Thermal Dynamics CUTMASTER 151 User manual

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

WE APPRECIATEYOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-
426-1888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product.
Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire
manual, especially the Safety Precautions. They will help you to
avoid potential hazards that may exist when working with this
product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market-
leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical
support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically
advanced products to achieve a safer working environment within
the welding industry.

WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operat-
ing, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Automated Plasma Cutting System
Automated CutMaster™ 151 Power Supply
SL100 Machine Torch
Operating Manual Number 0-4691
Covered under U.S. Patents.
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
© Copyright 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 2, 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 .................................................................................................. 1-3
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-4
1.06 Documents De Reference ............................................................................. 1-5
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty .................................................................................. 1-8
SECTION 2: SPECIFICATIONS ................................................................................................ 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 Power Supply Specifications......................................................................... 2-1
2.03 Input Wiring Specifications ........................................................................... 2-2
2.04 Power Supply Features ................................................................................. 2-3
2.05 Power Supply Options and Accessories ....................................................... 2-4
2.06 Torch Specifications ..................................................................................... 2-5
2.07 Torch Options and Accessories .................................................................... 2-6
2.08 Introduction to Plasma .................................................................................. 2-7
SECTION 3: INSTALLATION ..................................................................................................... 3-1
3.01 Unpacking .................................................................................................... 3-1
3.02 Lifting Options .............................................................................................. 3-1
3.03 Primary Input Power Connections ................................................................. 3-2
3.04 Gas Connections .......................................................................................... 3-4
3.05 Torch Connections ........................................................................................ 3-6
3.06 Torch Installation .......................................................................................... 3-8
3.07 Torch Parts Selection.................................................................................... 3-9
3.08 Power Supply Connection to SC-11 Standoff Control ...................................3-10
3.09 Power Supply Connection to Alternate Standoff Control ............................... 3-11
3.10 Automation Interface PC Board Set-up ........................................................ 3-13
3.11 Optional Remote Current Control Harness Installation .................................. 3-14
SECTION 4: OPERATION ......................................................................................................... 4-1
4.01 Product Features .......................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
4.03 Selection, Inspection and Replacement of Consumable Torch Parts ............. 4-6
4.04 Cut Quality ................................................................................................... 4-8
4.05 General Cutting Information .......................................................................... 4-9
4.06 Torch Operation ........................................................................................... 4-10
4.07 Cutting Parameters ...................................................................................... 4-12
4.08 Cutting Specifications .................................................................................. 4-13
4.09 Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip .................. 4-14
4.10 Cutting Speed Chart: Stainless Steel, SL100 Torch with Exposed Tip .......... 4-16
4.11 Cutting Speed Chart: Aluminum, SL100 Torch with Exposed Tip .................. 4-18
4.12 Cutting Speed Chart: Mild Steel, SL100 Torch with Shielded Tip ................... 4-20
4.13 Cutting Speed Chart: Stainless Steel, SL100 Torch with Shielded Tip .......... 4-22
4.14 Cutting Speed Chart: Aluminum, SL100 Torch with Shielded Tip................... 4-24
4.15 Operator's Custom Cutting Speed Charts .................................................... 4-26

TABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Common Faults ............................................................................................ 5-5
5.03 Basic Troubleshooting ................................................................................... 5-6
5.04 Advanced Troubleshooting Guide - General Information ............................... 5-11
5.05 Main Input and Internal Power Problems ...................................................... 5-13
5.06 Pilot Arc Problems ....................................................................................... 5-19
5.07 Main Arc Problems ......................................................................................5-24
5.10 Front Panel Parts Replacement ....................................................................5-27
5.11 Left Side Internal Parts Replacement .......................................................... 5-29
5.12 Right Side Internal Parts Replacement ........................................................5-38
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Complete Power Supply Replacement .......................................................... 6-1
6.04 Power Supply Options and Accessories ....................................................... 6-2
6.05 Power Supply Major External Replacement Parts ......................................... 6-3
6.06 Power Supply Front Panel Replacement Parts ............................................... 6-4
6.07 Rear Panel Replacement Parts .................................................................... 6-5
6.08 Power Supply Left Side Internal Replacement Parts .................................... 6-6
6.09 Right Side Internal Replacement Parts ........................................................ 6-8
6.10 Torch Replacement Parts .............................................................................6-10
6.11 Torch Replacement Parts .............................................................................6-12
6.12 Torch Consumables ..................................................................................... 6-14
6.13 Torch Spare Parts Kits ................................................................................. 6-14
6.14 Complete Torch Assembly Replacement ...................................................... 6-16
6.15 Torch Options & Accessories ...................................................................... 6-16
PATENT INFORMATION ...........................................................................................................6-17
APPENDIX 1: SEQUENCE OF OPERATION
(BLOCK DIAGRAM) .......................................................................................................... A-1
APPENDIX 2: DATA TAG INFORMATION ................................................................................ A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................. A-3
APPENDIX 4: TORCH PIN - OUT DIAGRAM ............................................................................ A-4
APPENDIX 5: TORCH CONNECTION DIAGRAM .................................................................... A-5
APPENDIX 6: CONTROL CABLE PIN - OUT DIAGRAM .......................................................... A-6
APPENDIX 7: INTERFACE PCB SWITCH SETTINGS (MOST COMMON SETTINGS) ............ A-7
APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24) ....................... A-8
APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30) ....................... A-9

TABLE OF CONTENTS (continued)
APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33) .............................................. A-10
APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36) .............................................. A-11
APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43) .............................................. A-12
APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50) .............................................. A-13
APPENDIX 14: AUTOMATION INTERFACE PC BOARDWIRING LAYOUT ...................................................... A-14
APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS ....................................... A-15
APPENDIX 16: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONSTO OEM CNC HARNESS ... A-16
APPENDIX 17: AUTOMATION INTERFACE PC BOARD WIRING CONNECTIONSTO ALTERNATE
CNC HARNESS ................................................................................................................................. A-17
APPENDIX 18: MAIN PC BOARD LAYOUT .................................................................................................... A-18
APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208/230-Volt POWER SUPPLIES) .................................... A-20
APPENDIX 20: MAIN PC BOARD WIRING LAYOUT (400-V, 415-V, 460-V, 600-V POWER SUPPLIES) .............. A-21
APPENDIX 21: LOGIC BOARD LAYOUT ....................................................................................................... A-22
APPENDIX 22: POT / LED BOARD LAYOUT ................................................................................................. A-23
APPENDIX 23: OUTPUT DIODE LAYOUT ..................................................................................................... A-24
APPENDIX 24: OUTPUT DIODE WIRING DIAGRAM ..................................................................................... A-25
APPENDIX 25: PILOT BOARD LAYOUT ........................................................................................................ A-26
APPENDIX 26: 28VAC CIRCUIT DIAGRAM ................................................................................................... A-27
APPENDIX 27: 208/230V SYSTEM SCHEMATIC ............................................................................................ A-28
APPENDIX 28: 208/230V SYSTEM SCHEMATIC ............................................................................................ A-30
APPENDIX 29: 400 / 415 / 460V SYSTEM SCHEMATIC .................................................................................. A-32
APPENDIX 30: 400 / 415 / 460V SYSTEM SCHEMATIC .................................................................................. A-34
APPENDIX 31: 600V SYSTEM SCHEMATIC .................................................................................................. A-36
APPENDIX 32: 600V SYSTEM SCHEMATIC .................................................................................................. A-38
APPENDIX 33: Manual Publication History ..................................................................................................... A-40
Global Customer Service Contact Information ............................................................................. Inside Rear Cover

Manual 0-4691 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structions before using the equipment. Call 1-603-
298-5711 or your local distributor if you have any
questions.
GASESANDFUMES
Gasesandfumes produced during the plasmacuttingprocess
can be dangerous and hazardous to your health.
• Keepall fumes and gases fromthebreathingarea. Keep
yourheadoutof the welding fume plume.
• Use an air-supplied respirator if ventilation is not ad-
equate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc de-
pend on the kind of metal being used, coatings on the
metal, and the different processes. You must be very
carefulwhen cutting orweldingany metals which may
contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formation regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth de-
fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)

GENERAL INFORMATION 1-2 Manual 0-4691
ELECTRICSHOCK
Electric Shock can injure or kill. The plasma arc process uses
and produces high voltage electrical energy. This electric en-
ergy can cause severe or fatal shock to the operator or others
intheworkplace.
• Nevertouchanypartsthatareelectrically“live”or“hot.”
• Wear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repairorreplaceall worn or damaged parts.
• Extracaremustbe taken when the workplace ismoistor
damp.
• Installandmaintain equipment according to NECcode,
refer to item 9 in Subsection 1.03, Publications.
• Disconnectpowersourcebefore performing any service
orrepairs.
• Read and follow all the instructions in the Operating
Manual.
FIREANDEXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the
plasmaarc.
• Besurethere is no combustible orflammablematerialin
the workplace. Any material that cannot be removed
mustbe protected.
• Ventilateallflammableorexplosivevaporsfromthework-
place.
• Do not cut or weld on containers that may have held
combustibles.
• Provideafirewatch when working in an areawherefire
hazardsmayexist.
• Hydrogengasmaybeformedandtrappedunderalumi-
numworkpieceswhentheyarecutunderwaterorwhile
usinga water table. DO NOT cut aluminum alloys un-
derwater or on a water table unless the hydrogen gas
canbe eliminated or dissipated. Trappedhydrogengas
that is ignited will cause an explosion.
NOISE
Noisecancausepermanenthearing loss. Plasma arc processes
can cause noise levels to exceed safe limits. You must protect
your ears from loud noise to prevent permanent loss of hear-
ing.
• To protectyourhearingfromloudnoise,wearprotective
ear plugs and/or ear muffs. Protect others in the work-
place.
• Noiselevels should bemeasured to be surethe decibels
(sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in
Subsection 1.03, Publications, in this manual.
PLASMAARC RAYS
PlasmaArc Rays caninjureyoureyesandburnyourskin. The
plasmaarc process producesverybright ultra violet andinfra
redlight. Thesearc rays will damage youreyesandburnyour
skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or
shield. Alsoalwayswearsafetyglasseswithsideshields,
goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect
your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Re-
place lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use
protective booths, screens or shields.
• Use the shade of lens as suggested in the following per
ANSI/ASCZ49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is
clearly seen. Experience has shown that lighter
filters may be used when the arc is hidden by the
workpiece.

Manual 0-4691 1-3 GENERAL INFORMATION
1.03 Publications
Refer to the following standards or their latest revisions for
moreinformation:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDINGAND CUT-
TING, obtainable from theAmerican Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH,SAFETYANDHEALTHINARC WELDINGAND
GAS WELDING AND CUTTING, obtainable from the Su-
perintendent of Documents, U.S. Government Printing Of-
fice, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPA-
TIONAND EDUCATIONALEYEAND FACE PROTEC-
TION, obtainable fromAmerican National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-
TOE FOOTWEAR, obtainable from theAmerican National
Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSIStandardZ49.2,FIREPREVENTION IN THE USE OF
CUTTINGAND WELDING PROCESSES, obtainable from
AmericanNationalStandardsInstitute,1430Broadway,New
York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-
tainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Associa-
tion, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, obtainable from the National Fire ProtectionAs-
sociation, Batterymarch Park, Quincy, MA 02269
11. CGAPamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
GasAssociation, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY ob-
tainable from the National Welding Supply Association,
1900Arch Street, Philadelphia, PA19103
14. American Welding Society StandardAWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION
FOR WELDINGAND CUTTING OF CONTAINERS AND
PIPINGTHATHAVE HELDHAZARDOUSSUBSTANCES,
obtainable from theAmerican Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable fromAmerican National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
1.04 Note, Attention et
Avertissement
Danscemanuel,lesmots“note,” “attention,” et“avertissement”
sont utilisés pour mettre en relief des informations à caractère
important. Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.

GENERAL INFORMATION 1-4 Manual 0-4691
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de
l’énergie électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au person-
nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉEetGAZ
La fumée et les gaz produits par le procédé de jet de plasma
peuvent présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration.
Gardezvotre tête hors delaplume de fumée provenantdu
chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si
l’aération fournie ne permet pas d’éliminer la fumée et les
gaz.
• Lessortes de gazetde fumée provenantdel’arc de plasma
dépendent du genre de métal utilisé, des revêtements se
trouvantsurlemétaletdesdifférentsprocédés. Vousdevez
prendre soin lorsque vous coupez ou soudez tout métal
pouvant contenir un ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des
matières(sigle américain “MSDS”);celles-cidevraient être
fournies avec le matériel que vous utilisez. Les MSDS
contiennent des renseignements quant à la quantité et la
naturedelafuméeetdes gaz pouvant poser des dangers de
santé.
• Pour des informations sur la manière de tester la fumée et
les gaz de votre lieu de travail, consultez l’article 1 et les
documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de coupe
àdébitd’eau ou à courant descendantpourcapterlafumée
et les gaz.
• N’utilisezpasle chalumeau au jet de plasmadansunezone
où se trouvent des matières ou des gaz combustibles ou
explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ceproduit,dansle procéderdesoudageetdecoupe, produit
de la fumée ou des gaz pouvant contenir des éléments
reconnu dans L’état de la Californie, qui peuvent causer
des défauts de naissance et le cancer. (La sécurité de santé
en Californie et la code sécurité Sec. 25249.5 et seq.)
CHOCELECTRIQUE
Leschocsélectriquespeuventblesseroumêmetuer. Le procédé
aujetdeplasmarequiertetproduitdel’énergieélectriquehaute
tension.Cetteénergieélectriquepeutproduiredeschocsgraves,
voire mortels, pour l’opérateur et les autres personnes sur le
lieudetravail.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.

Manual 0-4691 1-5 GENERAL INFORMATION
INCENDIEETEXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
bustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les
pièces de travail en aluminium lorsqu’elles sont coupées
sous l’eau ou sur une table d’eau. NE PAS couper les
alliages en aluminium sous l’eau ou sur une table d’eau à
moinsque le gas hydrogène peut s’échapper ou sedissiper.
Legashydrogène accumulé explosera si enflammé.
RAYONS D’ARC DEPLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos
yeuxetbrûler votre peau. Le procédéàl’arcdeplasmaproduit
une lumière infra-rouge et des rayons ultra-violets très forts.
Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si
vous ne vous protégez pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un
écran de soudeur. Portez toujours des lunettes de sécurité
muniesde parois latéralesoudes lunettes de protectionou
une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le rec-
ommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est
observé clairement. L’experience a démontrer que
les filtres moins foncés peuvent être utilisés quand
l’arc est caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les
procédésde soudage à l’arcdeplasma peuvent provoquer des
niveauxsonoressupérieursauxlimitesnormalementacceptables.
Vous dú4ezvousprotégerlesoreilles contrelesbruitsforts afin
d’éviterune perte permanentedel’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des
tampons protecteurs et/ou des protections auriculaires.
Protégezégalement les autrespersonnesse trouvant surle
lieudetravail.
• Il faut mesurer les niveaux sonores afin d’assurer que les
décibels (le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit,
consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. NormeANSIZ49.1, LASÉCURITÉDES OPÉRATIONSDE
COUPEETDESOUDAGE,disponible auprès de la Société
Américaine de Soudage (American Welding Society), 550
N.W. LeJeune Rd.,Miami,FL33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402

GENERAL INFORMATION 1-6 Manual 0-4691
4. NormeANSIZ87.1,PRATIQUESSURESPOURLAPRO-
TECTIONDESYEUXETDU VISAGEAUTRAVAILET
DANS LES ECOLES, disponible de l’InstitutAméricain
desNormesNationales(AmericanNational Standards In-
stitute),1430 Broadway, NewYork, NY10018
5. NormeANSIZ41.1,NORMESPOURLESCHAUSSURES
PROTECTRICES, disponible auprès de l’American Na-
tionalStandardsInstitute,1430Broadway,NewYork, NY
10018
6. NormeANSIZ49.2,PRÉVENTIONDESINCENDIESLORS
DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de l’American National
StandardsInstitute,1430Broadway, NewYork, NY10018
7. NormeA6.0 de l’AssociationAméricaine du Soudage
(AWS),LESOUDAGEETLACOUPEDECONTENEURS
AYANTRENFERMÉDESPRODUITSCOMBUSTIBLES,
disponible auprès de laAmerican Welding Society, 550
N.W. LeJeune Rd.,Miami,FL33126
8. Norme51 de l’AssociationAméricainepourlaProtection
contre les Incendies (NFPA), LES SYSTEMESÀGAZ
AVEC ALIMENTATION EN OXYGENE POUR LE
SOUDAGE,LACOUPEETLESPROCÉDÉSASSOCIÉS,
disponibleauprèsdela National FireProtectionAssocia-
tion,BatterymarchPark,Quincy,MA02269
9. Norme70delaNFPA,CODEELECTRIQUENATIONAL,
disponibleauprèsdela National FireProtectionAssocia-
tion,BatterymarchPark,Quincy,MA02269
10. Norme 51B de la NFPA,LESPROCÉDÉS DE COUPE ET
DESOUDAGE,disponibleauprèsdela National FirePro-
tectionAssociation,BatterymarchPark,Quincy, MA02269
11. BrochureGCAP-1,LAMANIPULATIONSANSRISQUE
DES GAZ COMPRIMÉS EN CYLINDRES, disponible
auprèsdel’Associationdes GazComprimés(Compressed
GasAssociation), 1235 Jefferson Davis Highway, Suite
501,Arlington, VA22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE
SOUDAGE ET LA COUPE, disponible auprès de
l’AssociationdesNormes Canadiennes, Standards Sales,
178RexdaleBoulevard, Rexdale, Ontario, Canada, M9W
1R3
13. LivretNWSA,BIBLIOGRAPHIESUR LASÉCURITÉDU
SOUDAGE,disponibleauprèsdel’AssociationNationale
deFournituresdeSoudage(NationalWeldingSupplyAs-
sociation), 1900Arch Street, Philadelphia, PA19103
14. NormeAWSF4.1 de l’AssociationAméricainedeSoudage,
RECOMMANDATIONSDEPRATIQUESSURESPOURLA
PRÉPARATION ÀLACOUPE ET AU SOUDAGE DE
CONTENEURS ET TUYAUX AYANT RENFERMÉ DES
PRODUITSDANGEREUX,disponibleauprèsdelaAmeri-
canWeldingSociety,550N.W.LeJeuneRd.,Miami,FL33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE,disponibleauprèsdel’AmericanNational
StandardsInstitute,1430Broadway, NewYork, NY 10018

Manual 0-4691 1-7 GENERAL INFORMATION
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 forArc 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

GENERAL INFORMATION 1-8 Manual 0-4691
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
Product Power Supply Components
(Parts and Labor) Torch and Leads (Parts and Labor)
CUTMASTER™ 51 3 Years 1 Year
CUTMASTER™ 81 3 Years 1 Year
CUTMASTER™ 101 3 Years 1 Year
CUTMASTER™ 151 3 Years 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermal Dynamics whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermal Dynamics product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective January 15, 2004

Manual 0-4691 2-1 INTRODUCTION
2
SECTION 2: SPECIFICATIONS
2.01 Scope of Manual
This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynam-
ics Automated CutMaster 151 Plasma Cutting System. Servicing of this equipment is restricted to properly trained
personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this
manual, at the risk of voiding the Warranty.
Read this manual thoroughly. Acomplete understanding of the characteristics and capabilities of this equipment will
assure the dependable operation for which it was designed.
2.02 Power Supply Specifications
Output Current
Power Supply
Gas Filtering Ability
Ambient Temperature IEC
Rating TDC Rating IEC Rating TDC Rating IEC Rating TDC Rating
Duty Cycle
Current 100 - 73 - 50 -
DC Voltage 120 - 110 - 100 -
460 VAC (414 - 506 VAC), Three Phase, 50/60 Hz
25 - 100 Amps, Continuously Adjustable
CutMaster™ 151 Power Supply Specifications
208 / 230 VAC (187 - 253 VAC), Single Phase, 50/60 Hz
460 VAC (414 - 506 VAC), Single Phase, 50/60 Hz
Input Power
400 VAC (360-440 VAC), Single Phase, 50/60 Hz
400 VAC (360-440 VAC), Three Phase, 50/60 Hz
600 VAC (517-632 VAC), Three Phase, 60 Hz
415 VAC (370-460 VAC), Three Phase, 50 Hz
415 VAC (370-460 VAC), Single Phase, 50 Hz
* NOTE: The duty cycle will be reduced if the primary input power (AC) is low
or the output voltage (DC) is higher than shown in this chart.
Particulates to 20 Microns
CutMaster™ 151 Power Supply Duty Cycle *
40° C (104° F)
40% 60% 100%
NOTE:
IEC Rating is determined as specified by the International Electro-Technical Commission. These specifications in-
clude 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.

INTRODUCTION 2-2 Manual 0-4691
2
Power Supply Dimensions & Weight Ventilation Clearance Requirements
A-03572
27.5 in / 696 mm
12.4 in /
315 mm
17.3 in /
439 mm
83 lb / 37.6 kg
Art # A-03379
6"
150 mm
24"
0.6 m
6"
150 mm
6"
150 mm
2.03 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 (Non CSA) Wire (CSA)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50 na na 4 4
208 60 20.8 na 100 na 100 4 4
230 50 na na 6 4
2306021.2na92 na100 6 4
400 50/60 19.2 48 50 8 8
400 50/60 18 26 30 10 10
460 50/60 21.1 58 60 10 10
460 50/60 19 24 30 12 12
600 60 15.6 18 20 12 12
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
CutMaster™ 151 Input Wiring Specifications
Input Power Input Current Input Suggested Sizes (See Notes)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph
400/415 50 20 48 50 10
400/415 50 11 26 30 4
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
CE CutMaster 151 Input Wiring Specifications
Wire (mm2)
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer
to local or national codes.
Cable conductor temperature used is 167° F (75° C).
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS / LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.

Manual 0-4691 2-3 INTRODUCTION
2
Art # A-03578
Work Cable
and Clamp
Handle and Leads Wrap
Torch Leads Receptacle
Control Panel
2.04 Power Supply Features
Art # A-04214
Input Power Cord
Gas Inlet Port
Gas Pressure Regulator / Filter Assembly
Gas Pressure Gauge
CPC Connector for
Thermal Dynamics CNC Controller
Knockout for Alternate
CNC Controller
Wire Harness

INTRODUCTION 2-4 Manual 0-4691
2
2.05 Power Supply Options and Accessories
Section 6, Parts Lists, provides catalog numbers and ordering information.
A. Single-Stage Air Filter Kit
For use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least
0.85 microns. This filter increases performance and improves consumables parts life.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters moisture and contaminants from the air stream to at least 5.0
microns. This filter is pre-assembled at the factory and needs only to be installed on the power supply.
C. High Pressure Regulators
High pressure regulators are available. The regulators are used to set the proper compressed air pressure.
NOTE
Regulators should not be installed with In-Line Air Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft / 6.1 m work cable & clamp on the power supply, a 50 ft / 15.2 m work cable
with clamp is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for
the power supply and can also serve as a display cart. Top shelf is 12" / 305 mm x 20" / 508 mm. Steel handle is
30" / 762 mm high.
F. Wheel Kit
Akit with easy-rolling wheels, for maximum portability for the power supply.
G. Power Supply Dust Cover
A nylon canvas power supply dust cover with a water resistant finish