51 Cutmaster PDF

51 ™
CUTMASTER
PLASMA CUTTING SYSTEM
Art # A-04611
Operating Manual Rev. AA.01

Operating Features:
Date: October 20, 2006 Manual # 0-2971
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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™ 51
Operating Manual Number 0-2971
Covered under U.S. Patents.
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2003, 2004, 2005, 2006 by

Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: October 20, 2006
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 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 Front Panel Controls and Indicators .............................................................. 4-1
4.02 Preparations for Operation ............................................................................ 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

TABLE OF CONTENTS (continued)
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
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: TORCH CONNECTION DIAGRAMS ................................................................... A-5
APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS .......................................................... A-6
APPENDIX 7: SYSTEM SCHEMATIC, 400V & 460V UNITS ................................................... A-8
APPENDIX 8: Publication History ........................................................................................... A-10
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 0-2971 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-
cesses can cause noise levels to exceed safe limits. You ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
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 0-2971

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

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

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™ 38 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 basedupon
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


SECTION 2:
INTRODUCTION
2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dy-
namics CutMaster 51 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly
trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not cov-
ered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was designed.
NOTE
Refer to the Torch Manual for torch and cutting information.
2.02 Power Supply Specifications
CutMaster 51 Power Supply Specifications

208 / 230 VAC (187 - 253 VAC), Single Phase, 60 Hz
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
Power Supply includes input cable.
Input Power Cable
Cable for 208/230V input power includes molded plug.
Output Current 20 - 40 Amps, Continuously Adjustable
Power Supply Gas
Particulates to 20 Microns
Filtering Ability
CutMaster 51 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%
All Units Current 40 Amps n/a 25 Amps n/a n/a n/a
DC Voltage 96 vdc n/a 90 vdc n/a n/a n/a
* 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 0-2971 2-1 INTRODUCTION

Power Supply Dimensions & Weight Ventilation Clearance Requirements
10.75"
273 mm
Art # A-03379
Art # A-04612
16.375"
416 mm 6"
150 mm
24"
0.6 m
22.5" 6" 6"

150 mm 150 mm
0.57 m
58 lb / 26 kg
2.03 Input Wiring Specifications
CutMaster 51 Power Supply Input Wiring Requirements

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 60 9 42 60 10 10
230 60 9 37 60 10 10
400 50 8 11 15 12 12
400 60 8.5 12 15 12 12
460 60 14 17.5 25 12 12
460 60 8 10 15 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS / LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
INTRODUCTION 2-2 Manual 0-2971

2.04 Power Supply Features
Handle and Leads Wrap
Control Panel
Torch Leads Receptacle
Art # A-04613
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 0-2971 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.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 5.0 microns.
C. High Pressure Regulators
High pressure regulators are available. The regulators are used to set the proper pressure for the type gas being used.
NOTE
Regulators should not be installed with In-Line Air Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work cable with clamp
is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power
supply and can also serve as a display cart. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle is 30" / 762 mm high.
F. Wheel Kit
A kit with easy - rolling wheels, for maximum portability for the power supply.
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. Nylon Dust Cover
Nylon canvas power supply dust cover with water resistant finish, large outer pocket for storing manuals or spare consum-
ables, and adjustable draw cord for tight fit.
INTRODUCTION 2-4 Manual 0-2971

SECTION 3:
INSTALLATION
3.01 Unpacking
1. 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 0-2971 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).
B. Connections to 400 - Volt, or 460 - Volt Three - Phase Power
These Power Supplies are equipped with a four - conductor input power cable for three - phase input power. The
460 - Volt Power Supply will accept 460 - VAC, Single - Phase input power with a change of input power cable.
1. The input cable's outer covering is stripped back at the factory to expose the individual wires at the free end
of the cable.
2. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:
CAUTION
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.
INSTALLATION 3-2 Manual 0-2971

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
protection and wiring requirements (refer to table in Section 2).
5. Strip back the insulation on the individual wires.
6. Connect to main input contactor as follows:
• 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. Reinstall the Power Supply cover.


3.04 Gas Connections
A. Connecting Gas Supply to Unit
The connection is the same for compressed air or high pressure cylinders. Refer to subsection 3.4-B or 3.4-C if an
optional air line filter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical fittings as an example.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
Regulator/Filter
Assembly
Inlet Port
Bowl
1/4 NPT to 1/4"

(6mm) Fitting
Hose Clamp
Gas Supply
Art # A-02999 Hose
Air Connection to Inlet Port

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
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

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

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 300 scfh (141.5 lpm).
4. Connect supply hose to the cylinder.
NOTE
Pressure should be set at 100 psi (6.9 bar) at the high pressure cylinder regulator.
Supply hose must be at least 1/4 inch (6 mm) I.D.
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use

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)
1
2
ATC Male
Connector
Art # A-04614
Connecting the Torch to the Power Supply

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
30
25 35
1 2
20 40
A-03690

SECTION 4:
OPERATION
4.01 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 for
to 40 Amps may be used for drag cutting (with the operation. Blinking light indicates unit is in pro-
torch tip contacting the workpiece) or standoff cut- tective interlock mode. Shut unit off, shut off or
ting. disconnect input power, correct the fault, and re-
start the unit. Refer to Section 5 for details.
TEMP Indicator
A Indicator is normally OFF. Indicator is ON when

30 internal temperature exceeds normal limits. Shut
unit OFF; let the unit cool before continuing op-
25 35 eration.
20 40
GAS Indicator
Indicator is ON when minimum input gas pres-

sure for power supply operation is present. Mini-
mum pressure for power supply operation is not
sufficient for torch operation.
A-03742 DC Indicator
Indicator is ON when DC output circuit is active.
ON / OFF Switch
Controls input power to the power supply. Up is

ON, down is OFF.
RUN / RAPID AUTO RESTART / SET Switch
RUN (up) position is for general torch operation.

RAPID AUTO RESTART (middle) position is for an uninterrupted restart,
when cutting expanded metal or in gouging or trimming operations.
SET (down) position is for setting gas pressure and purging lines.
Manual 0-2971 4-1 OPERATION

4.02 Preparations for Operation
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 (40 amps maximum). Refer to Section 6.06 for torch parts selection.
B. Torch Connection
Check that the torch is properly connected. Only Thermal Dynamics model SL60 or SL100 Torches may be
connected to this Power Supply.
C. Check Primary 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.
D. Air Source
Ensure source meets requirements (refer to Section 2). Check connections and turn air 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 0-2971

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
30
25 35
20 40
A-03746

G. Set Operating Pressure
1. Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow.
A
30
25 35
1 2
20 40
A-03690
2. Adjust gas pressure to 65 - 85 psi / 4.5 - 5.9 bar. Refer to the chart for pressure setting details.
65 - 85 psi /
4.5- 5.9 bar
Pressure Control Knob /
Bouton De Contrôle
de Pression
CutMaster 51 Gas Pressure Settings

Leads SL60 SL100
Length (Hand Torch) (Machine Torch)
Up to 25' 75 psi 65 psi
(7.6 m) 5.2 bar 4.5 bar
Over 25' 85 psi 70 psi
(7.6 m) 5.9 bar 4.8 bar
Art # A-03831

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 output current output level.
A
2
30
25 35
20 40
A-03747
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.
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.

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
30
25 35
20 40
A-03748

SECTION 5:
SERVICE
5.01 General Maintenance

A. O-Ring Lubrication
An o-ring on the Torch ATC Male Connector requires lubrication on a scheduled basis. This will allow the o-ring to
remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant
is not used on a regular basis. This can lead to potential performance problems.
It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring 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 0-2971 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 0-2971

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.

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.

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
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
5. Difficult Starting
a. Worn torch parts
b. Non - Genuine Thermal Dynamics parts used
c. Incorrect gas pressure

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.

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 according to torch model and leads length per Section 4.02G.

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.

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.
L. Torch cuts but not adequately
1. Incorrect setting of output current (A) control
a. Check and adjust to proper setting.
2. Torch consumables worn
a. Check torch consumables per Torch manual; replace as needed.
3. Work cable connection to work piece is poor
a. Make sure that work cable has a proper connection to a clean, dry area of the workpiece.
4. Torch is being moved too fast across workpiece
a. Reduce cutting speed.
5. Excessive oil or moisture in torch
a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from
clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contami-
nants in the gas, additional filtering may be needed.

6. Fluctuations in input power
a. Have electrician check input line voltage.
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.
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

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-04615
2. Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit.

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.

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 51 Power Supply
1 208 / 230VAC, Single - Phase, 60Hz, with input power cable and plug 3-5120-1
1 400VAC, Three - Phase, 50 / 60Hz, with input power cable 3-5120-3
1 460VAC, Three - Phase, 60Hz, with input power cable 3-5120-2
Manual 0-2971 6-1 PARTS LISTS

6.04 Replacement Parts
Fuse
1 for 208 / 230VAC Power Supply 9-8110
1 for 400 VAC Power Supply 9-8583
1 for 460 VAC Power Supply 9-8583
1 Regulator / Filter Assembly Replacement Element 9-4414
1 Input Power Cord for 208 / 230 V Power Supply 8-4384
1 Input Power Cord for 400 V Power Supply 9-8562
1 Input Power Cord for 460 V Power Supply 9-8593
6.05 Options and Accessories

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 High - Pressure Air Regulator 9-3022
1 Wheel Kit 9-8510
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 9-7071
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 0-2971

6.06 Torch Parts
Cutting Parts
Standoff
Cutting Guide
8-3487 8-3486 Shield
O-Ring O-Ring Cup
(Black) (Red) 9-8207 (40A) 9-8218 9-8251
Electrode Start
9-8215 Cartridge
9-8213
Shield
Cup Body
9-8225 (40A) 9-8237 9-8241
Shield Cap, Gouging
Art # A-03816
Gouging Parts
Torch Head
Electrode
Start Cartridge
Tip
Shield Cup
Standoff Cutting Guide
Art # A-04070
Manual 0-2971 6-3 PARTS LISTS

PATENT INFORMATION
The following parts are licensed under U.S. Patent No(s). 5120930 and 5132512
Catalog Number 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 0-2971

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 0-2971 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 0-2971

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

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 5: TORCH CONNECTION DIAGRAMS
A. Hand Torch Connection Diagram
Torch: SL60 / SL100 Hand Torch

Leads: Torch Leads with ATC Connector
Power Supply: with ATC Receptacle Male
ATC Leads ATC Female
Connector Receptacle Power
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

APPENDIX 6: SYSTEM SCHEMATIC, 208/230V UNITS
1 2 3 4 5
E6
E8
E5
E13
W1 E18
A L1 (1)
208 / 230V
INPUT W1 E14
L2 (2) E16
INPUT DIODE
ASSY 19X2073
E3 E2 E1 COPPER STRAP
E14
CHASSIS E11
(FILTERING)
GND
P8 J8
(3)
1 1 K4
2 2
3 3 K4
(4)
4 4
F1 (6/10A 600V)
E12
B
R95 T1 E13
M1
FAN1 (0 ohm) E15
(6)
P26 J26
1 1
2 2 28VAC B 28VAC A
230V 3 3
(5)
4 4
J21 P21
K3
GATE DRIVE A RTN 1 1
GATE DRIVE A 2 2
J20 P20
P3 J3 GATE DRIVE B RTN 1 1
1 1 GATE DRIVE B 2 2
28VAC B (21) 2 2
28VAC A (22) 3 3
(23) 4 4 28VAC A
(24) 5 5 28VAC B
TO BIAS E35
(25) 6 6 SUPPLY
ON/OFF SW (26) 7 7 MAIN TRANSFORMER
TO BIAS SUPPLY
C 8 8 E22
SW1 T5
RUN +12V
MODE SW SET
SEC
PRI
(46) K4
RAR OFF
(PILOT PCB) (F6) E4
INRUSH +18V
SW2
K3 E9
CURRENT ADJUST:
FAN E8
20 - 40 AMPS J14 P14 P22 J22
(35)
1 1 (36) 1 1 POT HIGH
2 2 (37) 2 2 POT WIPER E21
3 3 (38) 3 3 POT LOW
CURRENT AC 4 4 (39) 4 4 +12V E20
CONTROL/ 5 5 (40) 5 5 AC
TEMP 6 6 (41) 6 6 GAS
LED PCB 7 7 (42) 7 7 OVERTEMP
19X1604 8 8 8 8 DC
GAS
D DC
E26 (CSR)
CSR
E25 (TS2)
P2 J2 TORCH SWITCH -
E23 (TS1)
1 1 TORCH SWITCH +
IGBT 2 2 E24 (NEG)
Vo
HEATSINK 3 3
TEMP NTC 4 4 E19
t
TS1 P23 J23 E18
1 1
2 2 E5
INDUCTOR
TEMP E10
TS2
E6
P1 J1 CURRENT
+12VDC 1 1 CSR SENSE E7
+12VDC 2 2 +18V
GND SIGNAL 3 3
GND SIGNAL 4 4 E17 (E17)
E W1 5 5 K2
GND SIGNAL 6 6 E34
RUN/SET 7 7 (E34)
PRESS GOOD 8 8 CONTACTOR ON ATC CONNECTION
OVERTEMP 9 9 DC COMMON J9 P9 CONFIGURATION
GND SIGNAL 10 10 (78)
PIP RTN 1 1 11
11T6
GND SIGNAL 11 11 +18V (79) PIP
GND SIGNAL 12 12 PIP 2 2 22 A B 15
28VAC A 13 13 55
GAS ON 14 14 K5 (80) 77 PRI
CSR 15 15 TORCH SW 3 3 (81) 33 TORCH
INV ON GND SIGNAL 16 16 TORCH SW RTN 4 4 44 SW
(RED) D8 DC OK 17 17 SOLENOID ON 88
ATC MALE
OVTEMP 18 18 J5 CONNECTOR SEC
AC OK 19 19 28VAC A 1 6 10
RTN 20 20 ATC RECEIVER
TORCH SWITCH 21 21 GND 2 TEST
+12VDC 22 22 28VAC B 3 CONN SOL1
POT HIGH 23 23 A B
POT WIPER 24 24 GAS FACTORY INSTALLED OPTIONAL
POT LOW 25 25 TORCH MOUNTED GAS SOLENOID
GATE DRIVE B RTN 26 26 SOLENOID
K5
GATE DRIVE B 27 27
MAIN BOARD F2, 0.9A, J4 P4
GATE DRIVE A RTN 28 28 (7)
(RESETABLE) 1 1
GATE DRIVE A 29 29 (8)
- OUT 30 30 ASSY 19X2001 2 2
3 3
(9) PRESSURE WHEN OPTIONAL TORCH
CURRENT SENSE 31 31 PRESS GOOD 4 4
(10) PS1 SWITCH MOUNTED GAS SOLENOID
CURRENT SENSE 32 32 (11)
F CURRENT SENSE RTN 33 33
5 5 (12) CLOSED WHEN IS USED,SOL1 IS POWERED
LOGIC 6 6 (13) PRESSURE OK BY T6 ONLY ,SOL2
CURRENT SENSE RTN 34 34 +12V 7 7
ASSY 19X2000 ISENSE 35 35 CHASSIS GND (14)
K2 8 8 POWERED BY P4-1,-2
TIP 36 36 THRU SCREW TERMINAL (19) W1
ASSY 19X2283 CSR 9 9 (20) MAIN
E16 E28 ISENSE 10 10
CONTACTOR
Art # A-07154 1 2 3 4 5

6 7 8 9 10
COMP DESCRIPTION LOCATION

F1 FUSE, 6/10A 600V KTK B3
W1 MAIN CONTACTOR F5
SW1 SWITCH, ON/OFF C2
SW2 SWITCH, RUN/SET/RAR C2
M1 FAN, 4.5" 220VAC B2
SOL1 GAS SOLENOID F5
PS1 PRESSURE SWITCH F5 A
TS1 TEMP. SENSOR, IGBT HEATSINK D2
TS2 TEMP. SENSOR, INDUCTOR E2
T1 AUX TRANSFORMER B3
T5 MAIN TRANSFORMER C5
L1 OUTPUT INDUCTOR E6
E28 NOTES: UNLESS OTHERWISE SPECIFIED

E29 GATE 1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
14 13 12 DRIVE J18 P18 IS FOR REFERENCE ONLY
2 2
28
1 1
23
E30
24 27
25 E31
GATE
DRIVE
1 J19 P19 B
E32 2 2
E33 1 1
76542
IGBT BOARD
ASSY 19X1721
OUTPUT DIODE
ASSEMBLY
19X1720
E36
E37
E38
E39
E40
E41 OPTIONAL AUTOMATION INTERFACE CONNECTIONS
ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
E42
E43
P1 J1
(CSR)
(51)
1 1 CSR D
2 2 DC COMMON
(52) J2
3 3 +12VDC J4 P4
4 4
(TS2)
(TS1)
5 5 TORCH SW - 20 20 1
2
+
TORCH SW + 19 19 TORCH SWITCH
(NEG)
6
7
6
7 18 18 3 -
8 8 Vo 17 17 4
16 16 5
15 15 6 OK TO MOVE
14 14 7
*
19X2041 13 13 8
PLUGS INTO J22
ON MAIN BOARD OPTIONAL
12 12
11 11
9
10
+ DIVIDED OUTPUT
AUTOMATION 10 10
INTERFACE
11
12
-
9 9
(LED PCB 19X1604) 8 8 13
7 7 14 REMOTE CURRENT CONTROL
6 6 15
J14 P14 P3 J3 5 5 16
OUTPUT INDUCTOR (47) 4 4 17 DC COMMON
1 1 1 1 1
L1 2 2 2 (48)
(49)
2 2 3 3 18
19
+
3 3 2 2 C&G
AC 4 4
3
4
3 3
1 1 20 -
ATC RECEIVER 5 5 5
ATC MALE CONNECTOR TEMP 6 6 6
7 7 7
8 8 8 (56)
GAS (57)
4 (+)
} TORCH SWITCH E
3 (-)
(58) 14
DC (59) 12 } OK TO MOVE
(60) 6 (+)
T (61) 5 (-) } SC-11
ADAPTER HARNESS USED (62) 8 LOGIC COMMON
O WHEN REMOTE CURRENT
(63) 9 (+)
} ARC VOLTS (C&G)
(64) 7 (-)
R CONTROL IS USED WITH
C AUTOMATION CPC
H (REPLACES CONNECTIONS HOUSING
FROM J22 TO J14)
(E62) WORK
E62
J1
PILOT BOARD (52)
1
ASSY 19X2086 2 Rev Revisions By Date PCB No:
(51)
AA ECO 101136 (REL) DLL 05/27/03
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2 Assy No: F
WEST LEBANON, NH 03784 Scale Supersedes
E58 AB ECO 101314 HAS 02/11/04
603-298-5711
12 3 5 8 AC ECO 101429 HAS 06/09/04
(E58) Date:
J28 AD ECO B028 RS 01/09/06 Information Proprietary to THERMAL DYNAMICS CORPORATION.
05/27/03
(46) AE ECO B016 RWH 01/27/06 Not For Release, Reproduction, or Distribution without Written Consent.
+12V RAR OFF Drawn: References
NOTE:
(MODE SW) (C2) Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. D.Lilja
GND
Capacitors are in Microfarads (UF) Chk: App: Sheet
CSR 1 of 1
ISENSE TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, January 27, 2006
CM51 208/230V SYSTEM D 42X1150
6 7 8 9 10 Art # A-07154

APPENDIX 7: SYSTEM SCHEMATIC, 400V & 460V UNITS
1 2 3 4 5
W1 E6
L1 (1)
E8
...OR... E5
400/460V 400/460V W1
L2 (2) E13
1 PHASE 3 PHASE
A INPUT INPUT E18
W1
L3 (44) E14
E16
INPUT DIODE
ASSY 19X2073
E3 E2 E1
400V E14
3 PHASE
INPUT
CHASSIS E11
(FILTERING)
GND
P8 J8
(3)
1 1
400V 'CE' VERSION 2 2 K4
K4
INCLUDES IN-LINE (4) 3 3
4 4
EMC FILTER F1 (1/4A 500V) E12
B
R94 (460V)
T1 E13
M1 R93 (400V)
FAN1 P26 J26 E15
(6)
1 1
2 2
230V 3 3
(5)
4 4 28VAC B 28VAC A J21 P21
K3 GATE DRIVE A RTN 1 1
GATE DRIVE A 2 2
SEE TABLE 1
J20 P20
P3 J3 GATE DRIVE B RTN 1 1
1 1 GATE DRIVE B 2 2
28VAC B (21) 2 2
28VAC A (22) 3 3
(23) 4 4 28VAC A
(24) 5 5 28VAC B
TO BIAS E35
(25) 6 6 SUPPLY
ON/OFF SW (26) 7 7 MAIN TRANSFORMER
C 8 8 E22
SW1 T5
+12V
RUN
MODE SW SET K4
PRI
SEC
(46)
RAR OFF INRUSH E4
+18V
(PILOT PCB) (F6)
SW2
K3
FAN
E9
CURRENT ADJUST: J14 P14 P22 J22 E8
20 - 40 AMPS (35)
1 1 (36) 1 1 POT HIGH
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
AC 4 4
(38)
4 4 +12V E21
CURRENT (39)
5 5 (40) 5 5 AC
CONTROL/ TEMP 6 6 (41) 6 6 GAS
7 7 (42) 7 7 OVERTEMP
LED PCB 8 8 8 8 DC E20
19X1604 GAS
D DC
E26 (CSR)
CSR
P2 J2 TORCH SWITCH -
E25 (TS2)
1 1 E23 (TS1)
IGBT 2 2
TORCH SWITCH +
HEATSINK Vo
E24 (NEG)
3 3
TEMP NTC 4 4
E19
t
TS1
P23 J23 E18
1 1
INDUCTOR 2 2 E5
TEMP
E10
TS2
E6
P1 J1 CURRENT
+12VDC 1 1 CSR SENSE E7
+12VDC 2 2 +18V
GND SIGNAL 3 3
GND SIGNAL 4 4 E17 (E17)
E W1 5 5 K2
GND SIGNAL 6 6
RUN/SET 7 7 E34 (E34)
PRESS GOOD 8 8 CONTACTOR ON ATC CONNECTION
OVERTEMP 9 9 DC COMMON J9 P9 CONFIGURATION
GND SIGNAL 10 10 (78)
PIP RTN 1 1 (79) 11 PIP
11T6
GND SIGNAL 11 11 +18V
GND SIGNAL 12 12 PIP 2 2 22 A B 15
55
28VAC A 13 13 77
GAS ON 14 14 K5 (80) PRI
TORCH SW 3 3 33 TORCH
CSR 15 15 (81) 44
TORCH SW RTN 4 4 SW
INV ON GND SIGNAL 16 16 SOLENOID ON
(RED) D8 DC OK 17 17 88
ATC MALE
OVTEMP 18 18 J5 CONNECTOR
SEC
AC OK 19 19 28VAC A 1 6 10
RTN 20 20 ATC RECEIVER
TORCH SWITCH 21 21 GND 2 TEST
+12VDC 22 22 28VAC B 3 CONN SOL1 B
POT HIGH 23 23 A
FACTORY INSTALLED OPTIONAL
POT WIPER 24 24 GAS
POT LOW 25 25 TORCH MOUNTED GAS SOLENOID
SOLENOID
GATE DRIVE B RTN 26 26 K5
GATE DRIVE B 27 27 F2, 0.9A, J4 P4
GATE DRIVE A RTN 28 28 MAIN BOARD (7)
(RESETABLE) 1 1
GATE DRIVE A 29 29 (8)
- OUT 30 30 ASSY 19X2033 (400V) 2 2 (9) PRESSURE
3 3 (10) WHEN OPTIONAL TORCH
CURRENT SENSE 31 31 ASSY 19X2060 (460V) PRESS GOOD 4 4 PS1 SWITCH
MOUNTED GAS SOLENOID
CURRENT SENSE 32 32 (11)
F CURRENT SENSE RTN 33 33
5 5 (12) CLOSED WHEN
IS USED, SOL1 IS POWERED
LOGIC 6 6 (13) PRESSURE OK
CURRENT SENSE RTN 34 34 CHASSIS GND +12V 7 7 BY T6 ONLY ,SOL2 POWERED
ASSY 19X2000 ISENSE 35 35 K2 (14)
TIP 36 36 THRU SCREW TERMINAL 8 8 (19) BY P4-1,-2
ASSY 19X2283 CSR 9 9 W1
E16 E28 ISENSE 10 10
(20) MAIN
CONTACTOR
Art # A-07155 1 2 3 4 5

6 7 8 9 10
COMP DESCRIPTION LOCATION

F1 FUSE, 1/4A 500V FNQ B3
W1 MAIN CONTACTOR F5
SW1 SWITCH, ON/OFF C2
SW2 SWITCH, RUN/SET/RAR C2
M1 FAN, 4.5" 220VAC B2
SOL1 GAS SOLENOID F5
PS1 PRESSURE SWITCH F5 A
TS1 TEMP. SENSOR, IGBT HEATSINK D2
TS2 TEMP. SENSOR, INDUCTOR E2
T1 AUX TRANSFORMER B3
T5 MAIN TRANSFORMER C5
L1 OUTPUT INDUCTOR E6
E28
E29 GATE NOTES: UNLESS OTHERWISE SPECIFIED
14 13 12 DRIVE J18 P18 1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
2 2
IS FOR REFERENCE ONLY
1 1
28
23 E30
24 27
25 E31
GATE TABLE 1
DRIVE
J19 P19 B
1 ASSEMBLY
E32 2 2
E33 COMP 19X2033 (400V) 19X2060 (460V)
76542 1 1
R93 115X465-2 (0 ohm) XXXXXXXX
IGBT BOARD
ASSY 19X1721 R94 XXXXXXXX 115X465-2 (0 ohm)
F1 1/4A 500V 1/4A 500V
OUTPUT DIODE
ASSEMBLY E36
19X1720
E37
E38
E39
E40
E41 OPTIONAL AUTOMATION INTERFACE CONNECTIONS
ALTERNATE 20-PIN HEADER
E42 20-POSITION TERMINAL STRIP
E43
P1 J1
(CSR) 1 1 CSR D
(51) 2 2 DC COMMON
(52) 3 3 +12VDC J4 P4 J2
4
(TS2) 4
5 5 TORCH SW - 20 20 1
2
+
(TS1) TORCH SW + 19 19 TORCH SWITCH
(NEG)
6
7
6
7 18 18 3 -
8 Vo 17 17 4
8 16 16 5
15 15 6 OK TO MOVE
14 14 7
*
19X2041 13 13 8
PLUGS INTO J22 OPTIONAL 12 12 9
10
+
ON MAIN BOARD AUTOMATION 11 11 DIVIDED OUTPUT
INTERFACE 10 10 11
12
-
9 9
(LED PCB 19X1604) 8 8 13
7 7 14 REMOTE CURRENT CONTROL
6 6 15
OUTPUT INDUCTOR J14 P14 P3 J3 5 5 16
(47) 4 4 17 DC COMMON
1 1 1 1 1
L1 2 2 2 (48)
(49) 2 2 3 3 18
19
+
3 3 2 2 C&G
ATC RECEIVER
AC 4 4
3
4
3 3
1 1 20 -
5 5 5
ATC MALE CONNECTOR TEMP 6 6 6
7 7 7
GAS
8 8 8 (56) 4 (+) E
(57) 3 (-) } TORCH SWITCH
(58) 14
DC (59) 12 } OK TO MOVE
(60) 6 (+)
T (61) 5 (-) }
SC-11
O (62) 8 LOGIC COMMON
ADAPTER HARNESS USED (63) (+)
9 } ARC VOLTS (C&G)
R WHEN REMOTE CURRENT (64) 7 (-)
C CONTROL IS USED WITH
AUTOMATION CPC
H (REPLACES CONNECTIONS HOUSING
FROM J22 TO J14)
(E62) WORK
TOROID (INSTALLED
ON 400CE ONLY)
E62
J1
(52)
PILOT BOARD 1
ASSY 19X2086 2 Rev Revisions By Date PCB No:
(51) THERMAL DYNAMICS F
AA ECO 101136 (REL) DLL 05/27/03 INDUSTRIAL PARK No. 2 Assy No:
WEST LEBANON, NH 03784 Scale Supersedes
E58 AB ECO 101314 HAS 02/11/04
603-298-5711
1 2 3 5 8 AC ECO 101429 HAS 06/09/04
(E58) J28 AD ECO B028 RS 01/09/06
Date:
Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/27/03
(46) RWH 01/27/06 Not For Release, Reproduction, or Distribution without Written Consent.
RAR OFF AE ECO B016
Drawn: References
+12V NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. D.Lilja
GND
(MODE SW) (C2) Capacitors are in Microfarads (UF) Chk: App: Sheet
CSR 1 of 1
ISENSE TITLE: SCHEMATIC, Size DWG No:
Last Modified: Friday, January 27, 2006
CM51 400/460V SYSTEM 1O/3O D 42X1151
6 7 8 9 10 Art # A-07155

APPENDIX 8: Publication History
Cover Date Revision Comments
12/18/03 -- Manual released.
1/12/04 -- Updated operating gas pressures per ECO 101276.
1/16/04 -- Updated warranty statement & system schematics, misc minor edits.
1/20/04 -- Corrected system schematics.
2/9/04 -- Deleted system schematics.
2/12/04 -- Added updated schematics, ECO 101314.
6/23/04 -- Updated system schematics per ECO 101429.
10/15/04 -- Corrected catalog number for replacement power cord.
3/22/05 -- Changed work clamp art to 17x1043 type per ECO 101599, added dust cover to options.
2/17/06 -- Updated system schematics per ECO B033.
10/20/06 AA.01 Added patent information, new manual standard style and revision control.
NOTE
Thermal Dynamics uses the manual cover date to indicate revision level.

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: sales@thermadyne.com 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: TDCSales@Thermadyne.com
www.thermadyne.com

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51 ™

Operating Manual Rev. AA.01

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This Operating Manual has been designed to instruct you on the

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-

Above all, we are committed to developing technologically

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Plasma Cutting Power Supply

Covered under U.S. Patents.

Copyright 2003, 2004, 2005, 2006 by

All rights reserved.

Printed in the United States of America

Publication Date: October 20, 2006

Record the following information for Warranty purposes:

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

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

APPENDIX 1: SEQUENCE OF OPERATION

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

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

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

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

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

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

APPENDIX 8: Publication History ........................................................................................... A-10

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

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Manual 0-2971 1-1 GENERAL INFORMATION

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GENERAL INFORMATION 1-2 Manual 0-2971

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Manual 0-2971 1-3 GENERAL INFORMATION

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National Standard and Technical Specifications

Manufacturers responsible representative: Giorgio Bassi

GENERAL INFORMATION 1-4 Manual 0-2971

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LIMITED WARRANTY PERIOD

Power Supply Components Torch and Leads

This warranty does not apply to:

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.

Effective January 15, 2004

Manual 0-2971 1-5 GENERAL INFORMATION

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2.01 Scope of Manual

2.02 Power Supply Specifications

CutMaster 51 Power Supply Specifications

Manual 0-2971 2-1 INTRODUCTION

22.5" 6" 6"

2.03 Input Wiring Specifications

CutMaster 51 Power Supply Input Wiring Requirements