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Thermal Dynamics
Welding System
CUTMASTER 151
Thermal Dynamics CUTMASTER 151 User Manual
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3
5
Table of Contents
Table of Contents
5
General Information
9
Notes, Cautions and Warnings
9
Important Safety Precautions
9
Publications
11
Note, Attention Et Avertissement
11
Precautions de Securite Importantes
12
Documents de Reference
13
Declaration of Conformity
15
Statement of Warranty
16
Section 2: Specifications
17
Scope of Manual
17
Power Supply Specifications
17
Input Wiring Specifications
18
Power Supply Features
19
Power Supply Options and Accessories
20
Torch Specifications
21
Torch Options and Accessories
22
Introduction to Plasma
23
Section 3: Installation
25
Unpacking
25
Lifting Options
25
Primary Input Power Connections
26
Gas Connections
28
Torch Connections
30
Torch Installation
32
Torch Parts Selection
33
Power Supply Connection to SC-11 Standoff Control
34
Power Supply Connection to Alternate Standoff Control
35
Automation Interface PC Board Set-Up
37
Optional Remote Current Control Harness Installation
38
Section 4: Operation
39
Product Features
39
Preparations for Operating
40
Selection, Inspection and Replacement of Consumable Torch Parts
44
Cut Quality
46
General Cutting Information
47
Torch Operation
48
Cutting Parameters
50
Cutting Specifications
51
Cutting Speed Chart: Mild Steel, SL100 Torch with Exposed Tip
52
Cutting Speed Chart: Stainless Steel, SL100 Torch with Exposed Tip
54
Cutting Speed Chart: Aluminum, SL100 Torch with Exposed Tip
56
Cutting Speed Chart: Mild Steel, SL100 Torch with Shielded Tip
58
Cutting Speed Chart: Stainless Steel, SL100 Torch with Shielded Tip
60
Cutting Speed Chart: Aluminum, SL100 Torch with Shielded Tip
62
Operator's Custom Cutting Speed Charts
64
Service
69
General Maintenance
69
Common Faults
73
Basic Troubleshooting
74
Advanced Troubleshooting Guide - General Information
79
Main Input and Internal Power Problems
81
Pilot Arc Problems
87
Main Arc Problems
92
Front Panel Parts Replacement
95
Left Side Internal Parts Replacement
97
Right Side Internal Parts Replacement
106
Parts Lists
113
Introduction
113
Ordering Information
113
Complete Power Supply Replacement
113
Section 6 Parts Lists
113
Power Supply Options and Accessories
114
Power Supply Major External Replacement Parts
115
Power Supply Front Panel Replacement Parts
116
Rear Panel Replacement Parts
117
Power Supply Left Side Internal Replacement Parts
118
Right Side Internal Replacement Parts
120
Torch Replacement Parts
122
Torch Consumables
126
Torch Spare Parts Kits
126
Complete Torch Assembly Replacement
128
Torch Options & Accessories
128
Patent Information
129
Appendix 1: Sequence of Operation (Block Diagram
131
Appendix 2: Data Tag Information
132
Appendix 3: Maintenance Schedule
133
Appendix 4: Torch Pin - out Diagram
134
Appendix 5: Torch Connection Diagram
135
Appendix 6: Control Cable Pin - out Diagram
136
Appendix 7: Interface Pcb Switch Settings (most Common Settings
137
APPENDIX 8: INTERFACE PCB SWITCH SETTINGS (Division Factors 16-24
138
APPENDIX 9: INTERFACE PCB SWITCH SETTINGS (Division Factors 24-30
139
APPENDIX 10: INTERFACE PCB SWITCH SETTINGS (Division Factors 30-33
140
APPENDIX 11: INTERFACE PCB SWITCH SETTINGS (Division Factors 33-36
141
APPENDIX 12: INTERFACE PCB SWITCH SETTINGS (Division Factors 36-43
142
APPENDIX 13: INTERFACE PCB SWITCH SETTINGS (Division Factors 43-50
143
Appendix 14: Automation Interface Pc Board Wiring Layout
144
APPENDIX 15: AUTOMATION INTERFACE PC BOARD LAYOUT and TEST POINTS
146
Appendix 16: Automation Interface Pc Board Wiring Connections to Oem Cnc Harness
146
Appendix 17: Automation Interface Pc Board Wiring Connections to Alternate Cnc Harness
147
Appendix 18: Main Pc Board Layout
148
APPENDIX 19: MAIN PC BOARD WIRING LAYOUT (208/230-Volt POWER SUPPLIES
150
Appendix 20: Main Pc Board Wiring Layout (400-V, 415-V, 460-V, 600-V Power Supplies
151
Appendix 21: Logic Board Layout
152
Appendix 22: Pot / Led Board Layout
153
Appendix 23: Output Diode Layout
154
Appendix 24: Output Diode Wiring Diagram
155
Appendix 25: Pilot Board Layout
156
Appendix 26: 28Vac Circuit Diagram
157
Appendix 27: 208/230V System Schematic
158
Appendix 28: 208/230V System Schematic
160
Appendix 29: 400 / 415 / 460V System Schematic
164
Appendix 30: 400 / 415 / 460V System Schematic
164
Appendix 31: 600V System Schematic
166
Appendix 32: 600V System Schematic
168
APPENDIX 33: Manual Publication History
170
Global Customer Service Contact Information
171
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Thermal Dynamics CUTMASTER 151 Specifications
General
Brand
Thermal Dynamics
Model
CUTMASTER 151
Category
Welding System
Language
English
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