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Thermal Dynamics CUTMASTER 151 Operating Manual

Automated plasma cutting system
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151
SL100SV
Operating Manual
CUTMASTER
AUTOMATED
PLASMA CUTTING SYSTEM
PLASMA CUTTING
MACHINE TORCH
Art # A-04611
Rev. AF.01
Date: April 2, 2007
Operating Features:
™
Manual # 0-4691

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Summary of Contents for Thermal Dynamics CUTMASTER 151

  • Page 1 ™ CUTMASTER AUTOMATED PLASMA CUTTING SYSTEM SL100SV PLASMA CUTTING MACHINE TORCH Art # A-04611 Operating Manual Rev. AF.01 Date: April 2, 2007 Manual # 0-4691 Operating Features:...
  • Page 2 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.
  • Page 3 Automated CutMaster™ 151 Power Supply SL100 Machine Torch Operating Manual Number 0-4691 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 2004, 2005, 2006, 2007 by Thermal Dynamics Corporation All rights reserved.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-3 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-4 1.06 Documents De Reference ................
  • Page 6 TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................... 5-1 5.01 General Maintenance ..................5-1 5.02 Common Faults .................... 5-5 5.03 Basic Troubleshooting ................... 5-6 5.04 Advanced Troubleshooting Guide - General Information ....... 5-11 5.05 Main Input and Internal Power Problems ............5-13 5.06 Pilot Arc Problems ..................
  • Page 7 TABLE OF CONTENTS (continued) APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33) ..........A-10 APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36) ..........A-11 APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43) ..........A-12 APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50) ..........A-13 APPENDIX 14: AUTOMATION INTERFACE PC BOARD WIRING LAYOUT ............

  • Page 9: General Information

    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. Keep Throughout this manual, notes, cautions, and warnings your head out of the welding fume plume.
  • Page 10 NOISE ELECTRIC SHOCK Noise can cause permanent hearing loss. Plasma arc processes Electric Shock can injure or kill. The plasma arc process uses can cause noise levels to exceed safe limits. You must protect and produces high voltage electrical energy. This electric en- your ears from loud noise to prevent permanent loss of hear- ergy can cause severe or fatal shock to the operator or others ing.

  • Page 11: Publications

    1.03 Publications 14. American Welding Society Standard AWSF4.1, RECOM- MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND Refer to the following standards or their latest revisions for PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, more information: obtainable from the American Welding Society, 550 N.W.

  • Page 12: Precautions De Securite Importantes

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

  • Page 13: Documents De Reference

    • Utilisez la nuance de lentille qui est suggèrée dans le rec- ommendation qui suivent ANSI/ASC Z49.1: INCENDIE ET EXPLOSION Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé Moins de 300* à...
  • Page 14 14. Norme AWSF4.1 de l’Association Américaine de Soudage, 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PRO- RECOMMANDATIONS DE PRATIQUES SURES POUR LA TECTION DES YEUX ET DU VISAGE AU TRAVAIL ET PRÉPARATION À LA COUPE ET AU SOUDAGE DE DANS LES ECOLES, disponible de l’Institut Américain CONTENEURS ET TUYAUX AYANT RENFERMÉ...

  • Page 15: Declaration Of Conformity

    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.

  • Page 16: Statement Of Warranty

    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.

  • Page 17: Section 2: Specifications

    This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynam- ics Automated CutMaster 151 Plasma Cutting System. Servicing of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

  • Page 18: Input Wiring Specifications

    50/60 50/60 21.1 50/60 15.6 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code CE CutMaster 151 Input Wiring Specifications Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq.

  • Page 19: Power Supply Features

    Control Panel Torch Leads Receptacle Art # A-03578 Work Cable and Clamp Gas Pressure Regulator / Filter Assembly CPC Connector for Thermal Dynamics CNC Controller Gas Inlet Port Knockout for Alternate CNC Controller Wire Harness Gas Pressure Gauge Art # A-04214...

  • Page 20: Power Supply Options And Accessories

    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.

  • Page 21: Torch Specifications

    35' / 10.6 m, with ATC Connector 50' / 15.2 m, with ATC Connector Plasma Power Supply Used With: Thermal Dynamics CutMaster 51, CutMaster 81, CutMaster 101, CutMaster 151 NOTE Torch duty cycle is greater than power supply duty cycle.

  • Page 22: Torch Options And Accessories

    B. Torch Connector Dimensions 8.5" / 216 mm 5.375" / 137 mm 1.9" / 50 mm Art # A-04056 C. Torch Parts Start Cartridge, Electrode, Tip, Shield Cup Body, Shield Cap D. Parts - In - Place (PIP) Torch Head has built - in switch 12 vdc circuit rating E.

  • Page 23: Introduction To Plasma

    2.08 Introduction to Plasma A. Plasma Gas Flow Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.
  • Page 24 C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work. D. Main Cutting Arc DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead.

  • Page 25: Section 3: Installation

    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.

  • Page 26: Primary Input Power Connections

    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.
  • Page 27 C. Connections to 400Volt or 460-Volt Single - Phase Power The 400-Volt and 460-Volt Power Supplies will accept Single-Phase input power with a change of input power cable. Remove the Power Supply cover per section 5.09-A. 2. Disconnect the original input power cable from the main input contactor and the chassis ground connection. Loosen the through-hole protector on the back panel of the power supply.

  • Page 28: Gas Connections

    3.04 Gas Connections A. Connecting Gas Supply to Unit Use only compressed air with this power supply. An in-line pneumatic dryer & evaporator type air filter, capable of filtering to at least 5 microns, is required when using air from a compressor.
  • Page 29 B. Optional Air Filters 1. Connect the Filter as illustrated. Use only Synflex or equivalent grade hose. The illustrations show typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

  • Page 30: Torch Connections

    3.05 Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 Torch (with ATC connector) to this power supply. Maximum torch leads length is 50 feet / 15.2 m. WARNING Disconnect primary power at the source before connecting the torch.
  • Page 31 B. Check Air Quality To test the quality of air: Put the ON / OFF switch in the ON (up) position. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position. 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! Art # A-04254 Manual 0-4691...

  • Page 32: Torch Installation

    3.06 Torch Installation WARNING Disconnect primary power at the source before disassembling the torch or torch leads. The machine torch includes a positioning tube with rack and pinch block assembly. 1. Mount the torch assembly on the cutting table. 2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece. Pinch Block Assembly Square...

  • Page 33: Torch Parts Selection

    3.07 Torch Parts Selection Check the torch for proper consumable parts. The parts supplied in the torch may not be correct for the operator's chosen amperage level. The torch parts must correspond with the type of operation. Art # A-04173 Torch Head Electrode Start Cartridge...

  • Page 34: Power Supply Connection To Sc-11 Standoff Control

    The power supply includes an Automation Interface PC Board connected to a CPC connector on the power supply rear panel. For connection to the Thermal Dynamics SC-11 Standoff Control, align and connect the cable from the Standoff Control to the CPC connector.

  • Page 35: Power Supply Connection To Alternate Standoff Control

    Carefully open the lower knockout (below the factory-installed CNC connector) on the Power Supply rear panel. Knockout for Alternate CNC Controller CPC Connector for Thermal Dynamics CNC Controller Art # A-04178 Install a customer-supplied through-hole protector ('Strain Relief') in the lower knockout hole.
  • Page 36 Connect the wire harness from the alternate CNC Control to the 20-position terminal strip (labeled 'J2') on the Automation Interface PC Board. Refer to the illustration. a. For divided voltage output, connect to terminals J2-11 (negative) and J2-9 (positive) on the Interface PC Board.. b.

  • Page 37: Automation Interface Pc Board Set-Up

    The Automation Interface PC board includes switches that must be set to adapt the Interface Board to the automation system being used. NOTE The switches are factory-set for the Thermal Dynamics SC-11 Standoff Control. For operation with any other CNC equipment, refer to the CNC system documents to determine the division factor the CNC system requires. Proceed as follows: Set the interface control board switches as indicated in the appropriate chart in the Appendix pages.

  • Page 38: Optional Remote Current Control Harness Installation

    3.11 Optional Remote Current Control Harness Installation Locate the power supply Pot/LED Board just inside the power supply front panel. Pot / LED Board Art # A-03964 Disconnect and remove the wire harness between the Pot/LED Board and receptacle J22 on the Main PC Board. Keep the harness for possible future use.

  • Page 39: Section 4: Operation

    SECTION 4: OPERATION 4.01 Product Features A. Power Supply Front Panel Controls and Indicators AC Indicator Steady light indicates power supply is ready for A) Output Current Control operation. Blinking light indicates unit is in pro- Sets the desired output current. At output settings tective interlock mode.

  • Page 40: Preparations For Operating

    Power Supply (80 amps maximum). B. Torch Connection Check that the torch is properly connected. Only Thermal Dynamics model SL100 Torches may be connected to this Power Supply. C. Check Primary Input Power Source 1.
  • Page 41 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. Art # 04255 Manual 0-4691 OPERATION...
  • Page 42 Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow. Art # A-04254 Adjust gas pressure per the settings chart. 65 - 75 psi / 4.5 - 5.2 bar Pressure Control Knob CutMaster 151 Gas Pressure Settings Leads Up to 25' Over 25' Length (7.6 m)
  • Page 43 H. Select Current Output Level Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops. Set the current output level, 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.

  • Page 44: Selection, Inspection And Replacement Of Consumable Torch Parts

    4.03 Selection, Inspection and Replacement of Consumable Torch Parts The type of operation to be done determines the torch parts to be used. Change the torch parts for a different operation as follows: WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
  • Page 45 2. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary. Worn Tip Good Tip A-03406 Tip Wear 3. Remove the start cartridge. Check for excessive wear, plugged gas holes, or discoloration. Check the lower end fitting for free motion.

  • Page 46: Cut Quality

    4.04 Cut Quality NOTES Cut quality depends heavily on setup and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability. Cut quality requirements differ depending on application. For instance, nitride build - up and bevel angle may be major factors when the surface will be welded after cutting.

  • Page 47: General Cutting Information

    4.05 General Cutting Information WARNINGS Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

  • Page 48: Torch Operation

    E. Dross When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. “Top dross” is nor- mally very easy to remove and can often be wiped off with a welding glove.
  • Page 49 B. Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate. The arc can be one of the following: Straight Arc A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

  • Page 50: Cutting Parameters

    C. Piercing With Machine Torch To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

  • Page 51: Cutting Specifications

    Cut Quality on Various Materials and 4.08 Cutting Specifications Thicknesses Torch Specifications For The following table defines the cut quality on various mate- CutMaster 101 Power Supplies rials and thicknesses: Cutting Range Material Most Metals Cut Quality on Various Materials Up to 1 inch / 25.4 mm Material...

  • Page 52: Cutting Speed Chart: Mild Steel, Sl100 Torch With Exposed Tip

    4.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip Ohmic Clip 9-8224 Tips: Shield Shield Cap, Deflector Cup Body, 9-8237 9-8243 Electrode 9-8205 Starter 9-8215 9-8206 Cartridge 9-8208 9-8213 50-55A 9-8209 9-8210 9-8231 Art # A-04671 9-8211 100A 9-8212 OPERATION 4-14...
  • Page 53 Material: Mild Steel Table: Dry Torch: SL100 with Exposed Tip and Deflector Gas: Compressed Air Power Supply: CutMaster 151 Automated Plasma Pierce Stand-off Recommended Material thickness Pierce Height Current Press.* Time voltage Height Travel Speed Cat. # Amps Volts mm/min 0.036...

  • Page 54: Cutting Speed Chart: Stainless Steel, Sl100 Torch With Exposed Tip

    4.10 Cutting Speed Chart: Stainless Steel, SL100 Torch with Exposed Tip Ohmic Clip 9-8224 Tips: Shield Cup Body, Shield Cap, Deflector 9-8237 9-8243 Electrode 9-8205 Starter 9-8215 9-8206 Cartridge 9-8208 9-8213 50-55A 9-8209 9-8210 9-8231 Art # A-04671 9-8211 100A 9-8212 OPERATION 4-16...
  • Page 55 Material: Stainless Steel Torch: SL100 with Exposed Tip and Deflector Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Current Plasma Pierce Stand-off Recommended Material thickness Pierce Height Press.* Time voltage Height Travel Speed Cat. # Amps Volts mm/min 0.038...

  • Page 56: Cutting Speed Chart: Aluminum, Sl100 Torch With Exposed Tip

    4.11 Cutting Speed Chart: Aluminum, SL100 Torch with Exposed Tip Ohmic Clip 9-8224 Tips: Shield Cup Body, Shield Cap, Deflector 9-8237 9-8243 Electrode 9-8205 Starter 9-8215 9-8206 Cartridge 9-8208 9-8213 50-55A 9-8209 9-8210 9-8231 Art # A-04671 9-8211 100A 9-8212 OPERATION 4-18 Manual 0-4691...
  • Page 57 Material: Aluminum Torch: SL100 with Exposed Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Plasma Pierce Stand-off Recommended Material thickness Pierce Height Current Press.* Time voltage Height Travel Speed Cat. # Amps Volts mm/min 0.040 8-8208 0.00 0.19 4.80...

  • Page 58: Cutting Speed Chart: Mild Steel, Sl100 Torch With Shielded Tip

    4.12 Cutting Speed Chart: Mild Steel, SL100 Torch with Shielded Tip Ohmic Clip 9-8224 Tip: Shield Cup Body, Shield Cap, Machine 9-8237 40A 9-8245 9-8205 9-8206 9-8208 Tips: Shield Shield Cap, Machine Cup Body, 50-60A 9-8238 9-8237 50-55A 9-8209 Electrode Starter 9-8215 9-8210...
  • Page 59 Material: Mild Steel Torch: SL100 with Shielded Tip Table: Dry Gas: Compressed Air Power Supply: CutMaster 151 Automated Torch Shield Plasma Pierce Stand-off Recommended Material thickness Pierce Height Current Press.* Time voltage Height Travel speed Cat. # Cat. # Amps...

  • Page 60: Cutting Speed Chart: Stainless Steel, Sl100 Torch With Shielded Tip

    4.13 Cutting Speed Chart: Stainless Steel, SL100 Torch with Shielded Tip Ohmic Clip 9-8224 Tip: Shield Cup Body, Shield Cap, Machine 9-8237 40A 9-8245 9-8205 9-8206 9-8208 Tips: Shield Shield Cap, Machine Cup Body, 50-60A 9-8238 9-8237 50-55A 9-8209 Electrode Starter 9-8215 9-8210...
  • Page 61 Material: Stainless Steel Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Current Pierce Height Press.* Time voltage Height Travel Speed Cat. # Cat. # Amps...

  • Page 62: Cutting Speed Chart: Aluminum, Sl100 Torch With Shielded Tip

    4.14 Cutting Speed Chart: Aluminum, SL100 Torch with Shielded Tip Ohmic Clip 9-8224 Tip: Shield Cup Body, Shield Cap, Machine 9-8237 40A 9-8245 9-8205 9-8206 9-8208 Tips: Shield Shield Cap, Machine Cup Body, 50-60A 9-8238 9-8237 50-55A 9-8209 Electrode Starter 9-8215 9-8210 Cartridge...
  • Page 63 Material: Aluminum Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Pierce Height Current Press.* Time voltage Height Travel Speed Cat. # Cat. # Amps Volts mm/min 0.04...

  • Page 64: Operator's Custom Cutting Speed Charts

    Shield Cap, Deflector Electrode Start Cartridge Shield Cup Body 9-8243 9-8215 9-8213 9-8237 Material: Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Current Pierce Height Press.*...
  • Page 65 Shield Cap, Deflector Electrode Start Cartridge Shield Cup Body 9-8243 9-8215 9-8213 9-8237 Material: Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Current Pierce Height Press.*...
  • Page 66 Shield Cap, Deflector Electrode Start Cartridge Shield Cup Body 9-8243 9-8215 9-8213 9-8237 Material: Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Current Pierce Height Press.*...
  • Page 67 Shield Cap, Deflector Electrode Start Cartridge Shield Cup Body 9-8243 9-8215 9-8213 9-8237 Material: Torch: SL100 with Shielded Tip Table: Dry Power Supply: CutMaster 151 Automated Gas: Compressed Air Torch Shield Plasma Pierce Stand-off Recommended Material thickness Current Pierce Height Press.*...
  • Page 68 This Page Left Blank OPERATION 4-30 Manual 0-4691...

  • Page 69: Service

    SECTION 5: SERVICE 5.01 General Maintenance A . 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.
  • Page 70 B. Single-Stage Filter Element Replacement These instructions apply to power supplies where the 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. 1.
  • Page 71 C. 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.
  • Page 72 D. Cleaning Torch Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch. WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads.

  • Page 73: Common Faults

    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 Incorrect gas pressure 4. Short Torch Parts Life a. Oil or moisture in air source b.

  • Page 74: Basic Troubleshooting

    5.03 Basic Troubleshooting 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. Follow all instructions as listed and complete each section in the order presented.
  • Page 75 6. Unit internal fuse blown or loose a. If blown, double-check input voltage and replace fuse per Section 5.09-C. 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. B.
  • Page 76 G . Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator 1. Start cartridge missing from torch a. Shut off power supply. Remove shield cup, install start cartridge. Reinstall torch tip and shield cup. Turn power supply ON / OFF switch to ON (up).
  • Page 77 I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC indicator 1. System is in protective interlock mode. (Torch switch in CNC Controller in ON position while turning on power supply ON / OFF switch.) a.
  • Page 78 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; replace as needed. 3. Work cable connection is poor a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece or cutting table. 4.

  • Page 79: Advanced Troubleshooting Guide - General Information

    5.04 Advanced Troubleshooting Guide - General Information 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. General Information This Section covers advanced troubleshooting, which requires power supply disassembly and live measurements.
  • Page 80 C. Main Input and Internal Power Tests 1. Connect main AC power to the unit. 2. Set the Power Supply ON/OFF switch to ON (up) and note the following: • AC indicator steady ON • Gas solenoid energizes (clicks) • Main PCB Relay energizes, pulling in main input contactor (W1) •...

  • Page 81: Main Input And Internal Power Problems

    5.05 Main Input and Internal Power Problems A. Opening Power Supply Enclosure The cover of the Power Supply must be removed for access to input power connections and test points. WARNING Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torch and leads assemblies.
  • Page 82 Locate your symptom below: A. Main power line fuses blow as soon as main disconnect is closed 1. Input power cable installed incorrectly or defective power cord. a. Refer to Subsection 5.07 and check that the input power cable is not defective or installed incorrectly. 2.
  • Page 83 Fuse Secondary Transformer Logic Board Not Shown IGBT Module Input Diode (mounts to center chassis) IGBT Module IGBT IGBT Art # A-04640 Main Printed Circuit Board Layout (logic board not shown) 6. Improper input power cable connections inside Power Supply a.
  • Page 84 11. Faulty ON/OFF switch Measure for 28 VAC on the Main PC Board between J18-5 to J18-6. a. If voltage is not present replace the ON/OFF Switch. 12. Faulty Main PC Board Measure for 12 vdc on Main PC Board from TP4 to TP1. a.
  • Page 85 F. Gas flows; AC indicator ON; GAS and DC indicator OFF 1. Gas pressure too low a. Set operating pressure per pressure setting label on power supply. NOTE Minimum pressure for power supply operation is lower than minimum required for torch operation. 2.
  • Page 86 TP10 TP11 Art # A-04641 Logic Board Layout H. 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. SERVICE 5-18 Manual 0-4691...

  • Page 87: Pilot Arc Problems

    I. Gas cycles on and off when power is turned on; AC indicator flashes 1. Shield cup is loose. a. Tighten shield cup by hand. Do not overtighten. 2. Torch tip, electrode, or start cartridge missing a. Turn off power supply. Remove shield cup, install missing parts. 3.
  • Page 88 B. Torch will not pilot; gas flows; AC and Gas indicators ON; TEMP and DC indicators 1. Gas pressure is below torch minimum requirement (Minimum pressure for power supply operation is lower than minimum required for torch operation.) a. Adjust gas pressure per pressure setting label on power supply. 2.
  • Page 89 5. Faulty Logic PC Board a. Check for (±) 12vdc on Main PC Board between J43-9 and TP1. If (±) 12vdc is present, replace Logic PC Board. 6. Faulty Main PC Board a. Check for (±) 0 vdc on Main PC Board between J43-9 and TP1. If (±) 0 vdc is present, replace Main PC Board. 7.
  • Page 90 E. Gas flows; AC indicator and GAS indicators ON; TEMP indicator off; ON; DC indicator off or blinks on/off once. 1. Faulty IGBT or Output Diode Module Assembly(s) a. Check per Subsection 5.08-C; repair as needed. 2. Faulty Main PCB a.
  • Page 91 G. No arc or intermittent arc in torch; Gas flows; AC , GAS , and DC indicators ON; TEMP indica- 1. Gas pressure set incorrectly (too high) a. Reset gas pressure per pressure setting label on power supply. 2. Oil/moisture in air lines a.

  • Page 92: Main Arc Problems

    5.07 Main Arc Problems Locate your symptom below: A. Main cutting arc will not start 1. Work cable not connected. a. Connect work cable. B. No cutting output 1. Torch not properly connected to power supply a. Check that torch leads are properly attached to power supply 2.
  • Page 93 6. Faulty Main PC Board or Logic Board. a. Measure for ±0 vdc at TP2 to TP1 on the Logic Board when attempting to transfer. Refer to Logic Board Layout. • If TP2 goes to 0 vdc replace Output Board. •...
  • Page 94 B. Tube Handle Replacement 1. Remove the power supply cover per Section 5.09-A. 2. Remove the four bolts and star washers securing the tube handles to the base of the unit. 3. Move the input power cable, torch leads and work cable inside the handle, then lift the base of the unit away from the Tube Handle.

  • Page 95: Front Panel Parts Replacement

    5.10 Front Panel Parts Replacement WARNING Disconnect input power at the source and bleed down the system before attempting these procedures. A . Current (A) Control Knob Replacement 1. Turn the control knob fully clockwise and note the location of the pointer on the knob. 2.
  • Page 96 C. RUN / RAPID AUTO RESTART / SET Switch (SW2) Replacement 1. Remove the power supply cover per Section 5.09-A. 2. Disconnect the wires on the rear of the Switch. Note the location of each wire, as shown: Top clip Wire #46 Wire #26 Wire #25...

  • Page 97: Left Side Internal Parts Replacement

    5.11 Left Side Internal Parts Replacement A. Fuse (F1) Replacement 1. Remove the power supply cover per Section 5.09-A. 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.
  • Page 98 B. Main Input Contactor (W1) Replacement 1. Remove the power supply cover per Section 5.09-A. 2. Label all wires connected to the Input Contactor. 3. Disconnect wires to the Input Contactor from the input cable. 4. Disconnect all other wires connected to the Input Contactor. 5.
  • Page 99 C. Logic PC Board Replacement Follow the antistatic instructions provided with the replacement part. The Logic PC Board connects to the Main PC Board through an extender board perpendicular to both boards. 1. Remove the power supply cover per Section 5.09-A. 2.
  • Page 100 7. The thermal pad, provided with the replacement part, is a thin metal pad. Remove any loose protective paper coverings from the pad. NOTE Protective coverings must be removed from the thermal pads. Installing thermal pads with protective coverings in place will cause equipment damage or failure.
  • Page 101 10. Use the hardware removed previously to re-connect wires per the appropriate diagram. Ensure that the star washers are in place between the screws and the wire ring terminals. 400V 415V Units 208/230V Units 460V 600V Copper Strap Input Input Diode Diode (mounts...
  • Page 102 E. IGBT Replacement 1. Note the placement of all wires to the IBGT(s) being replaced. 2. Carefully remove the 3 sets of hardware securing each IGBT PC board being replaced to the IGBT module mounted to thepower supply heat sink. Keep the hardware for re-use. 3.
  • Page 103 9. Secure replacement IGBT PC Board(s) with the hardware removed previously. Ensure that the washers are under the heads of the screws. IGBT Modules IGBT PC Boards Art # A-04643 10. Torque screw(s) to 22 in-lb. (2.5 Nm). NOTE Failure to torque properly will cause component damage. 11.
  • Page 104 E. Main PC Board Replacement Follow the antistatic procedures provided with the replacement part. 1. Remove the power supply cover per Section 5.09-A. 2. Remove the Logic PC Board. 3. Remove the POT/LED PC Board. 4. Disconnect all wire and cable connections to the Main PC Board, including the connections from the three smaller PC Boards.
  • Page 105 F. Input Power Cable Replacement 1. Remove the power supply cover per Section 5.09-A. 2. Locate and label the input power cable connections and disconnect the cable. Connections to To E2 Main PCB To E3 To E1 Input Side Main Contactor Main Contactor Input Side...

  • Page 106: Right Side Internal Parts Replacement

    5.12 Right Side Internal Parts Replacement A. Fan Replacement (M1, M2) 1. Remove the power supply cover per Section 5.09-A. 2. Label, then carefully remove the wiring connectors from the terminals on the Fans. 3. Disconnect the Work Cable from terminal E61 on the Power Output Board. 4.
  • Page 107 B. Work Cable Replacement 1. Remove the cover per Section 5.09-A. 2. Disconnect the Work Cable from the E61 (WORK) terminal on the Power Output PC Board, located on the right side of the unit. 3. Squeeze the top and bottom of the Work Cable Strain Relief and remove from the Front Panel. 4.
  • Page 108 D. Pressure Switch/Solenoid Assembly Replacement The Pressure Switch and Solenoid Valve are one Assembly. Disconnect primary input power and bleed down the system. 1. Remove the power supply cover per Section 5.09-A. 2. Disconnect the following wires: a. Wires #10 and #11 from the Pressure Switch Assembly. b.
  • Page 109 E. Output Diode PC Board Replacement Follow the antistatic procedures in subsection 5.02. 1. Remove cover per subsection 5.04-A. 2. Locate the Output Diode PCB(s) located within the Output Power PC Board on the right side of the power supply. 3.
  • Page 110 9. Connect wires as follows. Output Diodes Output Power Board Art # A-04645 F. Heatsink Shroud Assembly Removal The Heatsink Shroud Assembly must be disengaged for access to either the Main Transformer or the Output Inductor. Follow these steps for access to either component. 1.
  • Page 111 G. Main Transformer Removal and Replacement 1. Disengage the Heatsink Shroud per Paragraph E. 2. Disconnect wires #27 and 32, connected to terminals E27 and E32 on the Main Power PC Board. Pull these wires through the hole in the center chassis. 3.
  • Page 112 Heatsink Shroud Assembly Replacement 1. Pass transformer wires #45 and 49 through the upper hole in the right (rear) edge of the Heatsink Shroud. Pass trans- former wires #47 and 52 through the lower hole. 2. Route wires as follows: a.

  • Page 113: Parts Lists

    The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # CutMaster 151 Automation Power Supply 208 / 230VAC, Single-Phase, 50 / 60Hz, with input power cable 3-1724-1 208 / 230VAC, Single-Phase, 50 / 60Hz, with input power cable, CSA...

  • Page 114: Power Supply Options And Accessories

    6.04 Power Supply Options and Accessories Description Catalog # Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-7500 Bracket, Filter Mounting (not shown) 9-7535 Two-Stage Air Filter Assembly 9-7527 First Stage Cartridge 9-1021 Second Stage Cartridge 9-1022 Single-Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740...

  • Page 115: Power Supply Major External Replacement Parts

    6.05 Power Supply Major External Replacement Parts Item # Description Catalog # Cover with labels 9-8335 Rear Panel (provide data tag information when ordering) For 208/230-Volt Power Supplies 9-8668 For 400-Volt, 415V, 460-Volt, and 600-Volt Power Supplies 9-8322 Tube, roll handle 9-7998 Art # A-03709 NOTE: Illustration may vary slightly from unit.

  • Page 116: Power Supply Front Panel Replacement Parts

    6.06 Power Supply Front Panel Replacement Parts Item# Description Ref. # Catalog # Knob, Fluted, Skirted, 0.250 I.D. 9-8527 On/Off Rocker Switch 8-3258 Run / Rapid Auto Restart / Set Switch 9-1042 Assembly, Pot / LED PC Board 9-8004 for (RoHS) 9-0045 Work Cable, #4 AWG, with Clamp, 20 Ft.

  • Page 117: Rear Panel Replacement Parts

    6.07 Rear Panel Replacement Parts Item # Description Ref. Catalog # Assembly, Filter/Regulator 9-7514 Regulator/Filter Replacement Element 9-4414 Regulator Mounting Bracket 9-7589 Input Power Cable for 208/230-Volt Units 9-8596 for 208/230-Volt CSA Units 9-8665 for 400-Volt Three-Phase units 9-8562 for 400-Volt & 415-Volt CE units 9-8553 for 460-Volt Three-Phase units and 600-Volt Three-Phase units 9-8593...

  • Page 118: Power Supply Left Side Internal Replacement Parts

    6.08 Power Supply Left Side Internal Replacement Parts Item # Description Ref # Catalog # Fuse for 208/230-Volt Power Supplies 9-8588 for 400-Volt & 415-Volt Power Supplies 9-8602 for 460-Volt Power Supplies 9-8583 for 600-Volt Power Supplies 9-8638 Main Input Contactor for 208/230-Volt Power Supplies 9-8587 for 400-Volt, 415-Volt, 460-Volt and 600-Volt Power Supplies...
  • Page 119 Art # A-04514 NOTE: Illustration may vary slightly from unit. Manual 0-4691 PARTS LISTS...

  • Page 120: Right Side Internal Replacement Parts

    6.09 Right Side Internal Replacement Parts Item # Description Ref #. Catalog # Assembly, Pressure Switch/Solenoid Sol1, Ps1 9-8329 Assembly, Pilot Board 9-8337 for (RoHS) 9-0070 Fan, 220V, 115 CFM 9-7687 Assembly, Main Transformer for 208/230-Volt units 9-8345 for 400-Volt & 415-Volt units 9-8347 for 460-Volt units 9-8346...
  • Page 121 Heatsink Shroud IGBT Heatsink Output Diode Heatsink Work Cable Shroud Art # A-07121 NOTE: Illustration may vary slightly from unit. Manual 0-4691 PARTS LISTS...

  • Page 122: Torch Replacement Parts

    6.10 Torch Replacement Parts SL100 Torch (without solenoid on mounting tube) Item No. Qty Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486 PIP Switch Kit 9-7036 PIP Plunger and Return Spring Kit 9-7045...
  • Page 123 Art # A-03872 Manual 0-4691 6-11 PARTS LISTS...
  • Page 124 6.11 Torch Replacement Parts SL100SV Torch (with Solenoid on Mounting Tube) Item No. Description Catalog No. Torch Head Assembly without leads (includes items 2, 3, and 14) 9-8220 Large O - Ring 8-3487 Small O - Ring 8-3486 PIP Switch Kit 9-7036 PIP Plunger and Return Spring Kit 9-7045...
  • Page 125 Art # A-07113 Manual 0-4691 6-13 PARTS LISTS...

  • Page 126: Torch Consumables

    6.12 Torch Consumables The illustration shows all consumable parts for the SL100 torch. The Shield Cup Body with the Deflector Shield Cap provides extended parts life and improved resistance to reflected heat. The electrode and start cartridge are the same for all operations. 6.13 Torch Spare Parts Kits Automation Torch Spare Parts Kit Contents 40-Amp Kit,...
  • Page 127 Tip: Ohmic Clip 9-8224 9-8205 9-8206 Shield Cap, Machine 9-8208 40A 9-8245 Shield Cap, Machine Tips: 50-60A 9-8238 Shield Cup Body, 9-8237 Electrode 50-55A 9-8209 Shield Cap, Machine Start 9-8210 9-8215 70-100A 9-8239 Cartridge 9-8213 Tips: Shield Cap, Deflector 9-8243 9-8231 Art # A-04603 9-8211...

  • Page 128: Complete Torch Assembly Replacement

    6.14 Complete Torch Assembly Replacement Description Catalog # 100 - Amp Machine Torch and Leads Assemblies, Unshielded Leads: SL100 Machine Torch and 5 foot / 1.5 m Leads, with ATC Connector 7-5213 SL100 Machine Torch and 10 foot / 3.05 m Leads, with ATC Connector 7-5214 SL100 Machine Torch and 25 foot / 7.6 m Leads, with ATC Connector 7-5215...

  • Page 129: Patent Information

    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...
  • Page 130 This Page Left Blank PARTS LISTS 6-18 Manual 0-4691...

  • Page 131: Appendix 1: Sequence Of Operation (Block Diagram

    APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / ON / OFF switch to ON Close external RUN / Rapid Auto Restart / SET disconnect switch. Rapid Auto Restart / RESULT: switch to RUN SET switch RESULT: AC indicator to SET...

  • Page 132: Appendix 2: Data Tag Information

    APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...

  • Page 133: Appendix 3: Maintenance Schedule

    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.

  • Page 134: Appendix 4: Torch Pin - Out Diagram

    APPENDIX 4: TORCH PIN - OUT DIAGRAM A. Power Supply and SL100 Torch without Solenoid ATC Male Connector - ATC Female Receptacle - Front View Front View Negative / Plasma Negative / Plasma 4 - Not Used 8 - Open 8 - Open 4- Open 7 - Green /...

  • Page 135: Appendix 5: Torch Connection Diagram

    APPENDIX 5: TORCH CONNECTION DIAGRAM A. Power Supply and SL100 Torch without Solenoid Automated CutMaster Power Supply with ATC Torch Receptacle, Automated SL100 Torch with ATC Connector, ATC Female ATC Male Torch Receptacle Torch Leads Connector Power Supply Torch Head Torch Leads Socket Pin No.s...

  • Page 136: Appendix 6: Control Cable Pin - Out Diagram

    APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM 2 / White Alignment Spline 3 / Red / Torch Switch 1 / Black 6 / Blue / (Positive) SC-11 Controller 5 / Orange (Negative) SC-11 Controller 4 / Green / Torch Switch 7 / Yellow / Arc Volts (Negative) 10 / Violet 9 / Brown / Arc Volts (Positive)

  • Page 137: Appendix 7: Interface Pcb Switch Settings (Most Common Settings

    Volts Out Division SW 4 Factor 100vdc In 200vdc In 0 = DOWN = OFF, 1 = UP = ON Factory Default Settings Suitable for Thermal Dynamics SC-11 Standoff Control: 6.00 12.00 16.3:1 Other Common Settings: 5.00 10.00 20:1 30:1...

  • Page 138: Appendix 8: Interface Pcb Switch Settings (Division Factors 16-24

    APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24) Automation Interface Switch Setting Chart - Division Factors 16 - 24 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 16.56 16.70...

  • Page 139: Appendix 9: Interface Pcb Switch Settings (Division Factors 24-30

    APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30) Automation Interface Switch Setting Chart, Division Factors 24-30 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 24.22 24.36...

  • Page 140: Appendix 10: Interface Pcb Switch Settings (Division Factors 30-33

    APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33) Automation Interface Switch Setting Chart, Division Factors 30-33 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 30.01 30.03...

  • Page 141: Appendix 11: Interface Pcb Switch Settings (Division Factors 33-36

    APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36) Automation Interface Switch Setting Chart, Division Factors 33 - 36 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 33.01 33.04...

  • Page 142: Appendix 12: Interface Pcb Switch Settings (Division Factors 36-43

    APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43) Automation Interface Switch Setting Chart, Division Factors 36-43 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 36.03 36.16...

  • Page 143: Appendix 13: Interface Pcb Switch Settings (Division Factors 43-50

    APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50) Automation Interface Switch Setting Chart, Division Factors 43 - 50 Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 Divide Factor 0 = DOWN = OFF, 1 = UP = ON 43.04 43.19...

  • Page 144: Appendix 14: Automation Interface Pc Board Wiring Layout

    APPENDIX 14: AUTOMATION INTERFACE PC BOARD WIRING LAYOUT Automation Interface Pilot Board PCB Connector J4 Rear Panel Automation Interface PC Board CPC Connector Automation Interface PCB Connector J1 8 7 6 5 4 3 2 1 To Ground Stud Output Power Board Hooks for Raw Arc Voltage Main PC Board Art # A-04583...
  • Page 145 APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS Art # A-03903 Signals Connector J2 (To wiring harness for alternate Connector J4 (to CPC Connector on Power Supply Rear Panel) CNC Controller) J4-1 Arc Volts (-) (Through 100K ohm resistor) J2-1 Torch Switch (Positive) J4-2...

  • Page 146: Appendix 16: Automation Interface Pc Board Wiring Connections To Oem Cnc Harness

    APPENDIX 16: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO OEM CNC HARNESS 10 11 15 16 Terminal Block J4 To Main PC Board Terminal J27-3 To Main PC Board Terminal J27-2 To Main PC Board Terminal J27-1 Installed only with Optional Remote Current Control Automation Interface PC Board Art # A-04148...

  • Page 147: Appendix 17: Automation Interface Pc Board Wiring Connections To Alternate Cnc Harness

    APPENDIX 17: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONS TO ALTERNATE CNC HARNESS To Main PC Board Terminal Block J2 Terminal J27-3 To Main PC Board Automation Interface PC Board Terminal J27-2 To Main PC Board Terminal J27-1 Installed only with Optional Remote Current Control Output Power PC Board Raw Arc Voltage...

  • Page 148: Appendix 18: Main Pc Board Layout

    APPENDIX 18: MAIN PC BOARD LAYOUT Fuse Secondary Transformer Logic Board Not Shown IGBT Module Input Diode (mounts to center chassis) IGBT Module IGBT IGBT Art # A-04640 Main Power PC Board Signals J18-1 Not used J11-1 L1 Input J18-2 Not used J11-4 L3 Input...
  • Page 149 J25-1 Gate Drive J25-2 Gate Drive J43-1 + 12 vdc to Logic PCB J43-2 + 12 vdc to Logic PCB J26-1 Gate Drive J43-3 DC Com J26-2 Gate Drive J43-4 DC Com J27-1 Pot High J43-5 MC1 On J27-2 Pot Wiper J43-6 Tip Sense J27-3...

  • Page 150: Appendix 19: Main Pc Board Wiring Layout (208/230-Volt Power Supplies

    APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208/230-Volt POWER SUPPLIES) To Inductor Temp Sensor To Press Switch/Solenoid/Contactor To Power Output Board To Heat Sink Test Connector To On/Off and To Main Temp Sensor Run/Rapid Restart Input Contactor To Torch Set Switches To Chassis Ground To Fans Connector...

  • Page 151: Appendix 20: Main Pc Board Wiring Layout (400-V, 415-V, 460-V, 600-V Power Supplies

    APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-V, 415-V, 460-V, 600-V POWER SUPPLIES) To Inductor Temp Sensor To Press Switch/Solenoid/Contactor To Power Output Board To Heat Sink Test Connector To On/Off and To Main Temp Sensor Run/Rapid Restart Input Contactor To Torch Set Switches To Chassis Ground...

  • Page 152: Appendix 21: Logic Board Layout

    APPENDIX 21: LOGIC BOARD LAYOUT TP10 TP11 Art # A-04641 Logic Board Signals P1-27 Current Sense P1-28 Current Sense Return P1-1 +12vdcfrom Main Power PCB P1-29 Current Sense Return P1-2 +12vdcfrom Main PCB P1-30 DC Com P1-3 DC Com P1-31 DC Com P1-4 DC Com P1-32 Not Used...

  • Page 153: Appendix 22: Pot / Led Board Layout

    APPENDIX 22: POT / LED BOARD LAYOUT A-03712 Pot/LED PC Board Signals J14-1 from Main PC Board (J27-1) Pot High J14-2 Main PC Board (J27-2) Pot Wiper J14-3 from Main PC Board (J27-3) Pot Low J14-4 12vdc (J27-4) J14-5 Logic Low Signal for AC OK Indicator from Logic PC Board (J27-5) J14-6 Logic Low Signal for GAS Indicator from Logic PC Board (J27-6) J14-7...

  • Page 154: Appendix 23: Output Diode Layout

    APPENDIX 23: OUTPUT DIODE LAYOUT Art # A-04570 APPENDIX A-24 Manual 0-4691...

  • Page 155: Appendix 24: Output Diode Wiring Diagram

    APPENDIX 24: OUTPUT DIODE WIRING DIAGRAM To Pilot PCB To Main PCB To Pilot PCB To Torch B Output Diodes Chassis Ground A Output Diodes To Output Inductor To Pilot Board To Trans- former To Torch To Trans- former To Output Art # A-04605 Work Cable Inductor...

  • Page 156: Appendix 25: Pilot Board Layout

    APPENDIX 25: PILOT BOARD LAYOUT Connector J28 Connector J1 Art # A-04582 Connector E58 Connector E62 Pilot Board Signals J1-1 +12 vdc to Automation Interface PC Board J1-3 J1-2 DC Common to Automation Interface PC Board J1-2 J28-1 +12 vdc J28-2 DC Com J28-3...

  • Page 157: Appendix 26: 28Vac Circuit Diagram

    APPENDIX 26: 28VAC CIRCUIT DIAGRAM Line Voltage Fuse 3 4 5 6 ON/OFF Switch 1 2 5 6 primary J23 (Test) Auxiliary Transformer Voltage Protection CRT/+12 Regulator +12vdc Main Power PC Board A-03710 Manual 0-4691 A-27 APPENDIX...

  • Page 158: Appendix 27: 208/230V System Schematic

    APPENDIX 27: 208/230V SYSTEM SCHEMATIC Power Supply and SL100 Torch (without solenoid on mounting tube) E12A GATE E17A 208/230V DRIVE 1 PHASE INPUT E11A GATE DRIVE E19A E21A (78) INPUT DIODE IGBT BOARD (33) ASSY 19X1787 CHASSIS COPPER STRAP E12B GATE (FILTERING) E17B...
  • Page 159 603-298-5711 603-298-5711 603-298-5711 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 ASSEMBLY 19X2213 03/03/05 DC COMMON DC COMMON Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 160: Appendix 28: 208/230V System Schematic

    APPENDIX 28: 208/230V SYSTEM SCHEMATIC Power Supply and SL100SV Torch (with solenoid on mounting tube) E12A 208/230V GATE 1 PHASE E17A DRIVE INPUT E11A GATE DRIVE E19A (78) INPUT DIODE E21A IGBT BOARD (33) ASSY 19X1787 COPPER STRAP E12B GATE E17B (FILTERING) CHASSIS...
  • Page 161 RWH 01/27/06 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 ASSEMBLY 19X2213 03/03/05 Not For Release, Reproduction, or Distribution without Written Consent.
  • Page 162 APPENDIX 29: 400 / 415 / 460V SYSTEM SCHEMATIC Power Supply and SL100 Torch (without solenoid on mounting tube) E12A GATE E17A DRIVE 400/415V 208/230V /460 1 PHASE 3 PHASE INPUT INPUT E11A GATE DRIVE E19A E21A INPUT DIODE IGBT BOARD ASSY 19X1787 CHASSIS 400V...
  • Page 163 603-298-5711 ECO 101726 HAS 06/10/05 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 ASSEMBLY 19X2213 DC COMMON DC COMMON 03/03/05 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 164: Appendix 29: 400 / 415 / 460V System Schematic

    APPENDIX 30: 400 / 415 / 460V SYSTEM SCHEMATIC Power Supply and SL100SV Torch (with solenoid on mounting tube) E12A E17A GATE DRIVE 208/230V 400/415V 1 PHASE /460V 3 PHASE INPUT INPUT E11A GATE DRIVE E19A INPUT DIODE E21A IGBT BOARD 400V 3 PHASE E12B...
  • Page 165 OUTPUT DIODE Date: Date: Date: ECO B028 12/27/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 ASSEMBLY 19X2213 03/03/05 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 166: Appendix 31: 600V System Schematic

    APPENDIX 31: 600V SYSTEM SCHEMATIC Power Supply and SL100 Torch (without solenoid on mounting tube) E12A GATE E17A DRIVE 600VAC 3 PHASE INPUT E11A GATE DRIVE E19A E21A INPUT DIODE IGBT BOARD ASSY 19X1787 CHASSIS E12B GATE E17B (FILTERING) DRIVE E11B GATE (0 ohm)
  • Page 167 Supersedes Supersedes 603-298-5711 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 03/03/05 ASSEMBLY 19X2213 ASSEMBLY 19X2213 DC COMMON DC COMMON Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 168: Appendix 32: 600V System Schematic

    APPENDIX 32: 600V SYSTEM SCHEMATIC Power Supply and SL100SV Torch (with solenoid on mounting tube) E12A GATE E17A DRIVE 600VAC 3 PHASE INPUT E11A GATE DRIVE E19A INPUT DIODE E21A IGBT BOARD ASSY 19X1787 E12B CHASSIS GATE E17B (FILTERING) DRIVE E11B GATE (0 ohm)
  • Page 169 RWH 01/27/06 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: ECO B077 07/31/06 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 03/03/05 ASSEMBLY 19X2213 DC COMMON DC COMMON Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 170: Appendix 33: Manual Publication History

    APPENDIX 33: Manual Publication History Manual No. 0-4691 Cover Date Change(s) 3/18/05 First issue. 6/6/05 Corrected input wiring specs. Updated catalog number for 208/230 replacement cord per ECO 101685. Added catalog number for 600V replacement IGBT per ECO 101642. Updated catalog number for replacement EMI filter per ECO 101642. 7/6/05 Added 415V CE (Australian) units per ECO 101714, added 208/230V CSA units per ECO 101731.

  • Page 171: Global Customer Service Contact Information

    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 West Malaysia 800-426-1888 Telephone: 603+ 6092 2988 Fax: 800-535-0557...
  • Page 172 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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