Plasma Cutting Power Supply
CutMaster™ 100
Operating Manual Number 0-2859
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2001 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written per-
mission of the publisher 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: March 22, 2004
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, oper-
ating, 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.
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
1.07 Declaration of Conformity ............................................................................. 1-4
1.08 Statement of Warranty .................................................................................. 1-5
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ...................................................................................... 2-1
2.03 Specifications/Design Features .................................................................... 2-1
2.04 Power Supply Options and Accessories ....................................................... 2-2
SECTION 3:
INSTALLATION PROCEDURES ........................................................................................ 3-1
3.01 Introduction................................................................................................... 3-1
3.02 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Lifting Options .............................................................................................. 3-1
3.05 Primary Input Power Connections ................................................................. 3-2
3.06 Gas Connections .......................................................................................... 3-3
3.07 Torch Connections ........................................................................................ 3-5
3.08 Ground Connections For Mechanized Applications ....................................... 3-8
SECTION 4:
OPERATION...................................................................................................................... 4-1
4.01 Introduction................................................................................................... 4-1
4.02 Product Features .......................................................................................... 4-1
4.03 Preparations For Operating ........................................................................... 4-2
4.04 Sequence of Operation ................................................................................. 4-3
SECTION 5:
CUSTOMER & OPERATOR SERVICE .............................................................................. 5-1
5.01 Introduction................................................................................................... 5-1
5.02 General Maintenance .................................................................................... 5-1
5.03 Common Faults ............................................................................................ 5-2
5.04 Basic Troubleshooting Guide ......................................................................... 5-3
5.05 Power Supply Basic Parts Replacement....................................................... 5-5
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Power Supply Replacement .......................................................................... 6-2
6.04 Replacement Parts ....................................................................................... 6-2
6.05 Options and Accessories.............................................................................. 6-2
APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... A-2
APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM.................................................. A-3
APPENDIX 4: MAINTENANCE SCHEDULE ............................................................................. A-4
APPENDIX 5: SYSTEM SCHEMATIC, 208/230 VOLT UNITS .................................................. A-6
APPENDIX 6: SYSTEM SCHEMATIC, 400 and 460 V UNITS.................................................. A-8
APPENDIX 7: SYSTEM SCHEMATIC, 600 VOLT UNITS....................................................... A-10
January 27, 2004 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. Persons who
work near plasma arc cutting applications should
consult their medical health professional 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 instruc-
tions before using the equipment. Call 1-603-298-
5711 or your local distributor if you have any ques-
tions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
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, pro-
duces 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.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
GENERAL INFORMATION 1-2 January 27, 2004
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any ser-
vice or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwa-
ter or while using a water table. DO NOT cut alu-
minum alloys underwater or on a water table un-
less the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited
will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc pro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
• To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the deci-
bels (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.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding hel-
met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace 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/ASC Z49.1:
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.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
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 WELDING AND
CUTTING, obtainable from the American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-
PATION AND EDUCATIONAL EYE AND FACE PRO-
TECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
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
January 27, 2004 1-3 GENERAL INFORMATION
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING 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 Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-
ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDING AND CUTTING OF CONTAIN-
ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
GENERAL INFORMATION 1-4 January 27, 2004
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.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
January 27, 2004 1-5 GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal 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 customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
SureLok Torches 1 Year 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001
Manual 0-2859 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the Thermal Dy-
namics CutMaster 100 Plasma Cutting Power Supply
only. Servicing of this equipment is restricted to prop-
erly trained personnel; unqualified personnel are strictly
cautioned against attempting repairs or adjustments not
covered in this manual, at the risk of voiding the War-
ranty.
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip-
ment will assure the dependable operation for which it
was designed.
NOTE
Refer to the Torch Manual for torch and cutting
information.
2.02 General Description
The power supply provides 80 amp maximum output and
includes all control circuitry, electrical and gas inputs and
outputs, pilot circuitry, primary input power cable, and
work cable & clamp.
Section 2.04 lists power supply options and accessories.
2.03 Specifications/Design Features
1. Input Power (See Note)
Available for the following input power:
• 208 / 230VAC (±10%), Single-Phase, 50/60 Hz
• 400VAC (±10%), Three-Phase, 50/60 Hz
• 460VAC (±10%), Three-Phase, 60 Hz
• 460VAC (±10%), Single-Phase, 60 Hz
• 600VAC, (517-632 VAC), Three-Phase, 60 Hz
NOTE
Refer to Appendix 1 for input wiring requirements.
Units ordered as 208/230V, single-phase, have an
input cable and plug factory installed.
2. Output Power
Continuously variable from 20 to 80 amps maximum.
3. Duty Cycle (see NOTE)
NOTE
The duty cycle will be reduced if the primary input
voltage (AC) is low or the DC voltage is higher
than shown in the chart.
CutMaster 100, 208/230-Volt and 460-Volt Duty Cycle:
Ambient
Tem
p
erature 104° F
(40° C) 104° F
(40° C) 104° F
(40° C)
Duty Cycle 40% 60% 100%
Current 78 Amps 68 Amps 45 Amps
DC Voltage 120 vdc 111 vdc 98 vdc
CutMaster 100 208/230-Volt
and 460-Volt Power Su
pp
l
y
Dut
y
C
y
cle
Cutmaster 100, 400-Volt Power Supply Duty Cycle:
Ambient
Tem
p
erature 104° F
(40° C) 104° F
(40° C) 104° F
(40° C)
Duty Cycle 35% 60% 100%
Current 80 Amps 68 Amps 45 Amps
DC Voltage 112 vdc 111 vdc 98 vdc
CutMaster 100 400-Volt
Power Supply Duty Cycle
Cutmaster 100, 600-Volt Power Supply Duty Cycle:
Ambient
Tem
p
erature 104° F
(40° C) 104° F
(40° C) 104° F
(40° C)
Duty Cycle 35% 60% 100%
Current 78 Amps 68 Amps 43 Amps
DC Voltage 120 vdc 111 vdc 97 vdc
CutMaster 100 600-Volt
Power Supply Duty Cycle
4. Pilot Circuitry
Capacitive Discharge (CD), Ignition DC Pilot
5. Weight
83 lbs (37.6 kg)
Weight includes Power Supply w/Input Cable, Work
Lead, and Torch & Leads.
INTRODUCTION 2-2 Manual 0-2859
6. Overall Dimensions (including handles)
• Length: 27.5 inches (696 mm)
• Width: 12.4 inches (315 mm)
• Height: 17.3 inches (439 mm)
7. Gas Regulator/Filter Assembly Specifications
• Operating Pressure (Output): 70 psi (4.8 bar)
• Maximum input gas pressure: 125 psi (8.6 bar)
• Filter: Coalescent type filter
2.04 Power Supply Options and
Accessories
Refer to Section 6, Parts Lists, for catalog numbers and
ordering information.
A. Single Stage Air Filter Kit
For use with compressed air shop systems. Filters
moisture and particulate matter from the air stream
to at least 0.85 microns.
B. Two Stage Air Filter Kit
For use on compressed air shop systems. Filters mois-
ture and particulate matter from the air stream to at
least 5.0 microns.
C. High Pressure Regulators
High pressure regulators are available. The regula-
tors are used to set the proper pressure for the type gas
being used.
NOTE
Regulators should not be installed with In-Line Air
Filters.
D. Extended Work Cable with Clamp
As an alternative to the standard 20 ft (6.1 m) work
cable & clamp on the power supply, a 50 ft (15.2 m)
work cable with clamp is available.
E. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and
front-mounted swivel casters. Provides maximum
mobility for the power supply and can also serve as
a display cart. Top shelf is 12 " (305 mm) x 20 (508
mm). Steel handle is 30" (762 mm) high.
Manual 0-2859 3-1 INSTALLATION PROCEDURES
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This Section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; in-
stallation procedures for the Torch, Options, and Acces-
sories are given in Manuals specifically provided for those
units.
Depending on how the system was ordered, some Power
Supply Options may already be installed.
If option(s) have been factory installed some of the in-
structions may not apply. It is recommended that all sub-
sections be read for general information.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Gas
c. Torch Leads
d. Work cable
4. Grounding
5. Operator training
3.02 Site Selection
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
Review Important Safety Precautions (Section 1) to be sure
that the selected location meets all safety requirements.
The power supply is fan cooled by air flow through the
side panel to the front and rear panels. Air flow must not
be obstructed. Provide at least 2 feet (61 cm) in the rear
and at least 6 inches (152 mm) on each side for clearance.
Provide a minimum of 6 inches (or 152 mm) clearance in
front of the unit to allow access to the front panel con-
trols.
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
The product is packaged and protected to prevent dam-
age during shipping.
1. Unpack each item and remove any packing material.
2. Locate the packing list(s) and use the list(s) to iden-
tify and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with the instal-
lation.
3.04 Lifting Options
This unit is equipped with a handle designed for hand
lifting only. Be sure unit is lifted and transported safely
and securely.
• Only persons of adequate physical strength should
lift the unit.
• Lift unit by the handle, using two hands.
• Use hand cart or similar device of adequate capac-
ity to move unit.
• Place and secure unit on a proper skid before trans-
porting with a fork lift or other vehicle.
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
HANDLE is not for mechanical lifting.
INSTALLATION PROCEDURES 3-2 Manual 0-2859
3.05 Primary Input Power
Connections
Check the power source for correct voltage before con-
necting the unit.
A. 400-Volt, 460-Volt, or 600-Volt Power Supply
These Power Supplies are equipped with a four-conduc-
tor input power cable for three-phase input power. The
460-Volt Power Supply will accept 460-VAC, Single-Phase
input power with a change of input power cable.
For 400-Volt 460-Volt, or 600-Volt Three-Phase op-
eration:
1. Remove the Power Supply cover per section 5.05.
2. The cable's outer covering is stripped back at the
factory to expose the individual wires at the free
end of the cable.
3. Connect the ends of the individual wires to a cus-
tomer supplied plug or main disconnect as fol-
lows:
CAUTION
The primary power source and power cable must
conform to local electrical code and the recom-
mended circuit protection and wiring requirements
(refer to table in Appendix 1). All the input cable
wires must be connected for three-phase operation.
• L1 wire to Line 1.
• L2 wire to Line 2.
• L3 wire to Line 3, refer to Caution above.
• Ground wire to Ground.
4. Replace the Power Supply cover.
5. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.
For 460-VAC, Single-Phase operation:
1. Remove the Power Supply cover per section 5.05
2. Disconnect the original input power cable from
the main input contactor and the chassis ground
connection.
3. Loosen the strain relief on the back panel of the
power supply. Pull the original power cable out
of the power supply.
4. Pass a customer-supplied, three-conductor input
power cable through the access opening in the
back panel of the power supply. Refer to Appen-
dix 1 for power cable specifications. Tighten the
strain relief to secure the power cable.
CAUTION
The primary power source and power cable must
conform to local electrical code and the recom-
mended circuit protection and wiring requirements
(refer to table in Appendix 1).
5. Strip back the insulation on the individual wires.
6. Connect to main input contactor as follows:
• Line 1 wire to terminal L1.
• Line 3 wire to terminal L3.
7. Connect the ground wire to Ground (Earth). The
Ground wire connection requires a ring terminal.
A-03041
L1 L3
Ground Wire
with Ring
Terminal
Main Input
Contactor
Input Cable
L1 L2 L3
Input Power Connections, 460VAC, Single-Phase
8. Replace the Power Supply cover.
9. Connect the input power cable (or close the main
disconnect switch) to supply power to the system.
Manual 0-2859 3-3 INSTALLATION PROCEDURES
B. 208/230-Volt Power Supply
This power supply includes a factory-installed input
power cable and plug.
1. Check your power source for correct voltage before
plugging in the unit.
2. Connect the input power cable (or close the main dis-
connect switch) to supply power to the system.
CAUTION
The primary power source and power cable must
conform to local electrical code and the recom-
mended circuit protection and wiring requirements
(refer to table in Appendix 1).
3.06 Gas Connections
A. Gas Requirements
WARNING
This unit is not to be used with oxygen (O2).
Gases: Single Gas - Plasma/Secondary
Compressed Air Only
Pressure: 70 psi (4.8 bar)
CAUTION
Maximum pressure at inlet must not exceed 125 psi
(8.6 bar)
Flow: Cutting - 400 scfh (190 lpm)
Gouging - 400 scfh (190 lpm)
scfh = standard cubic feet per hour.
B. Checking Air Quality
To test the quality of air, place the RUN/SET switch to
SET position, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moisture in the air
will be visible on the lens. Do not initiate an arc!
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even com-
plete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
C. Connecting Gas to Power Supply
The gas supply is connected to the Regulator/Filter As-
sembly located on the rear of the unit. The connection is
the same for compressed air or high pressure gas cylin-
ders. If an optional air line filter is to be installed, refer to
procedures in subsection 3.06-D.
Connect the gas supply as follows:
1. Use customer-supplied fittings to connect the gas line
to the Regulator/Filter. Typical fittings are shown;
other fittings may be used.
Art # A-02999
Hose Clamp
1/4 NPT to 1/4"
(6mm) Fitting
Regulator/Filter
Assembly
Inlet Port
Gas Supply
Hose
Bowl
Gas Connection to Regulator/Filter Assembly
NOTE
For a secure seal, apply thread sealant to the fit-
ting threads, according to manufacturer's instruc-
tions. Do Not use Teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
D. Installing Optional Air Filter Kits
Additional filtering is recommended when using air from
a compressor to insure that moisture and debris from the
supply hose does not enter the torch. Although the Regu-
lator/Filter Assembly has its own filter, the optional fil-
ter kits are recommended for improved filtering.
1. Optional Single-Stage Air Filter Kit
This optional in-line air filter for use on compressed
air shop systems is highly effective at removing mois-
ture and particulate matter from the air stream to at
least 0.85 microns.
INSTALLATION PROCEDURES 3-4 Manual 0-2859
Art # A-03000
Regulator/Filter
Assembly Inlet Port
Bowl
1/4 NPT Hose Fitting
1/4" (6 mm) Gas Supply Hose
Hose Clamp
Optional Single-Stage Filter Installation
NOTE
For a secure seal, apply thread sealant to the fitting
threads, according to manufacturer's instructions.
Do Not use Teflon tape as a thread sealer as small
particles of the tape may break off and block the
small gas passages in the torch. Connect the gas
supply as follows:
a. Attach the Single-Stage Filter Hose to the Regu-
lator/Filter Assembly inlet port as shown.
b. Attach the Single-Stage Filter Assembly to the
filter hose.
c. Use customer-supplied fittings to connect the
gas line to the Filter. A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.
2. Optional Two-Stage Air Filter Kit
This optional two-stage air line filter is also for use
on compressed air shop systems. Filter removes mois-
ture and contaminants to at least 5 microns.
Connect the gas supply as follows:
a. Attach the Two Stage Filter bracket to the back
of the power supply per instructions supplied
with the filter assembly.
NOTE
For a secure seal, apply thread sealant to the fit-
ting threads according to manufacturer's instruc-
tions. Do Not use Teflon tape as a thread sealer as
small particles of the tape may break off and block
the small gas passages in the torch.
b. Connect the two stage filter outlet hose to the
inlet port of the Regulator/Filter Assembly.
c. Use customer-supplied fittings to connect the
gas line to the Filter. A 1/4 NPT to 1/4" hose
barbed fitting is shown as an example.
Art # A-03004
Regulator/Filter
Assembly
Hose
Clamp
1/4 NPT
Hose Fitting
1/4" (6 mm) Gas
Supply Hose)
2-Stage Filter
Inlet Port (IN)
Outlet Port
(OUT)
Regulator Inlet Port
Two Stage
Filter
Assembly
Optional Two-Stage Filter Installation
E. Using High Pressure Gas Cylinders
Refer to the following when using high pressure gas cyl-
inders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
1. Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-
rial. Momentarily open each cylinder valve to
blow out any dust which may be present.
3. The cylinder must be equipped with an adjust-
able high-pressure regulator capable of outlet
pressures up to 100 psi (6.9 bar) maximum and
flows of up to 400 scfh (190 lpm).
4. Use customer-supplied fittings to connect the gas
line to the cylinder.
NOTE
Supply hose must be at least 1/4 inch (6 mm) I.D.
Manual 0-2859 3-5 INSTALLATION PROCEDURES
3.07 Torch Connections
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub-section covers connecting the Torch for
the following applications:
A. Hand Systems
B. Machine Systems (Unshielded Leads)
C. Machine Systems (Shielded Leads)
D. Remote Pendant Control (Optional)
The Torch Leads must be properly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the Torch
Bulkhead Panel for the desired application.
A. Hand Systems
WARNING
Disconnect primary power at the source before dis-
assembling the torch or torch leads.
1. Remove the Cover of the Power Supply for ac-
cess to the Torch Bulkhead Panel. See Section 5.05.
2. Remove the retaining nut from the Strain Relief.
3. Feed the torch lead ends and the Strain Relief into
the hole in the front of the unit.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-03607
Negative /
Plasma Lead
Pilot Lead
Retaining Nut Removal
4. Secure the Strain Relief with the retaining nut re-
moved earlier.
5. Connect the Negative/Plasma Lead to the bulk-
head connection inside the Power Supply.
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Adapter
Connector
Pilot Lead Stud
Negative/Plasma
Lead Connection
A-03608
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Control Circuit
Connectors
Torch Lead Connections To Bulkhead
6. Connect the Control Circuit Connectors to the
mating connectors on the Power Supply Adapter.
7. Remove the top nut and washer from the Pilot
Stud.
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in Step 7.
9. Tighten the Strain Relief onto the Torch Leads.
10. Check the torch for proper parts assembly.
CAUTION
The torch parts must correspond with the type of
operation. Refer to the appropriate torch manual
for proper parts selection.
11. Reinstall the Power Supply Cover on the Power
Supply.
INSTALLATION PROCEDURES 3-6 Manual 0-2859
B. Machine Systems (Unshielded Leads)
1. Remove the Cover of the Power Supply for access
to the Torch Bulkhead Panel. See Section 5.05.
2. Remove the strain relief nut from the Strain Relief.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-03609
Remove Tie Wrap,
Remove Insulator,
Disconnect Wires
Strain Relief Nut Removal
3. Install the Torch Adapter as follows:
a. Inside the Power Supply Bulkhead area, route
the connector on the free end of the Adapter
through the Strain Relief Nut.
b. Continue routing the connector out the hole
in the front of the Power Supply.
c. Feed the end of the torch lead and the Strain
Relief into the hole in the unit while routing
the single black wire into the notch of the Strain
Relief.
d. Tighten the Strain Relief Nut to secure the
Strain Relief to the Power Supply.
4. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
5. If not previously done, remove the tie wrap from
the two mated and joined wires on the torch leads.
Disconnect the joined wires. Connect the Con-
trol Circuit Connectors to the mating connectors
on the Adapter supplied on the Power Supply.
Two wires on the Torch Leads remain unused.
6. Remove the top nut and washer from the Pilot
Stud.
7. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
Power Supply Adapter
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Negative/Plasma
Lead Connection
A-03610
Control Circuit
Connectors
Remote
Pendant
Adapter Open
Open
Adapter
Connector
Pilot Lead
Stud
Torch Lead Connections To Bulkhead
A-03611
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Control Circuit
Connectors
Open
Open
Power Supply Adapter
Wiring Connection Detail
8. Tighten the Strain Relief onto the Torch Leads.
9. Check the torch for proper parts assembly per the
torch manual.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04-A, Torch Parts
Selection.
10. Reinstall the Power Supply Cover.
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