Cutmaster 101

101 ™
CUTMASTER
PLASMA CUTTING SYSTEM
Art # A-06754
Service Manual
Rev. AC.01 Date: April 13, 2007 Manual # 0-2853
Operating Features:
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply

CutMaster™ 101
Operating Manual Number 0-2853
Covered under U.S. Patents
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 2003, 2004, 2005, 2006, 2007 by

Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the pub-
lisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: April 13, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-3
1.06 Documents De Reference ............................................................................. 1-5
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty .................................................................................. 1-8
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Scope Of Manual ......................................................................................... 2-1
2.02 General Service Philosophy ......................................................................... 2-1
2.03 Service Responsibilities ............................................................................... 2-1
SECTION 3: DESCRIPTION ................................................................................................... 3-1

3.01 Scope .......................................................................................................... 3-1
3.02 Power Supply Specifications ........................................................................ 3-1
3.03 Air Regulator/Filter Assembly Specifications ................................................ 3-3
SECTION 4:
TROUBLESHOOTING ....................................................................................................... 4-1
4.01 Introduction ................................................................................................... 4-1
4.02 Periodic Inspection & Cleaning Procedures ................................................... 4-1
4.03 System Theory ............................................................................................. 4-1
4.04 Common Operating Problems ....................................................................... 4-2
4.05 Troubleshooting Guide - General Information ................................................. 4-3
4.06 Circuit Fault Isolation .................................................................................... 4-4
4.07 Main Input and Internal Power Problems ....................................................... 4-5
4.08 Pilot Arc Problems ....................................................................................... 4-11
4.09 Main Arc Problems ...................................................................................... 4-14
4.10 Test Procedures ........................................................................................... 4-15
SECTION 5:
REPLACEMENT PROCEDURES ...................................................................................... 5-1
5.01 Scope ........................................................................................................... 5-1
5.02 Anti-Static Handling Procedures ................................................................... 5-1
5.03 Parts Replacement - General Information ..................................................... 5-1
5.04 Major External Parts Replacement ............................................................... 5-2
5.05 Front Panel Parts Replacement ..................................................................... 5-3
5.06 Left Side Internal Component Parts Replacement ......................................... 5-4
5.07 Rear Panel Parts Replacement ..................................................................... 5-7
5.08 Right Side Internal Component Parts Replacement ....................................... 5-8
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Major External Replacement Parts ............................................................... 6-2
6.04 Front Panel Replacement Parts .................................................................... 6-3
6.05 Left Side Internal Component Replacement Parts ........................................ 6-4
6.06 Rear Panel Replacement Parts .................................................................... 6-6
6.07 Right Side Internal Component Replacement Parts ...................................... 6-7
6.08 Options and Accessories ............................................................................. 6-8
PATENT INFORMATION ............................................................................................................ 6-9
APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1
APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .......................................................................................................... A-2
APPENDIX 3: LOGIC PC BOARD LAYOUT .............................................................................. A-3
APPENDIX 4: MAIN POWER PC BOARD LAYOUT .................................................................. A-4
APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT - 208/230-Volt Units ................................ A-6
APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT - 400-Volt, 415-Volt, 460-Volt, and
600-Volt Units .................................................................................................................... A-7
APPENDIX 6: LED/POT PC BOARD LAYOUT .......................................................................... A-8
APPENDIX 7: INPUT DIODE PC BOARD LAYOUT .................................................................. A-9
APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT ............................................................... A-10
APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT ............................................................. A-11
APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM ............................................................ A-12
APPENDIX 11: PILOT PC BOARD LAYOUT ........................................................................... A-13
APPENDIX 12: 28VAC CIRCUIT DIAGRAM .......................................................................... A-14
APPENDIX 13: DATA TAG INFORMATION .............................................................................. A-15
APPENDIX 14: TORCH PIN-OUT DIAGRAMS ........................................................................ A-16
APPENDIX 15: TORCH CONNECTION DIAGRAMS ............................................................... A-17

TABLE OF CONTENTS (continued)
APPENDIX 16A: SYSTEM SCHEMATIC (208/230-Volt Units) ................................................. A-18
APPENDIX 16B: SYSTEM SCHEMATIC (400-Volt, 415-Volt, 460-Volt Units) .......................... A-20
APPENDIX 16C: SYSTEM SCHEMATIC (600-Volt Units) ....................................................... A-22
APPENDIX 17: Publication History ......................................................................................... A-24
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,
produces 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
& Safety Code Sec. 25249.5 et seq.)
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes- ELECTRIC SHOCK
sional and the 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 in- electric energy can cause severe or fatal shock to the op-
structions before using the equipment. Call 1-603- erator or others in the workplace.
298-5711 or your local distributor if you have any
questions. • Never touch any parts that are electrically “live”
or “hot.”
Manual 0-2853 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
• Install and maintain equipment according to NEC eyes and burn your skin if you are not properly protected.
code, refer to item 9 in Subsection 1.03, Publica-
• To protect your eyes, always wear a welding hel-
tions.
met or shield. Also always wear safety glasses with
• Disconnect power source before performing any side shields, goggles or other protective eye wear.
service or repairs.
• Wear welding gloves and suitable clothing to pro-
• Read and follow all the instructions in the Operat- tect your skin from the arc rays and sparks.
ing Manual.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
FIRE AND EXPLOSION • Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or • Use the shade of lens as suggested in the following
the plasma arc. per ANSI/ASC Z49.1:
Minimum Protective Suggested
• Be sure there is no combustible or flammable ma-
Arc Current Shade No. Shade No.
terial in the workplace. Any material that cannot
be removed must be protected. Less Than 300* 8 9
• Ventilate all flammable or explosive vapors from 300 - 400* 9 12

the workplace. 400 - 800* 10 14
• Do not cut or weld on containers that may have
* These values apply where the actual arc is clearly
held combustibles.
seen. Experience has shown that lighter filters
• Provide a fire watch when working in an area where may be used when the arc is hidden by the work-
fire hazards may exist. piece.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under- 1.03 Publications
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table Refer to the following standards or their latest revisions
unless the hydrogen gas can be eliminated or dis- for more information:
sipated. Trapped hydrogen gas that is ignited will 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
cause an explosion. 1910, obtainable from the Superintendent of Docu-
ments, 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. Govern-
• To protect your hearing from loud noise, wear pro- ment 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 0-2853

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain- ATTENTION
able from American National Standards Institute, 1430
Broadway, New York, NY 10018 Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
7. AWS Standard A6.0, WELDING AND CUTTING CON-
respect de la procédure en question.
TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-
tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection Toute procédure pouvant provoquer des blessures
Association, Batterymarch Park, Quincy, MA 02269 de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, procédure en question.
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO- 1.05 Precautions De Securite
CESSES, obtainable from the National Fire Protection Importantes
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the AVERTISSEMENTS
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
L’OPÉRATION ET LA MAINTENANCE DU
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD- MATÉRIEL DE SOUDAGE À L’ARC AU JET
ING AND CUTTING, obtainable from the Canadian DE PLASMA PEUVENT PRÉSENTER DES
Standards Association, Standards Sales, 178 Rexdale RISQUES ET DES DANGERS DE SANTÉ.
Boulevard, Rexdale, Ontario, Canada M9W 1R3
Coupant à l’arc au jet de plasma produit de l’énergie
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY électrique haute tension et des émissions
obtainable from the National Welding Supply Associa- magnétique qui peuvent interférer la fonction
tion, 1900 Arch Street, Philadelphia, PA 19103
propre d’un “pacemaker” cardiaque, les appareils
14. American Welding Society Standard AWSF4.1, RECOM- auditif, ou autre matériel de santé electronique.
MENDED SAFE PRACTICES FOR THE PREPARA- Ceux qui travail près d’une application à l’arc au
TION FOR WELDING AND CUTTING OF CONTAIN- jet de plasma devrait consulter leur membre
ERS AND PIPING THAT HAVE HELD HAZARDOUS professionel de médication et le manufacturier de
SUBSTANCES, obtainable from the American Welding matériel de santé pour déterminer s’il existe des
Society, 550 N.W. LeJeune Rd, Miami, FL 33126 risques de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY Il faut communiquer aux opérateurs et au person-
PROTECTION, obtainable from American National nel TOUS les dangers possibles. Afin d’éviter les
Standards Institute, 1430 Broadway, New York, NY blessures possibles, lisez, comprenez et suivez tous
10018 les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
1.04 Note, Attention et Composez le + 603-298-5711 ou votre distributeur
Avertissement local si vous avez des questions.
Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des
FUMÉE et GAZ
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
La fumée et les gaz produits par le procédé de jet de
NOTE plasma peuvent présenter des risques et des dangers de
Toute opération, procédure ou renseignement santé.
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

• Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”;
tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous
provenant du chalumeau. de la pièce de travail ou des autres parties du circuit
de soudage.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée • Réparez ou remplacez toute pièce usée ou
et les gaz. endommagée.
• Les sortes de gaz et de fumée provenant de l’arc de • Prenez des soins particuliers lorsque la zone de tra-
plasma dépendent du genre de métal utilisé, des vail est humide ou moite.
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous • Montez et maintenez le matériel conformément au
coupez ou soudez tout métal pouvant contenir un ou Code électrique national des Etats-Unis. (Voir la page
plusieurs des éléments suivants: 5, article 9.)
antimoine cadmium mercure • Débranchez l’alimentation électrique avant tout tra-

argent chrome nickel vail d’entretien ou de réparation.
arsenic cobalt plomb • Lisez et respectez toutes les consignes du Manuel de
baryum cuivre sélénium consignes.
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci INCENDIE ET EXPLOSION
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements Les incendies et les explosions peuvent résulter des scories
quant à la quantité et la nature de la fumée et des gaz chaudes, des étincelles ou de l’arc de plasma. Le procédé
pouvant poser des dangers de santé. à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
• Pour des informations sur la manière de tester la
bustibles ou provoquer l’explosion de fumées
fumée et les gaz de votre lieu de travail, consultez
inflammables.
l’article 1 et les documents cités à la page 5.
• Soyez certain qu’aucune matière combustible ou in-
• Utilisez un équipement spécial tel que des tables de
flammable ne se trouve sur le lieu de travail. Protégez
coupe à débit d’eau ou à courant descendant pour
toute telle matière qu’il est impossible de retirer de la
capter la fumée et les gaz.
zone de travail.
• N’utilisez pas le chalumeau au jet de plasma dans une
• Procurez une bonne aération de toutes les fumées
zone où se trouvent des matières ou des gaz combus-
inflammables ou explosives.
tibles ou explosifs.
• Ne coupez pas et ne soudez pas les conteneurs ayant
• Le phosgène, un gaz toxique, est généré par la fumée
pu renfermer des matières combustibles.
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée. • Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des • Le gas hydrogène peut se former ou s’accumuler sous
éléments reconnu dans L’état de la Californie, qui les pièces de travail en aluminium lorsqu’elles sont
peuvent causer des défauts de naissance et le cancer. coupées sous l’eau ou sur une table d’eau. NE PAS
(La sécurité de santé en Californie et la code sécurité couper les alliages en aluminium sous l’eau ou sur
Sec. 25249.5 et seq.) une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le RAYONS D’ARC DE PLASMA
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut Les rayons provenant de l’arc de plasma peuvent blesser
produire des chocs graves, voire mortels, pour l’opérateur vos yeux et brûler votre peau. Le procédé à l’arc de
et les autres personnes sur le lieu de travail. plasma produit une lumière infra-rouge et des rayons

ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference
yeux et brûleront votre peau si vous ne vous protégez
pas correctement. Consultez les normes suivantes ou les révisions les plus
• Pour protéger vos yeux, portez toujours un casque ou récentes ayant été faites à celles-ci pour de plus amples
un écran de soudeur. Portez toujours des lunettes de renseignements :
sécurité munies de parois latérales ou des lunettes de 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
protection ou une autre sorte de protection oculaire. PROTECTION DE LA SANTÉ, 29CFR 1910,
• Portez des gants de soudeur et un vêtement protecteur disponible auprès du Superintendent of Documents,
approprié pour protéger votre peau contre les U.S. Government Printing Office, Washington, D.C.
étincelles et les rayons de l’arc. 20402
• Maintenez votre casque et vos lunettes de protection 2. Norme ANSI Z49.1, LA SÉCURITÉ DES
en bon état. Remplacez toute lentille sale ou OPÉRATIONS DE COUPE ET DE SOUDAGE,
comportant fissure ou rognure. disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
• Protégez les autres personnes se trouvant sur la zone LeJeune Rd., Miami, FL 33126
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection. 3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
• Utilisez la nuance de lentille qui est suggèrée dans le L’ARC ET AU GAZ, disponible auprès du Superin-
recommendation qui suivent ANSI/ASC Z49.1: tendent of Documents, U.S. Government Printing
Nuance Minimum Nuance Suggerée
Office, Washington, D.C. 20402
Courant Arc Protective Numéro Numéro
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
Moins de 300* 8 9 PROTECTION DES YEUX ET DU VISAGE AU TRA-
300 - 400* 9 12
VAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na-
400 - 800* 10 14 tional Standards Institute), 1430 Broadway, New York,
* Ces valeurs s’appliquent ou l’arc actuel est observé NY 10018
clairement. L’experience a démontrer que les filtres 5. Norme ANSI Z41.1, NORMES POUR LES
moins foncés peuvent être utilisés quand l’arc est CHAUSSURES PROTECTRICES, disponible auprès
caché par moiceau de travail. de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
BRUIT 6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American Na-
Le bruit peut provoquer une perte permanente de l’ouïe.
tional Standards Institute, 1430 Broadway, New York,
Les procédés de soudage à l’arc de plasma peuvent
NY 10018
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les 7. Norme A6.0 de l’Association Américaine du Soudage
oreilles contre les bruits forts afin d’éviter une perte (AWS), LE SOUDAGE ET LA COUPE DE
permanente de l’ouïe. CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
• Pour protéger votre ouïe contre les bruits forts, portez
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
des tampons protecteurs et/ou des protections
33126
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail. 8. Norme 51 de l’Association Américaine pour la Pro-
tection contre les Incendies (NFPA), LES SYSTEMES
• Il faut mesurer les niveaux sonores afin d’assurer que
À GAZ AVEC ALIMENTATION EN OXYGENE
les décibels (le bruit) ne dépassent pas les niveaux
POUR LE SOUDAGE, LA COUPE ET LES
sûrs.
PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-
• Pour des renseignements sur la manière de tester le tional Fire Protection Association, Batterymarch Park,
bruit, consultez l’article 1, page 5. Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, disponible auprès de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-
pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward

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

1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the
original retail purchaser that new Thermal Dynamics CUTMASTER™ 1Series plasma cutting systems sold after the effective date of this
warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable
period stated below, Thermal Dynamics Corporation shall, upon notification thereof and substantiation that the product has been stored
operated and maintained in accordance with Thermal Dynamics’ specifications, instructions, recommendations and recognized industry
practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at
which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods
begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Power Supply Components Torch and Leads

Product
(Parts and Labor) (Parts and Labor)
CUTMASTER™ 51 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective May 23, 2005

SECTION 2: 2.02 General Service Philosophy
INTRODUCTION Several key points are essential to properly support the
application and operation of this equipment.
A. Application
2.01 Scope Of Manual
The equipment should satisfy the customer’s require-
This manual provides service instructions for the CutMas- ments as supplied and as described in Section 3 of this
ter 101 Plasma Cutting Power Supply. Information in manual. Be sure to confirm that the equipment is capable
this manual is particularly applicable to the troubleshoot- of the application desired.
ing and repair of this power supply, and is intended for
use by properly-trained service technicians familiar with B. Modifications
this equipment.
No physical or electrical modifications other than selec-
For setup of this equipment, individual operating proce- tion of standard options and Accessories are to be made
dures, and basic troubleshooting, refer to Operating to this equipment.
Manual (0-2852).
C. Customer/Operator Responsibilities
Read both the operating manual and the service manual
It is the customer/operator's responsibility to maintain
thoroughly. A complete understanding of the capabili-
the equipment and peripheral accessories provided by
ties and functions of this equipment will assure obtain-
Thermal Dynamics in good operating order in accordance
ing the performance for which it was designed.
with the procedures outlined in the operating manual,
The CutMaster™ 101 Power Supply is available for the and to protect the equipment from accidental or mali-
following input voltages: cious damage.
• 208/230-Volt Single-Phase D. Repair Restrictions

• 400-Volt Three-Phase The electronics consists of Printed Circuit Board (PCB)
• 415-Volt Three-Phase Assemblies which must be carefully handled and must
be replaced as units. No replacement of printed circuit
• 460-Volt Three-Phase
solder-mounted components is allowed except as noted
• 600-Volt Three-Phase in this manual.
The 460-Volt Three-Phase unit may be converted for
If PC boards are to be returned, the replaced Printed Cir-
Single-Phase input power with a change of input power
cuit Board Assemblies must be properly packaged in pro-
cord.
tective material and returned intact per normal proce-
This Service Manual covers all types. Particular attention dures.
is required in the Trouble-Shooting Section (Section 4) to
ensure that the technician selects the proper test points 2.03 Service Responsibilities
and measurements for the Power Supply being serviced.
The service technician should be familiar with the equip-
ment and its capabilities and should be prepared to rec-
ommend arrangements of components which will pro-
vide the most efficient layout, utilizing the equipment to
its best possible advantage.
Maintenance work should be accomplished in a timely
manner. If problems are encountered, or the equip-
ment does not function as specified, contact the Tech-
nical Services Department at West Lebanon, NH for
assistance (1-603-298-5711).
Manual 0-2853 2-1 INTRODUCTION

This Page Left Blank
INTRODUCTION 2-2 Manual 0-2853

SECTION 3: DESCRIPTION
3.01 Scope
The purpose of this section is:
• To familiarize the service technician with the capabilities and limitations of the equipment;
• To provide an overall understanding which will allow the technician, in turn, to properly train customer operat-
ing personnel.
The power supply includes all control circuitry, electrical and air inputs and outputs, pilot circuitry, work cable with
clamp, and input power cable.
3.02 Power Supply Specifications
CutMaster 101 Power Supply Specifications

208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz
400 VAC (360 - 440 VAC), Three Phase, 50/60 Hz
415 VAC CE (370 - 460 VAC), Three Phase, 50 Hz
Input Power
460 VAC (414 - 506 VAC), Single Phase, 60 Hz
460 VAC (414 - 506 VAC), Three Phase, 60 Hz
600 VAC (517 - 632 VAC), Three Phase, 60 hz
Input Power Cable Cable for 208/230 VAC unit includes plug.
Output Current 20 - 80 Amps, Continuously Adjustable
Power Supply
Particulates to 20 Microns
Gas Filtering Ability
CutMaster 101 Power Supply Duty Cycle *
Ambient Temperature 40° C (104° F)
IEC TDC IEC TDC IEC TDC
Rating Rating Rating Rating Rating Rating
Duty Cycle 40% 60% 100%
208/230V
Current 80A 78A 68A 68A 45A 45A
and 460V Units
DC Voltage 112V 120V 107V 111V 98V 98V
Duty Cycle 35% 60% 100%
400V and 415V Units Current 80A n/a 68A n/a 45A n/a
DC Voltage 112V n/a 107V n/a 98V n/a
Duty Cycle 35% 60% 100%
600V Units Current 80A 78A 68A 68A 43A 43A
DC Voltage 112V 120V 107V 111V 97V 97V
NOTE:
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 0-2853 3-1 DESCRIPTION

Handle and Leads Wrap
Control Panel
Torch Leads Receptacle
Art # A-03578
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
DESCRIPTION 3-2 Manual 0-2853

1. Front Panel Controls and Features
• Main Power ON / OFF Switch
• RUN /RAPID AUTO RESTART SET Switch
• Output Current Control (A) Sets output current for drag cutting (up to 40 Amps for drag cutting, with the torch
tip in contact with the workpiece, or for standoff cutting (up to 80 amps).
2. Front Panel Indicators
• AC When lighted, indicates AC input power is present in thepower supply.
• GAS When lighted, indicates that adequate input air pressure for power supply operation is present.
• TEMP When lighted, indicates the power supply is overheated.
• DC When lighted, indicates that power supply output circuits are active.
NOTE
Minimum pressure for power supply operation is lower than minimum pressure for torch operation.
3. Dimensions and Weight
83 lb / 37.6 kg
17.3 in /
439 mm
27.5 in / 696 mm
12.4 in /
A-03572
315 mm
3.03 Air Regulator/Filter Assembly Specifications

The following specifications apply to the Air Regulator/Filter Assembly only:
1. Operating Pressure
65 psi (4.5 bar)
2. Maximum input air supply pressure
125 psi (8.6 bar)
Manual 0-2853 3-3 DESCRIPTION

DESCRIPTION 3-4 Manual 0-2853

SECTION 4: 4.03 System Theory
TROUBLESHOOTING A. Logic PC Board Functions
The Logic PC Board controls the timing and sequenc-
ing of the system. It monitors gas pressure and power
4.01 Introduction supply internal temperatures, and controls the gas flow.
This section provides service diagnostics for the CutMas- The Logic Board also controls the safety latch circuit.
ter 101 Power Supply, allowing the Technician to isolate After the ON/OFF switch is closed on the front panel,
any faulty subassemblies. Refer to Section 5, Repairs & the AC Indicator turns on.
Replacement Procedures, for parts replacement instruc-
tions.
The GAS indicator is ON when there is sufficient
Under no circumstances are field repairs to be attempted
on Printed Circuit Boards or other subassemblies of this gas pressure in the power supply to enable power sup-
unit. Evidence of unauthorized repairs will void the fac- ply operation.
tory warranty. NOTE
NOTE Minimum gas pressure for power supply operation
The troubleshooting contained in this manual is is lower than the minimum for torch operation.
for the Power Supply only. Troubleshooting other When the unit is at “idle” the AC indicator on
parts of the system is covered in the manuals for the Front Panel should be ON. When the torch is acti-
those products. vated, the gas begins to flow. After a brief preflow, the
INV ON signal is given, and the DC indicator on
4.02 Periodic Inspection & Cleaning the Front Panel turns ON.
Procedures An open circuit voltage of approximately 230 to 300 vdc
(depending on input power) is produced when the
switching of the IGBTs in the Main PC Board is turned
WARNING ON by an INV ON signal from the Logic PC Board. A
circuit on the Logic PC Board monitors the output volt-
age. When the output voltage drops below 60 vdc, indi-
Disconnect primary power and bleed down the sys- cating a problem exists, the Logic PC Board sends a sig-
tem before disassembling the torch, leads, or power nal which turns OFF the INV ON Enable signal. This
supply. happens in less than 50 milliseconds.
To clean the unit, open the enclosure per procedure in When the torch is activated, gas will flow for approxi-
section 5.05-A, Cover Removal, and use a vacuum cleaner mately two seconds before DC is established (indi-
to remove any accumulated dirt and dust. The unit cated on the front panel). Then the gas shuts off briefly.
should also be wiped clean. If necessary, solvents for The gas flow then starts again and the torch starts a
cleaning electrical apparatus may be used. pilot arc.
Refer to the Appendix for maintenance schedule and pro- When the torch is close to the workpiece, the cutting
cedures. arc "transfers" to the work.
The resulting current is sensed by the Current Sense
circuit, resulting in the demand level changing from
pilot current to the main current control setting, and
then the main cutting arc starts. If the torch is removed
from the workpiece while the torch switch is still
pressed, the main arc extinguishes and the pilot arc
automatically restarts.
CutMaster 101 Logic Board Indicators

Indicator Meaning
D13 Inverter ON
D33 Torch Switch ON
D25 Drag Circuit ON
Manual 0-2853 4-1 TROUBLESHOOTING

4.04 Common Operating Problems E. Dross
When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
WARNINGS dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
Disconnect primary power at the source before dis-
be wiped off with a welding glove. "Slow speed dross"
assembling the power supply, torch, or torch leads.
is normally present on the bottom edge of the plate.
Frequently review the Important Safety Precau- It can vary from a light to heavy bead, but does not
tions in Section 1. Be sure the operator is equipped adhere tightly to the cut edge, and can be easily
with proper gloves, clothing, and eye and ear pro- scraped off. "High speed dross" usually forms a nar-
tection. Make sure no part of the operator's body row bead along the bottom of the cut edge and is very
comes into contact with the workpiece while the difficult to remove. When cutting a troublesome steel,
torch is activated. it is sometimes useful to reduce the cutting speed to
produce "slow speed dross". Any resultant cleanup
Sparks from the cutting process can cause damage can be accomplished by scraping, not grinding.
to coated, painted, and other surfaces such as glass,
plastic and metal. F. Parts - In - Place Circuit
Handle torch leads with care and protect them from The power supply connects to Models SL60 or SL100
damage. Torches. Parts-In-Place circuitry in the power supply
checks for the presence of torch consumable parts in
A. Piloting the torch head. When the shield cup is properly in-
stalled, there is a slight gap between the shield cup
Piloting is harder on parts life than actual cutting be- and the torch handle. Gas vents through this gap as
cause the pilot arc is directed from the electrode to part of normal operation. Do not attempt to force the
the tip rather than to a workpiece. Whenever pos- shield cup to close this gap. Forcing the shield cup
sible, avoid excessive pilot arc time to improve parts against the torch head or torch handle can damage
life. torch components.
B. Torch Standoff G. Common Cutting Faults
Improper standoff (the distance between the torch tip 1. Insufficient Penetration
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect a. Cutting speed too fast
the bevel angle. Reducing standoff generally results b. Torch tilted too much
in a more square cut.
c. Metal too thick
C. Edge Starting
d. Worn torch parts
For edge starts, hold the torch perpendicular to the
workpiece with the front of the torch tip at the edge e. Cutting current too low
of the workpiece, not touching, at the point where the f. Non-Genuine Thermal Dynamics parts used
cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to “reach” 2. Main Arc Extinguishes
for the edge of the metal. Establish the cutting arc as a. Cutting speed too slow
quickly as possible.
b. Torch standoff too high from workpiece
D. Direction of Cut
c. Cutting current too high
The plasma gas stream swirls as it leaves the torch.
The purpose of the swirl is to maintain a smooth col- d. Work cable disconnected
umn of gas. The swirl effect results in one side of a e. Worn torch parts
cut being more square than the other. Viewed along
the direction of travel, the right side of the cut is more f. Non-Genuine Thermal Dynamics parts used
square than the left.
TROUBLESHOOTING 4-2 Manual 0-2853

3. Excessive Dross Formation The troubleshooting guide has subsections as follows:
a. Cutting speed too slow Section 4.06 - Circuit Fault Isolation
b. Torch standoff too high from workpiece Section 4.07 - Main Input and Internal Power Prob-
lems
c. Worn torch parts
Section 4.08 - Pilot Arc Problems
d. Improper cutting current
Section 4.09 - Main Arc Problems
e. Non-Genuine Thermal Dynamics parts used
Section 4.10 - Test Procedures
4. Short Torch Parts Life
Subsection 4.10 includes specific test procedures and in-
a. Moisture in air source
dicator status identification tables. The subsection is ref-
b. Exceeding system capability (material too thick) erenced by the troubleshooting guide for the specific test
to be performed. The Power Supply is available for sev-
c. Excessive pilot arc time eral input voltages. The technician must select the proper
d. Gas pressure too low test points and measurements for the Power Supply being
serviced.
e. Improperly assembled torch
B. How to Use the Troubleshooting Guide
f. Incorrect torch parts for the operation
The following information is a guide to help the Service
g. Non-Genuine Thermal Dynamics parts used Technician determine the most likely causes for various
symptoms. This guide is set up in the following manner:
4.05 Troubleshooting Guide -
1. Perform operational check(s) on the equipment to iso-
General Information late problem to possible circuit(s) per Subsection 4.06,
Circuit Fault Isolation.
2. Determine symptom and isolate to defective assem-
WARNING
bly using the following format:
X. Symptom (Bold Type)
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to Any Special Instructions (Text Type)
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot- 1. Cause (Italic Type)
ing techniques. a. Check/Remedy (Text Type)
3. Locate your symptom in the appropriate Subsection.
A. General Information
4. Check the causes (easiest listed first) for the symptom.
This Section covers advanced troubleshooting, which re-
quires power supply disassembly and live measurements. 5. Check the remedies listed for each cause.
Advanced troubleshooting and repair of this unit is a pro-
cess which should be undertaken only by those familiar 6. Repair as needed being sure to verify that unit is fully
with high voltage high power electronic equipment. operational after any repairs.
If major complex subassemblies are faulty, the faulty sub- NOTES

assembly must be returned for repair. Many signals are transferred between Printed Cir-
NOTE cuit Board Assemblies on Cables. If these cables
become faulty they can then cause various prob-
Follow all instructions as listed and complete each lems. Do not forget about these cables when
in the order presented. troubleshooting.
While troubleshooting visually inspect the internal
components for signs of overheating, fractures and
damage.

4.06 Circuit Fault Isolation B. Initial Setup Conditions
This section is to help isolate the defective circuit before
A. Controls and Indicators
troubleshooting, identify symptoms, and test the unit for
proper operation. Follow the instructions as given to iden-
tify the possible symptom(s) and the defective circuit.
4 After repairs are complete, run the following tests again
A to verify that the unit is fully operational.
40 5
3 60
6 1. Connect gas supply to rear of Power Supply.
7 2. Turn on gas supply and set operating pressure per

pressure setting label on power supply.
20 80 NOTE
Minimum gas pressure for power supply operation
2
1 is lower than the minimum for torch operation.
3. Set the Power Supply controls as follows:
• ON/OFF switch to OFF (Down)
Art # A-03846
• RUN / RAPID AUTO RESTART / SET switch to
SET (Down)
1. ON/OFF switch. This switch controls AC power to the • CURRENT control (A) to maximum
unit. Up is ON, down is OFF.
C. Main Input and Internal Power Tests
2. RUN / RAPID AUTO RESTART / SET switch. This
1. Connect main AC power to the unit.
switch controls gas flow to the torch. Up is RUN, for
general torch operation. Center position is RAPID 2. Set the Power Supply ON/OFF switch to ON (up) and
AUTO RESTART, for an uninterrupted restart when note the following:
cutting expanded metal or in gouging or trimming op-
erations. Down is SET, for setting gas pressure and • AC indicator is steady ON
purging lines. • Main PCB Relay energizes, pulling in main input
contactor (W1)
3. Current control knob (A) This control regulates cur-
rent to the torch. At output settings over 40 amps, cir-
cuitry in the power supply automatically reduces out- • TEMP Indicator is OFF
put current to 40 amps if the torch tip contacts the
workpiece. • GAS Indicator is ON if input pressure is suffi-
4. AC indicator When lit, indicates operating cient for power supply operation.
power is present in the unit.
NOTE
5. TEMP indicator turns on when internal sensors Minimum gas pressure for power supply operation
is lower than the minimum for torch operation.
detect temperatures above normal limits.
• DC indicator is OFF
6. GAS indicator Indicates adequate gas pressure • Gas flows
• Fans operate
for power supply operation.
3. Set the Power Supply RUN / RAPID AUTO RESTART
NOTE / SET switch to the RUN (up) position and note the
Minimum gas pressure for power supply opera- following:
tion is lower than the minimum for torch opera- • Gas flow stops
tion.
This completes the Main Input and Internal Power Tests.
7. DC indicator Indicates DC power output circuit If the above are all correct then proceed to paragraph 'D'. If
is active. (Torch must be activated). not, note the symptom and proceed to Subsection 4.07,
Main Input and Internal Power Problems.

D. Pilot Arc Test 3. Carefully lift the cover off the unit, and remove the nut
securing the ground wire to the side panel.
1. Activate the torch (press torch switch on the handle,
send START signal from CNC Control, or press the 4. Re-install the cover by reversing the above steps.
torch switch on the Remote Pendant) to establish a
pilot arc and note the following:
• Gas flows
Upper screws
• Preflow delay (approximately two seconds) then DC
indicator turns ON
• Pilot arc is established
Lower
This completes the Pilot Arc Test. If the above are all cor- screws
rect then proceed to paragraph 'E'. If the unit does not
function properly, then note the symptom and proceed
to Subsection 4.08, Pilot Arc Problems.
E. Main Arc Test Lower
screws
Make sure the work cable is firmly connected to the work-
piece. Activate the torch (press torch switch on the handle,
send START signal from CNC Control or press the torch Ground wire
switch on the Remote Pendant) to establish a pilot arc.
Bring the torch to within 1/8"-3/8" (3-10 mm) of the work-
piece to establish the main cutting arc, and note the fol-
lowing:
• Main cutting arc transfers to workpiece.

This completes the Main Arc Test. If the above are all
correct then the equipment should be operating properly.
If problems still persist then contact Technical Services.
Art # A-03792
If the torch does not function as noted then note the symp-
tom and proceed to Subsection 4.09, Main Arc Problems.
4.07 Main Input and Internal

Cover Removal
Power Problems
A. Opening Power Supply Enclosure Locate your symptom below:
The cover of the Power Supply must be removed for ac- A. Main power line fuses blow as soon as main
cess to input power connections and test points. disconnect is closed
1. Input power cable installed incorrectly or defective
power cord.
WARNING
a. Check that the input power cable is not defec-
tive or installed incorrectly. Section 4.10-D il-
Disconnect primary power at the source before as- lustrates wiring connections.
sembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies. 2. Main input contactor (W1) stuck.
a. Check contactor. Replace if stuck.
1. Remove the upper screws securing the cover to the
main assembly. B. Main power line fuses blow immediately after the
ON/OFF Switch is turned on.
2. Loosen, but do not remove, the lower screws.
1. Faulty Input Diode
NOTE
a. Test Input Diode per Subsection 4.10-C; repair
There is a ground wire attached from the cover to as necessary.
the main body of the unit.

C. Fans do not operate; all control panel indicators OFF 6. Improper input power cable connections inside Power
Supply
1. Front Panel ON/OFF switch in OFF position
a. Refer to System Schematic and correct if needed.
a. Place switch to ON (up) position.
7. Defective input power cable
2. Main power disconnect open
a. Replace input power cable.
a. Close main power disconnect.
8. Fuse blown inside Power Supply
3. Torch is not properly connected to Power Supply.
a. Replace internal Fuse per Subsection 5.06-A.
a. Check torch connections to Power Supply.
Tighten or adjust as needed. 9. Line voltage above 10% tolerance (over voltage protec-
tion)
4. Shield cup not fully tightened on torch head.
a. Reduce line supply.
a. Check shield cup for proper installation. Do
not overtighten. 10. Faulty Auxiliary Transformer (refer to Appendix pages,
28 VAC Circuit Diagram)
5. Main power line fuses blown
Measure for 28 VAC on Main PC Board from J23-1
a. Replace main power line fuses.
to J23-3.
a. If voltage is not present, replace the Main PC
Board.
E22 TP4 FUSE TP1 U1 J23 J24 J34 J32 J29 J33 J18
E5
J16
E6
J17
J15
J27
E1 J43
E2 E32
INPUT
E3 DIODE
J26
J11
E15 E27
E7
E30
J25
E10
E20
Art # A-03651 IGBT A E33 E4 J30 J31 E23 IGBT B
Main Printed Circuit Board Layout (logic board not shown)

11. Faulty ON/OFF switch 4. Faulty Temperature Sensor / Switch
Measure for 28 VAC on the Main PC Board be- a. Shut input power off. Check IGBT Heatsink
tween J18-5 to J18-6. Temp Sensor (TS1). Disconnect wire connector
P29 from terminal J29 on Main PC Board. Check
a. If voltage is not present replace the ON/OFF
connector pins 1 and 2 for 10K ohm (±25%) (at
Switch.
ambient temperature). If resistance is not 10K
12. Faulty Main PC Board ohm (±25%), replace TS1.
Measure for 12 vdc on Main PC Board from TP4 to b. Shut input power off. Check Inductor Temp
TP1. Switch (TS2). Disconnect wire connector P32
from terminal J32 on Main PC Board. Check
a. If voltage is not present, replace the Main PC connector pins 1 and 2 for resistance. If resis-
Board. tance is greater than 12K ohms, replace output
inductor (L1). If temp switch is open, replace
D. Fans do not run; AC , GAS and TEMP Main PC Board.
indicators ON, DC indicator off E. No gas flow; RUN / RAPID AUTO RESTART /SET
switch in SET position; AC indicator ON;
A TEMP GAS and DC indicators OFF

Art # A-03984
Art # A-03985
1. Air flow through unit is restricted

a. Provide adequate air flow
2. Exceeded Duty Cycle of Power Supply 1. Gas supply not connected to unit
a. Deactivate torch and wait for fan to cool unit. Refer a. Connect to gas supply.
to Specifications Section for proper duty Cycle for
this unit. 2. Gas supply not turned on
3. Faulty Fan(s) a. Turn gas supply on.
Measure for 230 VAC (±) on the Main PC Board 3. Gas pressure too low
from J15-1 to J15-5, and from J15-2 to J15-6. a. Adjust gas pressure per pressure setting label
• If voltage at J15-1 to J15-5 is correct, replace lower on power supply.
Fan (M1). 4. Faulty RUN / RAPID AUTO RESTART / SET switch
• If voltage at J15-2 to J15-6 is correct, replace up- a. Check continuity.
per Fan (M2).
5. Faulty Gas Solenoid circuit
a. Test Gas Solenoid circuit per Subsection 4.10-E;
repair as necessary.
6. Faulty Logic Board
a. Replace logic board.

F. RUN / RAPID AUTO RESTART /SET switch in 2. Faulty Components in Unit
RUN or RAPID AUTO RESTART position; AC
Measure for 12 vdc from wire #10 to wire #11 at the
indicator ON; TEMP , GAS , and DC Gas Pressure Switch, located on the right side of
the unit.
indicators OFF
a. If 12 vdc is present and pressure is above 50 psi
(3.4 bar), replace Gas Pressure Switch/Solenoid
A Assembly. Refer to Section 5.08-A.
b. If pressure is above 50 psi (3.4 bar) and 12 vdc is
not present, replace the Logic PC Board.
Art # A-03986
c. Remove one wire from the pressure switch.

Check for ± 0 vdc at Main PC Board pin J24-3 to
J24-4 from the Logic PC Board. Refer to Main
PC Board Layout.
• If less than a volt, replace Logic PC Board.
1. Gas pressure too low

a. Set operating pressure per pressure setting la-
bel on power supply.
D13 TP6 D33
TP4
P1-7
TP2 P1-9
TP1
TP9
TP3
TP10
TP11
TP5 D25 TP8 TP7 Art # A-03654
Logic Board Layout

G. Gas continues to flow with RUN / RAPID AUTO I. Gas cycles on and off when power is turned on; AC
RESTART / SET switch in RUN position.
indicator flashes; TEMP indicator off,
1. Damaged gas solenoid.
a. Turn the front panel ON/OFF switch to OFF. GAS indicator ON
• If gas continues to flow, debris from the air line
is preventing the solenoid from closing. Clean
or replace the solenoid. A
2. Faulty RUN / RAPID AUTO RESTART / SET switch.
Art # A-03987
a. Put switch in SET position. Disconnect wire
harness connector from Main PC Board recep-
tacle J18. Check continuity through wire har-
ness sockets 7 and 8. If no continuity, replace
switch.
3. Faulty Logic PCB.
a. Measure for approximately 12 vdc between
P1-7 and TP-1 on the Logic PCB. 1. Torch shield cup is loose.
• If 0 vdc is present, replace Logic PCB. a. Tighten shield cup by hand. Do not overtighten.
H. Gas flows continuously when power is turned on; 2. Torch tip, electrode, or starter cartridge missing
a. Turn off power supply. Remove shield cup, in-
AC indicator flashes, TEMP indicator off,
stall missing parts.
GAS indicator ON, DC indicator off 3. Torch starter cartridge is stuck

a. Turn off power supply. Bleed down the system.
Remove shield cup, tip, and starter cartridge.
A Check starter cartridge lower end fitting for free
movement. Replace cartridge if lower end fit-
ting does not move freely.
Art # A-03987
Start Cartridge
Lower End Fitting
1. Torch switch is activated (closed) before user turns power

on Art # A-03621
a. Release torch switch, turn power supply OFF,

4. Shorted power supply torch receptacle
then ON (with torch switch released).
a. Turn Power Supply OFF. Bleed down the system.
2. Faulty torch switch Disconnect the torch from the power supply.
a. Turn power supply OFF. Disconnect torch from Check the torch receptacle for continuity between
the pilot connection and the negative / plasma
power supply. Refer to Appendix Pages for connection. Refer to Appendix pages. There
Torch Pin-Out Diagrams. Check torch switch should be no continuity.
continuity through sockets 3 and 4.
5. Shorted output power PC Board.
NOTE
a. Turn Power Supply OFF. Bleed down the system.
In mechanized (machine) torch applications, remote Refer to Appendix pages, Output Board Wiring Dia-
pendant control switch must also be closed. gram. Check output power PC Board for continuity
between terminals E35 and E64. If continuity is found,
replace Output Power PC Board.

E5
J16
E6
J17
J15
J27
E1 J43
E2 E32
INPUT
E3 DIODE
J26
J11
E15 E27
E7
E30
J25
E10
E20
Main Printed Circuit Board Layout (Logic PCB Not Shown)

4.08 Pilot Arc Problems 3. Faulty IGBT(s)
a. Measure between the following points on the
IGBTs:
WARNING
• IGBT A: E4 to E10
E10 to E20
The following tests must be performed with the power
supply connected to primary input power. There • IGBT B: E23 to E27
are extremely dangerous voltage and power levels
present inside this unit. Do not attempt to diagnose E27 to E30
or repair without proper training in power elec- Voltage should be approximately 20 vdc before
tronics measurement and troubleshooting tech- the start signal is active. If voltage measures
niques. greater than 100 vdc when the start signal is
active, replace the respective IGBT(s).
Locate your symptom below:
B. Torch will not pilot; RUN / RAPID AUTO RE-
A. Torch will not pilot; gas flows; AC indicator START /SET switch in RUN or RAPID AUTO
ON, GAS , TEMP , and DC indicators RESTART; AC and GAS indicators ON;
OFF
Temp and DC indicators OFF
A
A
Art # A-03988
Art # A-03990
1. Gas pressure is below power supply minimum require-

ment 1. Gas pressure is below torch minimum requirement
a. Adjust gas pressure per pressure setting label (NOTE: Minimum pressure for power supply opera-
on power supply. tion is lower than minimum required for torch opera-
tion.)
2. Upper O-ring on torch head is in wrong position.
a. Adjust gas pressure per pressure setting label
a. Remove shield cup from torch; check position of on power supply.
upper O-ring. Correct if necessary.
2. Torch tip, starter cartridge, or electrode missing.
a. Turn off power supply. Remove shield cup, in-
stall missing parts.
Upper Groove
with Vent Holes
Must Remain Open
Upper O-Ring
in Correct Groove
Threads
Lower O-Ring Art # A-03725

3. Torch starter cartridge is stuck 4. Faulty Temperature Sensor / Switch
a. Turn off power supply. Remove shield cup, tip,
and starter cartridge. Check lower end fitting CAUTION
on starter cartridge for free movement. Replace
cartridge if lower end fitting does not move freely. Turn off input power for the following tests.
a. Check IGBT Heatsink Temp Sensor (TS1). Dis-
Start Cartridge connect wire connector P29 from terminal J29
on Main PC Board. Check connector pins 1 and
2 for 10k ohm (± 25%) (at ambient temperature).
Lower End Fitting If resistance is not 10K ohm (±25%), replace TS1.
b. Check Inductor Temp Switch (TS2). Disconnect
wire connector P32 from terminal J32 on Main
PC Board. Check connector pins 1 and 2 for at
Art # A-03621 least 12K ohms. If resistance is less than 12K
ohms, replace output inductor (L1). If temp
switch is open, replace Main PC Board.
4. Worn or faulty torch parts
5. Faulty Main PC Board
a. Inspect torch consumable parts. Replace if nec-
essary. a. Check for (±) 12 vdc on Main PC Board between
TP4 and TP1. If (±) 0 vdc is present, replace
C. Torch will not pilot; AC , TEMP , and Main PC Board.
6. Faulty Fan(s)
GAS indicators ON, DC indicator off
Measure for (±) 230VAC on Main PC Board from
J15-1 to J15-5, and from J15-2 to J15-6.
A • If voltage at 15-1 to J15-5 is correct, replace upper

fan (M1).
• If voltage at 15-2 to J15-6 is correct, replace lower
Art # A-03989
fan (M2).
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 Specifi-
cations Section.
3. Input Line Voltage is low
a. Check and connect to proper input power line.

D. Gas flows; AC indicator and GAS indicators 2. Oil/moisture in air lines
ON; TEMP indicator off; DC indicator a. Put the ON / OFF switch in the ON (up) posi-
tion. Put the RUN / RAPID AUTO RESTART /
off or blinks on/off once. SET switch in the SET (down) position.
b. Place a welding filter lens in front of the torch
A 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-03991
c. Purge system. If problem corrected, add filters

OR
in line with air source.
3. Incorrect torch parts
a. Inspect the torch parts; replace as needed.
4. Faulty leads
a. Check torch leads continuity.
1. Faulty IGBT or Output Diode Module Assembly(s)
5. Faulty torch
a. Check per Subsection 4.10-C; repair as needed.
a. Check torch.
2. Faulty Main PCB
6. Faulty connection of wire #58 or 62 to Pilot Board
a. Test per Subsection 4.10-F; repair as needed.
a. Check wiring connection. Refer to the System
E No arc or intermittent arc in torch; Gas flows;
Schematic in the Appendix. Connections
AC , GAS and DC indicators ON; should be:
• Wire #58 to Pilot Board terminal E58
TEMP indicator off
• Wire #62 to Pilot Board terminal E62
If wires 58 and 62 are not connected to the proper
terminals, replace the Pilot Board.
A
7. Faulty Main PC Board
Art # A-03992
a. Check for approximately 12 vdc at TP4 to TP1.

If less than 2 vdc, replace the Main PC Board.
8. Faulty Logic Board or Faulty Pilot Board
a. Install a jumper between wires 58 and 62 on
Pilot Board and retry piloting. If torch pilots
with jumper installed, replace Pilot Board. If
torch does not pilot, replace Logic Board.
1. Gas pressure set incorrectly (too high)
a. Reset gas pressure per pressure setting label on
power supply.

4.09 Main Arc Problems 5. Faulty Main Input Contactor.
a. Check per Subsection 4.10-D.
Locate your symptom below:
B. When operating the amperage drops off after the
A. Main cutting arc will not start
main cutting arc starts.
1. Work cable not connected.
1. Torch tip contacts workpiece
a. Connect work cable.
Lift the torch tip off the work. At output settings
2. Holding too high of a standoff. over 40 amps, circuitry in the power supply au-
tomatically reduces output current to 40 amps if
a. Refer to recommended standoff heights. Adjust the torch tip contacts the workpiece.
as needed.
2. Faulty Pilot Board
3. Workpiece is painted or rusty.
a. With power off and wires E58 and E62 discon-
a. Clean workpiece. nected from the pilot board, measure for conti-
4. Faulty Main PC Board or Logic Board. nuity between terminals #E58 and #E62. If con-
tinuity is found, replace Pilot Board.
a. Measure for ±0 vdc at TP2 to TP1 on the Logic
Board when attempting to transfer. Refer to
Logic Board Layout.
• If voltage goes to 0 vdc replace Output Board.
• If not, replace Main PC Board.
E5
J16
E6
J17
J15
J27
E1 J43
E2 E32
INPUT
E3 DIODE
J26
J11
E15 E27
E7
E30
J25
E10
E20
Main Printed Circuit Board Layout (logic board not shown)

4.10 Test Procedures 5. Connect the volt/ohmmeter positive lead to the an-
ode (+) of the diode and the negative lead to the
The test procedures in this subsection are referenced in cathode (-) of the diode for forward bias testing (re-
the troubleshooting section. fer to following figure). A properly functioning di-
ode will conduct in the forward bias direction and
A. Safety Precautions indicate between 0.3 to 0.9 volts.
1. Significant DC Voltage exists after removal of input
power. Allow two minutes for discharge time. Volt-
age measured on input capacitors must be zero be- Art # A-00307
fore performing service on the power supply.

0.75
2. Do Not touch electrical components with any part of
the human body when power is applied.
3. Keep away from any moving parts.
Forward Bias
4. Hot surfaces can cause severe burns. Allow equip- Diode Conducting
ment to cool before servicing.
5. Electrostatic discharge can damage printed circuit Diode Test Symbol
board assemblies. Transport printed circuit boards in VR COM

_
A
proper antistatic shielded packages. Use proper +
Anode
grounding techniques with wrist strap before handling
printed circuit boards.
6. Misaligned plugs can cause printed circuit board dam-
age. Be sure plugs are properly aligned and com-
pletely seated. Cathode
7. Excessive pressure can damage printed circuit boards.

Testing Diode Forward Bias
Use only minimal pressure and gentle movement
when disconnecting or connecting printed circuit
board plugs. 6. Reverse the meter leads across the diode for reverse
bias testing (refer to following figure). A properly
B. Diode Testing Basics functioning diode will block in the reverse bias di-
rection and depending on the meter function will
indicate an open or “OL”.
WARNING
Art # A-00306
Disconnect primary power at the source before dis-

assembling the power supply, torch, or torch leads. OL
Testing of diode modules requires a digital volt/ohm-

meter that has a diode test scale. Remember that even if
the diode module checks good, it may still be bad. If in Reverse Bias
doubt, replace the diode module. Diode Not Conducting
1. Locate the diode module to be tested.

2. Remove cables from mounting studs on diodes to iso-
late the module. VR COM A
+ _
Cathode
3. Set digital volt/ohmmeter to diode test scale.
4. Using the Figures for each test, check each diode in the
module. Each diode must be checked in forward bias
(plus to negative) and reverse bias (negative to plus)
direction.
Anode
Testing Diode Reverse Bias

7. If a diode checks bad, replace the diode module. For 208/230-Volt Power Supplies:
8. Reconnect all cables.
208/230V Input Diode PCB
C. Diode Module Board Tests Meter (+) Meter (-) Indication
E7 E1 Open
E1 E7 Diode Drop
WARNING
E15 E1 Diode Drop
E1 E15 Open
Disconnect primary power at the source before tak- E15 E7 Diode Drop *
ing any resistance checks. E7 E15 Open
* Indication can be twice
1. Input Diode Module Board Circuit Test other indications.
a. Remove AC power. Refer to Appendix 5-A or 5-B,
Main PCB Wiring diagram. c. The meter should indicate a diode drop in one di-
rection and an open in the other direction for each
b. Check Input Diode for shorted input diode. With check. Replace the Input Diode Module Board if
an ohmmeter set on the diode range make the fol- the readings do not match the chart.
lowing checks from Main PC Board to Input Di-
ode: d. If Input Diode Module Board is shorted, make the
following checks with an ohmmeter at the Main
For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Contactor (W1):
Supplies:
Meter (+) Meter (-) Indication
L1 T1 Open
400V, 415V, 460V, and 600V L2 T2 Open
Input Diode Indications L3 T3 Open
Meter + Meter - Indication If any test has resistance, then replace the Main Con-
E15 E1 Diode Drop tactor.
E1 E15 Open
2. Output Diode Module Board Circuit Test
E15 E2 Diode Drop
E2 E15 Open a. Use an ohmmeter set on the diode function and
E15 E3 Diode Drop make the following measurements on the Output
E3 E15 Open Diode Module Boards to Power Output PC Board.
E7 E1 Open
E1 E7 Diode Drop Output Diode A Output Diode B Indication
E7 E2 Open Meter + Meter - Meter + Meter -
E2 E7 Diode Drop E37 E58 E36 E57 Diode Drop *
E7 E3 Open E58 E37 E57 E36 Open
E3 E7 Diode Drop E37 E47 E36 E49 Diode Drop
E7 E15 Open E47 E37 E49 E36 Open
E15 E7 Diode Drop* E58 E47 E57 E49 Open
* Indication can be twice E47 E58 E49 E57 Diode Drop
other indications. * Indication can be twice other indications.
b. The meter should indicate a diode drop in one di-

rection and an open in the other direction for each
check. Replace the Output Diode Module Board(s)
if the readings do not match the chart.

3. IGBT Module Board Circuit Test D. Main Input Power Test
a. Use an ohmmeter set on the diode function and
make the following measurements on the IGBT
WARNING
Module Board(s) to the Main PC Board.
IGBT PCB A IGBT PCB B Indication
Meter + Meter - Meter + Meter - The following tests must be performed with the
power supply connected to primary input power.
E10 E4 E27 E23 Diode Drop
There are extremely dangerous voltage and power
E4 E10 E23 E27 Open
levels present inside this unit. Do not attempt to
E10 E20 E27 E30 Open
diagnose or repair without proper training in power
E20 E10 E30 E27 Diode Drop electronics measurement and troubleshooting tech-
E4 E20 E23 E30 Open niques.
E20 E4 E30 E23 Diode Drop *
* Indication can be twice other indications.
Reconnect power and observe proper start-up procedure.
AC indicator on the Front Panel should be ON. If
b. The meter should indicate a diode drop in one di- indicator is OFF there is no voltage to the Power Supply or
rection and an open in the other direction for each an overvoltage condition exists.
check. Replace IGBT Module Board(s) if readings 1. If AC indicator on Front Panel is OFF, check
are not the same as the chart. for proper AC input voltage between input cables
on the Main Contactor. Input voltage should be as
shown in the following chart. If not, check for
proper voltage at the main power source.
D13 TP6 D33
TP4
P1-7
TP2 P1-9
TP1
TP9
TP3
TP10
TP11
TP5 D25 TP8 TP7 Art # A-03654
Logic Board Layout

2. Check for 28 VAC at J23-1 to J23-3 on the Main PC
Contactor Voltage Readings Board.
Nominal Contactor Voltage a. If greater than 30 VAC, input line power is too
Input Voltage Points Range high.
208/230VAC L1, L2 187-253VAC
400VAC L1, L3 360-440VAC b. If there is no AC power, check the fuse. If the
415VAC L1, L3 370-460VAC fuse is okay, the auxiliary transformer is faulty.
460VAC L1, L3 414-506VAC Replace the Main PC Board.
600VAC L1, L3 517-632 VAC E. Gas Solenoid Circuit Test
Make the following voltage checks and replace the faulty
part as required.
To E2 Connections to
Main PCB 1. Place the RUN / RAPID AUTO RESTART / SET
To E3 Switch to the SET position.
T3
T2
To E1 2. Measure for 28 VAC across Solenoid wires #8 and

L3
T1
#9. Refer to System Schematic in Appendix Sec-

L2
tion.
L1
Input Side
• If 28 VAC is present, replace Solenoid/Pressure
Switch Assembly.
L3
• If 28 VAC is not present, check for 65 psi (4.5
L2
bar) at the pressure regulator.
L1
3. Check for less than 2 vdc at P1-7 to TP1 on Logic
#12 #5 #4 Board.
Main Contactor
• If less than 2 vdc, replace Main PC Board.
#13
Art # A-03194 • If more than 2 vdc, replace Logic PC Board.
400 / 415 / 460 / 600-Volt Main Input Contactor

(Three-Phase Input Power Shown)
#78
T4
#3
T3
#2
L4
T2
L3
#1
T1
L2
L1
L2
L1
Main Contactor
#5
#12 Input
#13 Side
#4 Art # A-03212
208/230-Volt Main Input Contactor

F. Output Power Tests 2. Gate Drive & Sensing
1. No DC Output 1. Shut off input power. Replace the torch tip and
electrode. Remove the jumper betweenthe work lead
1. Activate the torch. and terminal E35 or E62 on the Output Power PC
• If INV ON indicator D13 on Logic PC Board Board.
does not turn ON, then replace the Logic PCB. 2. Install a jumper between TP1 and TP7 on the Logic
• If the INV ON indicator D13 blinks ON then Board. Refer to Logic Board layout.
OFF immediately, perform the following test: 3. When the unit is turned on, the DC light should
2. Turn input power OFF, and bleed down the system. remain ON.
3. Attach a #12 wire jumper between the work lead 4. Activate the torch. After two seconds INV ON Indi-
and terminal E35 or E62 on the Output Power PC cator (D13) on the Logic PCB should come on and
Board on the right side of the power supply. remain on.
4. Remove the tip and electrode from the torch. • If INV ON indicator does not remain on, replace
Logic PCB.
• If INV ON indicator remains on, then check for
WARNING at least 2 vdc between TP-1 to TP-11 and be-
tween TP-1 to TP-10 on the Logic PCB. Refer to
The following tests must be performed with the power Logic Board Layout.
supply connected to primary input power. There • If no voltage, replace Logic PC Board.
are extremely dangerous voltage and power levels
present inside this unit. Do not attempt to diagnose • If voltage is correct, measure for at least 2
or repair without proper training in power electron- vdc between points as in the following chart:
ics measurement and troubleshooting techniques.
IGBT A IGBT B
The next step will defeat the safety interlock feature. E11 J3 E11 J2B
Proceed with caution. E19 J10A E19 J10B
5. Turn on primary input power and the gas supply. • If voltage is 0, replace Main PCB.
Activate the torch switch. Gas should flow, then This completes the test procedures.
stop after 2 seconds. Front panel DC indicator
should turn on.
6. Measure open circuit voltage between E61(+) to
E43 (-) at the Output Power PC Board. Voltage
should be greater than 200 V. If voltage is less
than 10 V, refer to the diode test measurements
in Section 4.10-C.


B. Procedure
SECTION 5:
1. Open the wrist strap and unwrap the first two folds
REPLACEMENT of the band. Wrap the adhesive side firmly around
PROCEDURES your wrist.
2. Unroll the rest of the band and peel the liner from
the copper foil at the opposite end.
5.01 Scope
3. Attach the copper foil to a convenient and exposed
This section describes parts replacement procedures electrical ground.
which may be performed on the CutMaster 101 Power 4. Connect the equipment primary cable ground to
Supply. the same electrical ground as the wrist strap.
Under no circumstances are field repairs to be attempted 5. Open the equipment enclosure and remove the
on Printed Circuits or other subassemblies of this unit. failed PC board.
Evidence of unauthorized repairs may void the factory
warranty. 6. Carefully open the ESD protective bag and remove
the replacement PC Board.
5.02 Anti-Static Handling 7. Install the replacement PC Board in the equipment
Procedures and make all necessary connections.
A. General 8. Place the failed PC Board in the ESD protective

bag and seal for return shipping.
Caution: PC Boards can be irreparably damaged by im-
proper handling due to electrostatic discharge (ESD). 9. Replace the power supply cover.
Replacement PC Boards are shipped in a protective en- 10. Remove the grounding wrist strap from your wrist
closure to prevent damage from electrostatic discharge and from the electrical ground connection before
(ESD) during shipping. A ground strap is included with reconnecting primary power to the equipment.
each replacement board to prevent static damage during
installation. 5.03 Parts Replacement - General
Information
WARNINGS The parts replacement procedures described in this
manual, except for filter replacement, require that the
Power Supply be disassembled. The part to be replaced
Read and understand these instructions and the will determine to what extent the Power Supply must be
instructions on the grounding wrist strap package disassembled.
before opening the equipment enclosure or remov-
ing the replacement PC board from its protective Before removing any connection mark each wire with the
enclosure. connection designation. When reassembling make sure
the wires go to the proper terminals.
Disconnect primary power to the system before dis-
assembling the torch, torch leads, or power supply Note the routing of wires and make sure the wires are
enclosure. put back in the same place when re-assembling the unit.
Where these instructions include specific torquing Each subsection is referenced to Section 6 for parts lists
instructions, failure to torque properly will cause and overall detailed drawings.
component damage.
Do not operate the equipment or test equipment WARNING
under power while wearing the grounding wrist
strap.
Disconnect primary power from the source before
opening or disassembling the power supply.
Before disassembling any part of the Power Supply first

read the procedure for the part to be replaced, then pro-
ceed with the disassembly.
Manual 0-2853 5-1 REPLACEMENT PROCEDURES

5.04 Major External Parts B. Tube Handle Replacement
Replacement 1. Remove the cover per subsection 5.04-A.
Refer to Section 6.03 for Major External Replacement Parts 2. Remove the Fan Assembly Panel per section
and overall detailed drawing. 5.08-C.
3. Remove the four bolts and star washers securing
the frame to the base of the unit.
WARNING
4. Move the input power cable, torch leads and work
cable inside the handle. Lift the base of the unit
Disconnect primary power from the source before away from the Tube Handle. Leave the rear panel
opening or disassembling the power supply. fastened to the base assembly.
5. With a rubber mallet, separate the two handle ends
A. Cover Removal and Replacement
as shown below.
1. Remove the upper screws securing the cover to the
6. Install the replacement Tube Handle by reversing
unit. Loosen the lower screws securing the cover to
steps 1-4.
the base.
7. Replace the Fan Assembly Panel per section 5.08-C.
8. Re-install the Power Supply cover.
Upper screws
Lower
screws
Lower
screws
Ground wire
Art # A-02847
Art # A-03792
2. Carefully lift the cover up and away from the unit

for access to the ground wire connection on the
inside of the cover.
3. Remove the nut and washer from the ground stud
on the inside of the cover.
4. Install the replacement cover by reversing the above
steps.
REPLACEMENT PROCEDURES 5-2 Manual 0-2853

5.05 Front Panel Parts C. RUN RAPID AUTO RESTART / SET Switch
Replacement
Replacement
1. Remove the cover per subsection 5.04-A.
Refer to Section 6.04 for Front Panel Replacement Parts
and overall detailed drawing. 2. Disconnect the wires on the rear of the Switch. Note
the location of each wire, as shown:
WARNING
Top clip
Disconnect primary power from the source before

Wire #46
A. Current (A) Control Knob Replacement

Wire #26
1. Turn the control knob fully clockwise and note the
location of the pointer on the knob. Wire #25
Art # A-03906
2. Loosen the screw securing the Knob to the poten-
tiometer shaft and remove the Knob.
3. Squeeze together the clips on the top and bottom of
3. Place the replacement Knob on the potentiometer the Switch, then remove the switch through the
shaft with the location of the pointer the same as Front Panel.
noted in step 1.
4. Install the replacement Switch by reversing the
4. Tighten the screw to secure the knob to the poten- above steps.
tiometer shaft.
D. POT/LED PC Board Replacement
B. ON/OFF Switch Replacement
Follow the antistatic procedures provided in subsection
1. Remove the cover per subsection 5.04-A. 5.02.
2. Disconnect the wires on the rear of the ON/OFF 1. Remove the cover per subsection 5.04-A.
Switch. Note the location of each wire, as shown
2. Remove Current Knob per Subsection 5.05-A.
below:
3. Disconnect wire harness Connector from POT/
LED PC Board.
Top clip
4. Remove PC Board from standoffs.
5. Install the replacement POT/LED PC Board by re-
Wire #21 versing the above steps.
Wire #22
E. Work Cable Replacement
Wire #24
Wire #23 1. Remove the cover per subsection 5.04-A.
2. Disconnect the Work Cable from the E61 (WORK)
terminal on the Power Output PC Board, located
Art # A-02774 on the right side of the unit.
3. Squeeze the top and bottom of the Work Cable
3. Squeeze together the clips on the top and bottom Strain Relief and remove from the Front Panel.
of the Switch. Remove the Switch through the
4. Remove Work Cable from the unit.
Front Panel.
5. Install the replacement Work Cable.
4. Install the replacement Switch by reversing the
above steps. a. Ensure that the replacement Work Cable passes
through the grommet in the Fan Assembly Panel.
b. Secure the Cable to the Work terminal on the
Power Output PC Board and securing the strain
relief.

5.06 Left Side Internal Component
Parts Replacement To E2 Connections to
Main PCB
Refer to subsection 6.05 Left Side Internal Component To E3
T3
Replacement Parts and overall detailed drawing.
T2
To E1
L3
T1
L2
L1
WARNING
Input Side
Disconnect primary power from the source before L3

L2
A. Fuse Replacement L1
#12 #5 #4
1. Remove the cover per subsection 5.04-A. Main Contactor
2. Locate the Fuse near the top edge of the Main Power
PC Board and remove the Fuse from the fuse holder. #13
Art # A-03194
3. Install replacement fuse.

4. Reinstall the power supply cover. 400-Volt, 415-Volt, 460-Volt, and 600-Volt Input
Contactor (3 - phase input power connections
B. Main Input Contactor Replacement
shown)
1. Remove the cover per subsection 5.04-A.
2. Label all wires connected to the Input Contactor.
3. Disconnect wires to the Input Contactor from the
input cable. #78
T4
4. Disconnect all other wires connected to the Input #3
T3
#2
L4
Contactor.
T2
L3
#1
T1
5. Remove the two nuts and washers securing the L2
Input Contactor to the base of the power supply.
L1
6. Position the replacement Input Contactor with the
L2
row of connectors labeled L toward the rear of the
L1
Power Supply. Fasten in place with the hardware
removed previously.
7. Complete the wiring connections as shown.
Main Contactor
NOTE #5
#12 Input
It is important that wires are installed correctly, as
#13 Side
shown, to prevent damage to the unit. #4 Art # A-03212
8. Reinstall the power supply cover.
208 / 230-Volt Input Contactor

C. Logic PC Board Replacement 6. Use isopropyl alcohol and a clean rag to clean the
heatsink or chassis area behind the component be-
Follow the antistatic procedures in Subsection 5.02. The ing replaced. Clean the large flat surface on the
Logic PC Board connects to the Main PC Board through back of the replacement component. Do not scratch
an extender board perpendicular to both boards. or abrade the surface.
1. Remove the cover per subsection 5.04-A. 7. The thermal pad(s), provided with the replacement
2. Refer to Section 6.05, Left Side Internal Replace- part, is a thin metal pad. Remove any loose pro-
ment Parts. tective paper coverings from the pad(s).
3. Remove the bolts in each corner of the Logic PC NOTE

Board. Protective coverings must be removed from the
4. Detach the Logic PC Board and the extender board thermal pads. Installing thermal pads with pro-
from the Main Power PC Board. Detach the ex- tective coverings in place will cause equipment
tender board from the Logic Board. damage or failure.
5. Install the replacement Logic PC Board by revers- 8. Install replacement components as follows:
ing the above steps. The pins on the right edge of For Input Diodes:
the Logic PC Board must fully engage the sockets
on the edge of the extender board. The extender
board must fully engage sockets on the Main Slot
Power PC Board.
Thermal Pad
D. IGBT Circuit Board or Input Diode Board
Replacement
Follow the antistatic procedures in subsection 5.02. The
Power Supply includes two IGBT Circuit PC Boards.
Diode
NOTE Assembly
Follow the electrostatic discharge instructions pro-

vided with the replacement component to prevent
damage to the component.
Thermal pads, heatsinks, and the large flat surface Art # A-03950
on the back of diodes and IGBTs must be kept clean.

Diodes and IGBTs must not be bent or allowed to
pick up any foreign material. A very clean instal- Input Diode Replacement
lation between the module and the heatsink or chas-
sis is essential for proper operation. a. Apply the thermal pad to the flat surface of the
diode. Align the pad with the rectangular flat
1. Remove cover per subsection 5.04-A.
surface on the back of the device.
2. Turn the Power Supply onto its side.
b. Align the diode horizontally, with its longer
3. Locate the IGBT Circuit PC Boards or Input Diode edges perpendicular to the power supply base.
mounted within the Main Power PC Board. Refer
c. Secure the device and rectangular pad to the
to Appendix pages for location and position.
chassis with the replacement screws and wash-
4. For IGBTs, remove the small jumpers between the ers.
IGBT and the Main PC Board. Transfer these jump-
9. Torque screw(s) to 35 in-lb. (3.95 Nm).
ers to the replacement IGBT. Label, then remove
all other wire connections to the Board(s) being NOTE
replaced. Note the routing of wires. Ensure that
the wires are put back in the same place when in- Failure to torque properly will cause component dam-
stalling the replacement module. age.
5. Remove screw(s) securing PC Board(s) to the heat-

sink and remove board(s) from the Power Supply.

10. Connect wires per the chart. E. Main Power PC Board Replacement
Follow the antistatic procedures in subsection 5.02.
CutMaster 101 Input Diode Connections
400V, 415V, 460V, 1. Remove cover per subsection 5.04-A.
208/230V Units
600V Units 2. Remove the Logic PC Board per subsection 5.06-C.
Input Diode To Main PCB Input Diode To Main PCB
E5 E1 E5 E1 3. Disconnect all wire and cable connections to the
E13 E2
Main PC Board. Refer to the Main PC Board Wir-
E13, E18 E2 ing Diagrams in the Appendix Pages if necessary.
E18 E3
Straighten the connections to the smaller PC
E6, E8 E7 E6, E8 E7
Boards to be perpendicular to the Main PC Board.
E14, E16 E15 E14, E16 E15
5. Remove the two long Transformer screws securing
For IGBTs: the Transformer to the Center Chassis.
a. Apply a round thermal pad to the heatsink with 6. Remove the other screws securing the PC Board to
a small piece of light-duty tape. The tape must the Center Chassis.
cover no more than 1/8" (3 mm) of the edge of
the thermal pad. Use the screw hole in the heat-
sink as a guide to position the board.
Round
Output Diode Tape Thermal Pad
or IGBT Screw locations
Washer
Screw
Tape
Art # A-03165
Art # A-03702
b. Secure replacement board(s) with the screw re- 7. Carefully remove the original PC Board from the
moved previously. Ensure that the washer is unit.
under the head of the screw.
8. Transfer the Logic PC Board standoffs to the re-
9. Torque screw(s) to 17 in-lb. (1.9 Nm). placement Main PC Board.
NOTE 9. Install the replacement PC Board by reversing the
steps above. It may be easier to install the PC Board
Failure to torque properly will cause component dam- if the Power Supply is turned on its right side first.
age. Refer to the charts in subsection 5.06-D for input
10. Connect wires per the chart. diode and IGBT wiring connection points.
CutMaster 101 IGBT Connections

IGBT A IGBT B
IGBT A To Main PCB IGBT B To Main PCB
Connector Connector Connector Connector
J3 J25 J3 J31
J7 J30 J7 J26
E9, E11 E10 E9, E11 E27
E19, E21 E20 E19, E21 E30
E12, E17 E4 E12, E17 E23
11. Stand the unit upright; reinstall the cover.

F. EMI Filter Replacement (CE Units only) B. Filter/Regulator Bracket Replacement
1. Label the input power cable connections and the 1. Remove the four bolts securing the Regulator
cable connections to the main input contactor. Bracket to the Rear Panel.
2. Disconnect all wire and cable connections to the 2. Remove the nut securing the Filter/Regulator As-
EMI Filter. sembly to the Regulator Bracket. Remove the
Bracket from the Filter-Regulator Assembly.
3. RemovethehardwaresecuringtheEMIFilter. Thishardware
passes upward through the base of the power supply. 3. Install the replacement Bracket by reversing the
above steps.
4. Put the replacement EMI Filter in position and secure it
with the hardware removed in Step 3. C. Input Power Cable Replacement
5. Connect the input power cables and the cable connec- 1. Remove the cover per subsection 5.04-A.
tions to the main input contactor.
2. Locate and label the input power cable connec-
6. Re-install the Power Supply cover. tions and disconnect the cable.
7. Test the Power Supply for proper operation. 3. Unthread the retaining nut on the Input Cable
Strain Relief on the inside of the Rear Panel and
5.07 Rear Panel Parts Replacement remove the Input Power Cable from the unit.
Refer to subsection 6.06 for parts list and overall detailed 4. Install the replacement Input Power Cable by re-
drawing. versing the above steps. The Input Power Cable
ground wire requires a ring terminal.
D. Rear Panel Replacement
WARNING
Disconnect primary power from the source before WARNING

Disconnect primary input power and the gas sup-
A. Filter/Regulator Assembly Replacement ply at the source and bleed down the system before
performing this procedure.
WARNING 1. Remove the cover per subsection 5.04-A.

2. Remove the primary input power cable per section 5.07-
Disconnect the gas supply at the source and bleed C.
down the system before attempting this procedure.
3. Remove the Regulator/Filter Assembly per section
5.07-A.
1. Disconnect the gas input hose from the Filter/Regu-
lator Assembly on the Rear Panel of the unit. 4. Remove two bolts at the bottom corners of the Rear
Panel.
2. Remove the four bolts securing the Regulator Mount-
ing Bracket to the Rear Panel. 5. Remove one nut on a stud on the inside of the Rear
Panel, at the rear edge of the center chassis.
3. Disconnect the black gas tube from the Filter/Regulator
Assembly Adapter Fitting. Hold a wrench or similar 6. Replace the Rear Panel by reversing the above steps.
tool against the locking ring on the Fitting and pull on
the tube to release it. 7. If not already done, attach the data tag(s), provided
with the replacement Rear Panel. Position these
4. Remove the nut securing the Filter/Regulator As- as on the original Rear Panel.
sembly to the Regulator Mounting Bracket. Re-
move the Filter-Regulator Assembly from the
Mounting Bracket.
5. Install the replacement Filter/Regulator Assembly by re-
versing the steps above. When connecting the gas tube
to the Adapter Fitting, simply insert the hose into the
fitting until fully seated and it will automatically lock.

5.08 Right Side Internal 5. Release the hose from the Adapter Fitting on the
output side of the Solenoid Assembly.
Component Parts
6. Install the replacement Pressure Switch/Solenoid
Replacement Assembly by reversing steps 2-5. Once installed,
Refer to Section 6.07 Right Side Internal Component Parts the Solenoid Assembly should fit securely on the
List and overall detailed drawing. Heatsink Shroud. It should not be moveable.
7. Re-install the power supply cover.
WARNING B. Pilot PC Board Assembly Replacement

Disconnect primary power from the source before 1. Remove the power supply cover per subsection
opening or disassembling the power supply. 5.04-A.
A. Pressure Switch/Solenoid Assembly 2. Label, then disconnect the wiring connections to

the Pilot PC Board Assembly.
Replacement
a. J28 Connector
The Pressure Switch and Solenoid Valve are one Assembly.
Disconnect primary input power and bleed down the sys- b. Wire connectors to terminals E58 and E62.
tem.
3. Remove the bolts securing the PC Board to the
1. Remove the cover per subsection 5.04-A. standoffs.
2. Disconnect the following wires: 4. Slide the PC Board upward to release it from its
bottom supports.
a. Wires #10 and #11 from the Pressure Switch
Assembly. 5. Install the replacement Pilot PC Board Assembly
by reversing the above steps.
b. Wires #8 and #9 from the Solenoid Assembly.
6. Reinstall the Power Supply cover.
3. Push the clip on the front of the Heatsink Shroud
to the left to release the Solenoid Assembly. Dis- C. Fan Replacement (M1, M2)
lodge the Assembly from underneath the clip on
the top of the Heatsink Shroud. 1. Remove the cover per subsection 5.04-A.
2. Label, then carefully remove the wiring connec-
tors from the terminals on the Fans.
3. Disconnect the Work Cable from terminal E61 on
the Power Output Board.
4. Remove one bolt from the Front Panel of the Power
Supply, near the Control Panel. Pull the Front
Panel slightly away from the Power Supply.
Dislodge Solenoid
Assembly 5. Remove one nut from a stud at the bottom of the
3
Fan Assembly Panel.
2
6. Lift the Fan Assembly Panel and pull it out of the
Push Clip Power Supply.
to the left to 1
release Solenoid 7. Remove two bolts per Fan. Set the Fan(s) aside.
Assembly
Heatsink
Art # A-03705 Shroud
4. Release the hose from the Adapter Fitting on the

input side of the Solenoid Assembly. Hold a
wrench or similar tool against the locking ring on
the Fitting, then pull on the hose to release it.

8. Install the replacement Fan Assembly as follows: D. Output Diode PC Board Replacement
a. Fasten Fan(s) in position with the wiring con- Follow the antistatic procedures in subsection 5.02.
nectors at the bottom of the Fan(s).
NOTE
2. Locate the Output Diode PCB(s) located within the
Only two screws are needed to attach the Fan to Output Power PC Board on the right side of the
the Fan Panel. They can be installed in any two power supply.
holes provided they are opposite each other. For
grounding purposes, one of those screws must be 3. Carefully remove all wire connections to the Out-
installed with a star washer. put Diode Board(s).
b. Place the Fan Assembly Panel in position in the 4. Remove screw(s) securing Output Diode PC
Power Supply. Board(s) to the Heatsink and remove board(s) from
the Power Supply.
1. The inner edge of the Panel has tabs that
engage slots in the center chassis. Ensure 5. Use isopropyl alcohol and a clean rag to clean the
that these tabs fully engage in the chassis. heatsink. Do not scratch or abrade the heatsink.
6. Apply the thermal pad provided with the replace-
2. Press the Panel downward. Press the bot-
ment PCB to the heatsink. Secure in place with
tom flange fully against the bottom panel
small pieces of masking tape. The tape must cover
of the Power Supply.
no more than 1/4" (6 mm) of the edge of the ther-
3. Ensure that the hole in the bottom flange of mal pad.
the Fan Assembly Panel engages the mount-
ing stud. Round
c. Replace nut on the bottom mounting stud. Output Diode Tape Thermal Pad
or IGBT
d. Ensure that the Fan Panel's top flange is fully
against the top forward edge of the Heatsink
Shroud. Washer
Screw
e. Press the front panel of the Power Supply Tape
against the Fan Panel, and fasten in place with
the bolt removed in Step 2. Art # A-03702
f. Secure the nut on the stud at the bottom of the

7. Use isopropyl alcohol to clean the large flat surface
Fan Panel.
on the back of the component.
9. Re-connect the wires to the Fan Assemblies.
8. Secure replacement board as follows:
10. Pass the Work Cable through the hole in the bottom
a. Position the hardware at the bottom of a recess
of the Fan Panel. Ensure that the grommet is in
in the face of the diode. Ensure that the washer
place in the hole.
is under the head of the screw(s).
11. Connect the Work Cable to terminal E61 on the
b. Torque hardware to 17 in-lb. (1.9 Nm).
Power Output PC Board. Secure the Work Cable
Strain Relief. NOTE
12. Re-install the Power Supply Cover. Failure to torque properly will cause component dam-
age.

9. Connect wires as follows. F. Heatsink Shroud Assembly Removal
The Heatsink Shroud Assembly must be disengaged for
CutMaster 101 Output Diode Connections access to either the Main Transformer or the Output In-
Output Diode A Output Diode B ductor. Follow these steps for access to either component.
From Output To Power From Output To Power
1. Remove the Power Supply cover per subsection
Diode A Output Diode B Output
5.04-A.
Terminals PCB Terminal Terminals PCB Terminal
E34, E39 E37 E34, E39 E36 2. Release the tab on the vertical face of the Heatsink
E48, E50 E47 E48, E50 E45 Shroud securing the Solenoid/Pressure Switch As-
E56, E60 E58 E56, E60 E57 sembly in position.
E53, E54 E52 E53, E54 E49
3. Remove the gas hose from the Regulator Fitting on
the back panel of the Power Supply by pressing on
E. Output Power PC Board Replacement the locking ring on the elbow fitting, while pulling
on the hose.
4. Remove the Power Supply Back Panel per subsec-
tion 5.07-D.
2. Locate the Power Output PC Board, mounted to the
Remove the grommets from the two holes on the
Heatsink Shroud.
right (rear) edge of the Heatsink Shroud.
3. Carefully remove all wire connections to the Out-
5. Remove the Fan Assembly per subsection 5.08C.
put Diodes.
6. Label and disconnect the wires connected to the
4. Straighten the Output Diode wires to be perpen-
Pilot PC Board.
dicular to the Output Power PC Board.
7. Remove the hardware securing the Pilot PC Board
5. Label, then disconnect all other wire connections
in place. Pull the PC Board off the center chassis.
to the Output Power PC Board. Refer to Appendix
10 for output power PC Board wiring details. 8. Label and disconnect wires No. 45, 47, 49, and 52
from the Power Output PC Board.
6. Remove the bolts at the top left and bottom right
corners of the Output Power PC Board. 9. Disconnect the wires from the Output Inductor to
terminal E43 on the Power Output PC Board.
Disconnect the torch receptacle ground wire con-
Screw Locations
nected to the center chassis.
10. Remove nuts on two studs at the top corners of the
Heatsink Shroud, and nuts on two studs on the
bottom flange of the Heatsink Shroud.
12. Remove the Heatsink Shroud as follows:
a. Use the open left end of the Heatsink Shroud
and the Pressure Switch/Solenoid opening as
handles.
Art # A-03166
b. Pull the Heatsink Shroud away from the center
7. Lift the Output Power PC Board off its supports, chassis, and then up. It may be necessary to pry
and set aside. the top and bottom flanges of the Heatsink
Shroud slightly to release them from their
8. Install the replacement Output Power PC Board by mounting studs. Movement will be limited by
reversing the above steps. the wiring harness.
9. Note that the output power PC Board includes a
jumper wire between studs E58 and E57. Refer to
Appendix 10 for output power PC Board wiring
details.

G. Main Transformer Removal and 5. Install the replacement Inductor.
Replacement a. Put the replacement Inductor in place, with the
1. Disengage the Heatsink Shroud per Paragraph H. wires oriented the same way as the original In-
ductor.
2. Disconnect wires #27 and 32, connected to termi-
nals E27 and E32 on the Main Power PC Board. b. Secure the Inductor in place with hex nuts at
Pull these wires through the hole in the center chas- opposite corners of the Inductor base.
sis. 6. Reconnect the wires to the thermal switch on the
3. Remove the transformer. Output Inductor.
a. Lift the Main Transformer slightly. Swing its 7. Replace the Heatsink Shroud per paragraph I.
left edge away from the center chassis. Pull its
I. Heatsink Shroud Assembly Replacement
right edge away from the center chassis.
1. Pass transformer wires #45 and 49 through the up-
b. Lift it out of the Power Supply through the open-
per hole in the right (rear) edge of the Heatsink
ing at the rear of the Power Supply.
Shroud. Pass transformer wires #47 and 52
4. Position the replacement Main Transformer behind through the lower hole.
the Heatsink Shroud Assembly. Position its wires
2. Route wires as follows:
at the right edge (as you face it) of the transformer.
a. Pass the red wires from the output inductor
5. Install the replacement transformer as follows:
through the upper hole in the right (rear) edge
a. Pass the tabs on the right edge of the base of of the Heatsink Shroud.
the transformer into slots in the center chassis
b. Pass the black wires from the output inductor
of the Power Supply.
through the lower hole in the right (rear) edge
b. Swing the transformer against the chassis, and of the Heatsink Shroud. Refer to Appendix 11,
pass the tabs on the left edge of the base into Power Output Board Layout.
slots in the chassis. Press the transformer
c. Pass the wires from the temperature switch on
downward to lock it into position.
the Output Inductor through the upper hole in
c. Check for proper installation; the transformer the Shroud.
should remain securely in place.
3. Re-install the Heatsink Shroud as follows:
6. Pass wires #27 and 32 through the hole in the cen-
a. Lift the Heatsink Shroud (Assembly) into posi-
ter of the main chassis. Connect wire #27 to termi-
tion. Studs on the Power Supply base pass
nal E27 and wire #32 to terminal E32 on the Main
through holes in the bottom flange of the
Power PC Board.
Shroud.
7. Replace the Heatsink Shroud Assembly per sub-
b. Swing the top edge of the Shroud Assembly
section I.
into place. Studs on the Center Chassis of the
H. Output Inductor Assembly Removal and Power Supply pass through holes in the top
Replacement flanges of the Shroud.
1. Disengage the Heatsink Shroud per paragraph H. c. Ensure that the rubber feet on the Main Trans-
former engage holes in the Shroud.
2. Disconnect the wires to the thermal switch on the
Output Inductor. d. Put hex nuts on the studs. Tighten the nuts on
the right (rear) top and bottom studs. Leave
3. Remove hex nuts at the left forward and right rear the nuts on the left (forward) studs loose tem-
corners of the Inductor base. porarily.
4. Remove the Inductor as follows:
a. Note the position of the wires leading from the
Inductor.
b. Lift out the Inductor through the opening at the
rear of the Power Supply. It may be necessary to
lift the Main Transformer slightly to create room
for the Inductor to pass through the rear opening.

4. Put the Fan Assembly in place per subsection 5.08-
C. Reconnect the work cable to terminal E61 on the
Power Output PC Board.
5. Tighten the nuts securing the left edge of the Heat-
sink Shroud Assembly. The stud and nut on the
bottom left edge fasten a wire stay to the Power
Supply.
6. Replace the grommets around the wire harnesses
passing through the right (rearward) edge of the
Heatsink Shroud.
7. Reinstall the Pilot Board. Reconnect the wires to
the Pilot Board.
Reconnect the torch receptacle ground wire to the
center chassis.
9. Replace the Pressure Switch/Solenoid Assembly.
This assembly fits into a slot in the top horizontal
surface of the Heatsink Shroud. A notched pin
holds the assembly in place.
10. Connect the gas hose between the Regulator/Filter
Assembly and the Gas Pressure Switch/Solenoid
Assembly.
11. Connect wiring to the Output Power PC Board.
Refer to the Appendix pages for wiring layout.
12. Replace the Power Supply rear panel per subsec-
tion 5.07-D.
This concludes the replacement procedures.

SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts lists provide a breakdown of all replaceable
components. The parts lists are arranged as follows:
Section 6.03 Major External Replacement Parts
Section 6.04 Front Panel Replacement Parts
Section 6.05 Left Side Internal Component
Replacement Parts
Section 6.06 Rear Panel Replacement Parts
Section 6.07 Right Side Internal Component
Replacement Parts
Section 6.08 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 authori-
zation 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 torch. Address all inquiries to your autho-
rized.
Manual 0-2853 6-1 PARTS LISTS

6.03 Major External Replacement Parts
Item # Qty Description Catalog #
1 1 Cover with labels 9-8321
2 Rear Panel (provide data tag information when ordering)
1 For 208/230-Volt Power Supplies 9-8323
1 For 400-Volt, 415-Volt, 460-Volt, and 600-Volt Power Supplies 9-8322
3 1 Tube, roll handle 9-7998
Art # A-03709
NOTE: Illustration may vary slightly from unit.
PARTS LISTS 6-2 Manual 0-2853

6.04 Front Panel Replacement Parts
Item# Qty Description Ref. # Catalog #
1 1 Knob, Fluted, Skirted 9-8527
2 1 On/Off Switch SW1 8-3258
3 1 Run / Rapid Auto Restart / Set Switch SW2 8-3259
4 1 Assembly, Pot/LED PC Board 9-8004
5 1 Work Cable, #6 AWG, 20 Ft. (6.1 m) with Clamp 9-8528
5
Art # A-03008

6.05 Left Side Internal Component Replacement Parts
Item # Qty Description Ref # Catalog #
1 1 Fuse F1
for 208/230-Volt Power Supplies 9-8588
for 400-Volt and 415-Volt Power Supplies 9-8602
for 460-Volt Power Supplies 9-8583
Main Input Contactor W1
2A for 208/230-Volt Power Supplies 9-8587
2 for 400-Volt, 415-Volt, 460-Volt and 600-Volt Power Supplies 9-8554
3 1 Connector PCB 9-8576
4 1 PCB Assembly, Logic Board, Non-mechanized units 9-7987
4 1 PCB Assembly, Logic Board, Mechanized units 9-9441
5 1 PCB Assembly Kit, IGBT Circuit
for 208/230-Volt, 400-Volt, 415-Volt and 460-Volt Power Supplies 9-8578
IGBT PCB
Round Thermal Pad
IGBT PCB
Round Thermal Pad
6 1 PCB Assembly Kit, Input Diode 9-7088
Input Diode PCB
Rectangular Thermal Pad
7 1 PCB Assembly, Main Power
for 208/230-Volt Power Supplies 9-7986
for 400-VoltPower Supplies 9-7990
for 415-VoltPower Supplies 9-8669
8 1 EMI Filter Kit (CE Power Supplies only) 9-7667

1 7
6
4
5 3 2A 2
OR
5
Art # A-03717

6.06 Rear Panel Replacement Parts
Item # Qty Description Ref. Catalog #
1 1 Assembly, Filter/Regulator 9-7514
2 1 Regulator/Filter Replacement Element 9-4414
3 1 Regulator Mounting Bracket 9-7589
4 Input Power Cable
1 for 208/230-Volt Units 9-8596
1 for 400-Volt Three-Phase units 9-8562
1 for 400-Volt and 415-Volt CE units 9-8553
5 1 Mounting Nut 9-5804
6 1 Pressure Gauge 9-1045
5
3 1
6
2
4 Art # A-03005

6.07 Right Side Internal Component Replacement Parts
Item # Qty Description Ref #. Catalog #
1 1 Assembly, Pressure Switch/Solenoid Sol1, Ps1 9-8329
2 1 Assembly, Pilot Board 9-8337
3 1 Fan, 220V, 115 CFM 9-7687
4 1 Assembly, Main Transformer T5
for 208/230-Volt units 9-8589
for 400-Volt and 415-Volt units 9-8603
for 460-Volt units 9-8584
for 600-Volt units 9-8635
5 1 Assembly, Output Inductor L1 9-8591
6 1 Assembly, Output Power PCB 9-7988
7 1 Assembly, Output Diode PCB 9-8580
1 Round Thermal Pad
Heatsink
Shroud
IGBT Heatsink
Output Diode
5 Heatsink
3
7
3 7
Fan
Work Cable
Shroud
Art # A-03718

6.08 Options and Accessories
Qty Description Catalog #
1 Single-Stage Filter Kit (Includes Filter And Hose) 7-7507
1 Replacement Filter Body 9-7740
1 Replacement Filter Element 9-7741
1 Replacement Filter Hose (Not Shown) 9-7742
1 Two Stage Air Line Filter Kit (Includes Hose & Mounting Screws) 7-7500
1 Bracket, Filter Mounting (Not Shown) 9-7535
1 Dual Stage Air Filter Assembly 9-7527
1 Replacement First Stage Cartridge 9-1021
1 Replacement Second Stage Cartridge 9-1022
Not Shown:
1 Extended Work Cable - 50 ft (15.2 m) 9-8529
1 Nylon Canvas Power Supply Dust Cover 9-7072
1 Wheel Kit 9-8331
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743) First & Second
Assembled Filter
Stage
Cartridges
Cover (as marked)
Barbed
Fitting Art # A-02476 Art # A-02942
Single-Stage Filter Kit Two-Stage Filter Kit

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


APPENDIX 1: INPUT WIRING REQUIREMENTS
CutMaster 101 Input Wiring Specifications

Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50 14.4 69 90 6 6
208 60 15.6 75 90 6 6
230 50 15 65 80 6 6
230 60 15.5 67 80 6 6
400 50/60 13.9 20 30 10 10
460 60 18 39 50 10 10
460 60 16 20 30 12 12
600 60 13.5 13 20 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
CE CutMaster 101 Input Wiring Specifications

Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Frequency 3-Ph 3-Ph Fuse (Amps) Wire (mm 2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
400/415 50 13.9 20 25 4
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electric Code
NOTES
The table above is based on the following output current and voltage: 125VDC @ 40A
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.
Manual 0-2853 A-1 APPENDIX

APPENDIX 2: 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
APPENDIX A-2 Manual 0-2853

APPENDIX 3: LOGIC PC BOARD LAYOUT
D13 TP6 D33
TP4
P1-7
TP2 P1-9
TP1
TP9
TP3
TP10
TP11
TP5 D25 TP8 TP7 Art # A-03654
Logic Board Signals

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
P1-5 MC1 ON signal P1-33 I Sense
P1-6 Tip Sense P1-34 Not Used
P1-7 RUN/SET Signal Logic Low for SET P1-35 Not Used
P1-8 Logic Low = PS1 Pressure Switch P1-36 TipVolts
closed = Pressure OK
P1-9 Logic Low = TS1 Closed = OVERTEMP INDICATORS:
P1-10 Logic Low = CSR D13 INV ON
P1-11 Logic Low = Gas ON D25 DRAG ON
D33 SWITCH ON
P1-12 Logic Low = DC OK
P1-13 Logic Low = OVTEMP TEST POINTS:
P1-14 Logic Low = AC OK TP-1 Common
P1-15 Logic Low = Torch Switch TP-2 Current Demand Signal
P1-16 Logic Low = Torch Switch Return TP-3 Converter Enable
P1-17 Logic Low = +12vdc TP-4 CSR (Logic Low)
P1-18 Logic Low = Pot High TP-5 Not used
P1-19 Logic Low = Pot High TP-6 Fault (Logic Low)
P1-20 Pot Low TP-7 DC OK (Logic Low)
P1-21 Gate Drive B Return TP-8 Tip Sense
P1-22 Gate Drive B TP-9 Current Sense
P1-23 Gate Drive A Return TP-10 Gate Drive A
P1-24 Gate Drive A TP-11 Gate Drive B
P1-25 - Out Sense
P1-26 Current Sense
P1-27 Current Sense

APPENDIX 4: MAIN POWER PC BOARD LAYOUT
E5
J16
E6
J17
J15
J27
E1 J43
E2 E32
INPUT
E3 DIODE
J26
J11
E15 E27
E7
E30
J25
E10
E20
Main Power PC Board Signals J18-1 Not used

J11-1 L1 Input J18-2 Not used
J11-4 L3 Input J18-3 28 VAC B
J18-4 28 VACA
J15-1 Fan (M1) J18-5 On-Off Switch
J15-2 Fan (M1) J18-6 On-Off Switch
J15-3 Not used J18-7 Run-Set Switch
J15-4 Not used J18-8 Run-Set Switch
J15-5 Fan (M2)
J15-6 Fan (M2) J23-1 Not used
J23-2 Not used
J16-1 Not used J23-3 Not used
J16-2 Not used
J24-1 Gas Solenoid (SOL1)
J17-1 Not used J24-2 Gas Solenoid (SOL1)
J17-2 Not used J24-3 Pressure Switch (PS1)
J24-4 Pressure Switch (PS1)
J24-5 Main Contactor (W1)
J24-6 Main Contactor (W1)
J24-7 Not used
J24-8 Not used

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 DCCom
J26-2 Gate Drive J43-4 DCCom
J27-1 Pot High J43-5 MC1 On
J27-2 Pot Wiper J43-6 Tip Sense
J27-3 Pot Low J43-7 Run / Set
J27-4 +12V J43-8 Pressure Good
J27-5 AC J43-9 Overtemp
J27-6 Gas J43-10 CSR
J27-7 Overtemp J43-11 Gas on
J27-8 DC J43-12 DCOK
J43-13 OVTEMP
J29-1 IGBT Heatsink Temp J43-14 AC OK
J29-2 IGBT Heatsink Temp J43-15 Torch Switch
J29-3 Jumper J43-16 Torch Switch Return
J29-4 Jumper J43-17 + 12 vdc
J43-18 POT High
J30-1 Gate Drive J43-19 POT Wiper
J30-2 Gate Drive J43-20 POT Low
J43-21 Gate Drive B Return
J31-1 Gate Drive J43-22 Gate Drive B
J31-2 Gate Drive J43-23 Gate Drive A Return
J43-24 Gate DriveA
J32-1 Inductor Temp Switch J43-25 - Out Sense
J32-2 Inductor Temp Switch J43-26 Current Sense
J43-27 Current Sense
J33-1 - Out Sense J43-28 Current Sense Return
J33-2 DCCom J43-29 Current Sense Return
J33-3 Tip Sense J43-30 DCCom
J33-4 + 12 vdc J43-31 DCCom
J33-5 CSR J43-32 Not Used
J33-6 I Sense J43-33 I Sense
J33-7 Not used J43-34 Not Used
J33-8 Tip volts J43-35 Not Used
J34-1 PIP Return J43-36 Tip Volts
J34-2 PIP
J34-3 Not used TP1 Ground
J34-4 Not used TP4 +12 vdc
J34-5 Torch Switch Return
J34-6 Torch Switch

APPENDIX 5A: MAIN PC BOARD WIRING LAYOUT -
208/230-Volt Units
To Press Switch/Solenoid/Contactor To Inductor Temp Sensor

To Power Output Board
LT1 Test Connector To Heat Sink To On/Off and

To Main Temp Sensor Run/Rapid Restart
Input Contactor To Torch
To Chassis Ground To Fans Set Switches
Fuse Connector
To Auto Interface
Board J1-5*
To Auto Interface
Board J1-6*
Secondary
Transformer To POT/LED PCB
Copper (or to
Strap E1
Optional Remote
Current Control )*
E2
To Logic Board
#1
via Connector
E3
INPUT
DIODE #32
To Main
Transformer
#27
J30 J31
#33 Art # A-03652
#2 Heat Sink
#78 To Input Temp Sensor
#1 To Input
#3 Contactor
Contactor
* If installed in conjuction with

* Automation Interface Board is not installed in all units. Automation Interface PC Board

APPENDIX 5B: MAIN PC BOARD WIRING LAYOUT -
400-Volt, 415-Volt, 460-Volt, and 600-Volt Units
To Press Switch/Solenoid/Contactor To Inductor Temp Sensor To Power Output

Board
LT1 To Heat Sink To On/Off and
Test
To Chassis Temp Sensor Run/Rapid Restart
Fuse Connector
Ground To Main To Torch Set Switches
To Fans Connector
Input Contactor
To Auto Interface
Board J1-5*
To Auto Interface
Board J1-6*
Secondary
Transformer To POT/LED PCB
(or to
Optional Remote
Current Control )*
To Logic Board
INPUT via Connector
DIODE #32 To Main
#27 Transformer
J30 J31
Art # A-03653
#3
Heat Sink
#2 To Input
Temp Sensor
#1 Contactor
* If installed in conjuction
* Automation Interface Board is not installed in all units. with Automation Interface PC Board

APPENDIX 6: LED/POT PC BOARD LAYOUT
J14
D4
D5
D6
D7
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 Logic Low Signal for TEMP Indicator from Logic PC Board (J27-7)
J14-8 Logic Low Signal fro DC Indicator from Logic PC Board (J27-8)
D4 Front Panel AC Indicator
D5 Front Panel GAS Indicator
D6 Front Panel TEMP Indicator
D7 Front Panel DC Indicator

APPENDIX 7: INPUT DIODE PC BOARD LAYOUT
E18 E13 E5
19x1811
E14 E16 E8 E6
Art # A-03703

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT
E9A E21A E9B E21B
E11A E19A E11B E19B
J3A J7A J3B J7B
TP1 TP1
B B
TP2 TP2
E12A E12B
E17A E17B
A-03704

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT
Output Diode A Output Diode B
E34 E48 E34 E48
E50 E50
E39 E39
E54 E54
E60 E60
E53 E53
E56 E56
A-03152

APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM
To Torch To Pilot PCB To Main PCB To Pilot PCB

TP1 Output
Chassis Ground E37 E35 E62 E47 J39 J40 E36 Diode B
E32
Output
Diode A
To Output
Inductor
To Pilot
Board E45
To Trans-
E64 former
E49
To Torch
To Trans-
former
To Output Art # A-03655

E43 E58 E52 Work Cable E61 E57
Inductor

APPENDIX 11: PILOT PC BOARD LAYOUT
OR
J28
J28
No Receptacle
2 - Pin
E58 E62 E58 E62
Receptacle (J1)
Art # A-03881
Pilot PC Board Signals
J28-1 +12 vdc

J28-2 DCCom
J28-3 Not used
J28-4 Not Used
J28-5 Logic Low CSR
J28-6 Not Used
J28-7 Not Used
J28-8 Not Used
E58 To Power Output PC Board Terminal E38

E62 to Power Output PC Board Terminal E62
NOTES
1. Pilot PC Board with receptacle J1 may replace PC Board without receptacle J1
2. Receptacle J1 is used only in automated applications.

APPENDIX 12: 28VAC CIRCUIT DIAGRAM
Line Voltage
1J8 4 J11
SOL
W1
Fuse J18 3 4 5 6
ON/OFF Switch
1 2 5 6 J24
primary
J23 (Test)
secondary
3 2 1
Auxiliary
Transformer
K5
K4
Voltage
Protection
CRT/+12 Regulator
+12vdc
A-03710 Main Power PC Board

APPENDIX 13: 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 14: 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. 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 15: 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. Machine 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 16A: SYSTEM SCHEMATIC (208/230-Volt Units)
1 2 3 4 5
E6
L1 W1 E8 E12A
(1)
E17A GATE
208/230V 14 13 12 J3A P3A
E5 DRIVE
1 PHASE 1 1
INPUT L2 W1 E13
(2)
28 2 2
E18 E9A
23
A 24 27
L3 W1 25
GATE E11A
(3)
E14 DRIVE
J7A P7A
1
E16 E19A 1 1
L4 W1 INPUT DIODE
(78) ASSY 19X2073 E21A 76542 2 2
IGBT BOARD
(33) ASSY 19X1756
E22 E33 E1 E2 E3
COPPER STRAP E12B
E7 GATE
CHASSIS (FILTERING) E17B 14 13 12
DRIVE J3B P3B
GND J11 1 1
(4)
1 1
2 2 K1 2 2
P11 K1 28
(5) 3 3
4 4 23 E9B
B E15 24 27
R30 25
E11B
GATE
(0 ohm) DRIVE
T1 E4 1 J7B P7B
M1 F1 E19B 1 1
FAN1 (6/10A 600V) E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 E23
K2 IGBT BOARD
3 3
4 4 ASSY 19X1756
(6) 28VAC B 28VAC A
(6) 5 5 E30
230V 6 6
M2
FAN2 J26 P26
1 1
P18 J18 2 2
1 1 J31 P31
28VAC B (21) 2 2 1 1
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 J30 P30
6 6 28VAC B TO BIAS SUPPLY
C ON/OFF SW (25) 1 1
(26) 7 7 2 2
SW1 8 8
RUN +12VDC J25 P25
1 1
MODE SW SET
K1 2 2
(46)
RAR OFF
(PILOT PCB) INRUSH
+18V
(F9) SW2
K2
CURRENT ADJUST:
E5 (TS2)
20 - 80 FOR CM101 FAN E6 (TS1)
20 - 60 FOR CM81
J14 P14 P27 J27
1 1
(35)
1 1 POT HIGH
E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
CURRENT AC 4 4
(38)
4 4 +12V E27
(39)
CONTROL/ 5 5 (40) 5 5 AC
MAIN TRANSFORMER
TEMP 6 6 6 6 GAS
LED PCB 7 7
(41)
7 7 OVERTEMP
(42)
19X1604 GAS
8 8 8 8 DC E32 T5
D CURRENT
DC SENSE
PRI
SEC
P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
TEMP NTC 4 4
PRI
SEC
t
TS1 P32 J32
1 1
2 2 E52 E47
INDUCTOR J33 P33 P39 J39
(70)
TEMP -OUT SENSE 1 1 (71) 1 1
TS2 DC COM 2 2 (72) 2 2
TIP SENSE 3 3 (73) 3 3
+12VDC4 4 (74) 4 4
LOGIC P1 P13 J12 J43 CSR5 5 (75) 5 5
ASSY 19X1913 - CM101 +12VDC 1 1 1 1 I SENSE6 6 6 6
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V
7 7 (77) 7 7
ASSY 19X1932 - CM81 DC COM 3 3 3 3 TIP VOLTS 8 8 8 8
ASSY 19X2284 - CM81 DC COM 4 4 4 4 ATC CONNECTION
E W1 ON 5 5 5 5 K5
CONFIGURATION
TIP SENSE 6 6 6 6
RUN/SET 7 7 7 7 CONTACTOR ON J34 P34 (STANDARD)
PRESS GOOD 8 8 8 8 +18V (78)
9 9 PIP RTN 1 1 11 SOL2
INV ON D13 OVERTEMP 9
CSR 10
9
10 10 10 PIP 2 2 (79) 22 PIP A B T6
GAS ON 11 11 11 11 3 3 55 11 15
K4
DRAG ON D25 DC OK 12 12 12 12 TORCH SW RTN 4 4 (80) 77
OVTEMP 13 13 13 13 5 5 (81) 4 4 TORCH PRI
SOLENOID ON TORCH SW 6 6 33
SW ON AC OK 14 14 14 14 SW
D33 15 15 88
TORCH SW 15 15
TORCH SW RTN 16 16 16 16 ATC MALE
+12V 17 17 17 17 CONNECTOR SEC
POT HIGH 18 18 18 18 J23 ATC RECEIVER
POT WIPER 19 19 19 19 6 10
POT LOW 20 20 20 20 28VAC A 1
GATE DRIVE B RTN 21 21 21 21 GND 2 TEST
GATE DRIVE B 22 22 22 22 28VAC B 3 CONN
GATE DRIVE A RTN 23 23 23 23
GATE DRIVE A 24 24 24 24 SOL1 FACTORY INSTALLED OPTIONAL
- OUT SENSE 25 25 25 25 A B
TORCH MOUNTED GAS SOLENOID
CURRENT SENSE 26 26 26 26
CURRENT SENSE 27 27 27 27 K4 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, J24 P24 SOLENOID
29 29 (RESETABLE) 1 1 (8)
CURRENT SENSE RTN 29 29 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
PRESS GOOD
F 32 32 32 32 4 4 (12)
ISENSE 33 33 33 33 5 5 PRESSURE
34 34 34 34 6 6 (13)
SWITCH
35 35 35
36
35
36
MAIN BOARD K5
7 7 PS1
CLOSED WHEN
TIP VOLTS 36 36 8 8
EXTENDER ASSY 19X1912 PRESSURE OK
ASSY 19X1775
W1
WHEN OPTIONAL TORCH MOUNTED GAS SOLENOID IS USED,
MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
Art # A-07153 1 2 3 4 5

6 7 8 9 10
COMP DESCRIPTION LOCATION

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

1. DEPICTIONS OF CIRCUITRY INSIDE PCB BLOCKS
IS FOR REFERENCE ONLY
OPTIONAL AUTOMATION INTERFACE CONNECTIONS B
* PLUGS INTO J27

ON MAIN BOARD ALTERNATE 20-PIN HEADER
20-POSITION TERMINAL STRIP
(LED PCB 19X1604)
J14 P14 P3 J3 J4 P4 J2
(47)
1
2
1
2
1
2 (48)
1
2
1
2
20
19
20
19
1
2
+
TORCH SWITCH
AC
3
4
3
4
3
4
(49)
3 3 18 18 3 -
17 17 4
5 5 5 16 16 5
TEMP 6 6 6 15 15 6 OK TO MOVE
7 7 7 19X2041 14 14 7
8 8 8 OPTIONAL 13 13 8
GAS
AUTOMATION 12
11
12
11
9
10
+ DIVIDED OUTPUT
INTERFACE
DC 10 10 11
12
-
9 9
8 8 13
ADAPTER HARNESS USED P1 J1 7 7 14 REMOTE CURRENT CONTROL
(CSR) 6 6 15
WHEN REMOTE CURRENT 1 1 CSR 5 5 16
(51) 2
CONTROL IS USED WITH (52) 3 2 DC COMMON 4 4 17 DC COMMON C
AUTOMATION 3 +12VDC 3 3 18 +
(REPLACES CONNECTIONS (TS2) 4 4 2 2 19 C&G
FROM J27 TO J14) (TS1) 5
6
5 TORCH SW - 1
6 TORCH SW +
1 20 -
(NEG) 7 7
8 8 Vo
CPC
HOUSING
(56) 4 (+)
(57) 3 (-) } TORCH SWITCH
(58) 14
(59) 12 } OK TO MOVE
(60) 6 (+)
(61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
(64) 7 (-) } ARC VOLTS (C&G)
OUTPUT INDUCTOR
L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)
(E35)
(E62)
(CSR) (NEG) T
E49 E45 E35 E61 E3 E1 O
E62 E43 E32 R
PILOT E64 CSR Vo C
H
CURRENT
SENSE
JUMPER
E37 E58 E36 E57 (E58)
WORK E
(C1) E58 E62

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

APPENDIX 16B: SYSTEM SCHEMATIC (400-Volt, 415-Volt,
460-Volt Units)
1 2 3 4 5
W1 E6 E12A
L1 (1)
E8 GATE
E17A 14 13 12 DRIVE J3A P3A
1 1
E5
208/230V 415/400V W1 2 2
/460V L2 (2) E13 28
1 PHASE 23 E9A
A INPUT 3 PHASE 24 27
INPUT E18 25
GATE E11A
DRIVE
J7A P7A
W1 1
L3 (3) E14 E19A 1 1
E16
E21A 76542 2 2
INPUT DIODE
ASSY 19X2073 IGBT BOARD
ASSY 19X1756
CHASSIS GND E33 E1 E2 E3
400V E22
3 PHASE
INPUT E12B
E7 GATE
(FILTERING) E17B 14 13 12 DRIVE J3B P3B
P11 J11 1 1
(4)
1 1
400V 'CE' VERSION 2 2 K1
K1
28 2 2
INCLUDES IN-LINE (5) 3 3
4 4 23 E9B
B EMC FILTER R29 (415/460/600V) E15 24 27
25 E11B
GATE
R78 (400V)
DRIVE
R30 (208/230V) T1 E4 1 J7B P7B
M1 F1 E19B 1 1
FAN1 E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 E23
K2 IGBT BOARD
3 3
4 4 ASSY 19X1756
(6) 28VAC B 28VAC A
(6) 5 5 E30
230V 6 6 SEE TABLE 1 FOR
M2 F1, R29,R30 & R78
FAN2 J26 P26
1 1
2 2
P18 1 1 J18
J31 P31
2 2 1 1
28VAC B (21)
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 28VAC B TO BIAS SUPPLY J30 P30
C ON/OFF SW (25) 6 6 1 1
(26) 7 7 2 2
SW1 8 8
RUN +12VDC J25 P25
1 1
MODE SW
SET K1 2 2
(46)
RAR OFF
(PILOT PCB) INRUSH ARC HOLD E34
+18V
(F9) SW2 28VAC A E36
K2
28VAC B E35
CURRENT ADJUST:
E5 (TS2)
20 - 80 FOR CM101 FAN E6 (TS1)
20 - 60 FOR CM81
J14 P14 P27 J27
1 1
(35)
1 1 POT HIGH E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
AC 4 4
(38)
4 4 +12V E27
CURRENT (39)
5 5 (40) 5 5 AC
CONTROL/ TEMP 6 6 (41) 6 6 GAS MAIN TRANSFORMER
7 7 7 7 OVERTEMP
LED PCB 8 8
(42)
8 8 DC T5
19X1604 GAS E32
D CURRENT
DC SENSE
PRI
SEC
P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
TEMP NTC 4 4
PRI
SEC
t
TS1 P32 J32
1 1
2 2 E52 E47
INDUCTOR J33 P33 P39 J39
(70)
TEMP -OUT SENSE 1 1 (71) 1 1
TS2 DC COM 2 2 (72) 2 2
TIP SENSE 3 3 (73) 3 3
+12VDC4 4 (74) 4 4
LOGIC P1 P13 J12 J43 CSR5 5 (75) 5 5
ASSY 19X1913 - CM101 I SENSE6 6 6 6
+12VDC 1 1 1 1
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V
7 7 (77) 7 7
ASSY 19X2284 - CM81 DC COM 4 4 4 4 ATC CONNECTION
E W1 ON 5 5 5 5 K5 CONFIGURATION
TIP SENSE 6 6 6 6 J34 P34 (STANDARD)
RUN/SET 7 7 7 7 CONTACTOR ON
PRESS GOOD 8 8 8 8 +18V (78) 11
9 9 PIP RTN 1 1 PIP SOL2
INV ON D13 OVERTEMP 9 9 PIP 2 2 (79) 22
CSR 10 10 10 10 A B T6
GAS ON 11 11 11 11 3 3 55 11 15
K4
DRAG ON D25 DC OK 12 12 12 12 TORCH SW RTN 4
5
4 (80)
5 (81)
77
44
OVTEMP 13 13 13 13 SOLENOID ON TORCH SW 6 PRI
AC OK 14 14 14 14 6 33 TORCH
SW ON D33 88 SW
TORCH SW 15 15 15 15
TORCH SW RTN 16 16 16 16 ATC MALE
+12V 17 17 17 17 SEC
POT HIGH 18 18 18 18 CONNECTOR
POT WIPER 19 19 19 19 J23 6 10
POT LOW 20 20 20 20 28VAC A 1 ATC RECEIVER
GATE DRIVE A RTN 23 23 23 23 FACTORY INSTALLED OPTIONAL
GATE DRIVE A 24 24 24 24 SOL1 TORCH MOUNTED GAS SOLENOID
- OUT SENSE 25 25 25 25 A B
CURRENT SENSE 27 27 27 27 K4 J24 P24 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, SOLENOID
29 29 (RESETABLE) 1 1 (8)
CURRENT SENSE RTN 29 29 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
F ARC HOLD 32 32 32 32 PRESS GOOD 4 4
33 33 (12) PRESSURE
ISENSE 33 33 5 5
34 34 34 34 MAIN BOARD 6 6 (13) SWITCH
35 35 35 35 ASSY 19X1930 (400V) 7 7 PS1
TIP VOLTS 36 36 36 36 K5 8 8 CLOSED WHEN
EXTENDER
ASSY 19X2228 (415V) PRESSURE OK
ASSY 19X1775 ASSY 19X1929 (460V)
W1
MAIN
CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
Art # A-07152 1 2 3 4 5

6 7 8 9 10
TABLE 1 COMP DESCRIPTION LOCATION

19X1930 19X2228 19X1929 F1 SEE CHART 1 B2
400V 415V 460V F2 0.9A, (RESETABLE) F3
R78 ZERO-OHM XXXXX XXXXX
M1 FAN, 4.5" 220VAC B1
115X465-2
M2 FAN, 4.5" 220VAC C1
R29 XXXXX ZERO-OHM ZERO-OHM
115X465-2 115X465-2
R30 XXXXX XXXXX XXXXX
F1 4/10, 500V 4/10, 500V 1/4A, 500V
21X186 21X186 21X183

* PLUGS INTO J27

(LED PCB 19X1604)
J14 P14 P3 J3 J4 P4 J2
(47)
1
2
1
2
1
2 (48)
1
2
1
2
20
19
20
19
1
2
+
TORCH SWITCH
AC
3 3 3 (49)
3 3 18
17
18
17
3 -
4 4 4 4
5 5 5 16 16 5
TEMP 6 6 6 15 15 6 OK TO MOVE
7 7 7 19X2041 14 14 7
8 8 8 OPTIONAL 13 13 8
GAS AUTOMATION 12
11
12
11
9
10
+ DIVIDED OUTPUT
INTERFACE
DC 10 10 11
12
-
9 9
8 8 13
7 7 14 REMOTE CURRENT CONTROL
ADAPTER HARNESS USED P1 J1 6 6 15
WHEN REMOTE CURRENT (CSR)
(51)1 1 CSR 5 5 16
CONTROL IS USED WITH (52)2 2 DC COMMON 4 4 17 DC COMMON C
AUTOMATION (TIP) 3
4
3 +12VDC
4 TIP
3 3 18
19
+
2 2 C&G
(REPLACES CONNECTIONS
FROM J27 TO J14)
(TS2)
(TS1) 5
6
5 TORCH SW - 1
6 TORCH SW +
1 20
21
-
(NEG) 7 7 22
8 8 Vo 23
9 9 ARC HOLD 24 } OHMIC SENSE RELAY
25 ARC HOLD
26 ARC HOLD RETURN
CPC
HOUSING
(56) 4 (+)
(58) 14
(60) 6 (+)
OUTPUT INDUCTOR (61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
(64) 7 (-) } ARC VOLTS (C&G)
L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)
(E35)
(E62)
(CSR) (NEG) T
E65 E49 E45 E35 E32 E61 E3 E1 O
E62 E43 E64 R
TIP PILOT CSR Vo C
H
CURRENT
SENSE
JUMPER
E37 E58 E36 E57 (E58)
WORK E
(C1) E58 E62

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

APPENDIX 16C: SYSTEM SCHEMATIC (600-Volt Units)
1 2 3 4 5
E6
E8
L1 W1 E12A
(1)
E17A GATE
E5 14 13 12 DRIVE J3A P3A
1 1
E13
600VAC L2 W1 2 2
(2) E18 28
3 PHASE 23 E9A
A INPUT 24 27
25 E11A
GATE
E14 DRIVE
1
J7A P7A
L3 W1 E16
(3) E19A 1 1
INPUT DIODE
ASSY 19X2073 E21A 76542 2 2
IGBT BOARD
ASSY 19X1815
E33 E1 E2 E3
E22
E12B
CHASSIS E7 GATE
(FILTERING) E17B 14 13 12
GND DRIVE J3B P3B
1 1
(4) P11 J11
1 1
2 2 K1 2 2
K1 28
(5) 3 3
4 4 23 E9B
B R29 E15 24 27
25 E11B
GATE
(0 ohm) DRIVE
F1 T1 E4 1 J7B P7B
M1
E19B 1 1
FAN1 (3/10A 600V) E20
P15 J15 E21B 76542 2 2
230V (7)
1 1
(7) 2 2 K2 E23
3 3 IGBT BOARD
(6) 4 4 ASSY 19X1815
5 5 28VAC B 28VAC A
(6)
6 6
E30
230V
M2
FAN2 J26 P26
1 1
P18 J18 2 2
1 1 J31 P31
28VAC B (21) 2 2 1 1
28VAC A (22) 3 3 2 2
(23) 4 4 28VAC A
(24) 5 5 J30 P30
6 6 28VAC B TO BIAS SUPPLY
C ON/OFF SW (25) 1 1
(26) 7 7 2 2
SW1 8 8
RUN J25 P25
1 1
MODE SW SET
+12VDC
2 2
(46) K1
RAR OFF
(PILOT PCB)
(F9) SW2 INRUSH
+18V
K2 E5 (TS2)
FAN E6 (TS1)
CURRENT ADJUST:
20 - 80 FOR CM101 J14 P14 P27 J27
20 - 60 FOR CM81 1 1
(35)
1 1 POT HIGH
E10
(36)
2 2 (37) 2 2 POT WIPER
3 3 3 3 POT LOW
AC 4 4
(38)
4 4 +12V E27
(39)
CURRENT 5 5 (40) 5 5 AC
TEMP 6 6 6 6 GAS MAIN TRANSFORMER
CONTROL/ 7 7
(41)
7 7 OVERTEMP
(42)
LED PCB GAS
8 8 8 8 DC E32 T5
D 19X1604 CURRENT
DC SENSE
PRI
SEC
P29 J29
1 1
IGBT 2 2
HEATSINK 3 3
NTC 4 4
TEMP
PRI
SEC
t TS1
P32 J32
1 1
INDUCTOR 2 2 E52 E47
TEMP
J33 P33 P39 J39
-OUT SENSE (70)
TS2 1 1 (71) 1 1
DC COM 2 2 (72) 2 2
LOGIC TIP SENSE 3 3 (73) 3 3
P1 P13 J12 J43 +12VDC4 4 4 4
ASSY 19X1913 - CM101 (74)
+12VDC 1 1 1 1 CSR5 5 (75) 5 5
ASSY 19X2285 - CM101 +12VDC 2 2 2 2 +18V I SENSE6 6 6 6
ASSY 19X1932 - CM81 DC COM 3 3 3 3 7 7 (77) 7 7
ATC CONNECTION
E W1 ON 5 5 5 5 K5
CONFIGURATION
TIP SENSE 6 6 6 6
RUN/SET 7 7 7 7 CONTACTOR ON J34 P34 (STANDARD)
PRESS GOOD 8 8 8 8 +18V (78) 1 1
9 9 PIP RTN 1 1 PIP SOL2
INV ON D13 OVERTEMP 9 9 PIP 2 2 (79) 2 2 A B
CSR 10 10 10 10
3 3 5 5 T6
GAS ON 11 11 11 11 K4 11 15
DRAG ON D25 DC OK 12 12 12 12 TORCH SW RTN 4 4 (80) 7 7
13 13 5 5 (81) 4 4 TORCH
OVTEMP 13 13 SOLENOID ON TORCH SW 6 6 3 3 PRI
SW ON AC OK 14 14 14 14 SW
D33 15 15 8 8
TORCH SW 15 15 ATC MALE
TORCH SW RTN 16 16 16 16 CONNECTOR
+12V 17 17 17 17 SEC
POT HIGH 18 18 18 18 ATC RECEIVER
POT WIPER 19 19 19 19 J23 6 10
POT LOW 20 20 20 20 28VAC A 1
23 23 FACTORY INSTALLED OPTIONAL
GATE DRIVE A RTN 23 23
GATE DRIVE A 24 24 24 24 SOL1 TORCH MOUNTED GAS SOLENOID
- OUT SENSE 25 25 25 25 A B
CURRENT SENSE 27 27 27 27 K4 GAS
CURRENT SENSE RTN 28 28 28 28 F2, 0.9A, J24 P24
(8) SOLENOID
CURRENT SENSE RTN 29 29 29 29 (RESETABLE) 1 1 (9)
DC COM 30 30 30 30 2 2 (10)
DC COM 31 31 31 31 3 3 (11)
F 32
ISENSE 33
32
33
32
33
32
33
MAIN BOARD PRESS GOOD 4
5
4
5
(12)
(13) PRESSURE
34
35
34
35
34
35
34
35 ASSY 19X1931 6
7
6
7 PS1 SWITCH
TIP VOLTS 36 36 36 36 K5 8 8
CLOSED WHEN
EXTENDER PRESSURE OK
ASSY 19X1775
W1
MAIN CONTACTOR SOL1 IS POWERED BY T6 ONLY ,SOL2 POWERED BY P24-1,-2
Art # A-07151 1 2 3 4 5

6 7 8 9 10
COMP DESCRIPTION LOCATION

F1 FUSE, 3/10A 600V FNQ-R B2
F2 FUSE, 0.9A, RESETABLE F3
M1 FAN, 4.5" 220VAC B1
M2 FAN, 4.5" 220VAC C1

* PLUGS INTO J27

(LED PCB 19X1604)
J14 P14 P3 J3
(47)
1 1 1 1 1
2 2 2 (48) 2 2
(49) J2
AC
3 3 3 3 3 J4 P4
4 4 4
5 5 5 20
19
20
19
1
2
+
TORCH SWITCH
TEMP 6
7
6
7
6
7 19X2041 18 18 3 -
8 17 17 4
8 8 OPTIONAL 16 16 5
GAS
AUTOMATION 15 15 6 OK TO MOVE
INTERFACE 14 14 7
DC 13 13 8
12
11
12
11
9
10
+ DIVIDED OUTPUT
ADAPTER HARNESS USED
(CSR)
P1 J1 10 10 11
12
-
WHEN REMOTE CURRENT 9 9
(51) 1 1 CSR
2 DC COMMON 8 8 13
CONTROL IS USED WITH (52) 2 7 7 14 REMOTE CURRENT CONTROL C
AUTOMATION 3 3 +12VDC 6 6 15
(REPLACES CONNECTIONS (TS2) 4 4 16
(TS1) 5 5 TORCH SW - 5 5
17 DC COMMON
FROM J27 TO J14) 6 6 TORCH SW + 4 4
(NEG) 7 7 3 3 18
19
+
2 2 C&G
8 8 Vo
1 1 20 -
CPC
HOUSING
(56) 4 (+)
(58) 14
(60) 6 (+)
(61) 5 (-) } SC-11
(62) 8 LOGIC COMMON
(63) 9 (+)
OUTPUT INDUCTOR (64) 7 (-) } ARC VOLTS (C&G)
L1
D
ATC RECEIVER
ATC MALE CONNECTOR
(E64)
(E64)
(E35)
(E62)
(CSR) (NEG) T
E49 E45 E35 E61 E3 E1 O
E62 E43 E32 R
PILOT E64 CSR Vo C
H
CURRENT
SENSE
JUMPER
E37 E58 E36 E57 (E58)
WORK E
(C1)
E58 E62
(MODE SW)
RAR OFF
OUTPUT DIODE OUTPUT DIODE E34B (52)
ASSEMBLY E34A ASSEMBLY 1 J1
(51)
19X1757 19X1757 2
E39A E39B J40 P40
(14)
+12VDC 1 1 1
(15)
DC COM 2 2 2
E50A E50B 3 3 (46)
3
4 4 (17)
E48A E48B CSR 5 5 5
6 6
7 7 (18)
ASSY 19X2157
CHASSIS GND
E63 THRU SCREW TERMINAL
E56A E56B
AA ECO 101136 (REL) DLL 05/07/03
THERMAL DYNAMICS
INDUSTRIAL PARK No. 2
Assy No: F
AB ECO 101314 HAS 02/11/04 WEST LEBANON, NH 03784 Scale Supersedes
AC ECO 101429 HAS 06/09/04
Date:
AD ECO 101614 HAS 03/22/05 Information Proprietary to THERMAL DYNAMICS CORPORATION. 05/07/03
POWER OUTPUT BOARD ASSY 19X1914 AE ECO 101664 HAS 03/24/05 Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: References
AF ECO B028 RS 01/09/06 NOTE:
Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%. D.Lilja
AG ECO B016 RWH 01/27/06 Capacitors are in Microfarads (UF) Chk: App: Sheet
AH ECO B077 RWH 07/31/06 1 of 1
Last Modified: Friday, January 27, 2006
CM81/101 600V 3PH SYSTEM D 42X1134
6 7 8 9 10 Art # A-07151

APPENDIX 17: Publication History
Cover Date Rev Description
5/5/04 -- Manual Released.
6/23/04 -- Updated system schematics per ECO 101429.
6/23/05 -- Updated main PC board for 415V Australian use. ECO 101726.
4/28/06 AA Updated schematics per ECO B016. Added c/n for logic board for mechanized
units. Updated torque spec for replacement input diode. Started using new cover
style.
9/29/06 AA.01 Udated end of section 6 with patent information. Added inside rear cover info
and new rev. numbering.
3/14/07 AB.01 Updated 600 volt schematic to show new fuse.
4/13/07 AC.01 Updated C & Cr, revised Troubleshooting section (Pg. 4-12) made text corrections,
revised Section 6, Parts List - 6.07, Item # 2 - Catalog # 9-8337, updated Inside &
Rear Cover.

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@thermalarc.com Fax : 603+ 6092 1085
Thermadyne Canada Cigweld, Australia

2070 Wyecroft Road 71 Gower Street
Oakville, Ontario Preston, Victoria
Canada, L6L5V6 Australia, 3072
Telephone: (905)-827-1111 Telephone: 61-3-9474-7400
Fax: 905-827-3648 Fax: 61-3-9474-7510
Thermadyne Europe Thermadyne Italy

Europe Building OCIM, S.r.L.
Chorley North Industrial Park Via Benaco, 3
Chorley, Lancashire 20098 S. Giuliano
England, PR6 7Bx Milan, Italy
Telephone: 44-1257-261755 Tel: (39) 02-98 80320
Fax: 44-1257-224800 Fax: (39) 02-98 281773
Thermadyne, China Thermadyne International

RM 102A 2070 Wyecroft Road
685 Ding Xi Rd Oakville, Ontario
Chang Ning District Canada, L6L5V6
Shanghai, PR, 200052 Telephone: (905)-827-9777
Telephone: 86-21-69171135 Fax: 905-827-9797
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

Cutmaster 101

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101 ™

Plasma Cutting Power Supply

Covered under U.S. Patents

© Copyright 2003, 2004, 2005, 2006, 2007 by

All rights reserved.

Printed in the United States of America

Publication Date: April 13, 2007

Record the following information for Warranty purposes:

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

SECTION 3: DESCRIPTION ................................................................................................... 3-1

PATENT INFORMATION ............................................................................................................ 6-9

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION

APPENDIX 3: LOGIC PC BOARD LAYOUT .............................................................................. A-3

APPENDIX 4: MAIN POWER PC BOARD LAYOUT .................................................................. A-4

APPENDIX 6: LED/POT PC BOARD LAYOUT .......................................................................... A-8

APPENDIX 7: INPUT DIODE PC BOARD LAYOUT .................................................................. A-9

APPENDIX 8: IGBT CIRCUIT PC BOARD LAYOUT ............................................................... A-10

APPENDIX 9: OUTPUT DIODE PC BOARD LAYOUT ............................................................. A-11

APPENDIX 10: OUTPUT BOARD WIRING DIAGRAM ............................................................ A-12

APPENDIX 11: PILOT PC BOARD LAYOUT ........................................................................... A-13

APPENDIX 12: 28VAC CIRCUIT DIAGRAM .......................................................................... A-14

APPENDIX 13: DATA TAG INFORMATION .............................................................................. A-15

APPENDIX 14: TORCH PIN-OUT DIAGRAMS ........................................................................ A-16

APPENDIX 15: TORCH CONNECTION DIAGRAMS ............................................................... A-17

APPENDIX 16A: SYSTEM SCHEMATIC (208/230-Volt Units) ................................................. A-18

APPENDIX 16C: SYSTEM SCHEMATIC (600-Volt Units) ....................................................... A-22

APPENDIX 17: Publication History ......................................................................................... A-24

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

Manual 0-2853 1-1 GENERAL INFORMATION

• Ventilate all flammable or explosive vapors from 300 - 400* 9 12

GENERAL INFORMATION 1-2 Manual 0-2853

Dans ce manuel, les mots “note,” “attention,” et

Manual 0-2853 1-3 GENERAL INFORMATION

antimoine cadmium mercure • Débranchez l’alimentation électrique avant tout tra-

GENERAL INFORMATION 1-4 Manual 0-2853

Manual 0-2853 1-5 GENERAL INFORMATION

GENERAL INFORMATION 1-6 Manual 0-2853

National Standard and Technical Specifications

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

Manufacturers responsible representative: Steve Ward

Manual 0-2853 1-7 GENERAL INFORMATION

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 May 23, 2005

GENERAL INFORMATION 1-8 Manual 0-2853

• 208/230-Volt Single-Phase D. Repair Restrictions

Manual 0-2853 2-1 INTRODUCTION

INTRODUCTION 2-2 Manual 0-2853

3.02 Power Supply Specifications

CutMaster 101 Power Supply Specifications

Manual 0-2853 3-1 DESCRIPTION

Torch Leads Receptacle

Gas Pressure Regulator /

Gas Inlet Port

Ports for Optional Automation

Gas Pressure Gauge

Input Power Cord