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Thermal Dynamics CutMaster 51 Operating

1. ANAT RTENE ADAPTER HARNESS USED WHEN REMOTE CURRENT CONTROL IS USED WITH 4 HE 459 TORCH SWITCH 2 5 OK TO MOVE 8 11 8 9 7 LOGIC COMMON ARC VOLTS C amp G AUTOMATION REPLACES CONNECTIONS HOUSING t J 22 14 E62 WORK PILOT BOARD ASSY 19X2086 Rev Revisions By Date No 1 11 __ Ret 27103 IHERMAL DYNAMICS CYRUS assy Nor Eco 101314 HAS 02 11 04 a EST LEBANON Scale Supersedes E58 Eco 101429 HAS 06 09 04 Company 128 ECO B028 RS 01 09 06 information Proprietary to THERMAL DYNAMICS CORPORATION 05 27 03 MN 46 RAR OFF AE B016 RWH 01 27 06 Not For Release Reproduction or Distibuton without Conse GND MODE SW C2 NOTE Unies Otherwise Specified Resistors are in Ohms 14W 5 Capacitors in Microfarads UF Shear 1 of t ISENSE TITLE SCHEMATIC DWG No 51 208 230 SYSTEM D 42 1150 6 7 8 9 10 07154 Manual 0 2971 A 7 APPENDIX APPENDIX 7 SYSTEM SCHEMATIC 400V amp 46
2. IGBT BOARD ASSY 19X1721 OUTPUT DIODE ASSEMBLY 19 1720 6 E37 _ OPTIONAL AUTOMATION INTERFACE CONNECTIONS COMP 1 DESCRIPTION FUSE 6 10A 600V KTK MAIN CONTACTOR SWITCH ON OFF SWITCH RUN SET RAR FAN 4 5 220VAC GAS SOLENOID LOCATION PRESSURE SWITCH TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR AUX TRANSFORMER MAIN TRANSFORMER OUTPUT INDUCTOR NOTES UNLESS OTHERWISE SPECIFIED DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY ALTERNATE 20 PIN HEADER 20 POSITION TERMINAL STRIP TORCH SWITCH Pi J1 ei J 2 2 Dc common A 12VDC asa 5 5 TORCH Sw 151 6 TORCH sw nes 171710 OUTPUT INDUCTOR L1 ATC RECEIVER MALE i PLUGS INTO J22 ON MAIN BOARD J14 OK TO MOVE 19X2041 OPTIONAL AUTOMATION DIVIDED OUTPUT INTERFACE BRASOBVONAON REMOTE CURRENT CONTROL J3 Doan DC COMMON 2 wna 1 2 3 GAS 4
3. A 5 APPENDIX 6 SYSTEM SCHEMATIC 208 230V 5 A 6 APPENDIX 7 SYSTEM SCHEMATIC 400V amp 460V UNITS A 8 APPENDIX 8 Publication History A 10 Global Customer Service Contact 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 high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system me CAUTION A procedure which if not properly followed may cause damage to the equipment 2 2 7 A procedure which if not properly followed cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS 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
4. Pilot 5 Open SS ATC Female Front Receptacle View AX Negative A 03701 Plasma 2 1 Manual 0 2971 APPENDIX 5 TORCH CONNECTION DIAGRAMS A Hand Torch Connection Diagram Torch SL60 SL100 Hand Torch Leads Torch Leads with ATC Connector Power Supply with ATC Receptacle Male ATC Leads ATC Female Connector Receptacle Power ___ Leads PIP Switch To Power Supply Circuitry Torch Se Green To Power Supply Switch Ls White Circuitry OD Negative Plasma Negative Plasma Pilot Pilot Art A 03797 B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector To Remote Control Power Supply with ATC Female Receptacle Male Z q ATC Female ATC Leads AN Receptacle Connector aN ____ Power Torch Supply Head Leads PIP 4 Black Switch O Orange White Power Supply Circuitry To Power Supply Circuitry gt Negative Plasma Lead Negative Plasma Pilot Lead Pilot Art A 03798 Manual 0 2971 5 APPENDIX APPENDIX 6 SYSTEM SCHEMATIC 208 230V UNITS 208 230V INPUT
5. DYNAMICS 1 CUTMASTER PLASMA CUTTING SYSTEM Rev AA 01 Date October 20 2006 Operating Features THERMAL DYNAMICS 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 1 800 426 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 market leading 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 sale
6. 5 01 General Maintenance 5 02 Fault seiirt 5 03 Basic Troubleshooting Guide 5 04 Power Supply Basic Parts TABLE OF CONTENTS continued SECTION 6 PARTS 6 1 6 1 6 02 Ordering Information 22 0 0 6 1 6 03 Power Supply Replacement 6 1 6 04 Replacement Parts 0 08 0 0 0 6 2 6 05 Options 0 2204 6 2 6 06 TORCH 6 3 PATENT INFORMATION 6 4 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM 6 sae 1 APPENDIX 2 DATA TAG INFORMATION A 2 APPENDIX 3 MAINTENANCE SCHEDULE 0 cccecceeeeeeeeeeeeeeneeeeeeeeeeseneeeeseaeeeesaeeesenaeees A 3 APPENDIX 4 TORCH PIN OUT A 4 APPENDIX 5 TORCH CONNECTION DIAGRAMS
7. 4 f Cutting speed too slow Torch standoff too high from workpiece Worn torch parts Improper cutting current Non Genuine Thermal Dynamics parts used Incorrect gas pressure 4 Short Torch Parts Life a b 4 f Oil or moisture in air source Exceeding system capability material too thick Excessive pilot arc time Gas pressure too low Improperly assembled torch Non Genuine Thermal Dynamics parts used 5 Difficult Starting a b Worn torch parts Non Genuine Thermal Dynamics parts used Incorrect gas pressure Manual 0 2971 5 5 SERVICE 5 03 Basic Troubleshooting Guide There 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 prod uct B How to Use This Guide The following information will help the Customer Operator determ
8. 49 E4 PILOT PCB F6 sw2 gt 9 CURRENT ADJUST P14 P22 22 E8 20 40 AMPS 1 1 POT HIGH 2 H374 2 2 POT WIPER 3 EH POT Low 21 4 4 CURRENT 51915 5 ac CONTROL 8 5 LED PCB 4 5 20 19 1604 D E26 CSR P2 IGBT 2 2 HEATSINK 24 4 19 TS1 P23 E18 INDUCTOR 2 E5 TEMP E10 E6 CURREN 12VDC SENSE SIGNAL GND SIGNAL E17 E17 E GND SIGNAL E34 E34 RUNSET CONTACTOR ON CONNECTION OVERTEMP DC COMMON 9 7a CONFIGURATION GND SIGNAL PIP RTN RTN 79 PIP NB SNA TORCH SW 2 anos TORCH SW RTN 81 4 4 TORCH BOOK 1 SOLENOID 88 ATC MALE OVTEME PEN 77 NS CONNECTOR 2 GND RECEIVER 512 66 28VAC B CONN SOL1 POT FACTORY INSTALLED OPTIONAL POT WIPER POT LOW TORCH MOUNTED GAS SOLENOID CAT GATE DRIVES GATE DRIVE MAIN BOARD RESETABLE 7 0 2 ASSY 19 2033 400V av 2 o O PRESSURE WHEN OPTIONAL TORCH CURRENT SENSE ASSY 19X2060 460V 1 SWITCH MOUNTED GAS SOLENOID F CURRENT SENSE 5 t2 CLOSED WHEN S USED SOL1 IS POWERED CURRENT SENSE 6 PRESSURE S USED LOGIC CURRENT SENSE CHASSIS GND sav 7 BY 6 ONLY SOL2 POWERED ASSY 19X2000 THRU SCREW TERMINAL Desai we BY P412 ASSY 19X2283 E16 E28 frl 20
9. C TEMP Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal limits Shut unit OFF let the unit cool before continuing op eration GAS Indicator Indicator is ON when minimum input gas pres sure for power supply operation is present Mini mum pressure for power supply operation is not sufficient for torch operation DC Indicator Indicator is ON when DC output circuit is active RUN 62 7 RAPID AUTO RESTART 62 SET Switch ESTE amag RUN up position is for general torch operation RAPID AUTO RESTART middle position is for an uninterrupted restart when cutting expanded metal or in gouging or trimming operations SET down position is for setting gas pressure and purging lines Manual 0 2971 OPERATION 4 02 Preparations for Operation Byrn G Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies At the start of each operating session 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 40 amps maximum Refer to Section 6 06 for torch parts selection B Torch Connection Check that the torch is properly connected Only Thermal Dynamics model SL60 or SL100 Torches may be connected to this Power Supply C Check Primary Inp
10. CSR GND SIGNAL DC OK 1 BONBOOSNOMAWN CONTACTOR ON SOLENOID ON MAIN BOARD ASSY 19X2001 CHASSIS GND THRU SCREW TERMINAL E16 E28 SUPPLY MAIN TRANSFORMER T5 E4 gj E9 E8 19 18 5 10 E6 CURREN SENSE E7 E17 E17 E34 E34 ATC CONNECTION DC COMMON J9 9 CONFIGURATION PIP RTN 111 2 75 2 2 gt F PIP A 80 TORCH SW TORCH SW 81 4 2 TORCH 818 _ J5 rh Xe CONNECTOR 1 test ATC RECEIVER 2 28VAC B CONN x 5011 5 FACTORY INSTALLED OPTIONAL SOLENOID TORCH MOUNTED GAS SOLENOID F2 0 9 Sa RESETABLE 2 201 2 0 cae WHEN OPTIONAL TORCH D 4 a Psi SWITCH MOUNTED GAS SOLENOID 5 5 1 CLOSED WHEN 15 USED SOL1 IS POWERED 28 PRESSURE OK BY T6 ONLY 5012 4 f p POWERED BY P4 1 2 ts 9 91 179 W1 MAIN 57 10 10 20 My CONTACTOR Art A 07154 1 APPENDIX Manual 0 2971 10 GATE 2 DRIVE J18
11. M1 FAN1 L1 12 CHASSI 5 INPUT DIODE ASSY 19X2073 F1 6 10A 600V E 28VAC B P3 28 A 12 1 15 28VAC A 421 21 GATE DRIVE GATE DRIVE J20 P20 GATE DRIVE B RTN GATE DRIVE B TO BIAS ON OFF SW orh MODE SW 46 RAR OFF lt o PILOT PCB F6 CURRENT ADJUST 20 40 AMPS RUN BIAS SUPPLY swi SET sw2 J22 CURRENT CONTROL LED PCB 19X1604 wera gg WIPER POT LOW 12V AC GAS 2 IGBT HEATSINK TEMP 23 INDUCTOR TEMP LOGIC ASSY 19X2000 ASSY 19X2283 4 INV ON RED 12VDC 12VDC GND SIGNAL GND SIGNAL Wi GND SIGNAL RUN SET PRESS GOOD GND SIGNAL GND SIGNAL GND SIGNAL 28VAC A GAS 14 POT WIPER POT LOW GATE DRIVE B RTN GATE DRIVE B GATE DRIVE GATE DRIVE A OUT CURRENT SENSE CURRENT SENSE CURRENT SENSE RTN CURRENT SENSE RTN ISENSE
12. 51 400 460V SYSTEM 10 30 D 42 1151 6 7 9 10 07155 Manual 0 2971 9 APPENDIX APPENDIX 8 Publication History Cover Date Revision Comments 12 18 03 Manual released 1 12 04 Updated operating gas pressures per ECO 101276 1 16 04 Updated warranty statement amp system schematics misc minor edits 1 20 04 Corrected system schematics 2 9 04 Deleted system schematics 2 12 04 Added updated schematics ECO 101314 6 23 04 Updated system schematics per ECO 101429 10 15 04 Corrected catalog number for replacement power cord 3 22 05 Changed work clamp art to 17x1043 type per ECO 101599 added dust cover to options 2 17 06 Updated system schematics per ECO B033 10 20 06 1 Added patent information new manual standard style and revision control NOTE Thermal Dynamics uses the manual cover date to indicate revision level APPENDIX A 10 Manual 0 2971 DYNAMICS Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Email sales thermadyne 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 Chile Piloto Lazo 90 Cerrillos Santiago Chile 7278 654 Tel
13. Input Wiring Requirements 8 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual 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 Gas flows continuously Torch will not pilot when torch switch is activated AC indicator ON 1 System isin SET mode a Change RUN Rapid Auto Restart SET switch to RUN up D No gas flow Rapid Auto Restart SET switch in SET position Fans operate AC indicator 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 IE 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 Torch will not pilot gas flows and Gas indicators and TEMP f indicators OFF 1 Gas pressure is below torch minimum requirement Minimum pressure for power supply operation is lower than mini mum required for torch operation a Adjust gas pressure according to torch model and leads l
14. 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 Manual 0 2971 1 5 GENERAL INFORMATION GENERAL INFORMATION 1 6 Manual 0 2971 SECTION 2 INTRODUCTION 2 01 Scope of Manual This manual contains descriptions operating instructions and basic maintenance procedures for the Thermal Dy namics CutMaster 51 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 cov ered 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 51 Power Supply Specifications 208 230 VAC 187 253 VAC Single Phase 60 Hz inout P w r 00 VAC 360 440 VAC Three Phase 50 60 Hz 460 VAC 414 506 VAC Single Phase 60 Hz 60 VAC 414 506 VAC Three Phase 60 Hz Power Supply includes input cable Input P Cable for 208 230V input power includes molded plug Output Current 20 40 Amps Continuously Adj
15. Cart High Pressure Air Regulator Wheel Kit Automation Interface Kit 25 7 6 m CNC Cable for Automation Interface Kit 50 15 2 m CNC Cable for Automation Interface Kit Nylon Dust Cover Art A 02476 6 2 Stage Cartridges as marked Catalog 9 8110 9 8583 9 8583 9 4414 8 4384 9 8562 9 8593 Catalog 7 7507 9 7740 9 7742 9 7741 7 7500 9 7535 9 7527 9 1021 9 1022 9 8529 7 8888 9 3022 9 8510 9 8310 9 8312 9 8313 9 7071 First amp Second Art A 02942 Optional Two Stage Filter Kit Manual 0 2971 6 06 Torch Parts Cutting Parts 1 Standoff Cutting Guide 9 8207 aan D E 8 3487 8 3486 O Ring O Ring Black Red 9 8218 9 8251 1 cK 9 8215 9 8213 Shield 0 629 9 8225 40 Sa 9 8237 Shield Gouging Art 03816 Gouging Parts an 1 Torch Head Electrode Start Cartridge Shield 5 Standoff Cutting Guide KA Art A 04070 Manual 0 2971 6 3 PARTS LISTS PATENT INFORMATION The following parts are licensed under U S Patent No s 5120930 and 5132512 Catalog Number 9 8235 9 8236 9 8237 9 8238 9 8239 9 8244 9 8245 PARTS LISTS Description Shield Cap Drag 50 60A Sheild Cap Drag 70 100A
16. MAIN Art 07155 1 2 3 4 5 APPENDIX Manual 0 2971 10 DRIVE J18 IGBT BOARD ASSY 19X1721 OUTPUT DIODE E38 E39 E40 E41 _OPTIONAL AUTOMATION INTERFACE CONNECTIONS COMP LOCATION DESCRIPTION FUSE 1 4A 500V FNQ MAIN CONTACTOR SWITCH ON OFF SWITCH RUN SET RAR FAN 4 5 220VAC GAS SOLENOID PRESSURE SWITCH TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR AUX TRANSFORMER MAIN TRANSFORMER OUTPUT INDUCTOR NOTES UNLESS OTHERWISE SPECIFIED DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS IS FOR REFERENCE ONLY TABLE 1 ASSEMBLY cone 2033 400 19x2060 460v 115 465 2 0 ohm 1 4A 500V 1 4A 500V CSR 51 2 2 DC COMMON 62 3 TS2 4 5 TORCH SW 751 8 6 TORCH Sw 7 NEG 2 1 KF OUTPUT INDUCTOR ATC RECEIVER ATC MALE CONNECTOR PLUGS INTO J22 ON MAIN BOARD J14 19X2041 OPTIONAL AUTOMATION INTERFACE J3 4 RON 1 2 3 ALTERNATE 20 PIN HEADER 20 POSITION TERMIN
17. SERVICE 5 8 Manual 0 2971 Torch cannot be activated AC indicator flashing Gas indicator ON Temp indicator 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 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 No cutting output Torch pilots Gas flows Fans operate _ DC indicator E 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 rep
18. 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 me 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 B Connections to 400 Volt or 460 Volt Three Phase Power These Power Supplies are equipped with a four conductor input power cable for three phase input power The 460 Volt Power Supply will accept 460 VAC Single Phase input power with a change of input power cable 1 The input cable s outer covering is stripped back at the factory to expose the individual wires at the free end of the cable 2 Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements refer to table in Section 2 All the input cable wires must be connected for three phase operation e Green Yellow wire to Ground e Remaining wires to L1 L2 L3 input Connect the input power cable or close the main disconnect switch to supply power to the system INSTALLATION 3 2 Manual 0 2971 Connections to 460 Volt S
19. 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 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual 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 2971 5 04 Power Supply Basic Parts Replacement 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 Screws Ground wire Art 04615 2 Loosen but donot remove the lower screws then carefully pull the Cover up and away from the unit Manual 0 2971 5 11 SERVICE Cover Installation Reconnect the ground wire if necessary Place the cover onto
20. 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 eS O ring 15 Cat 9 9743 Assembled Filter Cover O Barbed amp Fitting Art 02476 Optional Single Stage Filter Element Replacement Remove the Filter Element from the Housing and set Element aside to dry Wipe inside of housing clean then insert the replacement Filter Element open side first Replace Housing on Cover p Reattach gas supply NOTE If unit leaks between housing and cover inspect the O Ring for cuts or other damage Manual 0 2971 5 3 SERVICE 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 s
21. the power supply so that slots in the bottom edges of the cover engage the lower screws Tighten lower screws Reinstall and tighten the upper screws C Fuse Replacement 1 Remove the unit cover per paragraph A above 2 Locate the internal fuse on the left side of the center chassis 3 Replace the fuse A replacement fuse is located inside the power supply Refer to Section 6 Parts Lists for replacement fuse catalog number 4 Reinstall the cover by reversing the steps in paragraph above Internal Fuse Location This completes the parts replacement procedures SERVICE 5 12 Manual 0 2971 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 distribu
22. to capture fumes and gases Do not use the plasma torch in an area where com bustible 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 pro duces fumes or gases which contain chemicals known to the State of California to cause birth de fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq Electric Shock can injure or kill plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION e Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding circuit e Repair or replace all worn or damaged parts e Extra care must be taken when the workplace is moist or damp e Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications e Disconnect power source before performing any ser vice or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is combustible or flammable mate rial
23. 0V UNITS 1 2 3 4 5 w1 L1 1 7 5 400 460V 400 460 42 1 PHASE 3 PHASE A INPUT INPUT E18 11 L 11 11 4 INPUT DIODE 11 ASSY 19 2073 400V 3 PHASE Ji INPUT CHASSIS FILTERING GND 8 9 400V VERSION 2 K4 INCLUDES IN LINE 4 3 EMC FILTER 1 500 Ei2 R94 460V M1 R93 400V 1 P26 E15 h 2 5 4 28VAC A J21 P21 GATE DRIVE A RTN GATE DRIVE A J20 P20 GATE DRIVE RTN 1 GATE DRIVE 28VAC B 21 2 3 28 22 13 23 1515 TOBIAS E35 ot 21 66 SUPPLY ON OFF SW 225 26 1 MAIN TRANSFORMER Swi 5 RUN MODE SW g
24. AL STRIP RO ONOOSINGRTBIBS nn RM ONOBOSINGRABISS 5 TORCH SWITCH OK TO MOVE DIVIDED OUTPUT 1 REMOTE CURRENT CONTROL DC COMMON t j TORCH SWITCH gt DC MOVE i EE ADAPTER HARNESS USED Ca LOGIC COMMON WHEN REMOTE CURRENT ARC VOLTS CONTROL IS USED WITH AUTOMATION REPLACES CONNECTIONS HOUSING 22 14 662 _ TOROID INSTALLED ON 400CE ONLY PILOT BOARD ASSY 19X2086 Rev Revisions By Date THERMAL Dy 10113 DLL 052703 JHERMAL LIYNAMICS 101314 HAS 02 11 04 Scale Supersedes 58 Eco 101429 HAS 060904 Company Eco B028 RS 01 09 06 Infomation Proprietary to THERMAL DYNAMICS CORPORATION 050703 12V 46 gt RAR OFF ECO B016 RWH 01727106 Not For Release Reproduction or Distribution without Witton Consent GND NOTE Uniess Otherwise Specified Resistors in Ohms 1 4W 5 27 MODE SW C2 Capacitors are in Mcrofarada UF aaa ISENSE TITLE SCHEMATIC Size DWG No dass ea ete
25. Gas Supply Hose Art A 03000 Optional Single Stage Filter Installation Manual 0 2971 3 5 INSTALLATION Installing Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5 microns Connect the air supply as follows a Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filter assembly NOTE For 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 b Connect the two stage filter outlet hose to the inlet port of the Regulator Filter Assembly c Use customer supplied fittings to connect the air line to the Filter A1 4 NPT to 1 4 hose barbed fitting is shown as an example Regulator Inlet Port Regulator Filter 9 Assembly 2 Stage Filter Inlet Port IN Outlet OUT Two Stage Filter clamp 4 Assembly 1 4 6 mm Gas Supply Hose 1 4 NPT Hose Fitting MMB Optional Two Stage Filter Installation INSTALLATION 3 6 Manual 0 2971 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 fo
26. LDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 14 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS 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 Manual 0 2971 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 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 flammabi
27. Shield Cup Body Shield Cap Machine 50 60 Shield Cap Machine 70 100A Shield Cap Drag 40A Shield Cap Machine 40A 6 4 Manual 0 2971 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ON OFF switch to ON ACTION Close external disconnect switch RESULT Power to system RESULT AC indicator ON Fan s ON GAS indicator ON when input pressure is adequate for power supply operation Power circuit ready ACTION Connect work cable to workpiece Set output amperage RESULT System is ready for operation ACTION Protect eyes and activate torch RESULT Gas flows briefly then stops Gas restarts DC indicator Pilot arc established ACTION Release torch trigger RESULT Main arc stops Gas flow stops after post flow ACTION ACTION RUN Rapid Auto Restart SET switch to RUN for most applications or to Rapid Auto Restart RUN Rapid Auto Restart SET switch to SET 5 RESULT Gas flows to set pressure for gouging trimming or expanded metal applications RESULT Gas flow stops ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc automatically restarts PILOT ARC ACTION Torch moved within transfer distance of workpiece RESULT Main arc transfers Pilot arc off ACTION ACTION Unplug input power cord or open exter
28. 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 A WARNINGS Disconnect input power cord before moving unit Do not touch live electrical parts FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting e Only persons of adequate physical strength should lift the unit e 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 e Place unit ona proper skid and secure in place before transporting with a fork lift or other vehicle Manual 0 2971 3 1 INSTALLATION 3 03 Primary Input Power Connections 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
29. air 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 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 contami nants in the gas additional filtering may be needed Manual 0 2971 5 9 SERVICE 6 Fluctuations in input power a Have electrician check input line voltage 7 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 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 E indicator ON a Check and clear blades 3 Airflow obstructed TEMP indicator Check for obstructed air flow around the unit and correct
30. cks DO NOT use the locking nut to pull the connection together Do not use tools to secure the connection 3 Thesystem is ready for operation ATC Female Receptacle Panel Mounted Cable Connector Mechanized ATC Male Connector Art 04614 Connecting the Torch to the Power Supply INSTALLATION 3 8 Manual 0 2971 Check Quality To test the quality of air 1 Put the ON OFF switch in the up position 2 Put the RUN RAPID AUTO RESTART SET switch in the SET down position 3 Place a welding filter lens in front of the torch and turn on the air Any oil or moisture in the air will be visible on the lens Do not start an arc A 03690 Manual 0 2971 3 9 INSTALLATION INSTALLATION 3 10 Manual 0 2971 SECTION 4 OPERATION 4 01 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 or standoff cut ting ON J OFF Switch Controls input power to the power supply Up is ON down is OFF _ Indicator Steady light indicates power supply is ready for operation Blinking light indicates unit is in pro tective interlock mode Shut unit off shut off or disconnect input power correct the fault and re start the unit Refer to Section 5 for details
31. dards Institute 1430 Broadway New York NY 10018 5 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 1 2 Manual 0 2971 6 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED 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 WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WE
32. e used to set the proper pressure for the type gas being used NOTE Regulators should not be installed with In Line Air Filters D Extended Work Cable with Clamp As analternative to the standard 20ft 6 1m work cable amp clamp on the power supply a50ft 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 asa display cart Top shelf is 12 305 mm x20 508 mm Steel handle is30 762 mm high F Wheel Kit Akit with easy rolling wheels for maximum portability for the power supply 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 auto mation 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 mand 50 15 m lengths for use with this kit G Nylon Dust Cover Nylon canvas power supply dust cover with water resistant finish large outer pocket for storing manuals or spare consum ables and adjustable draw cord for tight fit INTRODUCTION 2 4 Manual 0 2971 SECTION 3 INSTALLATION 3 01 Unpacking 1
33. ength per Section 4 02G Manual 0 2971 5 7 SERVICE Torch will not pilot gas flow AC indicator ON GAS indicator ON DCindicator 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 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 H Torch will not pilot AC _ GAS 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 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
34. ephone 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 Global Customer Service Contact Information Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn 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 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 Suite 300 St Louis 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com 16082 Single Ridge JHERMAL DYNAMICS
35. et or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect 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 ANSI ASC 749 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 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 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 OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan
36. in the workplace Any material that cannot be removed must be protected e Ventilate all flammable or explosive vapors from the workplace e Donot cut or weld on containers that may have held combustibles e Provide a fire watch when working area where fire hazards may exist e Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwa ter or while using a water table DO NOT cut alu minum alloys underwater or on a water table un less the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion Aho Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the deci bels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION IPLASMA 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 e To protect your eyes always wear a welding hel m
37. ine 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 ACindicator OFF 1 Switchat 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 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 0 297 1 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
38. ingle 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 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 Passa 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 me 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 5 Strip back the insulation on the individual wires 6 Connect to main input contactor as follows e Line 1 wire to terminal L1 e Line 3 wire to terminal L3 7 Connect the ground wire to Ground Earth The Ground wire connection requires a ring terminal Ground Wire with Ring Terminal Input Cable Main Input 03041 Contactor Input Power Connections 460 VAC Single Phase 8 Reinstall the Power Supply cover 9 Connect the input power cable or close the main disconnect switch to supply power to the system Manual 0 2971 3 3 INSTALLATION 3 04 Gas Connections A C
39. lity 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 Manual 0 2971 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
40. naasa 1 01 Notes Cautions and Warnings 1 02 Important Safety Precautions 1 08 1 04 Declaration of Conformity 2 2 1 05 Statement of Warranty SECTION 2 INTRODUCTION a void du 2 01 Scope of Manual 2 02 Power Supply 2 03 Input Wiring Specifications 2 04 Power Supply Features 2 05 Power Supply Options and Accessories SECTION 3 INSTALLATION evades SOW UNPACKING 3 02 Lifting OPtioNS 02024 00 0 3 03 Primary Input Power Connections 3 04 Gas 3 05 Torch SECTION 4 OPERATION 4 01 Front Panel Controls Indicators 4 02 Preparations for Operation SECTION 5 ae tase
41. nal disconnect ON OFF switch to OFF RESULT RESULT All indicators off No power to system ower supply fan s shuts off Manual 0 2971 Art A 03706 APPENDIX of Power L Supply Note 1 Plasma Cutting gt SS y Symbol Input Power Symbol Input Power Specifications Phase AC or DC Hertz Rating APPENDIX 2 DATA TAG INFORMATION THERMAL DYNAMICS A Company Date of Mfr West Lebanon NH USA 03784 Made in USA 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 Current Type Duty Cycle Factor Output Range Amperage Voltage Duty Cycle Data Note 3 Conventional Load Voltage Rated No Load Voltage Rated Maximum Supply Current 1MAX 10 Effective p U1 Supply Current Manufacturer s Electrical Schematic File Number Rated Supply Voltage Note 2 Degree of Protection NOTES 1 2 Symbol shown indicates single or three phase AC input static frequency converter transformer rectifier DC output Indicates input voltages for this power supply Most power supplies carry a label at the input power cord showing inpu
42. of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and instruc tions before using the equipment Call 1 603 298 5711 or your local distributor if you have any ques tions Manual 0 2971 1 1 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 met als which may contain one or more of the follow ing 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 5055 will give you the in formation 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
43. onnecting Gas Supply to Unit The connection is the same for compressed air or 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 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 Gas Supply Art 02999 Hose Air Connection to Inlet Port INSTALLATION 3 4 Manual 0 2971 Installing Optional Single Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air to keep moisture and debris out of the torch 1 Attach the Single Stage Filter Hose to the Inlet Port 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instructions Do Not use 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 Inlet Port Regulator Filter Assembly Bowl 1 4 NPT Hose Fitting Hose Clamp 1 4 6 mm
44. or cutting guide while still producing cuts of excellent quality Manual 0 2971 4 5 OPERATION Postflow Release the trigger to stop the cutting arc Gas continues to flow for approximately 6 seconds During post flow if the user moves the trigger release to the rear and presses the trigger the pilot arc starts The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece L Shutdown 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 2 03748 4 6 Manual 0 2971 SECTION 5 SERVICE 5 01 General Maintenance A O Ring Lubrication An o ring on the Torch ATC Male Connector requires lubrication on a scheduled basis 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 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 pe
45. ower 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 Check all contactor points for severe arcing or pits replace if necessary Manual 0 2971 A 3 APPENDIX APPENDIX 4 TORCH PIN OUT DIAGRAMS ATC Female Receptacle Front View Negative Plasma A Hand Torch Pin Out Diagram ATC Male Connector Front View 8 8 Grou Ke 7 Open 7 Open Negative Plasma _ 4 Green Switch Ul 3 White Switch 2 Pilot 65 6 Open 7 9 El 6 5 Mechanized Machine Torch Pin Out Diagram ATC Male Connector Front View 8 Green 8 Ground 3 White Pendant 4 7 Open Connector IM e Not Used 6 Open 2 Orange 1 5 Si ay 6 Open 5 White 1 Black aooo Not Used Pilot Art A 03799 4 APPENDIX UNSHIELDED MACHINE TORCH Negative Plasma nd Tie lrg n Ya ZAC Oe 72 5
46. r high pressure regula tors 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 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 300 scfh 141 5 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 LD For 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 2971 3 7 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 A 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 cli
47. rds 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 suchas 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
48. rformance or poor parts life Art 03791 7 O Ring Manual 0 2971 5 1 SERVICE 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 witha 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 Filter Element No 9 4414 Art A 02995 Regulator Filter Element Replacement 6 Reinstall the bowl 7 Turn on the air supply SERVICE 5 2 Manual 0 2971 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
49. s and marketing expertise Above all we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry GS Read and understand this entire Manual and your employer s safety practices before installing operat ing 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 51 Operating Manual Number 0 2971 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 2003 2004 2005 2006 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher 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 October 20 2006 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION
50. sdiction 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 or one time fuses like UL Class K5 INTRODUCTION 2 2 Manual 0 2971 2 04 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art 04613 Work Cable and Clamp Gas Pressure Regulator Filter Assembly Gas Inlet Port Ports for Optional Automation Interface Cable h Art A 03738 Manual 0 2971 2 3 INTRODUCTION 2 05 Power Supply Options and Accessories Section 6 Parts Lists provides catalog numbers and ordering information Single Stage Air Filter Kit For use with compressed air shop systems Filters moisture and particulate matter from the air stream to at least 0 85 microns B Two Stage Air Filter Kit For use on compressed air shop systems Filters moisture and particulate matter from the air stream to at least 5 0 microns C High Pressure Regulators High pressure regulators are available The regulators ar
51. ssion CutMaster 51 Gas Pressure Settings Leads 5160 51100 Length Hand Torch Machine Torch Up to 25 75 psi 65 psi Over 25 85 psi 70 psi Art A 03831 OPERATION 4 4 Manual 0 2971 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 output current output level ay 03747 4 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 Auto Restart position when cutting expanded metal or gratings or in gouging or trimming operations when an uninterrupted restart is desired 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
52. t voltage requirements for the power supply as built 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 Sections of the Data Tag may be applied to separate areas of the power supply APPENDIX A 2 and Revision Level Standard Symbols AC DE 00 Art 03288 Manual 0 2971 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 me CAUTION Do not blow air into the p
53. 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 Power Supply Components Torch and Leads Parts and Labor Parts and Labor CUTMASTER 38 Product CUTMASTER 51 CUTMASTER 81 CUTMASTER 101 This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused basedupon industry standa
54. tor 6 03 Power Supply Replacement The following items are included with the replacement power supply work cable amp clamp input power cable gas pressure regulator filter and operating manual Qty Description Catalog CutMaster 51 Power Supply 1 208 230VAC Single Phase 60Hz with input power cable and plug 3 5120 1 1 400VAC Three Phase 50 60Hz with input power cable 3 5120 3 1 460VAC Three Phase 60Hz with input power cable 3 5120 2 Manual 0 2971 6 1 PARTS LISTS 6 04 Replacement Parts Qty PRP PRP PRR Description Fuse for 208 230VAC Power Supply for 400 VAC Power Supply for 460 VAC Power Supply Regulator Filter Assembly Replacement Element Input Power Cord for 208 230 V Power Supply Input Power Cord for 400 V Power Supply Input Power Cord for 460 V Power Supply 6 05 Options and Accessories Qty PRP RRP RP RP RP RP RP RP RP PNR PARTS LISTS Housing Filter Element 8 soo Cat No 9 92743 Assembled Filter Cover Barbed Fitting Optional Single Stage Filter Kit Description Single Stage Filter Kit includes Filter amp Hose Replacement Filter Body Replacement Filter Hose not shown Replacement Filter Element Two Stage Filter Kit includes Hose amp Mounting Screws Bracket Filter Mounting not shown Two Stage Air Filter Assembly First Stage Cartridge Second Stage Cartridge Extended Work Cable 50 ft 15 2 m with Clamp Multi Purpose
55. upply and bleed down system 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 amp Second Stage Cartridges as marked Art 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 2971 5 02 Common Faults 1 Insufficient Penetration a b f 2 Cutting speed too fast Torch tilted too much Metal too thick Worn torch parts Cutting current too low Non Genuine Thermal Dynamics parts used Incorrect gas pressure 2 Main Arc Extinguishes a b 4 f Cutting speed too slow Torch standoff too high from workpiece Cutting current too high Work cable disconnected Worn torch parts Non Genuine Thermal Dynamics parts used 3 Excessive Dross Formation a b
56. ustable Power Supply Gas Particulates to 20 Filtering Ability articulates to 20 Microns CutMaster 51 Power Supply Duty Cycle Ambient Temperature 40 104 F IEC TDC IEC TDC EC TDC Rating Rating Rating Rating Rating Rating 109 40 Amps DC Voltage n a n a n a NOTE duty cycle will be reduced if the primary input power is low or the output voltage DC is higher than shown in this chart 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 2971 2 1 INTRODUCTION Power Supply Dimensions amp Weight Ventilation Clearance Requirements Art A 03379 Art A 04612 CutMaster 51 Power Supply Input Wiring Requirements Suggested Sizes See Notes 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 juri
57. ut Power Source 1 Check the power source for proper input voltage Make sure the input power source meets the power re quirements for the unit per Section 2 Specifications 2 Connect the input power cable or close the main disconnect switch to supply power to the system D Air Source Ensure source meets requirements refer to Section 2 Check connections and turn air supply 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 2971 Place the Power Supply ON OFF switch to the ON up position AC indicator Gas indicator turns on if there is sufficient gas pressure for power supply operation NOTE Minimum pressure for power supply operation is lower than minimum for torch operation A Bat 30 25 35 Os 4 6 20 T ol a A 03746 Manual 0 2971 4 3 OPERATION Set Operating Pressure 1 Place the Power Supply RUN Rapid Auto Restart SET switch to the SET down position Gas will flow A 03690 2 Adjust gas pressure to 65 85 psi 4 5 5 9 bar Refer to the chart for pressure setting details 65 85 psi 4 5 5 9 bar Pressure Control Knob Bouton De Contr le de Pre

Thermal Dynamics CutMaster 51 Operating

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