34 35 36
TS2
1 2 3 4 5 6 7 8 9
J14
TS1
P13
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
EXTENDER ASSY 19X1775
W1
W1
W1
(4)
(5)
(7) (7)
(6) (6)
1 2 3 4 5 6 7 8
(1)
(2)
(3)
E22
CHASSIS GND
P11
P18 J18
(21) (22) (23) (24) (25) (26)
P14 P27
(35)
1
(36)
2
(37)
3
(38)
4
(39)
5
(40)
6
(41)
7
(42)
8
P29 J29
P32
J12 J43
141 2 3
1 2 3 4 5 6
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
1 2 3 414
11
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
J11
2 3 4
J15P15
1 2 3 4 5 6
1 2 3 4 5 6 7 8
J27
1 2 3 4 5 6 7 8
2 3
J32
22
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
POT HIGH POT WIPER POT LOW +12V AC GAS OVERTEMP DC
2
E33
(FILTERING)
K1
R29
(0 ohm)
F1
(3/10A 600V)
K2
+12VDC
K1
INRUSH
K2
FAN
K5
CONTACTOR ON
K4
SOLENOID ON
MAIN BOARD ASSY 19X1931
2
T1
28VAC A 28VAC B
+18V
+18V
+18V
E3E2E1
K1
28VAC A28VAC B
TO BIAS SUPPLY
PRESS GOOD
E5
E13
E18
K4
K5
3
INPUT DIODE
ASSY 19X2073
CURRENT SENSE
TORCH SW RTN
F2, 0.9A, (RESETABLE)
3
-OUT SENSE DC COM
TIP SENSE
+12VDC
I SENSE
TIP VOLTS
PIP RTN
TORCH SW
28VAC A
28VAC B
E6 E8
E14 E16
E7
E15
E4
E20
E23
E30
J26 P26
1
1
2
2
J31 P31
11 2
2
J30
11
22
J25 P25
1
1 2
2
E5 E6
E10
E27
E32
J33 P33
1
1 2
2 3
3
4
4
CSR
5
5 686 7
7 8
J34 P34
1
1
PIP
2
2 3
3 4
4 5
5 66
J23
1
TEST
GND
2
CONN
3
J24 P24
1
1
2
2
3
3
4
4
5
5
6
6
7
7 8
8
P30
(TS2)
(TS1)
(70) (71) (72) (73) (74) (75)
(77)
ATC CONNECTION CONFIGURATION
(STANDARD)
(78) (79)
(80) (81)
(8)
(9) (10) (11) (12) (13)
MAIN
4
MAIN TRANSFORMER
T5
PRI
PRI
1
1
PIP
2
2
575 7 4
4
TORCH
3
3
SW
8
8
ATC MALE CONNECTOR
ATC RECEIVER
SOL1
BA
GAS SOLENOID
PS1
W1
CONTACTOR
4
5
E12A
E17A
24 25
E19A
E21A
E12B
E17B
24 25
E19B
E21B
SEC
SEC
SOL2
BA
T6
11 15
PRI
SEC
6
FACTORY INSTALLED OPTIONAL TORCH MOUNTED GAS SOLENOID
PRESSURE SWITCH
CLOSED WHEN PRESSURE OK
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED, SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
12231314
6
7
IGBT BOARD
ASSY 19X1815
12231314
24567
IGBT BOARD
ASSY 19X1815
P39
1
1
2
2
3
3
4
4
5
5 686 7
7 8
10
GATE
J3A
DRIVE
28
27
GATE DRIVE
J7A
1
245
GATE
J3B
DRIVE
28
27
GATE DRIVE
J7B
1
J39
5
2112
2112
2112
2112
P3A
E9A
E11A
P7A
P3B
E9B
E11B
P7B
74E25E
APPENDIX A-10 Manual 0-4668
6
7
8
9
10
COMP DESCRIPTION LOCATION
F1
FUSE, 3/10A 600V FNQ-R
F2
FUSE, 0.9A, RESETABLE
OUTPUT INDUCTOR
L1
M1M2FAN, 4.5" 220VAC
FAN, 4.5" 220VAC
PS1 PRESSURE SWITCH
SOL1 GAS SOLENOID
SWITCH, ON/OFF
SW1
SWITCH, RUN/SET/RAR
SW2
MAIN TRANSFORMER
TS1
TEMP. SENSOR, IGBT HEATSINK
TEMP. SENSOR, INDUCTOR
W1
MAIN CONTACTOR
NOTES: UNLESS OTHERWISE SPECIFIED -
1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY
B2
F3
D7
B1
C1 F4
F4
C1
C1
4D5T
D1
1E2ST
F4
A
OUTPUT DIODE ASSEMBLY 19X1757
E34A
E39A
E50A
E48A
E53A E54A
E56A E60A
DC COMMON
POWER OUTPUT BOARD ASSY 19X1914
6
E58E37
PLUGS INTO J27
*
ON MAIN BOARD
(LED PCB 19X1604)
ADAPTER HARNESS USED
WHEN REMOTE CURRENT CONTROL IS USED WITH AUTOMATION (REPLACES CONNECTIONS FROM J27 TO J14)
OUTPUT INDUCTOR
54E94E
E35
E62
PILOT
E43
JUMPER
OUTPUT DIODE ASSEMBLY 19X1757
E50B
E48B
E53B E54B
7
E34B
OPTIONAL AUTOMATION INTERFACE CONNECTIONS
P3
J14 P14
AC
TEMP
GAS
DC
L1
E32
E64
E36 E57
E39B
E56B E60B
1
1
1
2
2
2
3
3
3
4
4
4
5
5
5
6
6
6
7
7
7 8
8
8
E61 E3 E1
CURRENT SENSE
DC COMMON
CSR
(47) (48) (49)
+12VDC DC COM
CSR
ISENSE
8
J40 P40
E63
2112 3
3
P1
(CSR)
1
1
(51)
2
2
(52)
3
3
4
4
(TS2)
5
5
(TS1)
6
6
7
7
(NEG)
8
8
(NEG)(CSR)
Vo
(C1)
(MODE SW)
RAR OFF
(14)
1
1
(15)
2
2
3
3
4
4
(17)
5
5
6
6
7
7
(18)
8
8
CHASSIS GND THRU SCREW TERMINAL
J3
19X2041
OPTIONAL AUTOMATION INTERFACE
J1
CSR DC COMMON +12VDC
TORCH SW ­TORCH SW +
Vo
(E64)
(E64)
(E35)
(E62)
(E58)
(52) (51)
(46)
ECO 101136
AA AB AC
ECO 101614 HASAD03/22/05
ECO 101664 HAS 03/24/05
AE AF
ECO B028
AG
ECO B016 RWH 01/27/06
ECO B077
AH
Friday, January 27, 2006
Friday, January 27, 2006
Friday, January 27, 2006
Last Modified:
Last Modified:
Last Modified:
J4
P4
20
20
19
19
18
18
17
17
16
16
15
15
14
14
13
13
12
12
11
11
10
10
9
9 8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
E58 E62
J1
1 2
1 2
3
5
8
J28
PILOT BOARD ASSY 19X2157
(REL) DLL
ALTERNATE 20-PIN HEADER
DateByRevisionsRev
DateByRevisionsRev
DateByRevisionsRev
05/07/03
HASECO 101314
02/11/04
HASECO 101429
06/09/04
RS
01/09/06
07/31/06
RWH
9
20-POSITION TERMINAL STRIP
J2
1
+
2
TORCH SWITCH
3
-
4 5 6
OK TO MOVE 7 8 9
+
10
DIVIDED OUTPUT
11
-
12 13 14
REMOTE CURRENT CONTROL
15 16
DC COMMON
17 18
+
19
C&G
20
-
(57)
(59)
(61)
(63)
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
Not For Release, Reproduction, or Distribution without Written Consent.
NOTE:
NOTE:
NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
Capacitors are in Microfarads (UF)
TITLE:
TITLE:
TITLE:
CM81/101 600V 3PH SYSTEM 42X1134D
CPC
HOUSING
(56)
4 3
(58)
14 12
(60)
6 5
(62)
8 9
(64)
7
ATC RECEIVER ATC MALE CONNECTOR
T O R C H
WORK
SCHEMATIC,
SCHEMATIC,
SCHEMATIC,
(+)
TORCH SWITCH
}
(-)
}
OK TO MOVE
(+)
SC-11
}
(-)
LOGIC COMMON
(+)
ARC VOLTS (C&G)
}
(-)
THERMAL DYNAMICS INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784 603-298-5711
10
PCB No:
PCB No:
PCB No:
Assy No:
Assy No:
Assy No:
SupersedesScale
SupersedesScale
SupersedesScale
Date:
Date:
Date:
05/07/03
Drawn: References
Drawn: References
Drawn: References
D.Lilja
Sheet
Sheet
Sheet
Chk: App:
Chk: App:
Chk: App:
11
11
11
DWG No:
DWG No:
DWG No:
Size
Size
Size
Art # A-07151
B
C
D
E
F
of
of
of
Manual 0-4668 A-11 APPENDIX

APPENDIX 9: Publication History

Cover Date Revision Comments
3/15/05 -- Manual released.
5/5/05 -- Added 400V & 600V units.
6/6/05 -- Corrected Wiring Specs.
6/10/05 -- Corrected Wiring Specs.
7/8/05 -- Added 230V CSA rear panel parts per ECO 101731
10/12/05 -- Changed input wiring chart to show Non CSA and CSA with some new cable ratings.
2/17/06 -- Updated schematic per ECO B033.
7/5/06 -- Updated all control panel art.
10/5/06 AA.01 Added patent information, new manual standard and revision control
1/5/07 AB.01 Updated schematic for RoHS compliance
3/14/07 AC.01 Updated 600 volt schematic to show new fuse.
NOTE
Thermal Dynamics uses the manual cover date to indicate manual revision level.
APPENDIX A-12 Manual 0-4668
Global Customer Service Contact Information
Thermadyne USA
2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.com
Thermadyne Victor Brasil
Avenida Brasil 13629-Cordovil Rio de Janeiro, Brazil 21012-351 Telephone: 55-21-2485-8998 Fax: 55-21-2-485-8735
Thermadyne Canada
2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-1111 Fax: 905-827-3648
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone: 603+ 6092 2988 Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street Preston, Victoria Australia, 3072 Telephone: 61-3-9474-7400 Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L. Via Benaco, 3 20098 S. Giuliano Milan, Italy Tel: (39) 02-98 80320 Fax: (39) 02-98 281773
Thermadyne Chile
Piloto Lazo #90 Cerrillos Santiago, Chile 7278-654 Telephone: 56-2-557-2465 Fax: 56-2-557-5349
Thermadyne Europe
Europe Building Chorley North Industrial Park Chorley, Lancashire England, PR6 7Bx Telephone: 44-1257-261755 Fax: 44-1257-224800
Thermadyne, China
RM 102A 685 Ding Xi Rd Chang Ning District Shanghai, PR, 200052 Telephone: 86-21-69171135 Fax: 86-21-69171139
Thermadyne South Africa
209 Risi Ave. Linmeyer Johannesberg, 2197 South Africa Tel: (27) 11-917 3600 Fax: (27) 11-917 8580
Thermadyne International
2070 Wyecroft Road Oakville, Ontario Canada, L6L5V6 Telephone: (905)-827-9777 Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com
www.thermadyne.com
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