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.