101 ™

CUTMASTER
PLASMA CUTTING SYSTEM

Art # A-06754

Operating Manual
Rev. AB.01 Date: March 14, 2007 Manual # 0-2852
Operating Features:

80 600
AMP v
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 sales and marketing expertise.

Above all, we are committed to developing technologically

advanced products to achieve a safer working environment within
the welding industry.
 WARNINGS

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™ 101
Operating Manual Number 0-2852

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, 2007 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: March 14, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

 TABLE OF CONTENTS

SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Declaration of Conformity ............................................................................. 1-4
1.05 Statement of Warranty .................................................................................. 1-5

SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 Power Supply Specifications ......................................................................... 2-1
2.03 Input Wiring Specifications ........................................................................... 2-2
2.04 Power Supply Features ................................................................................. 2-3
2.05 Power Supply Options and Accessories ....................................................... 2-4

SECTION 3: INSTALLATION ..................................................................................................... 3-1

3.01 Unpacking .................................................................................................... 3-1
3.02 Lifting Options .............................................................................................. 3-1
3.03 Primary Input Power Connections ................................................................. 3-2
3.04 Gas Connections .......................................................................................... 3-4
3.05 Torch Connections ........................................................................................ 3-8

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

4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2

SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-5
5.03 Basic Troubleshooting Guide ......................................................................... 5-6
5.04 Power Supply Basic Parts Replacement ...................................................... 5-11

SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Power Supply Replacement .......................................................................... 6-1
6.04 Replacement Parts ....................................................................................... 6-2
6.05 Options and Accessories .............................................................................. 6-2
6.06 Torch Parts ................................................................................................... 6-3
 TABLE OF CONTENTS (continued)

PATENT INFORMATION ........................................................................................................... 6-4

APPENDIX 1: SEQUENCE OF OPERATION

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

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

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

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

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

APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS .......................................................... A-6

APPENDIX 7: SYSTEM SCHEMATIC, 400-460V UNITS .......................................................... A-8

APPENDIX 8: SYSTEM SCHEMATIC, 600V UNITS ............................................................... A-10

APPENDIX 9: Publication History ........................................................................................... A-12

Global Customer Service Contact Information ..................................................... Inside Rear Cover

 SECTION 1:
GASES AND FUMES
GENERAL INFORMATION
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
1.01 Notes, Cautions and Warnings
• Keep all fumes and gases from the breathing area.
Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.
are used to highlight important information. These high-
• Use an air-supplied respirator if ventilation is not
lights are categorized as follows:
adequate to remove all fumes and gases.
NOTE • The kinds of fumes and gases from the plasma arc
An operation, procedure, or background informa- depend on the kind of metal being used, coatings
tion which requires additional emphasis or is help- on the metal, and the different processes. You must
ful in efficient operation of the system. be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
CAUTION
Antimony Chromium Mercury
Arsenic Cobalt Nickel
A procedure which, if not properly followed, may
Barium Copper Selenium
cause damage to the equipment.
Beryllium Lead Silver
Cadmium Manganese Vanadium
WARNING • Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
A procedure which, if not properly followed, may formation regarding the kind and amount of fumes
cause injury to the operator or others in the oper- and gases that may be dangerous to your health.
ating area.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
1.02 Important Safety Precautions Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
WARNINGS • Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
OPERATION AND MAINTENANCE OF • Phosgene, a toxic gas, is generated from the vapors
PLASMA ARC EQUIPMENT CAN BE DAN- of chlorinated solvents and cleansers. Remove all
GEROUS AND HAZARDOUS TO YOUR sources of these vapors.
HEALTH. • This product, when used for welding or cutting, pro-
duces fumes or gases which contain chemicals
Plasma arc cutting produces intense electric and
known to the State of California to cause birth de-
magnetic emissions that may interfere with the
fects and, in some cases, cancer. (California Health
proper function of cardiac pacemakers, hearing aids,
& Safety Code Sec. 25249.5 et seq.)
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the ELECTRIC SHOCK
manufacturer of the health equipment to determine
whether a hazard exists.
Electric Shock can injure or kill. The plasma arc process
To prevent possible injury, read, understand and uses and produces high voltage electrical energy. This
follow all warnings, safety precautions and instruc- electric energy can cause severe or fatal shock to the op-
tions before using the equipment. Call 1-603-298- erator or others in the workplace.
5711 or your local distributor if you have any ques-
tions. • Never touch any parts that are electrically “live” or
“hot.”

Manual 0-2852 1-1 GENERAL INFORMATION

 • Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
PLASMA ARC RAYS
circuit.
• Repair or replace all worn or damaged parts.
Plasma Arc Rays can injure your eyes and burn your skin.
• Extra care must be taken when the workplace is The plasma arc process produces very bright ultra violet
moist or damp. and infra red light. These arc rays will damage your eyes
• Install and maintain equipment according to NEC and burn your skin if you are not properly protected.
code, refer to item 9 in Subsection 1.03, Publications.
• To protect your eyes, always wear a welding hel-
• Disconnect power source before performing any ser- met or shield. Also always wear safety glasses with
vice or repairs. side shields, goggles or other protective eye wear.
• Read and follow all the instructions in the Operat- • Wear welding gloves and suitable clothing to pro-
ing Manual. tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
FIRE AND EXPLOSION Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Fire and explosion can be caused by hot slag, sparks, or Use protective booths, screens or shields.
the plasma arc. • Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
• Be sure there is no combustible or flammable mate-
Minimum Protective Suggested
rial in the workplace. Any material that cannot be
Arc Current Shade No. Shade No.
removed must be protected.
Less Than 300* 8 9
• Ventilate all flammable or explosive vapors from
the workplace. 300 - 400* 9 12

• Do not cut or weld on containers that may have held 400 - 800* 10 14
combustibles.
* These values apply where the actual arc is clearly
• Provide a fire watch when working in an area where seen. Experience has shown that lighter filters may
fire hazards may exist. be used when the arc is hidden by the workpiece.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwa- 1.03 Publications
ter or while using a water table. DO NOT cut alu-
minum alloys underwater or on a water table un- Refer to the following standards or their latest revisions
less the hydrogen gas can be eliminated or for more information:
dissipated. Trapped hydrogen gas that is ignited 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
will cause an explosion. 1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
NOISE
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
Noise can cause permanent hearing loss. Plasma arc pro- CUTTING, obtainable from the American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per- 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
manent loss of hearing. AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
• To protect your hearing from loud noise, wear pro- Printing Office, Washington, D.C. 20402
tective ear plugs and/or ear muffs. Protect others
in the workplace. 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-
PATION AND EDUCATIONAL EYE AND FACE PRO-
• Noise levels should be measured to be sure the deci-
TECTION, obtainable from American National Stan-
bels (sound) do not exceed safe levels.
dards Institute, 1430 Broadway, New York, NY 10018
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual. 5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-2 Manual 0-2852

6. ANSI Standard Z49.2, 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. NFPA 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. NFPA 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, WELDING 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 0-2852 1-3 GENERAL INFORMATION

1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

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

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.

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

Manufacturers responsible representative: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

GENERAL INFORMATION 1-4 Manual 0-2852

1.05 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original
retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this warranty
are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated
below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored operated and
maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry practice, correct
such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.

Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at
which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.

Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods
begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.

LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads

Product
(Parts and Labor) (Parts and Labor)
CUTMASTER™ 51 3 Years 1 Year
CUTMASTER™ 81 3 Years 1 Year
CUTMASTER™ 101 3 Years 1 Year
CUTMASTER™ 151 3 Years 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.

2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermal Dynamics product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective January 15, 2004

Manual 0-2852 1-5 GENERAL INFORMATION

This Page Intentionally Blank

GENERAL INFORMATION 1-6 Manual 0-2852

 SECTION 2:
INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dy-
namics CutMaster 101 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 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
Input Power 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
Input Power Cable Cable for 208/230 VAC unit includes plug.
Output Current 20 - 80 Amps, Continuously Adjustable
Power Supply
Particulates to 20 Microns
Gas Filtering Ability
CutMaster 101 Power Supply Duty Cycle *
Ambient Temperature 40° C (104° F)
IEC TDC IEC TDC IEC TDC
Rating Rating Rating Rating Rating Rating
Duty Cycle 40% 60% 100%
208/230V
Current 80A 78A 68A 68A 45A 45A
and 460V Units
DC Voltage 112V 120V 107V 111V 98V 98V
Duty Cycle 35% 60% 100%
400V Units Current 80A n/a 68A n/a 45A n/a
DC Voltage 112V n/a 107V n/a 98V n/a
Duty Cycle 35% 60% 100%
600V Units Current 80A 78A 68A 68A 43A 43A
DC Voltage 112V 120V 107V 111V 97V 97V
* 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.
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 0-2852 2-1 INTRODUCTION

Power Supply Dimensions & Weight Ventilation Clearance Requirements

Art # A-03379

83 lb / 37.6 kg

6"
150 mm
17.3 in /
439 mm

24"
0.6 m
27.5 in / 696 mm
12.4 in / 6" 6"
315 mm 150 mm 150 mm
A-03572

2.03 Input Wiring Specifications

CutMaster 101 Input Wiring Specifications

Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50 14.4 69 90 6 6
208 60 15.6 75 90 6 6
230 50 15 65 80 6 6
230 60 15.5 67 80 6 6
400 50/60 13.9 20 30 10 10
460 60 18 39 50 10 10
460 60 16 20 30 12 12
600 60 13.5 13 20 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code

NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS / LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

INTRODUCTION 2-2 Manual 0-2852

2.04 Power Supply Features

Handle and Leads Wrap

Control Panel

Torch Leads Receptacle

Art # A-04507

Work Cable
and Clamp

Gas Pressure Regulator /

Filter Assembly

Gas Inlet Port

Ports for Optional Automation

Interface Cable

Gas Pressure Gauge

Art # A-03738

Input Power Cord

Manual 0-2852 2-3 INTRODUCTION

2.05 Power Supply Options and Accessories
Section 6, Parts Lists, provides catalog numbers and ordering information.
A. Single-Stage Air Filter Kit
For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least
0.85 microns. This filter increases performance and improves consumables parts life.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0
microns. This filter is pre-assembled at the factory and needs only to be installed on the power supply.
C. High Pressure Regulators
High pressure regulators are available. The regulators are used to set the proper compressed air pressure.
NOTE
Regulators should not be installed with In-Line Air Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work
cable with clamp is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility
for the power supply and can also serve as a display cart. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle
is 30" / 762 mm high.
F. Automation Interface Kit
This kit allows the user to convert a non automated power supply for use as part of a fully automated system.
The kit includes an automation interface board, wiring harness, mounting hardware and instructions. The 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 m and 50' / 15.m lengths for use with this kit.
G. Vinyl Cover
Nylon canvas power supply dust cover with water resistant finish, large outer pocket for storing manuals or spare
consumables, and adjustable draw cord for tight fit.

INTRODUCTION 2-4 Manual 0-2852

 SECTION 3: INSTALLATION

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

3.02 Lifting Options

The Power Supply includes a handle for hand lifting only. Be sure unit is lifted and transported safely and securely.

WARNINGS

Do not touch live electrical parts.

Disconnect input power cord before moving unit.
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
HANDLE is not for mechanical lifting.

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

• Lift unit by the handle, using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.

Manual 0-2852 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, 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. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end
of the cable.
2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2 ). All the input cable wires must be connected for three
- phase operation.
• Green / Yellow wire to Ground.
• Remaining wires to L1, L2, L3 input.
3. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

INSTALLATION 3-2 Manual 0-2852

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 5.04.
2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.
3. Loosen the through - hole protector on the back panel of the power supply. Pull the original power cable out
of the power supply.
4. Pass a customer - supplied, three - conductor input power cable through the access opening in the back panel
of the power supply. Refer to Section 2 for power cable specifications. Tighten the through - hole protector to
secure the power cable.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit
protection and wiring requirements (refer to table in Section 2.03).
5. Strip back the insulation on the individual wires.
6. Connect to main input contactor as follows:
• Line 1 wire to terminal L1.
• Line 3 wire to terminal L3.
7. Connect the ground wire to Ground (Earth). The Ground wire connection requires a ring terminal.

L1
L3

L3
L2
L1

Ground Wire
with Ring
Terminal
Input Cable
Main Input
A-03041 Contactor

Input Power Connections, 460 VAC, Single - Phase

8. Replace the Power Supply cover.

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

Manual 0-2852 3-3 INSTALLATION

3.04 Gas Connections
A. Connecting Gas Supply to Unit
Use only compressed air with this power supply.
The connection is the same for compressed air from a compressor from high pressure cylinders. Refer to subsection
3.4-B or 3.4-C if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical fittings as an example. Other fittings can be
used.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Regulator/Filter
Assembly

Inlet Port

Bowl

1/4 NPT to 1/4"

(6mm) Fitting

Hose Clamp
Gas Supply
Art # A-02999 Hose

Air Connection to Inlet Port

INSTALLATION 3-4 Manual 0-2852

B. 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) Gas Supply Hose
Art # A-03000

Optional Single - Stage Filter Installation

Manual 0-2852 3-5 INSTALLATION

C. 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 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.
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. A 1/4 NPT to 1/4" hose barbed fitting
is shown as an example.

Regulator Inlet Port

Regulator/Filter
Assembly
2-Stage Filter
Inlet Port (IN)

Outlet Port
(OUT)
Two Stage
Hose
Filter
Clamp
Assembly

1/4" (6 mm) Gas

Supply Hose) 1/4 NPT
Hose Fitting Art # A-03004

Optional Two - Stage Filter Installation

INSTALLATION 3-6 Manual 0-2852

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 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.
3. The cylinder must be equipped with an adjustable high - pressure regulator capable of outlet pressures up to 100 psi
(6.9 bar) maximum and flows of at least 500 scfh (236 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

Manual 0-2852 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.

WARNING

Disconnect primary power at the source before connecting the torch.

1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into
the female receptacle. The connectors should push together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull
the connection together. Do not use tools to secure the connection.
3. The system is ready for operation.

ATC Female Receptacle

(Panel Mounted) Control Cable
Connector (Mechanized
Torches Only)

ATC Male
Connector

Art # A-05556

Connecting the Torch to the Power Supply

INSTALLATION 3-8 Manual 0-2852

B. Check Air Quality
To test the quality of air:
1. Put the ON / OFF switch in the ON (up) position.
2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position.
3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible
on the lens. Do not start an arc!

A
40 60

1 2
20 80

Art # A-03577

Manual 0-2852 3-9 INSTALLATION

This Page Intentionally Blank

INSTALLATION 3-10 Manual 0-2852

 SECTION 4: OPERATION

4.01 Product Features

A. Front Panel Controls and Indicators

(A) Output Current Control AC Indicator

Sets the desired output current. Output settings up Steady light indicates power supply is ready
to 40 Amps may be used for drag cutting (with the for operation. Blinking light indicates unit
torch tip contacting the workpiece). At output set- is in protective interlock mode. Shut unit off,
tings over 40 Amps, the power supply automati- shut off or disconnect input power, correct
cally reduces output current to 40 Amps if the tip the fault, and restart the unit. Refer to Sec-
touches the workpiece. tion 5 for details.

Art # A-03744
TEMP Indicator

A Indicator is normally OFF. Indicator is ON

DRAG when internal temperature exceeds normal
40 60 limits. Shut unit OFF; let the unit cool before
CUTTING continuing operation.
RANGE

20 80 GAS Indicator
STANDOFF
CUTTING Indicator is ON when minimum input gas
pressure for power supply operation is
RANGE present. Minimum pressure for power sup-
ply operation is not sufficient for torch op-
eration.

ON / OFF Switch DC Indicator

Indicator is ON when DC output circuit is
Controls input power to the power supply.
active.
Up is ON, down is OFF.

RUN / RAPID AUTO RESTART / SET Switch

RUN (up) position is for general torch operation.

RAPID AUTO RESTART (middle) position is for an uninterrupted restart,
when cutting expanded metal or in gouging or trimming operations.
SET (down) position is for setting gas pressure and purging lines.

Manual 0-2852 4-1 OPERATION

4.02 Preparations For Operating
Perform the following steps at the start of each operating session:

WARNING

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

A. Torch Parts Selection

Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond with the type
of operation, and with the amperage output of this Power Supply (80 amps maximum). Refer to the Torch
Manual.
B. Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics model SL60 or SL100 Torches may be
connected to this Power Supply.
C. Check Primary Input 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. Gas Selection
Ensure compressed air source meets requirements (refer to Section 3.4). Check connections and turn gas supply
on.
E. Connect Work Cable
Clamp the work cable to the workpiece or cutting table. The area must be free from oil, paint and rust. Connect
only to the main part of the workpiece; do not connect to the part to be cut off.

Art # A-04509

OPERATION 4-2 Manual 0-2852

F. Power On
Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator

turns on if there is sufficient gas pressure for power supply operation.

NOTE
Minimum pressure for power supply operation is lower than minimum for torch operation.

A
40 60

20 80

Art # A-03580

Manual 0-2852 4-3 OPERATION

G. Set Operating Pressure
1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow.

A
40 60

1 2
20 80

Art # A-03577

2. Adjust gas pressure per the settings chart.

70 - 75 psi /
4.5 - 5.2 bar
Pressure Control Knob /
CutMaster 101 Bouton De Contrôle
de Pression
Gas Pressure Settings
SL100
Leads
(Hand Torch or
Length
Machine Torch)
Up to 25' 70 psi
(7.6 m) 4.8 bar
Over 25' 75 psi
(7.6 m) 5.2 bar

Art #A-03793

OPERATION 4-4 Manual 0-2852

H. Select Current Output Level
1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops.
2. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece), or
up to 80 amps for standoff cutting. At output settings higher than 40 amps, the power supply automatically
reduces output current to 40 amps if the torch tip contacts the workpiece.

2 A
40 60

20 80

Art # A-03579

I. Cutting Operation
Refer to the manual supplied with the torch for details on cutting operation, cutting speeds, parts selection and
replacement, etc.
When the torch leaves the workpiece during cutting operations with the RUN / Rapid Auto Restart / SET switch
in the RUN (up) position, there is a brief delay in restarting the pilot arc. With the switch in the 'Rapid Auto
Restart' (middle) position, when the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc
restarts instantly when the pilot arc contacts the workpiece. Use the 'Rapid Auto Restart' position when cutting
expanded metal or gratings, or in gouging or trimming operations when an uninterrupted restart is desired.
NOTE
When the shield cup is properly installed, there is a slight gap between the shield cup and the torch handle. Gas
vents through this gap as part of normal operation. Do not attempt to force the shield cup to close this gap. Forcing
the shield cup against the torch head or torch handle can damage components.
J. Typical Cutting Speeds
Cutting speeds vary according to torch output amperage, the type of material being cut, and operator skill. Refer
to the Torch Manual for details.
Output current setting or cutting speeds may be reduced to allow slower cutting when following a line, or using
a template or cutting guide while still producing cuts of excellent quality.

Manual 0-2852 4-5 OPERATION

K. 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.

A
40 60

20 80

Art # A-03584

OPERATION 4-6 Manual 0-2852

 SECTION 5:
SERVICE

5.01 General Maintenance

A. O-Ring Lubrication
An o-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently
the torch is disconnected and re-connected. This will allow the o-ring to remain pliable and provide a proper seal.
The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can
lead to potential performance problems.
It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.
NOTE
DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain
“unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch.
Either of these conditions can lead to inconsistent performance or poor parts life.

ATC Male Connector

Gas Fitting

Art #A-03791 O-Ring

Manual 0-2852 5-1 SERVICE

B. Filter Element Replacement
The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter
element should be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced.
1. Remove power from the power supply; turn off the gas supply and bleed down the system.
2. Unscrew the bowl on the bottom of the Regulator/Filter Assembly. The filter element will be visible and still
attached to the main body of the Regulator/Filter.
3. Grasp the filter element and unscrew it from the Regulator/Filter body. The filter element will come off with a
spool and some additional pieces.
4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace
it.
5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the
Regulator body by compressing the spring on the spool. Tighten firmly by hand.

Regulator/Filter
Assembly

Baffle
Ring

Filter
Element
No. 9-4414

Spring
Spool

Bowl

Art # A-02995

Regulator/Filter Element Replacement

6. Reinstall the bowl.

7. Turn on the air supply.

SERVICE 5-2 Manual 0-2852

C. Optional Single-Stage Filter Element Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter
Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts
List, for replacement filter element catalog number.
1. Remove power from power supply.
2. Shut off air supply and bleed down system before disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is located inside the
Housing.

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring
(Cat. No. 9-7743) Assembled Filter

Cover

Barbed
Fitting Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE
If unit leaks between housing and cover, inspect the "O" Ring for cuts or other damage.

Manual 0-2852 5-3 SERVICE

D. Optional Two-Stage Filter Element Replacement
The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will
continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter
element catalog number.
1. Shut off primary input power.
2. Shut off air supply and bleed down system.

WARNING

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

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.
4. Note the location and orientation of the old Filter Elements.
5. Slide out the old Filter Elements.

First & Second

Stage
Cartridges
(as marked)

Art # A-02942

Optional Two-Stage Filter Replacement

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4
above.
7. Hand tighten the two bolts evenly, then torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm). Improper torque may
damage the gasket.
8. Slowly apply air pressure to the assembly, checking for leaks.
NOTE
A small amount of air leakage from the bottom fitting is normal.

SERVICE 5-4 Manual 0-2852

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

Manual 0-2852 5-5 SERVICE

5.03 Basic Troubleshooting Guide

WARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair
unless you have had training in power electronics measurement and troubleshooting techniques.

A. Basic Troubleshooting: Overview

This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this
system. If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual for this prod-
uct.
B. How to Use This Guide
The following information will help the Customer / Operator determine the most likely causes for various symptoms.
Follow all instructions as listed and complete each section in the order presented.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions
1. Cause
a. Check / Remedy
Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that
unit operates properly after any repairs.
C. Common Symptoms
A. AC indicator OFF
1. Switch at main power panel in OFF (open) position.
a. Close main power switch.
2. Power Supply ON / OFF switch in OFF (down) position.
a. Turn switch to ON (up).
3. Torch is not connected properly to Power Supply
a. Turn power supply ON / OFF switch to OFF (down). Check torch connection to Power Supply. Tighten or
adjust as required. Do not use tools. Turn power supply ON / OFF switch to ON (up).
4. Shield cup not fully tightened on torch head
a. Check shield cup for proper installation. Do not overtighten. Do not use tools to tighten.
5. Main power line fuse(s) or circuit breaker(s) blown
a. Check main power panel fuse(s). Replace as required.

SERVICE 5-6 Manual 0-2852

 6. Unit internal fuse blown or loose
a. If blown, double-check input voltage and replace fuse per Section 5.04-C. If fuse blows again, return unit to
an authorized service center.
7. Actual input voltage does not correspond to voltage of unit
a. Verify that the input line voltage is correct. Refer to Section 2, Input Wiring Requirements.
8 . Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
B. Gas flows continuously when power is turned on, AC indicator flashes
1. Torch switch is activated (closed) before user turns power on.
a. Release torch switch.
2. Faulty torch switch
a. Check torch switch for continuity. Replace if necessary.
C. Gas flows continuously; Torch will not pilot when torch switch is activated; AC indicator ON
1. System is in SET mode
a. Change RUN / Rapid Auto Restart / SET switch to RUN (up).
D. No gas flow; RUN / Rapid Auto Restart / SET switch in SET position; Fans operate; AC indicator ON;

GAS indicator OFF

1. Gas not connected

a. Check gas connections.
2. Gas pressure too low for power supply operation
a. Adjust gas pressure per torch manual.
3. Faulty components in unit
a. Return for repair or have qualified technician repair.

E. Torch will not pilot; gas flows; AC indicator ON, GAS , TEMP , and DC indicators OFF

1. Gas pressure is below power supply minimum requirement.

a. Adjust pressure to 60 - 75 psi / 4.1 - 5.2 bar.

F. Torch will not pilot; gas flows; AC and Gas indicators ON; DC and TEMP indicators OFF

1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower than mini-
mum required for torch operation.)
a. Adjust gas pressure per torch manual.

Manual 0-2852 5-7 SERVICE

G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator ON

1. Starter cartridge missing from torch

a. Shut off power supply. Remove shield cup, install starter cartridge. Reinstall torch tip and shield cup. Turn
power supply ON / OFF switch to ON (up).
2. Shield cup is loose on torch
a. Check shield cup; tighten if necessary.
NOTE
When operating the torch in a normal condition, a small amount of gas vents through the gap between the shield cup and
torch handle. Do not attempt to over tighten the shield cup as irreparable damage to internal components may result.
3. Upper O-ring on torch head is in wrong position.
a. Remove shield cup from torch; check position of upper O-ring. Correct if necessary.

Art # A-03640

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring Threads

in Correct Groove Lower O-Ring

H. Torch will not pilot; AC , GAS , and TEMP indicators ON, DC indicator OFF

1. Air flow blocked

a. Check for blocked air flow around the unit and correct condition.
2. Unit is overheated
a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to duty cycle data in Section 2.
3. Input line voltage is low
a. Check and connect to proper input power line.
4. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.

SERVICE 5-8 Manual 0-2852

I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC
indicator OFF
1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.)
a. Release torch trigger.
2. System is in protective interlock mode. (Torch parts are missing or loose.)
a. Release torch trigger, and set power supply ON / OFF switch to OFF (down). Open main disconnect switch.
Check torch parts. Replace parts as needed. Reinstall shield cup; hand - tighten it securely against the torch
head. Do not overtighten. Do not use tools. Close main disconnect switch. Set ON / OFF switch to ON (up)
position.

J. Gas cycles on and off without torch switch being activated; AC indicator Flashing; Gas indicator
ON; DC indicator OFF
1. Torch tip or electrode missing
a. Shut off power supply. Remove shield cup, install missing part(s). Turn power supply ON / OFF switch to
ON (up).

K. No cutting output; Torch pilots; Gas flows; Fans operate; AC , Gas , and DC indicator ON;

TEMP indicator OFF

1. Work cable not connected to work piece, or connection is poor

a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
2. Faulty Torch
a. Return for repair or have qualified technician repair.
3. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
L. Torch cuts but not adequately
1. Incorrect setting of output current (A) control
a. Check and adjust to proper setting.
2. Torch consumables worn
a. Check torch consumables per Torch manual; replace as needed.
3. Work cable connection to work piece is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
4. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
5. Torch being dragged on work. ('Tip saver' circuit active) At output current settings greater than 40 amps, the power
supply automatically reduces current to 40 amps if the torch tip contacts the workpiece.
a. Lift torch off work.

Manual 0-2852 5-9 SERVICE

 6. Excessive oil or moisture in torch
a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from
clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contami-
nants in the gas, additional filtering may be needed.
7. Fluctuations in input power
a. Have electrician check input line voltage.
8. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.

M. Arc shuts off during operation; arc will not restart when torch switch is activated.

1. Power Supply is overheated (TEMP indicator ON)

a. Let unit cool down for at least 5 minutes. Make sure the unit has not been operated beyond Duty Cycle limit.
Refer to Section 2 for duty cycle specifications.

2. Fan blades blocked (TEMP indicator ON)

a. Check and clear blades.

3. Air flow obstructed (TEMP indicator ON)

a. Check for obstructed air flow around the unit and correct condition.

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

a. Check source for at least 60 psi / 4.1 bar; adjust as needed. (Minimum pressure for power supply operation
is lower than minimum required for torch operation.)
5. Torch consumables worn
a. Check torch consumables per Torch manual; replace as needed.
6. Faulty components in unit
a. Return for repair or have qualified technician repair per Service Manual.
N. AC indicator remains ON when shield cup is removed
1. Faulty PIP switch in torch
a. Check PIP switch for continuity; replace if necessary

SERVICE 5-10 Manual 0-2852

5.04 Power Supply Basic Parts Replacement

WARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to
the Power Supply Service Manual.
A. Cover Removal
1. Remove the upper screws which secure the cover to the main assembly.
NOTE
There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there
is a need for more room to work.

Upper screws

Lower
screws

Lower
screws

Ground wire

Art # A-04510

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

Manual 0-2852 5-11 SERVICE

B. Cover Installation
1. Reconnect the ground wire, if necessary.
2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws.
3. Tighten lower screws.
4. Reinstall and tighten the upper screws.
C. Fuse Replacement
1. Remove the unit cover per paragraph "A" above.
2. Locate the internal fuse on the left side of the center chassis.
3. Replace the fuse. A replacement fuse is located inside the power supply. Refer to Section 6, Parts Lists, for
replacement fuse catalog number.
4. Reinstall the cover by reversing the steps in paragraph "B" above.

Fuse Location

Art # A-03002

Internal Fuse Location

This completes the parts replacement procedures.

SERVICE 5-12 Manual 0-2852

 SECTION 6:
PARTS LISTS

6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Complete Power Supply Replacement

Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your distributor. Materials returned without proper authorization
will not be accepted.

6.02 Ordering Information

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

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, input power cable, gas
pressure regulator / filter, and operating manual.
Qty Description Catalog #
CutMaster 101 Power Supply
1 208 / 230VAC, Single - Phase, 50/60 Hz, with 3-1320-1
input power cable and plug
1 400VAC, Three - Phase, 50/60 Hz, with input power cable 3-1320-3
1 460VAC,Three - Phase, 60 Hz, with input power cable 3-1320-2
1 600VAC, Three - Phase, 60 Hz, with input power cable 3-1320-5

Manual 0-2852 6-1 PARTS LISTS

6.04 Replacement Parts
Qty Description Catalog #
Fuse
1 for 208 / 230VAC Power Supply 9-8588
1 for 400VAC Power Supply 9-8602
1 for 460 Power Supply 9-8583
1 for 600VAC Power Supply 9-8638
1 Regulator / Filter Assembly Replacement Element 9-4414
Input Power Cord
for 208 / 230VAC Power Supply 9-8596
1 for 400VAC Power Supply 9-8562
1 for 460 Power Supply 9-8593
1 for 600VAC Power Supply 9-8593

6.05 Options and Accessories

Qty Description Catalog #
1 Single-Stage Filter Kit (includes Filter & Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Hose (not shown) 9-7742
2 Replacement Filter Element 9-7741
1 Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-7500
1 Bracket, Filter Mounting (not shown) 9-7535
1 Two-Stage Air Filter Assembly 9-7527
1 First Stage Cartridge 9-1021
1 Second Stage Cartridge 9-1022
1 Extended Work Cable ( 50 ft /15.2 m ) with Clamp 9-8529
1 Multi-Purpose Cart 7-8888
1 Automation Interface Kit 9-8310
1 25' / 7.6 m CNC Cable for Automation Interface Kit 9-8312
1 50' /15.2 m CNC Cable for Automation Interface Kit 9-8313
1 Nylon Dust Cover 9-7072

Housing

Filter
Element
(Cat. No. 9-7741)

Spring

O-ring First & Second

(Cat. No. 9-7743) Assembled Filter Stage
Cartridges
Cover (as marked)

Barbed Art # A-02942

Fitting Art # A-02476

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

PARTS LISTS 6-2 Manual 0-2852

6.06 Torch Parts

Shield
Cup
8-3487 9-8207 (40A) 9-8218
8-3486
O-Ring O-Ring
Shield Cap, Drag
(Black) (Red) Shield 9-8236 (70-100A)
Cup Body
9-8237 Shield Cap, Deflector
9-8243
Starter 9-8211 (80A)
Electrode Shield Standoff
Cartridge
9-8215 9-8213 Cup Cutting Guide
9-8281
9-8218

Shield
Art # A-03796
Cup Body
9-8225 - A (40A) 9-8237 9-8241
9-8226 - B Shield Cap, Gouging
9-8227 - C
9-8228 - D

Torch Head

Electrode

Start Cartridge

Tip

Shield Cup

Standoff Cutting Guide

Art # A-04070

Manual 0-2852 6-3 PARTS LISTS

 PATENT INFORMATION
The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512
Catalog Number Description
9-8235 Shield Cap, Drag 50-60A
9-8236 Sheild Cap, Drag 70-100A
9-8237 Shield Cup, Body
9-8238 Shield Cap, Machine 50-60A
9-8239 Shield Cap, Machine 70-100A
9-8244 Shield Cap, Drag 40A
9-8245 Shield Cap, Machine 40A

PARTS LISTS 6-4 Manual 0-2852

 APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
ACTION: ACTION: ACTION: ACTION:
Close external ON / OFF switch to ON RUN /
RUN /
disconnect switch. Rapid Auto Restart / SET
RESULT: Rapid Auto Restart /
switch to RUN
RESULT: SET switch
AC indicator ON. to SET
Power to system. (for most applications)
Fan(s) ON.
or to
Rapid Auto Restart
GAS indicator ON RESULT:
when input
Gas flows to set pressure. (for gouging, trimming,
pressure is adequate
or expanded metal
for power supply operation.
applications)
Power circuit ready.
RESULT:
Gas flow stops.

ACTION:
Connect work cable to workpiece.
Set output amperage. ACTION:

RESULT: Torch moved away from work (while

still activated).
System is ready
for operation. RESULT:

Main arc stops.

Pilot arc automatically
restarts.
ACTION:
Protect eyes and activate torch.
PILOT ARC
RESULT:
Gas flows briefly, then stops.
Gas restarts. ACTION:

DC indicator ON Torch moved within

Pilot arc established. transfer distance of workpiece.
RESULT:

Main arc transfers.

Pilot arc off.
ACTION:
Release torch trigger.
RESULT: ACTION:
ACTION:
Main arc stops. Unplug input
Gas flow stops after post - flow. ON / OFF switch power cord or
to OFF open external
disconnect.
RESULT:
RESULT:
All indicators off. No power to system.
Power supply fan(s) shuts off.
Art #A-03706

Manual 0-2852 A-1 APPENDIX

 APPENDIX 2: DATA TAG INFORMATION

West Lebanon, NH USA 03784 Manufacturer's Name and/or

Logo, Location, Model and
Model: Revision Level, Serial Number
S/N
Date of Mfr: and Production Code
Made in USA
Type of Power Regulatory Standard Covering
Supply (Note 1) 1/3 f1
f2 This Type of Power Supply

Output Current Type Duty Cycle Factor

Output Range (Amperage/
Voltage)
Plasma Cutting
Symbol X
I Duty Cycle Data (Note 3)
U0 =
U2
Rated No- Conventional
Load Voltage Load Voltage
Rated Maximum
Supply Current
Input Power
Symbol
U1 I 1max 3Ø I 1eff Maximum Effective
1
1Ø 1
1Ø 3Ø
Supply Current

Input Power
Specifications
(Phase, AC or DC
Hertz Rating) Manufacturer's Electrical
Schematic File Number
and Revision Level
Degree of Protection Rated Supply
Voltage (Note 2)

NOTES:
1. Symbol shown indicates single- or three-phase AC input, Standard Symbols
static frequency converter-transformer-rectifier, DC output. AC
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input DC
voltage requirements for the power supply as built. Ø Phase
3. Top row: Duty cycle values.
IEC duty cycle value is calculated as specified by
the International ElectroTechnical Commission. Art # A-03288
TDC duty cycle value is determined under the power supply
manufacturer's test procedures.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
4. Sections of the Data Tag may be applied to separate areas
of the power supply.

APPENDIX A-2 Manual 0-2852

 APPENDIX 3: MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts
listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air flow.
2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere
with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.

Manual 0-2852 A-3 APPENDIX

 APPENDIX 4: TORCH PIN - OUT DIAGRAMS
A. Hand Torch Pin - Out Diagram

ATC Male Connector ATC Female Receptacle

Negative / Front View Front View Negative /
Plasma Plasma

4 - Green / 8 - Open 8 - Ground

Switch 4 - Switch

7 - Open 7 - Open 3 - Switch

3 - White / 4 8 8 4
Switch 3 7 7 3
2 6 6 - Open 6 2
2- Orange / 6 - Open
1 5 5 1 2 - PIP
PIP
5 - Open 5 - Open
1 - PIP
1 - Black /
PIP Pilot
Pilot A-03701

B. Mechanized (Machine) Torch Pin - Out Diagram

ATC Male Connector UNSHIELDED MACHINE TORCH ATC Female Receptacle

Front View Front View
Negative / Plasma
Negative / Plasma
8 - Green -
4- Black -
Pendant
Pendant
Connector 8 - Ground 4 - Switch
Connector
Ground
3 - White -
4 8 7 - Green / 3 - Switch
Pendant 7 - Open 8 4
3 7 Not Used
Connector 7 3
2 6 6 2
6 - Open
2 - Orange / 1 5 5 1
6 - Open 2 - PIP
PIP

5 - White / 1 - PIP
1 - Black / 5 - Open
Not Used
PIP
Pilot Pilot

Art # A-03799

APPENDIX A-4 Manual 0-2852

 APPENDIX 5: CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram

Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
5 5
6 6
Torch Green 4 4 To Power Supply
Switch White 3 3 Circuitry
8 8
7 7
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
Remote
Male ATC Female
Pendant
ATC Leads Receptacle
Connector
Connector
Power
Torch Torch Supply
Head Leads
PIP Black 1 1 To Power Supply
Switch Orange 2 2 Circuitry
White 5 5
6 6
Not Black 4 4 To Power Supply
Used
White 3 3 Circuitry
Green 8 8
Green 7 7
Negative / Plasma Lead Negative / Plasma
Pilot Lead
Pilot

Art # A-03798

Manual 0-2852 A-5 APPENDIX

 APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS
1 2 3 4 5
E6
L1 W1 E8 E12A
(1)
E17A GATE
208/230V 14 13 12 J3A P3A
E5 DRIVE
1 PHASE 1 1
INPUT L2 W1 E13
(2)
28 2 2
E18 E9A
23
A 24 27
L3 W1 25
GATE E11A
(3)
E14 DRIVE
J7A P7A
1
E16 E19A 1 1
L4 W1 INPUT DIODE
(78) ASSY 19X2073 E21A 76542 2 2

IGBT BOARD
(33) ASSY 19X1756

E22 E33 E1 E2 E3
COPPER STRAP E12B
E7 GATE
CHASSIS (FILTERING) E17B 14 13 12
DRIVE J3B P3B
GND J11 1 1
(4)
1 1
2 2 K1 2 2
P11 K1 28
(5) 3 3
4 4 23 E9B
B E15 24 27
R30 25
E11B
GATE
(0 ohm) DRIVE
T1 E4 1 J7B P7B
M1 F1 E19B 1 1
FAN1 (6/10A 600V) E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 E23
K2 IGBT BOARD
3 3
4 4 ASSY 19X1756
(6) 28VAC B 28VAC A
(6) 5 5 E30
230V 6 6
M2
FAN2 J26 P26
1 1
P18 J18 2 2
1 1 J31 P31
28VAC B (21) 2 2 1 1
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 J30 P30
6 6 28VAC B TO BIAS SUPPLY
C ON/OFF SW (25) 1 1
(26) 7 7 2 2
SW1 8 8
RUN +12VDC J25 P25
1 1
MODE SW SET
K1 2 2
(46)
RAR OFF
(PILOT PCB) INRUSH
+18V
(F9) SW2

K2
CURRENT ADJUST:
E5 (TS2)
20 - 80 FOR CM101 FAN E6 (TS1)
20 - 60 FOR CM81
J14 P14 P27 J27
1 1
(35)
1 1 POT HIGH
E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
CURRENT AC 4 4
(38)
4 4 +12V E27
(39)
CONTROL/ 5 5 (40) 5 5 AC
MAIN TRANSFORMER
TEMP 6 6 6 6 GAS
LED PCB 7 7
(41)
7 7 OVERTEMP
(42)
19X1604 GAS
8 8 8 8 DC E32 T5
D CURRENT
DC SENSE
PRI

SEC

P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
TEMP NTC 4 4
PRI

SEC

t
TS1 P32 J32
1 1
2 2 E52 E47
INDUCTOR J33 P33 P39 J39
(70)
TEMP -OUT SENSE 1 1 (71) 1 1
TS2 DC COM 2 2 (72) 2 2
TIP SENSE 3 3 (73) 3 3
+12VDC4 4 (74) 4 4
LOGIC P1 P13 J12 J43 CSR5 5 (75) 5 5
ASSY 19X1913 - CM101 +12VDC 1 1 1 1 I SENSE6 6 6 6
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V
7 7 (77) 7 7
ASSY 19X1932 - CM81 DC COM 3 3 3 3 TIP VOLTS 8 8 8 8
ASSY 19X2284 - CM81 DC COM 4 4 4 4 ATC CONNECTION
E W1 ON 5 5 5 5 K5
CONFIGURATION
TIP SENSE 6 6 6 6
RUN/SET 7 7 7 7 CONTACTOR ON J34 P34 (STANDARD)
PRESS GOOD 8 8 8 8 +18V (78)
OVERTEMP 9 9 9 9 PIP RTN 1 1
(79)
11
PIP SOL2
INV ON D13 PIP 2 2 22 A B
CSR 10 10 10 10 T6
GAS ON 11 11 11 11 3 3 55 11 15
K4
DRAG ON D25 DC OK 12 12 12 12 TORCH SW RTN 4 4 (80) 77
OVTEMP 13 13 13 13 5 5 (81) 44 TORCH PRI
SOLENOID ON TORCH SW 6 6 33
SW ON AC OK 14 14 14 14 SW
D33 15 15 88
TORCH SW 15 15
TORCH SW RTN 16 16 16 16 ATC MALE
+12V 17 17 17 17 CONNECTOR SEC
POT HIGH 18 18 18 18 J23 ATC RECEIVER
POT WIPER 19 19 19 19 6 10
POT LOW 20 20 20 20 28VAC A 1
GATE DRIVE B RTN 21 21 21 21 GND 2 TEST
GATE DRIVE B 22 22 22 22 28VAC B 3 CONN
GATE DRIVE A RTN 23 23 23 23
GATE DRIVE A 24 24 24 24 SOL1 FACTORY INSTALLED OPTIONAL
- OUT SENSE 25 25 25 25 A B
TORCH MOUNTED GAS SOLENOID
CURRENT SENSE 26 26 26 26
CURRENT SENSE 27 27 27 27 K4 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, J24 P24 SOLENOID
29 29 (RESETABLE) 1 1 (8)
CURRENT SENSE RTN 29 29 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
PRESS GOOD
F 32 32 32 32 4 4 (12)
ISENSE 33 33 33 33 5 5 PRESSURE
34 34 34 34 6 6 (13)
SWITCH
35 35 35
36
35
36
MAIN BOARD K5
7 7 PS1
CLOSED WHEN
TIP VOLTS 36 36 8 8
EXTENDER ASSY 19X1912 PRESSURE OK
ASSY 19X1775
W1
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

Art # A-07153 1 2 3 4 5

APPENDIX A-6 Manual 0-2852

 6 7 8 9 10

COMP DESCRIPTION LOCATION

F1 FUSE, 6/10A 600V KTK B2
F2 FUSE, 0.9A, RESETABLE F3
L1 OUTPUT INDUCTOR D7
M1 FAN, 4.5" 220VAC B1
M2 FAN, 4.5" 220VAC C1
PS1 PRESSURE SWITCH F4
SOL1 GAS SOLENOID F4 A
SW1 SWITCH, ON/OFF C1
SW2 SWITCH, RUN/SET/RAR C1
T5 MAIN TRANSFORMER D4
TS1 TEMP. SENSOR, IGBT HEATSINK D1
TS2 TEMP. SENSOR, INDUCTOR E1
W1 MAIN CONTACTOR F4

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

OPTIONAL AUTOMATION INTERFACE CONNECTIONS B

* PLUGS INTO J27

ON MAIN BOARD ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
(LED PCB 19X1604)

J14 P14 P3 J3 J4 P4 J2
(47)
1
2
1
2
1
2 (48)
1
2
1
2
20
19
20
19
1
2
+
TORCH SWITCH
AC
3
4
3
4
3
4
(49)
3 3 18 18 3 -
17 17 4
5 5 5 16 16 5
TEMP 6 6 6 15 15 6 OK TO MOVE
7 7 7 19X2041 14 14 7
8 8 8 OPTIONAL 13 13 8
GAS
AUTOMATION 12
11
12
11
9
10
+ DIVIDED OUTPUT
INTERFACE
DC 10 10 11
12
-
9 9
8 8 13
ADAPTER HARNESS USED P1 J1 7 7 14 REMOTE CURRENT CONTROL
(CSR) 6 6 15
WHEN REMOTE CURRENT
(51) 1 1 CSR 5 5 16
CONTROL IS USED WITH (52) 2 2 DC COMMON 4 4 17 DC COMMON C
AUTOMATION 3 3 +12VDC 3 3 18 +
(REPLACES CONNECTIONS (TS2) 4 4 2 2 19 C&G
FROM J27 TO J14) (TS1) 5
6
5 TORCH SW - 1
6 TORCH SW +
1 20 -
(NEG) 7 7
8 8 Vo
CPC
HOUSING
(56) 4 (+)
(57) 3 (-) } TORCH SWITCH
(58) 14
(59) 12 } OK TO MOVE
(60) 6 (+)
(61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
(64) 7 (-) } ARC VOLTS (C&G)
OUTPUT INDUCTOR

L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)

(E35)

(E62)
(CSR) (NEG) T
E49 E45 E35 E61 E3 E1 O
E62 E43 E32 R
PILOT E64 CSR Vo C
H
CURRENT
SENSE

JUMPER
E37 E58 E36 E57 (E58)
WORK E

(C1) E58 E62

(MODE SW)
RAR OFF
OUTPUT DIODE OUTPUT DIODE (52)
E34A E34B 1 J1
ASSEMBLY ASSEMBLY (51) 2
19X1757 19X1757 J40 P40
(14)
E39A E39B +12VDC 1 1 1
(15)
DC COM 2 2 2
E50A E50B 3 3 (46)
3
4 4 (17)
E48A E48B CSR 5 5 5
6 6
7 7 (18)
E53A E53B ISENSE 8 8 8
E54A E54B J28 PILOT BOARD
ASSY 19X2157
CHASSIS E63 THRU SCREW TERMINAL
E56A E56B GND
E60A E60B Rev Revisions By Date PCB No:
AA ECO 101136 (REL) DLL 05/07/03
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2 Assy No: F
AB ECO 101314 HAS 02/11/04 WEST LEBANON, NH 03784 Scale Supersedes
DC COMMON DC COMMON 603-298-5711
AC ECO 101429 HAS 06/09/04
Date:
AD ECO 101614 HAS 03/22/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03
POWER OUTPUT BOARD ASSY 19X1914 AE ECO B028 RS 01/09/06 Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
AF ECO B016 RWH 01/27/06 NOTE: D.Lilja
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, January 27, 2006 11:05:29
CM81/101 208/230V SYSTEM D 42X1136
6 7 8 9 10 Art # A-07153

Manual 0-2852 A-7 APPENDIX

 APPENDIX 7: SYSTEM SCHEMATIC, 400-460V UNITS
1 2 3 4 5

W1 E6 E12A
L1 (1)
E8 GATE
E17A 14 13 12 DRIVE J3A P3A
1 1
E5
208/230V 415/400V W1 2 2
/460V L2 (2) E13 28
1 PHASE 23 E9A
A INPUT 3 PHASE 24 27
INPUT E18 25
GATE E11A
DRIVE
J7A P7A
W1 1
L3 (3) E14 E19A 1 1
E16
E21A 76542 2 2
INPUT DIODE
ASSY 19X2073 IGBT BOARD
ASSY 19X1756
CHASSIS GND E33 E1 E2 E3
400V E22
3 PHASE
INPUT E12B
E7 GATE
(FILTERING) E17B 14 13 12 DRIVE J3B P3B
P11 J11 1 1
(4)
1 1
400V 'CE' VERSION 2 2 K1
K1
28 2 2
INCLUDES IN-LINE (5) 3 3
4 4 23 E9B
B EMC FILTER R29 (415/460/600V) E15 24 27
25 E11B
GATE
R78 (400V)
DRIVE
R30 (208/230V) T1 E4 1 J7B P7B
M1 F1 E19B 1 1
FAN1 E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 E23
K2 IGBT BOARD
3 3
4 4 ASSY 19X1756
(6) 28VAC B 28VAC A
(6) 5 5 E30
230V 6 6 SEE TABLE 1 FOR
M2 F1, R29,R30 & R78
FAN2 J26 P26
1 1
2 2
P18 1 1 J18
J31 P31
2 2 1 1
28VAC B (21)
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 28VAC B TO BIAS SUPPLY J30 P30
C ON/OFF SW (25) 6 6 1 1
(26) 7 7 2 2
SW1 8 8
RUN +12VDC J25 P25
1 1
MODE SW
SET K1 2 2
(46)
RAR OFF
(PILOT PCB) INRUSH ARC HOLD E34
+18V
(F9) SW2 28VAC A E36
K2
28VAC B E35
CURRENT ADJUST:
E5 (TS2)
20 - 80 FOR CM101 FAN E6 (TS1)
20 - 60 FOR CM81
J14 P14 P27 J27
1 1
(35)
1 1 POT HIGH E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
AC 4 4
(38)
4 4 +12V E27
CURRENT (39)
5 5 (40) 5 5 AC
CONTROL/ TEMP 6 6 (41) 6 6 GAS MAIN TRANSFORMER
7 7 7 7 OVERTEMP
LED PCB 8 8
(42)
8 8 DC T5
19X1604 GAS E32
D CURRENT
DC SENSE
PRI

SEC

P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
TEMP NTC 4 4
PRI

SEC

t
TS1 P32 J32
1 1
2 2 E52 E47
INDUCTOR J33 P33 P39 J39
(70)
TEMP -OUT SENSE 1 1 (71) 1 1
TS2 DC COM 2 2 (72) 2 2
TIP SENSE 3 3 (73) 3 3
+12VDC4 4 (74) 4 4
LOGIC P1 P13 J12 J43 CSR5 5 (75) 5 5
ASSY 19X1913 - CM101 I SENSE6 6 6 6
+12VDC 1 1 1 1
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V
7 7 (77) 7 7
ASSY 19X1932 - CM81 DC COM 3 3 3 3 TIP VOLTS 8 8 8 8
ASSY 19X2284 - CM81 DC COM 4 4 4 4 ATC CONNECTION
E W1 ON 5 5 5 5 K5 CONFIGURATION
TIP SENSE 6 6 6 6 J34 P34 (STANDARD)
RUN/SET 7 7 7 7 CONTACTOR ON
PRESS GOOD 8 8 8 8 +18V (78) 11
9 9 PIP RTN 1 1 PIP SOL2
INV ON D13 OVERTEMP 9 9 PIP 2 2 (79) 22 A B
CSR 10 10 10 10
3 3 55 T6
GAS ON 11 11 11 11 K4 11 15
DRAG ON D25 DC OK 12 12 12 12 TORCH SW RTN 4
5
4 (80)
5 (81)
77
44
OVTEMP 13 13 13 13 SOLENOID ON TORCH SW 6 PRI
AC OK 14 14 14 14 6 33 TORCH
SW ON D33 88 SW
TORCH SW 15 15 15 15
TORCH SW RTN 16 16 16 16 ATC MALE
+12V 17 17 17 17 SEC
POT HIGH 18 18 18 18 CONNECTOR
POT WIPER 19 19 19 19 J23 6 10
POT LOW 20 20 20 20 28VAC A 1 ATC RECEIVER
GATE DRIVE B RTN 21 21 21 21 GND 2 TEST
GATE DRIVE B 22 22 22 22 28VAC B 3 CONN
GATE DRIVE A RTN 23 23 23 23 FACTORY INSTALLED OPTIONAL
GATE DRIVE A 24 24 24 24 SOL1 TORCH MOUNTED GAS SOLENOID
- OUT SENSE 25 25 25 25 A B
CURRENT SENSE 26 26 26 26
CURRENT SENSE 27 27 27 27 K4 J24 P24 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, SOLENOID
29 29 (RESETABLE) 1 1 (8)
CURRENT SENSE RTN 29 29 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
F ARC HOLD 32 32 32 32 PRESS GOOD 4 4
33 33 (12) PRESSURE
ISENSE 33 33 5 5
34 34 34 34 MAIN BOARD 6 6 (13) SWITCH
35 35 35 35 ASSY 19X1930 (400V) 7 7 PS1
TIP VOLTS 36 36 36 36 K5 8 8 CLOSED WHEN
EXTENDER
ASSY 19X2228 (415V) PRESSURE OK
ASSY 19X1775 ASSY 19X1929 (460V)
W1
MAIN
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

Art # A-07152 1 2 3 4 5

APPENDIX A-8 Manual 0-2852

 6 7 8 9 10

TABLE 1 COMP DESCRIPTION LOCATION

19X1930 19X2228 19X1929 F1 SEE CHART 1 B2
400V 415V 460V F2 0.9A, (RESETABLE) F3
L1 OUTPUT INDUCTOR D7
R78 ZERO-OHM XXXXX XXXXX
M1 FAN, 4.5" 220VAC B1
115X465-2
M2 FAN, 4.5" 220VAC C1
R29 XXXXX ZERO-OHM ZERO-OHM
PS1 PRESSURE SWITCH F4
115X465-2 115X465-2
SOL1 GAS SOLENOID F4 A
R30 XXXXX XXXXX XXXXX
SW1 SWITCH, ON/OFF C1
SW2 SWITCH, RUN/SET/RAR C1
F1 4/10, 500V 4/10, 500V 1/4A, 500V
T5 MAIN TRANSFORMER D4
21X186 21X186 21X183
TS1 TEMP. SENSOR, IGBT HEATSINK D1
TS2 TEMP. SENSOR, INDUCTOR E1
W1 MAIN CONTACTOR F4

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

OPTIONAL AUTOMATION INTERFACE CONNECTIONS B

* PLUGS INTO J27

ON MAIN BOARD ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
(LED PCB 19X1604)

J14 P14 P3 J3 J4 P4 J2
(47)
1
2
1
2
1
2 (48)
1
2
1
2
20
19
20
19
1
2
+
TORCH SWITCH
AC
3 3 3 (49)
3 3 18
17
18
17
3 -
4 4 4 4
5 5 5 16 16 5
TEMP 6 6 6 15 15 6 OK TO MOVE
7 7 7 19X2041 14 14 7
8 8 8 OPTIONAL 13 13 8
GAS AUTOMATION 12
11
12
11
9
10
+ DIVIDED OUTPUT
INTERFACE
DC 10 10 11
12
-
9 9
8 8 13
7 7 14 REMOTE CURRENT CONTROL
ADAPTER HARNESS USED P1 J1 6 6 15
WHEN REMOTE CURRENT (CSR)
(51)1 1 CSR 5 5 16
CONTROL IS USED WITH (52)2 2 DC COMMON 4 4 17 DC COMMON C
AUTOMATION (TIP) 3
4
3 +12VDC
4 TIP
3 3 18
19
+
2 2 C&G
(REPLACES CONNECTIONS
FROM J27 TO J14)
(TS2)
(TS1) 5
6
5 TORCH SW - 1
6 TORCH SW +
1 20
21
-
(NEG) 7 7 22
8 8 Vo 23
9 9 ARC HOLD 24 } OHMIC SENSE RELAY
25 ARC HOLD
26 ARC HOLD RETURN
CPC
HOUSING
(56) 4 (+)
(57) 3 (-) } TORCH SWITCH
(58) 14
(59) 12 } OK TO MOVE
(60) 6 (+)
OUTPUT INDUCTOR (61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
(64) 7 (-) } ARC VOLTS (C&G)

L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)

(E35)

(E62)
(CSR) (NEG) T
E65 E49 E45 E35 E32 E61 E3 E1 O
E62 E43 E64 R
TIP PILOT CSR Vo C
H
CURRENT
SENSE

JUMPER
E37 E58 E36 E57 (E58)
WORK E

(C1) E58 E62

(MODE SW)
RAR OFF
OUTPUT DIODE OUTPUT DIODE
ASSEMBLY
E34A ASSEMBLY
E34B (52)
1 J1
(51) 2
19X1757 E39A 19X1757 E39B J40 P40
(14)
+12VDC 1 1 1
(15)
DC COM 2 2 2
E50B 3 3 (46)
E50A 4 4 (17)
3
E48A E48B CSR 5 5 5
6 6
7 7 (18)
E53A E53B ISENSE 8 8 8
E54A E54B J28 PILOT BOARD
CHASSIS GND ASSY 19X2157
E63 THRU SCREW TERMINAL
E56A E56B
E60A E60B Rev Revisions By Date PCB No:
AJ ECO B028 RS 01/09/06
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2 Assy No:
F
AK ECO B016 RWH 01/27/06 WEST LEBANON, NH 03784 Scale Supersedes
DC COMMON DC COMMON 603-298-5711
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION.
05/07/03
Not For Release, Reproduction, or Distribution without Written Consent.
POWER OUTPUT BOARD ASSY 19X1914 Drawn: References
NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. D.Lilja
Capacitors are in Microfarads (UF) Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, January 27, 2006
CM81/101 400/415/460V SYSTEM D 42X1135
6 7 8 9 10 Art # A-07152

Manual 0-2852 A-9 APPENDIX

 APPENDIX 8: SYSTEM SCHEMATIC, 600V UNITS

1 2 3 4 5
E6
E8
L1 W1 E12A
(1)
E17A GATE
E5 14 13 12 DRIVE J3A P3A
1 1
E13
600VAC L2 W1 2 2
(2) E18 28
3 PHASE 23 E9A
A INPUT 24 27
25 E11A
GATE
E14 DRIVE
1
J7A P7A
L3 W1 E16
(3) E19A 1 1
INPUT DIODE
ASSY 19X2073 E21A 76542 2 2

IGBT BOARD
ASSY 19X1815
E33 E1 E2 E3
E22
E12B
CHASSIS E7 GATE
(FILTERING) E17B 14 13 12
GND DRIVE J3B P3B
1 1
(4) P11 J11
1 1
2 2 K1 2 2
K1 28
(5) 3 3
4 4 23 E9B
B R29 E15 24 27
25 E11B
GATE
(0 ohm) DRIVE
F1 T1 E4 1 J7B P7B
M1
E19B 1 1
FAN1 (3/10A 600V) E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 K2 E23
3 3 IGBT BOARD
(6) 4 4 ASSY 19X1815
5 5 28VAC B 28VAC A
(6)
6 6
E30
230V
M2
FAN2 J26 P26
1 1
P18 J18 2 2
1 1 J31 P31
28VAC B (21) 2 2 1 1
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 J30 P30
6 6 28VAC B TO BIAS SUPPLY
C ON/OFF SW (25) 1 1
(26) 7 7 2 2
SW1 8 8
RUN J25 P25
1 1
MODE SW SET
+12VDC
2 2
(46) K1
RAR OFF
(PILOT PCB)
(F9) SW2 INRUSH
+18V

K2 E5 (TS2)

FAN E6 (TS1)
CURRENT ADJUST:
20 - 80 FOR CM101 J14 P14 P27 J27
20 - 60 FOR CM81 1 1
(35)
1 1 POT HIGH
E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
AC 4 4
(38)
4 4 +12V E27
(39)
CURRENT 5 5 (40) 5 5 AC
TEMP 6 6 6 6 GAS MAIN TRANSFORMER
CONTROL/ 7 7
(41)
7 7 OVERTEMP
(42)
LED PCB GAS
8 8 8 8 DC E32 T5
D 19X1604 CURRENT
DC SENSE
PRI

SEC

P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
NTC 4 4
TEMP
PRI

SEC

t TS1
P32 J32
1 1
INDUCTOR 2 2 E52 E47
TEMP
J33 P33 P39 J39
-OUT SENSE (70)
TS2 1 1 (71) 1 1
DC COM 2 2 (72) 2 2
LOGIC TIP SENSE 3 3 (73) 3 3
P1 P13 J12 J43 +12VDC4 4 4 4
ASSY 19X1913 - CM101 (74)
+12VDC 1 1 1 1 CSR5 5 (75) 5 5
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V I SENSE6 6 6 6
ASSY 19X1932 - CM81 DC COM 3 3 3 3 7 7 (77) 7 7
ASSY 19X2284 - CM81 DC COM 4 4 4 4 TIP VOLTS 8 8 8 8
ATC CONNECTION
E W1 ON 5 5 5 5 K5
CONFIGURATION
TIP SENSE 6 6 6 6
RUN/SET 7 7 7 7 CONTACTOR ON J34 P34 (STANDARD)
PRESS GOOD 8 8 8 8 +18V (78) 1 1
9 9 PIP RTN 1 1 PIP SOL2
INV ON D13 OVERTEMP 9 9 PIP 2 2 (79) 2 2
CSR 10 10 10 10 A B T6
GAS ON 11 11 11 11 3 3 5 5 11 15
K4 TORCH SW RTN 4 4 (80) 7 7
DRAG ON D25 DC OK 12 12 12 12
13 13 5 5 (81) 4 4 TORCH
OVTEMP 13 13 SOLENOID ON TORCH SW 6 6 3 3 PRI
SW ON AC OK 14 14 14 14 SW
D33 15 15 8 8
TORCH SW 15 15 ATC MALE
TORCH SW RTN 16 16 16 16 CONNECTOR
+12V 17 17 17 17 SEC
POT HIGH 18 18 18 18 ATC RECEIVER
POT WIPER 19 19 19 19 J23 6 10
POT LOW 20 20 20 20 28VAC A 1
GATE DRIVE B RTN 21 21 21 21 GND 2 TEST
GATE DRIVE B 22 22 22 22 28VAC B 3 CONN
23 23 FACTORY INSTALLED OPTIONAL
GATE DRIVE A RTN 23 23
GATE DRIVE A 24 24 24 24 SOL1 TORCH MOUNTED GAS SOLENOID
- OUT SENSE 25 25 25 25 A B
CURRENT SENSE 26 26 26 26
CURRENT SENSE 27 27 27 27 K4 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, J24 P24
(8) SOLENOID
CURRENT SENSE RTN 29 29 29 29 (RESETABLE) 1 1 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
F 32
ISENSE 33
32
33
32
33
32
33
MAIN BOARD PRESS GOOD 4
5
4
5
(12)
(13) PRESSURE
34
35
34
35
34
35
34
35 ASSY 19X1931 6
7
6
7 PS1 SWITCH
TIP VOLTS 36 36 36 36 K5 8 8
CLOSED WHEN
EXTENDER PRESSURE OK
ASSY 19X1775
W1
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2

Art # A-07151 1 2 3 4 5

APPENDIX A-10 Manual 0-2852

 6 7 8 9 10

COMP DESCRIPTION LOCATION

F1 FUSE, 3/10A 600V FNQ-R B2
F2 FUSE, 0.9A, RESETABLE F3
L1 OUTPUT INDUCTOR D7
M1 FAN, 4.5" 220VAC B1
M2 FAN, 4.5" 220VAC C1
PS1 PRESSURE SWITCH F4
SOL1 GAS SOLENOID F4 A
SW1 SWITCH, ON/OFF C1
SW2 SWITCH, RUN/SET/RAR C1
T5 MAIN TRANSFORMER D4
TS1 TEMP. SENSOR, IGBT HEATSINK D1
TS2 TEMP. SENSOR, INDUCTOR E1
W1 MAIN CONTACTOR F4

NOTES: UNLESS OTHERWISE SPECIFIED -

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY

OPTIONAL AUTOMATION INTERFACE CONNECTIONS B

* PLUGS INTO J27

ON MAIN BOARD ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
(LED PCB 19X1604)

J14 P14 P3 J3
(47)
1 1 1 1 1
2 2 2 (48) 2 2
(49) J2
AC
3 3 3 3 3 J4 P4
4 4 4
5 5 5 20
19
20
19
1
2
+
TORCH SWITCH
TEMP 6
7
6
7
6
7 19X2041 18 18 3 -
8 17 17 4
8 8 OPTIONAL 16 16 5
GAS
AUTOMATION 15 15 6 OK TO MOVE
INTERFACE 14 14 7
DC 13 13 8
12
11
12
11
9
10
+ DIVIDED OUTPUT
ADAPTER HARNESS USED
(CSR)
P1 J1 10 10 11
12
-
WHEN REMOTE CURRENT 9 9
(51) 1 1 CSR
2 DC COMMON 8 8 13
CONTROL IS USED WITH (52) 2 7 7 14 REMOTE CURRENT CONTROL C
AUTOMATION 3 3 +12VDC 6 6 15
(REPLACES CONNECTIONS (TS2) 4 4 16
(TS1) 5 5 TORCH SW - 5 5
17 DC COMMON
FROM J27 TO J14) 6 6 TORCH SW + 4 4
(NEG) 7 7 3 3 18
19
+
2 2 C&G
8 8 Vo
1 1 20 -
CPC
HOUSING

(56) 4 (+)
(57) 3 (-) } TORCH SWITCH
(58) 14
(59) 12 } OK TO MOVE
(60) 6 (+)
(61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
OUTPUT INDUCTOR (64) 7 (-) } ARC VOLTS (C&G)

L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)

(E35)

(E62)
(CSR) (NEG) T
E49 E45 E35 E61 E3 E1 O
E62 E43 E32 R
PILOT E64 CSR Vo C
H
CURRENT
SENSE

JUMPER
E37 E58 E36 E57 (E58)
WORK E

(C1)
E58 E62
(MODE SW)
RAR OFF
OUTPUT DIODE OUTPUT DIODE E34B (52)
ASSEMBLY E34A ASSEMBLY 1 J1
(51)
19X1757 19X1757 2
E39A E39B J40 P40
(14)
+12VDC 1 1 1
(15)
DC COM 2 2 2
E50A E50B 3 3 (46)
3
4 4 (17)
E48A E48B CSR 5 5 5
6 6
7 7 (18)
E53A E53B ISENSE 8 8 8
E54A E54B J28 PILOT BOARD
ASSY 19X2157
CHASSIS GND
E63 THRU SCREW TERMINAL
E56A E56B
E60A E60B Rev Revisions By Date PCB No:
AA ECO 101136 (REL) DLL 05/07/03
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2
Assy No: F
AB ECO 101314 HAS 02/11/04 WEST LEBANON, NH 03784 Scale Supersedes
DC COMMON DC COMMON 603-298-5711
AC ECO 101429 HAS 06/09/04
Date:
AD ECO 101614 HAS 03/22/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03
POWER OUTPUT BOARD ASSY 19X1914 AE ECO 101664 HAS 03/24/05 Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
AF ECO B028 RS 01/09/06 NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. D.Lilja
AG ECO B016 RWH 01/27/06 Capacitors are in Microfarads (UF) Chk: App: Sheet
AH ECO B077 RWH 07/31/06 1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, January 27, 2006
CM81/101 600V 3PH SYSTEM D 42X1134
6 7 8 9 10 Art # A-07151

Manual 0-2852 A-11 APPENDIX

 APPENDIX 9: Publication History

Date Revision Comments

6/3/2003 -- Manual released.

7/18/03 -- Added 600V units per ECO 100979.
12/5/03 -- Updated w/ new schematics & input from Sales/Tech Service
1/5/04 -- Updated gas pressures & flows.
1/16/04 -- Updated warranty statement & system schematics, misc minor edits.
2/9/04 -- Deleted system schematics.
2/12/04 -- Inserted corrected system schematics.
6/23/04 -- Updated system schematics per ECO 101429.
9/21/05 -- Updated system schematics and art work for new work-lead clamp
2/17/06 -- Updated system schematics per ECO B033.
9/29/06 AA.01 Added Patent information and new Rev. AA.01. Updated format of manual.
3/14/07 AB.01 Updated 600 volt schematic to show new fuse.

NOTE
Thermal Dynamics uses the manual cover date to indicate manual revision level.

APPENDIX A-12 Manual 0-2852

 Global Customer Service Contact Information

Thermadyne USA Thermadyne Asia Sdn Bhd

2800 Airport Road Lot 151, Jalan Industri 3/5A
Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang
Telephone: (940) 566-2000 48000 Rawang Selangor Darul Ehsan
800-426-1888 West Malaysia
Fax: 800-535-0557 Telephone: 603+ 6092 2988
Email: [email protected] Fax : 603+ 6092 1085

Thermadyne Victor Brasil Cigweld, Australia

Avenida Brasil 71 Gower Street
13629-Cordovil Preston, Victoria
Rio de Janeiro, Brazil 21012-351 Australia, 3072
Telephone: 55-21-2485-8998 Telephone: 61-3-9474-7400
Fax: 55-21-2-485-8735 Fax: 61-3-9474-7510

Thermadyne Canada Thermadyne Italy

2070 Wyecroft Road OCIM, S.r.L.
Oakville, Ontario Via Benaco, 3
Canada, L6L5V6 20098 S. Giuliano
Telephone: (905)-827-1111 Milan, Italy
Fax: 905-827-3648 Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne Chile
Piloto Lazo #90 Thermadyne South Africa
Cerrillos 209 Risi Ave.
Santiago, Chile 7278-654 Linmeyer
Telephone: 56-2-557-2465 Johannesberg, 2197
Fax: 56-2-557-5349 South Africa
Tel: (27) 11-917 3600
Thermadyne Europe Fax: (27) 11-917 8580
Europe Building
Chorley North Industrial Park Thermadyne International
Chorley, Lancashire 2070 Wyecroft Road
England, PR6 7Bx Oakville, Ontario
Telephone: 44-1257-261755 Canada, L6L5V6
Fax: 44-1257-224800 Telephone: (905)-827-9777
Fax: 905-827-9797
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: [email protected]
www.thermadyne.com