Tweco CutMaster User Manual

Name: Tweco CutMaster
Brand: Tweco
SKU: 1733570
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4 (3)

101

SL100SV

™

CUTMASTER

AUTOMATED PLASMA CUTTING SYSTEM

PLASMA CUTTING MACHINE TORCH

Art # A-04611

Operating Manual

Rev. AD.01 Date: April 2, 2007 Manual # 0-4642 Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800426-1888, or visit us on the web at www.thermal-dynamics.com.

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

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

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

W ARNINGS

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

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

Automated Plasma Cutting System Automated CutMaster™ 101 Power Supply SL100 / SL100SV Machine Torch Operating Manual Number 0-4642

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

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: April 2, 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 .................................................................................................. 1-3

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

1.05 Precautions De Securite Importantes ........................................................... 1-4

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

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

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

SECTION 2: SPECIFICATIONS ................................................................................................ 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

2.06 Torch Specifications ..................................................................................... 2-5

2.07 Torch Options and Accessories .................................................................... 2-6

2.08 Introduction to Plasma .................................................................................. 2-7

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 ........................................................................................ 3-7

3.06 Torch Installation .......................................................................................... 3-9

3.07 Torch Parts Selection................................................................................... 3-10

3.08 Power Supply Connection to SC-11 Standoff Control ................................... 3-11

3.09 Power Supply Connection to Alternate Standoff Control ............................... 3-12

3.10 Automation Interface PC Board Set-up ........................................................ 3-14

3.11 Optional Remote Current Control Harness Installation .................................. 3-15

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

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

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

4.03 Selection, Inspection and Replacement of Consumable Torch Parts ............. 4-6

4.04 Cut Quality ................................................................................................... 4-8

4.05 General Cutting Information .......................................................................... 4-9

4.06 Torch Operation ........................................................................................... 4-10

4.07 Cutting Parameters ...................................................................................... 4-12

4.08 Cutting Specifications ..................................................................................4-13

4.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip .................. 4-14

4.10 Cutting Speed Charts: Stainless Steel, SL100 Torch with Exposed Tip ........ 4-15

4.11 Cutting Speed Charts: Aluminum, SL100 Torch with Exposed Tip ................4-16

4.12 Cutting Speed Charts: Mild Steel, SL100 Torch with Shielded Tip ................ 4-17

4.13 Cutting Speed Charts: Stainless Steel, SL100 Torch with Shielded Tip ........ 4-18

4.14 Cutting Speed Charts: Aluminum, SL100 Torch with Shielded Tip ................ 4-19

4.15 Operator's Custom Cutting Speed Charts .................................................... 4-20

TABLE OF CONTENTS (continued)

SECTION 5:

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

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

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

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

5.04 Advanced Troubleshooting Guide - General Information ............................... 5-11

5.05 Main Input and Internal Power Problems ...................................................... 5-13

5.06 Pilot Arc Problems .......................................................................................5-19

5.07 Main Arc Problems ...................................................................................... 5-24

5.08 Test Procedures........................................................................................... 5-25

5.09 Power Supply Major External Parts Replacement ........................................5-31

5.10 Front Panel Parts Replacement.................................................................... 5-33

5.11 Left Side Internal Parts Replacement .......................................................... 5-35

5.12 Right Side Internal Parts Replacement ........................................................ 5-42

SECTION 6:

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

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

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

6.03 Complete Power Supply Replacement .......................................................... 6-1

6.04 Power Supply Basic Replacement Parts ....................................................... 6-2

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

6.06 Power Supply Major External Replacement Parts ......................................... 6-3

6.07 Power Supply Front Panel Replacement Parts ............................................. 6-4

6.08 Rear Panel Replacement Parts .................................................................... 6-5

6.09 Power Supply Left Side Internal Replacement Parts .................................... 6-6

6.10 Right Side Internal Replacement Parts ........................................................ 6-8

6.11 Torch Replacement Parts .............................................................................6-10

6.12 Torch Replacement Parts .............................................................................6-12

6.13 Torch Consumables ..................................................................................... 6-14

6.14 Torch Spare Parts Kits .................................................................................6-14

6.15 Complete Torch Assembly Replacement ...................................................... 6-16

6.16 Torch Options & Accessories ...................................................................... 6-16

PATENT INFORMATION ...........................................................................................................6-17

APPENDIX 1: SEQUENCE OF OPERATION

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

APPENDIX 2: DATA TAG INFORMATION ................................................................................ A-2

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

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

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

APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM .......................................................... A-6

APPENDIX 7: INTERFACE PCB SWITCH SETTINGS (MOST COMMON SETTINGS) ............ A-7

TABLE OF CONTENTS (continued)

APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24) ....................... A-8

APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30) ....................... A-9

APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33) ................... A-10

APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36) ................... A-11

APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43) ................... A-12

APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50) ................... A-13

APPENDIX 14: AUTOMATION INTERFACE PC BOARD WIRING LAYOUT ............................ A-14

APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS ........... A-15

APPENDIX 16: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO

OEM CNC HARNESS .................................................................................................... A-16

APPENDIX 17: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO

ALTERNATE CNC HARNESS .......................................................................................... A-17

APPENDIX 18: MAIN PC BOARD LAYOUT ............................................................................ A-18

APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208 /230-Volt POWER SUPPLIES) ...... A-20

APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-Volt, 415-Volt, 460-Volt,

600-Volt POWER SUPPLIES) ......................................................................................... A-21

APPENDIX 21: LOGIC BOARD LAYOUT ................................................................................ A-22

APPENDIX 22: POT / LED BOARD LAYOUT .......................................................................... A-23

APPENDIX 23: OUTPUT BOARD WIRING DIAGRAM ............................................................ A-24

APPENDIX 24: OUTPUT DIODE BOARD LAYOUT ................................................................ A-25

APPENDIX 25: PILOT BOARD LAYOUT ................................................................................. A-26

APPENDIX 26: 28VAC CIRCUIT DIAGRAM ........................................................................... A-27

APPENDIX 27: INPUT DIODE LAYOUT.................................................................................. A-28

APPENDIX 28: 208/230V SYSTEM SCHEMATIC ................................................................... A-30

APPENDIX 29: 208/230V SYSTEM SCHEMATIC ................................................................... A-32

APPENDIX 30: 400 / 415V / 460V SYSTEM SCHEMATIC ..................................................... A-34

TABLE OF CONTENTS (continued)

APPENDIX 31: 400 / 415V / 460V SYSTEM SCHEMATIC ..................................................... A-36

APPENDIX 32: 600V SYSTEM SCHEMATIC ........................................................................... A-38

APPENDIX 33: 600V SYSTEM SCHEMATIC ........................................................................... A-40

APPENDIX 34: Publication History .......................................................................................... A-42

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.

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 M ercury 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.)

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

Manual 0-4642 1-1 GENERAL INFORMATION

ELECTRIC SHOCK

NOISE

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.”

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any service or repairs.

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

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from the workplace.

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

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

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

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.

GENERAL INFORMATION 1-2 Manual 0-4642

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 SAFETYTOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

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

1.04 Note, Attention et

Avertissement

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

NOTE

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

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

ATTENTION

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

AVERTISSEMENT

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

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

Manual 0-4642 1-3 GENERAL INFORMATION

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

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

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

FUMÉE et GAZ

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

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

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

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

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

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

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

• Réparez ou remplacez toute pièce usée ou endommagée.

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

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

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

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

GENERAL INFORMATION 1-4 Manual 0-4642

INCENDIE ET EXPLOSION

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

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

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

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

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

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

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

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

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

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

BRUIT

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

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

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

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

1.06 Documents De Reference

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

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

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

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

Manual 0-4642 1-5 GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

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

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

GENERAL INFORMATION 1-6 Manual 0-4642

1.07 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.

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

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical 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.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

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

ated accessories.

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

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

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

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

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

Manufacturers responsible representative: Steve Ward

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

Manual 0-4642 1-7 GENERAL INFORMATION

1.08 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 Component s

(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

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

GENERAL INFORMATION 1-8 Manual 0-4642

SECTION 2: SPECIFICATIONS

%60%35%

%35%

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynamics Automated CutMaster 101 Plasma Cutting System. 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.

2.02 Power Supply Specifications

Automated CutM aster 101 Power Supply Specifications

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

Input Power

Input Power Cable Output Current Power Supply Gas Filtering Ability

Ambient Temperature

208/230V,

and 460V Units

400V / 415V Units

600V Units

* NOTE: The duty cycle will be reduced if the primary input power (AC) is low

or the output voltage (DC) is higher than shown in this chart.

415 VAC (370 - 460 VAC), Three Phase, 50 Hz, CE 460 VAC (414 - 506 VAC), Single Phase, 60 Hz 460 VAC (414 - 506 VAC), Three Phase, 60 Hz 600 VAC (517 - 632 VAC), Three Phase, 60 hz Cable for 208/230 VAC unit includes plug. 20 - 80 Amps, Continuously Adjustable

Particulates to 20 Microns

CutMaster 101 Power Supply Duty Cycle *

40° C (104° F)

IEC

Rating Duty Cyc le Current 80A 78A 68A 68A 45A 45A

DC Voltage 112V 120V 107V 111V 98V 98V Duty Cyc le Current 80A 78A 68A 68A 45A 45A DC Voltage 112V 120V 107V 111V 98V 98V Duty Cyc le Current 80A 78A 68A 68A 43A 43A DC Voltage 112V 120V 107V 111V 97V 97V

TDC

Rating

40% 60% 100%

IEC

Rating

TDC

Rating

IEC

Rating

100

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 0-4642 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

27.5 in / 696 mm

12.4 in /

A-03572

315 mm

2.03 Input Wiring Specifications

CutMaster 101 Input Wiring Specification

Input Power Input Current Input Suggested Sizes (See Notes)

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

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

208 50 14.4 69 90 6 6 208 60 15.6 75 90 6 6 230 50 15 65 80 6 6 230 60 15.5 67 80 6 6 400 50/60 13.9 20 30 10 10 460 60 18 39 50 10 10 460601620301212

600 60 13.5 13 20 12 12

Line Voltages wi th Suggested Circ ui t Protec tion and Wire Si z es

Based on Nati onal Electric Code and Canadian Electri cal Code

24"

0.6 m

150 mm

CE CutMaster 101 Input Wiring Specifications

Input Suggested Sizes (See Notes)

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

Power Input Current Input

Wire (mm

)

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

400 / 415 50 13.9 20 25 4

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric Code

NOTES

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

refer to local or national codes. Cable conductor temperature used is 167° F (75° C). An energy limiting fuse UL Class RK-1 (examples: BUSS LPS / LPN-RK or Gould-Shawmut AZK-A6K) should be

used to minimize damage to Plasma Cutting, Welding or power distribution equipment.

NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

INTRODUCTION 2-2 Manual 0-4642

2.04 Power Supply Features

Handle and Leads Wrap

Art # A-04507

Control Panel

Torch Leads Receptacle

Work Cable and Clamp

Gas Pressure Regulator / Filter Assembly

CPC Connector for Thermal Dynamics CNC Controller

Knockout for Alternate CNC Controller Wire Harness

Gas Pressure Gauge

Input Power Cord

Gas Inlet Port

Art # A-04214

Manual 0-4642 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.

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. Wheel Kit

A kit with easy-rolling wheels, for maximum portability for the power supply.

G. Nylon 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.

NOTE

INTRODUCTION 2-4 Manual 0-4642

2.06 Torch Specifications

SL100SV Machine Torch Specifications

Ambient Temperature 104° F / 40° C Duty Cy c le Maximum Current 100 Amps Voltage (V Arc Striking Voltage 7kV

Type of Cooling

Current Rating Up to 100 Amps, DC, Straight Polarity

Gas (Plasma and Secondary) Operating Pressure (Varies According to Power Supply and Torch Leads Length) Maximum Input Pressure 125 psi / 8.6 bar Gas Flow

NOT

Thermal Dynamics CutMaster 51, CutMaster 81, CutMaster 101, CutMaster 151

(Refer to NOTE)

) 500V

p eak

: Operating pressure varies with operating amperage and torch leads length.

Torch duty cycle is greater than power supply duty cycle.

Torch Ratings

100% @ 100 Amps @ 400 scfh

Combination of Ambient Air and

Gas Flow Through Torc h

Gas Requirement

Compressed Air (

300 - 500 scfh / 142 - 235 lpm

Torch Leads Length

25' / 7.6 m, with ATC Connector 35' / 10.6 m, with ATC Connector 50' / 15.2 m, with ATC Connector

Plasma Power Supply Used With

NOT

60 - 75 psi

4.1 - 5.2 bar

ONLY

)

A. Torch Configuration

The standard machine torch has a positioning tube with rack & pinch block assembly.

2.875” / 73 mm

1.75" / 44.5 mm

15.875" / 403 mm

0.625" / 16 mm

9.285" / 236 mm

1.375" / 35 mm

4.95" / 126 mm

1.175" / 30 mm

Art # A-07402

Manual 0-4642 2-5 INTRODUCTION

B. Torch Connector Dimensions

Art # A-04056

C. Torch Parts

Start Cartridge, Electrode, Tip, Shield Cup Body, Shield Cap

D. Parts - In - Place (PIP)

Torch Head has built - in switch

12 vdc circuit rating

E. Direct Contact Hazard

For exposed tip the recommended standoff is 3/16 inches / 4.7 mm.

8.5" / 216 mm

5.375" / 137 mm

1.9" / 50 mm

2.07 Torch Options and Accessories

These items can adapt a standard system to a particular application or further enhance performance (refer to Section 6 for ordering information).

• Spare Parts Kits - Various kits containing replacement consumable torch parts.

• Pinion Assembly (for machine torches)

• Leather Leads Covers

INTRODUCTION 2-6 Manual 0-4642

2.08 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.

In a Plasma Cutting Torch a cool gas enters Zone B, where a pilot arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

Power

Supply

Workpiece

Typical Torch Head Detail

By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C. Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.

Zone A channels a secondary gas that cools the torch. This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag - free cut.

B. Gas Distribution

The single gas used is internally split into plasma and secondary gases.

The plasma gas flows into the torch through the negative lead, through the start cartridge, around the electrode, and out through the tip orifice.

The secondary gas flows down around the outside of the torch start cartridge, and out between the tip and shield cup around the plasma arc.

A-00002

C. Pilot Arc

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

Manual 0-4642 2-7 INTRODUCTION

D. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.

E. Parts - In - Place (PIP)

The torch leads include a ‘Parts - In - Place’ (PIP) circuit. When the torch shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.

To Control

Cable Wiring

PIP Switch

Parts - In - Place Circuit Diagram

Shield Cup

A-03504

INTRODUCTION 2-8 Manual 0-4642

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 wheel kit, 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 0-4642 3-1 INSTALLATION

3.03 Primary Input Power Connections

CAUTION

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

A. Connections to 208 / 230-Volt Power

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

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

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

CAUTION

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

B. Connections to 400-Volt, 415-Volt, 460-Volt, or 600-Volt Three-Phase Power

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

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

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

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

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring 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.

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

INSTALLATION 3-2 Manual 0-4642

C. Connections to 460-Volt Single - Phase Power

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

1. Remove the Power Supply cover per section 5.09-A.

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.

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.

8. Tighten the through-hole protector to secure the power cable.

L1 L2 L3

Ground Wire with Ring Terminal

Input Cable

A-03041

Main Input Contactor

Input Power Connections, 460 VAC, Single-Phase

9. Replace the Power Supply cover.

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

Manual 0-4642 3-3 INSTALLATION

3.04 Gas Connections

A. Connecting Gas Supply to Unit

Use only compressed air with this power supply.

An in-line pneumatic dryer & evaporator type air filter, capable of filtering to at least 5 microns, is required when using air from a compressor. This type filter will insure that moisture, oil, dirt, chips, rust particles, and other contaminants from the supply hose do not enter the torch. For highly automated applications, a refrigerated drier may be used.

The connection is the same for compressed air from a compressor from high pressure cylinders. Refer to subsection 3.4-B or 3.4C if an additional 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 0-4642

B. Optional Air Filters

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

Outlet Por

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

Manual 0-4642 3-5 INSTALLATION

D. Using High Pressure Air Cylinders

When using high pressure air cylinders as the air supply:

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

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

3. The cylinder must be equipped with an adjustable high-pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows of at least 500 scfh (236 lpm).

4. Connect supply hose to the cylinder.

NOTE

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

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

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

INSTALLATION 3-6 Manual 0-4642

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