Thermal Dynamics CE CutMaster 50, CE CutMaster 75, CE CutMaster 100 Operating Manual

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Plasma Cutting

Power Supply

CE CutMaster CE CutMaster

CE CutMaster

50 75

100

March 22, 2004 Manual No. 0-2844

A-02766

Operating Manual

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100 Operating Manual Number 0-2844

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

Reproduction of this work, in whole or in part, without written permission 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 W arranty purposes:

Where Purchased:_________________________________________

Purchase Date:____________________________________________

Model Number:____________________________________________

Power Supply Serial #:_____________________________________

Torch Serial #:_____________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMA TION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.0 2 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.0 4 Note, Attention et Avertissement .................................................................. 1-3

1.0 5 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.0 1 Scope of Manual .......................................................................................... 2-1

2.02 General Description ...................................................................................... 2-1

2.03 Specifications/Design Features .................................................................... 2-1

2.0 4 Power Supply Options and Accessories ....................................................... 2-2

SECTION 3:

INST ALLA TION PR OCEDURES ........................................................................................ 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

3.0 6 Gas Connections ......................................................................................... 3-2

3.07 T orch Connections ........................................................................................ 3-5

3.08 Ground Connections For Mechanized Applications ....................................... 3-7

SECTION 4:

OPERATION...................................................................................................................... 4-1

4.01 Introduction................................................................................................... 4-1

4.02 Product Features .......................................................................................... 4-1

4.03 Preparations For Operating ........................................................................... 4-3

4.04 Sequence of Operation ................................................................................. 4-3

SECTION 5:

CUSTOMER/OPERA T OR SERVICE.................................................................................. 5-1

5.01 Introduction................................................................................................... 5-1

5.02 General Maintenance.................................................................................... 5-1

5.03 Common F aults ............................................................................................ 5-2

5.04 Basic T roubleshooting Guide......................................................................... 5-3

5.0 5 Power Supply Basic P arts 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 P ower Supply Replacement .......................................................................... 6-2

6.0 4 Basic Replacement Parts ............................................................................. 6-2

6.0 5 Options and Accessories.............................................................................. 6-2

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

APPENDIX 2A: SEQUENCE OF OPERATION (BLOCK DIA GRAM - CE CutMaster 50).......... A-2

APPENDIX 2B: SEQUENCE OF OPERATION (BLOCK DIAGRAM - CE CutMaster 75,

CE CutMaster 100) ............................................................................................................A-3

APPENDIX 3: TORCH CONTR OL CABLE WIRING DIA GRAM..................................................A-4

APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE ........................................................... A-5

APPENDIX 5: SYSTEM SCHEMATIC (CE CutMaster 50) ........................................................A -6

APPENDIX 6: SYSTEM SCHEMATIC (CE CutMaster 75) ........................................................A -8

APPENDIX 7: SYSTEM SCHEMATIC (CE CutMaster 100)..................................................... A-10

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful 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 operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEAL TH.

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 instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

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 pr ocesses. Y ou must be very careful when cutting or welding any 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 information 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 combustible 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 defects 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 operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

Date: January 27, 2004 1- 1 GENERAL INFORMA TION

• 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 service or repairs.

• Read and follow all the instructions in the Operating 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 material 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 underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing 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 hearing.

• T o protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the 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.

PLASMA ARC RA YS

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 pr otected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, 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. 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 HEAL TH 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 Society, 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 OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMA TION 1- 2 Date: January 27, 2004

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable 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 PROCESSES, 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 Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W1 17.2, 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 obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédur e 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.

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.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “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.

Date: January 27, 2004 1- 3 GENERAL INFORMA TION

Il faut communiquer aux opérateurs et au personnel 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 votr e distributeur local si vous avez des questions.

FUMÉE et GAZ

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. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• 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.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez 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-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des 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 à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone 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.

• Ce produit, dans le procéder de soudage et de coupe, 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.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (V oir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

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 combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable 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 moins que le gas hydrogène peut s’échapper ou se dissiper . Le gas hydrogène accumulé explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

GENERAL INFORMA TION 1- 4 Date: January 27, 2004

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit 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 munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculair e.

• 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 recommendation 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.

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 TRA VAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. V ous dú4ez vous pr otéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• 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.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS A YANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park, Quincy, MA 02269

Date: January 27, 2004 1- 5 GENERAL INFORMA TION

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMA TION 1- 6 Date: January 27, 2004

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est 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" (European 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 requir ements. Among them ar e:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* CENELEC EN50199 EMC Product Standard for Ar c W elding 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

Date: January 27, 2004 1- 7 GENERAL INFORMA TION

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 W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A P ARTICULAR PURPOSE.

LIMIT A TION 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 Y ears 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year Control PC Board 3 Y ears 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year

But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Year 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year SureLok T orches 1 Y ear 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 char ges 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: November 15, 2001

GENERAL INFORMA TION 1- 8 Date: January 27, 2004

SECTION 2:

INTRODUCTION

2.03 Specifications/Design Features

A. Power Supply Technical Specifications

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the CE CutMaster Plasma Cutting Power Supply only. 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. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

NOTE

Refer to the T orch Manual pr ovided with this Power Supply for torch and cutting information.

2.02 General Description

The power supply includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, primary input power cable, and work cable & clamp.

NOTE

Refer to Section 2.04 for a list of power supply options and accessories.

The following specifications apply to the Power Supply only:

1. Front Panel Features

• Main power ON/OFF switch

• RUN/SET switch

• output current control

• torch leads access

• work lead

2. Rear Panel Features

• Primary input power cable

• Gas pressure regulator/filter assembly

• Gas supply connection

• Grounding stud (CE CutMaster 75 & 100)

3. Front Panel Indicators

4. Input Power (See Note)

400V AC (±10%), Three Phase. Power Supply includes 4-conductor input power cable with filtering beads.

Refer to Appendix 1 for input wiring requirements.

, TEMP , GAS , DC

NOTE

5. Output Power

Continuously variable.

• CE CutMaster 50: from 20 to 40 amps maximum.

• CE CutMaster 75: from 15 to 60 amps maximum.

• CE CutMaster 100: from 20 to 80 amps maximum.

A-02766

CE CutMaster Power Supply

Manual 0-2844 2-1 INTRODUCTION

6. 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.

CE CutMaster 50 Power Supply:

CE CutMaster 50 Power Supply Duty Cycle

Ambient

Tem

erature

Duty Cy cle

104° F

(40° C)

40% 60%

104° F (40° C)

104° F

(40° C)

100%

B. Gas Regulator/Filter Assembly

Specifications

The following specifications apply to the standard Gas Regulator/Filter Assembly only:

1. Operating Pressure (Output)

70 psi (4.8 bar)

2. Maximum input gas pressure

125 psi (8.6 bar)

3. Filter

Particulate Type Filter (to 20 microns)

Current

DC Voltage

40 Amps 33 Amps n/a Amps

110 vdc 105 vdc

CE CutMaster 75 Power Supply:

CE CutMaster 75 Power Supply Duty Cycle

Ambient

erature

Tem

Duty Cy cle

Current

DC Voltage

104° F

(40° C)

50% 60%

60 Amps 60 Amps

109 vdc 109 vdc

104° F

(40° C)

CE CutMaster 100 Power Supply:

CE CutMaster 100 Power Supply Duty Cycle

Ambient

Tem

erature

Duty Cy cle

Current

DC Voltage

104° F

(40° C)

35% 60%

80 Amps 68 Amps

112 vdc 111 vdc

104° F

(40° C)

n/a vdc

104° F

(40° C)

100%

45 Am

98 vdc

104° F

(40° C)

100%

45 Am

98 vdc

2.04 Power Supply Options and Accessories

The following options and accessories are available for this power supply . Refer to Section 6, Parts Lists, for catalog numbers and ordering information.

A. Single-Stage Air Filter Kit

A single-stage air filter for use on compr essed air shop systems. Highly effective at removing moisture and

particulate matter from the air stream to at least 0.85 microns.

B. Two-Stage Air Filter Kit

This two-stage air filter is for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. The filter assembly is preassembled at the factory and need only be attached to the power supply.

C. Extended Work Cable with Clamp

As an alternative to the factory installed 20 ft (6.1 m) work cable & clamp on the power supply, a 50 ft (15.2 m) work cable with clamp is available.

7. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

8. Overall Dimensions (incl. handles) and Weight

CE CutM ast er Dimensions and W ei ght s

CE CutMaster 50 CE CutMaster 75, 100

Length: 22.5 in. (572 mm) 27.5 in (696 mm)

W idth: 10.75 in (273 mm) 12. 4 in (315 m m)

Height: 16.37 in ( 416 mm ) 17. 3 i n (439 mm )

W eight : 54 lb (2 4. 5 kg) 85 lb (3 8. 5 kg)

W eight includes Power Supply w/Input Cable, W ork Lead, and Torch & Leads.

INTRODUCTION 2-2 Manual 0-2844

D. Wheel Kit (CE CutMaster 50 only)

A kit with easy-r olling wheels, for maximum portability for the power supply.

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. T op shelf is 12 " (305 mm) x 20 (508 mm). Steel handle is 30" (762 mm) high.

SECTION 3:

CAUTION

INSTALLATION

PROCEDURES

3.01 Introduction

NOTES

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 instructions may not apply. It is recommended that all sub-sections be read for general information.

This Section describes installation of the Power Supply and connecting the Torch.

These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply a. Input power b. Gas c. To r ch Leads d. Work cable

4. Grounding

5. Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and adequate working space around all components.

NOTE

Review Important Safety Precautions (Section 1) to be sure that the selected location meets all safety requirements.

Operation without proper air flow will inhibit proper cooling and reduce duty cycle.

3.03 Unpacking

The product is packaged and protected to prevent damage during shipping.

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list(s) to identify 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 installation.

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.

WARNINGS

Do not touch live electrical parts. Disconnect input power conductors from de-ener-

gized supply line before moving unit.

HANDLE is not for mechanical lifting. F ALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.

• Only persons of adequate physical strength should lift the unit.

• Lift unit by the handle, using two hands.

• Install optional wheel kit (CE CutMaster 50 only) or use multi-purpose cart or similar device of adequate capacity to move unit.

• Place and secure unit on a proper skid before transporting with a fork lift or other vehicle.

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 (0.6 m) in the rear and at least 6 inches (150 mm) on each side for clearance. Provide a minimum of 6 inches (or 150 mm) clearance in front of the unit to allow access to the front panel controls.

Manual 0-2844 3-1 INST ALLATION PROCEDURES

3.05 Primary Input Power

Connections

The CE CutMasterTM Power Supply operates on three phase, 400VAC (± 10%), input power.

CAUTION

The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requir ements (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

The Power Supply is equipped with a three-phase, four conductor, input EMC power cable attached. Connect the cable to the customer's power source as follows:

NOTE

The input power cable must not be modified in any way as filtering beads are installed on the cable.

1. The outer covering of the cable is stripped back approximately 3 inches (76 mm) at the factory to expose the individual wires at the free end of the cable.

2. Cut back the insulation on the individual wires approximately 1/8 - 3/16 inch (3-5 mm).

3. Connect the ends of the individual wires to a customer supplied plug or main disconnect per the following:

NOTE

All the input cable wires must be connected for three-phase operation.

• Blue wire to Line 2 (Live)

• Black wire to Line 3 (Live), refer to Note above

• Brown wire to Line 1 (Live)

• Green/Y ellow wir e to Ground (Earth)

4. (CE CutMaster 75, CE CutMaster 100 only): Connect a customer-supplied grounding cable to the grounding stud on the rear panel as required by applicable Local and National Codes or local authority having jurisdiction. Grounding stud is

CAUTION

Maximum pressure at inlet must not exceed 125 psi (8.6 bar)

CE Cut M ast er Gas Requirem ents

Output Pressure

CE Cut M ast er 50 70 ps i (4.8 bar)

CE CutMaster

75, 100

70 psi (4.8 bar)

Flow

(Cuttin 200 scfh

(94.4 l pm )

400 scfh

(188.8 l pm )

)

(Gouging)

230 scfh

(108.5 l pm )

400 scfh

(188.8 l pm )

Flow

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 moistur e 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 complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.

identified with this symbol:

5. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

INST ALLATION PROCEDURES 3-2 Manual 0-2844

C. Connecting Gas Supply to Unit

D. Installing Optional Air Filter Kits

The gas supply is connected to the Regulator/Filter Assembly located on the rear of the unit. The connection is the same for compressed air or high pressure gas cylinders.

Connect the gas supply as follows:

1. If an optional air line filter is to be installed, refer to procedures in subsection 3.06-D.

2. Connect the gas line to the filter. A typical installation using a barbed fitting is illustrated; other fittings may be used.

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.

3. Connect the gas line to the Regulator/Filter Assembly.

Regulator/Filter Assembly

Inlet Port

Bowl

Additional filtering is recommended when using air from a compressor to insure that moisture and debris fr om the supply hose does not enter the torch. Although the Regulator/Filter Assembly does have its own filter, the optional Single-Stage Air Filter Kit or optional Two-Stage Air Filter Kit 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 moisture and particulate matter from the air stream to at least 0.85 microns.

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 below.

b. Connect the gas line to the optional filter. A

typical installation using a barbed fitting is illustrated; other fittings may be used.

c. Attach the gas supply hose to the Single-Stage

Filter Assembly .

1/4 NPT to 1/4"

(6mm) Fitting

Hose Clamp

Gas Supply

Art # A-02999

Hose

Gas Connection to Regulator/Filter Assembly

Regulator/Filter Assembly

Bowl

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

Inlet Port

Optional Single Stage Filter Installation

Art # A-03000

Manual 0-2844 3-3 INST ALLATION PROCEDURES

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 moisture and contaminants to at least 5 microns.

E. Using High Pressure Gas Cylinders

Refer to the following when using high pressure gas cylinders as the gas supply:

Connect the gas supply as follows: a. Attach the Two Stage Filter to the back of the

power supply per instructions supplied with the filter assembly.

NOTE

For a secure seal, apply thread sealant to the barbed fitting threads according to manufacturer's instructions. Do Not use T eflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch.

b. Install the two stage filter hose in the inlet port

of the Regulator/Filter Assembly, as shown below.

c. Connect the gas line to the optional filter. A

typical installation using a barbed fitting is illustrated; other fittings may be used.

d. Attach the gas supply hose to the Two-Stage

Filter Assembly .

Regulator/Filter Assembly

Regulator Inlet Port

2-Stage Filter Inlet Port (IN)

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 installation 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 material. Momentarily open each cylinder valve to blow out any dust which may be present.

3. The cylinder must be equipped with an adjustable high-pressure regulator capable of outlet pressur es and flows as follows:

CE CutM ast er Cyl i nder Gas Requirement s

Maximum

Pres sure

Flow

Rate CE CutM ast er 50 100 ps i (6. 9 bar) 200 scfh CE CutM ast er 75 100 ps i (6. 9 bar) 400 scfh CE CutM ast er 100 100 ps i (6. 9 bar) 400 scfh

4. Connect the gas supply hose to the cylinder valve.

NOTE

Supply hose must be at least 1/4 inch (6 mm) I.D.

Hose

Clamp

1/4" (6 mm) Gas

Supply Hose)

1/4 NPT

Hose Fitting

Optional Two-Stage Filter Installation

Outlet Port

(OUT)

Two Stage

Filter

Assembly

Art # A-03004

INST ALLATION PROCEDURES 3-4 Manual 0-2844

3.07 Torch Connections

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. Remote Pendant Control (Optional)

The T orch Leads must be pr operly installed to the Power Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the T or ch Bulkhead Panel for the desired application.

A. Hand Systems

WARNING

Disconnect primary power at the source before disassembling the torch or torch leads.

1. Remove the Cover of the Power Supply to gain access to the T orch Bulkhead Panel. See Section 5.05.

2. Remove the retaining nut from the Strain Relief.

Torch Leads

Assembly or ATC Adapter

Strain Relief

Note: Actual Bulkhead configuration may differ from that shown.

Adapter

Control Circuit

Connectors

Torch Leads Assembly or

ATC Adapter

A-03527

Adapter

Connector

Plug

Negative/Plasma

Pilot Lead Stud

Negative/Plasma Lead

Connection

Pilot Lead

Lead

Torch Lead Connections To Bulkhead

6. Connect the Control (PIP) 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 T orch 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. Re-install the Power Supply Cover on the Power Supply.

Negative / Plasma Lead

A-03529

Pilot Lead

Strain Relief

Nut

Retaining Nut Removal

3. Feed the torch lead ends and the Strain Relief into the hole in the unit.

4. Secure the Strain Relief with the retaining nut removed earlier .

5. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.

Manual 0-2844 3-5 INST ALLATION PROCEDURES

B. Machine Systems (Unshielded Leads)

1. Remove the Cover of the Power Supply to gain access to the T orch Bulkhead Panel. See Section 5.05.

2. Remove the strain relief nut from the Strain Relief.

Strain Relief

Torch Leads

Assembly

4. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.

Adapter Connector

Control Circuit

Connectors

Adapter

Not

Used

Negative/Plasma Lead Connection

Not

Used

Pilot Lead

Negative / Plasma Lead

A-03567

Pilot Lead

Strain Relief

Nut

Strain Relief Nut Removal

3. The Adapter supplied with the Power Supply must be installed 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 secur e the Strain

Relief to the Power Supply .

Negative/Plasma

Lead

A-03528

Torch Lead

Assembly

Remote Cable Connector

Torch Lead Connections To Bulkhead

5. Connect the Control (PIP) Circuit Connectors to the mating connectors on the Adapter supplied on the Power Supply (see W arning).

WARNING

The Adapter supplied with the Power Supply has two additional Shield Connectors that are used for Shielded Systems only. These two connectors are not used and must be taped out of the way to prevent contacting the Negative/Plasma or Pilot Leads.

6. Remove the top nut and washer from the Pilot Stud.

INST ALLATION PROCEDURES 3-6 Manual 0-2844

7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed in the above Step.

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. Re-install the Power Supply Cover on the Power Supply.

C. Remote Pendant Control (Optional)

In machine type operations the Power Supply has an Adapter that has a cable connector supplied at each end of the Adapter. One end is connected at the factory to the mating connector on the Power Supply Bulkhead area. The other end allows connection of a Remote Pendant. The remote pendant lead connector allows connection to a remote pendant or CNC cable while using Control (PIP) Circuit connections in the T orch Assembly .

Connect the remote pendant control cable to the connector provided on the Adapter fr om the Power Supply.

Remote Pendant/CNC

Cable Connector

Control

OK-To-Move

14 13

3 4

PIP

Circuit

Torch Control

Cable Connector

2 3

4 12 14 13

3.08 Ground Connections For Mechanized Applications

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems:

B. Grounding

1. The preferred grounding arrangement is a single point

or “Star” ground. The single point, usually on the cutting table, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (refer to paragraph ‘C’, Creating An Earth Ground). The ground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible. Long wires will have increased resistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better .

A-01366

Remote Pendant Connector Diagram

NOTE

Refer to Appendix 3, Torch Control Cable Wiring Diagram For Mechanized Systems, for detailed schematic of the Adapter.

2. Grounding for components mounted on the cutting

table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations.

For Thermal Dynamics components it is recommended to use a minimum of 10 A WG (Eur opean 6 mm2) wire or flat copper braid with cross section equal to or greater than 10 A WG connected to the cutting table frame. The connection point must be clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used and may improve noise protection.

3. The cutting machine frame is then connected to the

“Star” point using 1/0 AWG (European 50 mm2) or larger wire.

4. The plasma power supply work cable (see NOTE) is

connected to the cutting table at the single point “Star” ground.

NOTE

Do Not connect the work cable directly to the ground rod.

Manual 0-2844 3-7 INST ALLATION PROCEDURES

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended.

6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.

When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the cutting table, if possible.

115VAC: 3.0 VAC 230VAC: 1.5 VAC

Meter set to VAC setting

WARNING

Use extreme caution. This

test uses live voltage.

Neutral

115 or 230VAC

Line (Hot)

Art # A-02971

100W

Light Bulb

VR COM A

Ground

Rod

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interference than with no shield at all.

C. Creating An Earth Ground

1. T o create a solid, low r esistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground rod and the star ground point on the cutting table.

NOTE

Ideally, a properly installed ground rod will have a resistance of three ohms or less.

T o test for a proper earth ground, r efer to the following diagram. Ideally , the reading on the multimeter should be as follows:

• For 115VAC: 3.0 V AC

• For 230V AC: 1.5 VAC

Ground Testing

CAUTION

No other connections should be made at the ground rod being tested. This test assumes that the 1 15 or 230-VAC source neutral is connected to the utility earth ground.

2. Increasing the ground rod length beyond 20 - 30 ft (6,1 – 9,1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference.

INST ALLATION PROCEDURES 3-8 Manual 0-2844

SECTION 4:

OPERATION

4.01 Introduction

This section describes the power supply operating controls and procedures, identifies the front and rear components, and describes the operating procedures.

4.02 Product Features

This subsection provides specific functional descriptions of the power supply features, controls, and indicators.

5. Torch Bulkhead Panel

The torch bulkhead panel is under the power supply cover.

• Pilot Lead Stud

Connects the pilot control wire on the torch to the unit.

• Control Cable Connector

Connects the torch switch to the unit. In machine torch applications connects the torch switch on the pendant to the unit.

• Gas/Power Lead Connection

Connects the torch gas/negative lead to the unit.

A. Front and Side Panel Features

1. Control Panel

All operator controls, except gas pressure adjustment, are located on this panel: power ON/OFF switch, RUN/SET switch; CURRENT control; indicators for AC Power , TEMP , GAS, and DC.

A-02772

Front and Side Panel Features

2. Torch Leads Input

Hole in the front panel to feed the torch leads through to the internal bulkhead connections.

B. Control Panel Features

A-03641

4 5

6 7

Operating Controls (CE CutMaster 50)

4 5

3. Work Cable and Clamp

20 ft. (6.1 m) work cable with clamp, factory installed.

4. Roll Handle/Torch Leads Wrap

The torch leads and work cable wrap around the handle for easy storage.

Manual 0-2844 4-1 OPERATION

Operating Controls (CE CutMaster 75, 100)

1. ON / OFF Power Switch

ON (up) position supplies AC power to activate all system control circuits. OFF (down) position deactivates control circuits.

2. RUN / SET Switch

RUN (up) position is used for general torch operation. Torch switch must be held. SET (down) position used for setting gas pressure and purging lines.

3. Current Control (A)

Adjustment to set the desired output current. On CE CutMaster 75 and 100, circuitry in the Power Supply automatically reduces output current to 40 amps if the torch tip touches the work.

4. AC Power Indicator

Green indicator blinks ON-OFF for approximately eight seconds and then stays ON after the ON/OFF power switch is set to ON. Indicates operating power is present in the unit.

C. Rear Panel Features

1. Gas Input Port

Connection for gas input.

WARNING

This unit is not to be used with oxygen (O2).

5. TEMP Indicator

Normally OFF . Yellow indicator will come ON when the internal temperature sensors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation.

6. GAS Indicator

Green indicator will come ON when the input gas pressure is set to 35 psi (2.4 bar) or higher. Indicator will be OFF when the pressure falls below 35 psi (2.4 bar).

7. DC Indicator

Green indicator will come ON while the torch switch is pressed. Indicates DC output circuit is active.

A-03278

Rear Panel

2. Primary Input Power Cable/Strain Relief

Factory installed primary input power cable with strain relief, capable of handling the input voltage for which this unit was designed.

3. Gas Pressure Regulator/Filter Assembly

Pressure regulator to adjust the input gas pr essur e to the Power Supply . The pressur e regulator has its own built-in filter. For improved filtering, other filtering packages are available as options.

4. Grounding Stud (CE CutMaster 75 & 100 only)

Connection point for grounding as required by Local or National Codes or local authority having jurisdiction. The grounding stud is identified with this sym-

OPERA TION 4-2 Manual 0-2844

bol:

4.03 Preparations For Operating

H. Set Operating Pressure

This procedure should be followed at the beginning of each shift:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate front end torch parts. The torch parts (shield cup, tip, gas distributor , and electr ode) must corr espond with the type of operation (cutting or gouging). Refer to the torch manual for proper parts selection.

B. Check Primary Input Power Source

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per subsection 2.03-A, Specifications/Design Features.

2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

C. Gas Selection

Select desired single gas supply . Make sur e gas source meets requirements (refer to subsection 3.06, Gas Re- quirements). Check connections and turn gas supply on.

D. Work Cable Connection

Check for a solid work cable connection to the workpiece.

Place the RUN/SET switch to the SET (down) position. Gas will flow . Adjust gas pr essur e control to 70 psi / 4.8 bar.

I. Prepare to Cut

Return the RUN/SET switch to RUN (up) position. Gas will not flow until the Torch Trigger is pr essed.

The system is now ready for operation. Push the T orch Trigger to start the pilot arc. There is a 2 second preflow before the arc starts.

4.04 Sequence of Operation

The following is a typical sequence of operation for this power supply. Refer to Appendix 2 for block diagram.

1. Close main power source disconnect switch. a. AC power is available at the Power Supply.

2. Place RUN/SET switch to RUN (up) position.

3. Place the ON/OFF power switch on the front panel of the Power Supply to ON (up) position.

a. AC Power Indicator blinks ON and OFF

for eight seconds then stays ON.

b. Fan turns on.

NOTE

Gas comes on if T or ch Trigger is pressed (although unit will not pilot until switch is released and reclosed after the light stops blinking).

4. Place RUN/SET switch to SET (down) position. a. Gas solenoid opens and gas flows to set pres-

sure. Gas Pressure Regulator/Filter Assembly should be set to 70 psi / 4.8 bar.

E. Torch Connection

Check that the torch is properly connected.

F. Power On

On the Power Supply place the ON/OFF switch to the ON (up) position.

G. Select Current Output Level

On the Control Panel, set the desired current output level.

Manual 0-2844 4-3 OPERATION

b. GAS indicator turns ON.

NOTE

GAS Indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Gas

Pressure Regulator/Filter Assembly.

5. Place RUN/SET switch to RUN (up) position. a. Gas flow stops.

b. GAS Indicator turns OFF .

6. Protect eyes and press or activate torch switch. a. Gas pre-flow starts (approximately 2 seconds).

b. GAS Indicator turns ON.

7. After gas pre-flow: a. Power Supply enabled. b. DC indicator turns ON. c. Pilot Relay closes.

8. Pilot arc is established.

9. Move Torch within transfer distance of workpiece. a. Main arc transfer. b. Pilot arc OFF.

10. Complete cutting operation.

NOTE

If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc will automatically restart.

11. Deactivate the torch. a. Main arc stops. b. Pilot arc stops (power supply enable signal re-

moved). If torch is activated during post-flow, the pilot

arc will immediately restart. If tor ch is within 1/4 inch (6.4 mm) transfer distance to workpiece, the main arc will transfer.

12. Gas will flow for 10 seconds (post-flow). a. Gas solenoid closes. b. Gas flow stops.

c. GAS indicator turns OFF.

13. Place the ON/OFF power switch on the front panel of the unit to OFF (down) position.

a. AC Power indicator turns OFF. b. Fan turns OFF .

14. Place the main power disconnect to open. a. Main AC power is removed from the system.

For information on cutting techniques, cutting problems, cutting speeds, cut quality, etc., refer to the torch manual supplied with the torch.

OPERA TION 4-4 Manual 0-2844

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

5. The filter element and spool, with the baffle ring in place (teeth facing downward) can be screwed back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand.

This section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted other than by properly trained personnel.

5.02 General Maintenance

A. Maintenance Schedule

W ARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

To clean the unit, open the enclosure per procedures in section 5.05-A, Cover Removal, and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean. If necessary, solvents for cleaning electrical apparatus may be used.

Refer to Appendix 4 for maintenance schedule and procedures.

B. Regulator/Filter Element Replacement

The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter element should be checked per the Maintenance Schedule, and either cleaned or replaced. Refer to Section 6 for replacement element catalog number .

1. Remove power from the power supply; turn off the gas supply.

2. Unscrew the bowl on the bottom of the Filter Regulator Assembly. The filter element will be visible and still attached to the main body of the Filter Regulator .

Regulator/Filter

Assembly

Baffle Ring

Filter Element No. 9-4414

Spring

Spool

Bowl

Art # A-02995

Filter Regulator Element Replacement

6. Reinstall the bowl.

7. Turn on the air supply.

C. Optional Single-Stage Filter Element

Replacement

NOTES

These instructions apply to power supplies where the optional Single-Stage Filter has been installed.

The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6 for replacement element catalog number .

3. Grasp the filter element and unscrew it from the Filter Regulator body . The filter element will come off with a spool and some additional pieces.

4. Note the correct assembly of the filter/spool then remove the filter from the spool and either clean it or replace it.

Manual 0-2844 5- 1 CUSTOMER/OPERATOR SERVICE

1. Remove power from power supply .

2. Shut off air supply and bleed down system before disassembling Filter to change Filter Element.

3. Disconnect gas supply hose.

4. Turn the Cover counter-clockwise and remove it from the Filter Housing. The Filter Element is located inside the Housing.

W ARNING

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

Optional Single-Stage Filter Element Replacement

5. Remove the Filter Element from the Housing and set Element aside to dry .

6. Wipe inside of housing clean, then insert the replacement Filter Element open side first, as shown in the figure.

Always turn off the air supply and bleed the system before disassembling the Filter Assembly as injury could result.

3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to move freely.

First & Second Stage Cartridges (as marked)

Art # A-02942

7. Replace Housing on Cover.

8. Reattach gas supply hose.

NOTE

If unit leaks between housing and cover , inspect the "O" Ring for cuts or other damage.

D. Optional Two-Stage Filter Element

Replacement

NOTES

These instructions apply to any power supply where the optional T wo-Stage Filter has been installed.

The T wo-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6 for replacement element catalog number .

1. Remove power from power supply .

2. Shut off air supply and bleed down system before changing Filter Elements.

Two-Stage Filter Replacement

4. Note the location and orientation of the old Filter Elements.

5. Slide out the old Filter Elements.

6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted in Step 4 above.

7. Hand tighten the two bolts evenly , then tor que each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

8. Slowly apply air pressure to the assembly, checking for leaks.

5.03 Common Faults

1. Insufficient Penetration

a. Cutting speed too fast b. T or ch tilted too much c. Metal too thick

CUSTOMER/OPERA T OR SERVICE 5- 2 Manual 0-2844

d. Worn torch parts e. Cutting current too low f. Non-Genuine Thermal Dynamics Parts used

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non-Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Non-Genuine Thermal Dynamics Parts

4. Short T orch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Air pressure too low e. Improperly assembled torch f. Non-Genuine Thermal Dynamics parts used

Follow all instructions as listed and complete each section in the order presented.

For major troubleshooting and parts replacement procedures refer to the Power Supply Service Manual.

B. How to Use This Guide

The following information is a guide to help the Customer/ Operator determine the most likely causes for various symptoms. Follow all instructions as listed and complete each section in the order presented.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (T ext T ype)

1. Cause (Italic Type)

a. Check/Remedy (T ext T ype)

Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to verify that unit is fully operational after any repairs.

Common Symptoms

A. AC Power indicator OFF

1. Switch at customer's main power panel in OFF position.

a. Close main power panel switch.

2. Customer's main power line fuse(s) blown

5.04 Basic Troubleshooting Guide

W ARNING

There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques.

A. Basic Tr oubleshooting: Overview

This guide covers a basic level of troubleshooting that re- quires limited disassembly and measurements. It is helpful for solving many of the common problems that can arise with this system.

If major complex subassemblies are faulty, the unit must be returned to an authorized service center for repair .

a. Check main power panel fuse(s) and replace as

required.

3. Actual input voltage does not correspond to voltage of unit

a. Verify that the input line voltage is 400 VAC

(±10%), three phase.

4. Unit internal fuse blown or loose

a. If blown, double check input voltage and replace

fuse per subsection 5.05-B. If fuse blows again, return unit to an authorized service center .

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

B. AC Power indicator ON; TEMP indicator

1. Airflow obstructed

a. Check for obstructed air flow around the unit

and correct condition.

Manual 0-2844 5- 3 CUSTOMER/OPERATOR SERVICE

2. Fan(s) blocked

E. Low cutting output

a. Check and correct condition.

3. Unit is overheated

a. Allow unit to cool down for at least 5 minutes.

Make sure the unit has not been operated beyond Duty Cycle limit. Refer to Section 2.03.

4. Input line voltage is below 75% of rated level

a. Check and connect to proper input power line.

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

C. T orch will not pilot when torch switch is activated

1. RUN/SET switch in SET position

a. Move switch to RUN position.

2. Faulty torch parts a. Inspect torch parts and replace if necessary (re-

fer to Instruction Manual .

3. Gas pressure too high or too low

a. Set pressure to 70 psi / 4.8 bar .

4. Faulty components in unit

1. Incorrect setting of CURRENT (A) control

a. Check and adjust to proper setting.

2. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

F . Limited output with no control

1. Poor input or output connections

a. Check all input and output connections.

2. Faulty components in unit a. Return for repair or have qualified technician

repair per Service Manual.

G. Erratic or improper cutting output

1. Poor input or output connections

a. Check all input and output connections.

2. Poor ground or work connection is poor.

a. Check connection.

H. Arc shuts off during operation; Arc will not re-start

when torch switch is activated.

a. Return for repair or have qualified technician

repair per Service Manual.

D. AC Power indicator

ON; Gas flowing; Fan operating; T orch trigger activated; No cutting output

1. T orch not properly connected to power supply

a. Check that torch leads are properly attached to

power supply .

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against torch

head. Refer to the torch manual for details.

3. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

4. Faulty T orch

a. Return for repair or have qualified technician

repair per T or ch Manual.

1. Unit is overheated (TEMP indicator ON)

a. Allow unit to cool down for at least 5 minutes.

Make sure the unit has not been operated beyond Duty Cycle limit. See Section 2 for duty cycle specifications.

2. Fan blades blocked (TEMP indicator ON)

a. Check and clear blades.

3. Airflow obstructed (TEMP indicator ON)

a. Check for obstructed air flow around the unit

and correct condition.

4. Gas pressure too low (GAS indicator OFF when torch switch is activated)

a. Check source for proper supply pressure; ad-

just as needed.

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

CUSTOMER/OPERA T OR SERVICE 5- 4 Manual 0-2844

I. AC POWER indicator ON; Fan operating;

No gas flow

1. Gas not connected or pressure too low

A. Cover Removal

1. Remove the upper screws which secure the cover to the main assembly .

a. Check source for proper supply pressure.

2. Gas supply pressure too high

a. Maximum 125 psi (8.6 bar) inlet pressure

3. Shield Cup not properly installed.

a. Check to see that Control Circuit (PIP) pins are

installed. Refer to the torch manual for details.

4. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

J. T orch cuts but not adequately

1. Current set too low

a. Increase current setting.

2. T orch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Torch Instr uction

Manual.

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

while purging and observe oil or moisture buildup (do not activate torch).

NOTE

There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there is a need for more room to work.

2. Loosen, but do not remove, the lower screws, then carefully pull the Cover up and away from the unit to gain access to the inside of the unit.

Upper Screws

Lower Screws (2 or 3 per side)

K. Cutting output drops during operation (CE CutMas-

ter 75 and 100 only)

1. Tor ch tip touches work; Tip Saver circuit active. Circuitry in the Power Supply automatically reduces output current to 40 amps if the torch tip touches the work.

a. Lift torch tip off work or install optional stand-

off guide.

5.05 Power Supply Basic Parts Replacement

W ARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply.

This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual.

Ground wire

A-02962

Cover Removal

Manual 0-2844 5- 5 CUSTOMER/OPERATOR SERVICE

3. Reinstall the cover as follows: a. Reconnect the ground wire, if necessary. b. Place the cover onto the frame so that it rests on

the lower screws. c. Tighten lower screws. d. Reinstall and tighten the upper screws.

B. Fuse Replacement

1. Remove the unit cover per paragraph "A" above.

2. Locate the internal fuse on the left side of the center chassis.

3. Replace the fuse. Refer to Section 6.04 for proper fuse specification.

4. Reinstall the cover by reversing the steps in paragraph "A" above.

Fuse Location

A-02957

Internal Fuse Location

CUSTOMER/OPERA T OR SERVICE 5- 6 Manual 0-2844

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable components. The parts lists are arranged as follows:

Section 6.03 Complete Power Supply Replacement Section 6.04 Basic Replacement Parts Section 6.05 Options and Accessories

B. Returns

If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly , as listed for each type item. Also include the model and serial number of the power supply. Address all inquiries to your authorized distributor.

Manual 0-2844 6-1 P A RTS LISTS

6.03 Power Supply Replacement

The following items are included with the replacement power supply: work cable & clamp, gas pressur e regulator/ air filter, input power cable, and operating manual.

Qty Description Catalog #

1 CE CutMaster 50 Power Supply, 400V AC, Three-Phase 3-5830 1 CE CutMaster 75 Power Supply, 400VAC, Three-Phase 3-1850 1 CE CutMaster 100 Power Supply, 400VAC, Three-Phase 3-2050

6.04 Basic Replacement Parts

Qty Description Catalog #

1 Fuse

for CE CutMaster 50 9-8110

for CE CutMaster 75, CE CutMaster 100 9-8602 1 Regulator/Filter Assembly Element Replacement 9-4414 1 Input Power Cable, CE 9-8553

6.05 Options and Accessories

Qty Description Catalog #

1 Single-Stage Air Line Filter Kit (includes Filter & Hose) 7-7507 1 Replacement Filter Body 9-7740 1 Replacement Filter Hose (not shown) 9-7742 2 Replacement Filter Element 9-7741

1 Two-Stage Air Line Filter Kit (includes Hose & Mounting Screws) 7-7500 1 Bracket, Filter Mounting (not shown) 9-7535 1 T wo-Stage Air Filter Assembly 9-7527 1 First Stage Cartridge 9-1021 1 Second Stage Cartridge 9-1022

Not shown:

1 Extended Work Cable (50 ft/15.2 m) with Clamp 9-8529 1 Wheel Kit (CE CutMaster 50 only) 9-8510 1 Multi-Purpose Cart 7-8888

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

(Cat. No. 9-7743)

Cover

Barbed

Fitting

Assembled Filter

Art # A-02476

First & Second Stage Cartridges (as marked)

Art # A-02942

Single-Stage Filter Kit Two-Stage Air Filter Kit

PARTS LISTS 6-2 Manual 0-2844

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Sugge sted S ize s (S ee Notes)

Voltage Fre quency 3-Ph 3-Ph Fuse (Amps)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

CE CutM ast er 50 400 50/60 7.9 11.5 15 4

CE CutM ast er 75 400 50 11.1 16 20 4 CE CutM ast er 100 400 50 13.9 20 25 4

Line Vol t ages wit h S uggest ed Circ uit P rot ect ion and Wire S i zes

Bas ed on Nat i onal E l ec tric Code and Canadian Elec tric Code

Pow er Input Current Input

Wire (mm

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 0-2844 A-1 APPENDIX

APPENDIX 2A: SEQUENCE OF OPERATION

(BLOCK DIAGRAM - CE CutMaster 50)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8 seconds then steady on.

Fans on.

Pilot relay closes.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed)

post-flow, pilot arc will immediately restart.

(1/4 in/6.4mm) of workpiece, main arc

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (10 seconds)

NOTE - If torch is activated during

If torch is within transfer distance

will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system

A-03568

APPENDIX A-2 Manual 0-2844

APPENDIX 2B: SEQUENCE OF OPERATION

(BLOCK DIA GRAM - CE CutMaster 75, CE CutMaster 100)

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8 seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch moved within

transfer distance of workpiece.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed)

post-flow, pilot arc will immediately restart.

(1/4 in/6.4mm) of workpiece, main arc

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (10 seconds)

NOTE - If torch is activated during

If torch is within transfer distance

will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-02778

Manual 0-2844 A-3 APPENDIX

APPENDIX 3: TORCH CONTROL CABLE WIRING

FOR MECHANIZED SYSTEMS

T o Torch

Control Device

Torch Control

Cable

DIAGRAM

Control Connector

Plug with Connectors

Torch Control

Connectors

To Power Supply

Control Connector

Control Shield

Connector

Shield

Return

Power Supply

Control

OK-To-Move

Relay

A-02821

12 14

Torch Lead

Assembly

Mate & Lock

2 1 3 4

Connectors

Lead Shield

Connector

Torch Leads

Connectors only on

Shielded Leads

Mate & Lock

Connectors

Torch Head

PIP Pin

Shield Cup

PIP Pin

3 4

OK-To-Move

A-02801

Control

Torch Control

Cable Connector

APPENDIX A-4 Manual 0-2844

Pendant Ground

Remote Pendant/CNC

Cable Connector

APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow .

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary.

3. Check all contactor points for severe arcing or pits, r eplace if necessary.

Manual 0-2844 A-5 APPENDIX

APPENDIX 5: SYSTEM SCHEMATIC (CE CutMaster 50)

A-02967

APPENDIX A-6 Manual 0-2844

Manual 0-2844 A-7 APPENDIX

A-02967

APPENDIX 6: SYSTEM SCHEMATIC (CE CutMaster 75)

460VAC 1 PHASE INPUT

ON/OFF SW

RUN/SET SW

CURRENT CONTROL

LED PCB 19X1604 CURRENT ADJUST 20 - 60

460VAC 3 PHASE INPUT

CHASSIS GND

FAN2

FAN1

PILOT RELAY

PCR

28VAC B 28VAC A

SW1

SW2

IGBT HEATSINK

INDUCTOR TEMP

400VAC 3 PHASE INPUT

230V

TEMP

GAS

TEMP

NTC

TS1

TS2

EMC

FILTER

400V CE

ONLY

J14

(1)

(2)

(3)

CHASSIS

E22

GND

P11

(4)

(5)

J15

P15

(6)

(7)

J18

P18

(19)

(20)

(21)

(22)

(23)

(24)

(25)

(26)

P27

J27

(35)

(36)

(37)

(38)

(39)

(40)

(41)

(42)

J29

P29

P32

J32

J11

+18V

POT HIGH POT WIPER POT LOW +12V AC GAS OVERTEMP DC

FILTERING

PILOT ON

J23

TEST CONNECTOR

(8)

SOL1

GAS SOLENOID

1 2

LT1

ZERO OHM

R29

FOR 460V ONLY

ZERO OHM

R78

FOR 400V ONLY

FUSE

(SEE NOTES)

0.9A

J24

P24

(9)

INPUT DIODE ASSEMBLY 19X1811

E13

E18

RESETABLE

(11)(10)

PRESSURE SW

460V

400V

230V

(12)

PS1

PRESS GOOD

MAIN CONTACTOR

(13)

9 10

E6 E8

E14 E16

INRUSH

28VAC A

TO BIAS SUPPLY

28VAC B

E15

+12VDC

+18V

FAN

+18VDC

SOLENOID ON RELAY

+18VDC

CONTACTOR ON RELAY

MAIN BOARD ASSEMBLY 400-VOLT: 19X1778 460-VOLT: 19X1753

CD ON

D20

D21

INV ON

D37

DRAG ON

SW ON

D32

LOGIC BOARD ASSEMBLY 19X1784

E20

E23

E30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

IGBT PCB ASSEMBLY 19X1756

E12A

E17A

24 25

E19A

E21A

IGBT PCB ASSEMBLY 19X1756

E12B

E17B

24 25

E19B

E21B

J13

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

EXTENDER BOARD ASSEMBLY 19X1775

+12VDC

+12VDC DC COM DC COM

MC1ON

TIP SENSE

RUN/SET

PRESS GOOD

OVERTEMP

INRUSH DONE

CD ENABLE CD ENABLE

GAS ON

PILOT ON

OVTEMP

TORCH SW RTN

TORCH SW

+12VDC

POT HIGH

POT WIPER

POT LOW

GATE DRIVE B RTN

GATE DRIVE B

GATE DRIVE A RTN

GATE DRIVE A

CURRENT SENSE

CURRENT SENSE CURRENT SENSE RTN CURRENT SENSE RTN

DC COM DC COM

12231314

DC OK

AC OK

-OUT

GATE

12231314

DRIVE

GATE DRIVE

24567

GATE DRIVE

24567

J43

J12

1 2

2 3

3 4

6 7

7 8

8 9

1010 11

11 12

CSR

16 17

17 18

18 19

21 22

22 23

26 27

27 28

28 29

35 36

A-03222

APPENDIX A-8 Manual 0-2844

E11A

E11B

P25J25

J3A

E9A

J7A

J3B

E9B

J7B

212

P3A

E32

MAIN

P7A

E10

J30 P30

212

J31 P31

212

P3B

E27

P7B

P26J26

212

DC COM

TIP SENSE

TORCH SW

TORCH SW RTN

CD ENABLE

PRI

P33

J33

-OUT

+12VDC

CSR

(70) (71) (72) (73) (74) (75) (76) (77)

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E45

E48B

E49

E53B

SEC

E54B

OUTPUT DIODE ASSEMBLY 19X1757

E50A

E47

E48A

E52

E53A E54A

J39

P39

2 3

3 4

7 8

E34B

POWER OUTPUT BOARD ASSEMBLY 19X1754

E39B

E56B E60B

E34A E39A

E56A

E60A

E36

E57

E37

E58

CURRENT SENSE

CD ENABLE

E47

E45

DC COM

+12VDC

E32

E62

E35

E43

E64

E63

J40

1 2 3 4 5 6 7 8

E61

P41

J41

OUTPUT INDUCTOR

E(62)

E(35)

PILOT

THRU SCREW TERMINAL

CHASSIS GND

CD ASSEMBLY 19X1751

P40

(14)

(15)

2 3 4

(17)

5 6 7

(18)

E(58)

J42

(30)

(31)

PCR

T10

J28

T O

R C H

WORK

(30)

(31)

TORCH SWITCH

COMP DESCRIPTION LOCATION

F2 L1 M1 M2 PCR PS1 PRESSURE SWITCH SOL1 GAS SOLENOID SW1 SW2 T5 T10 CD TRANSFORMER C 10 TS1 TS2 W1

AB AC

Last Modified:

Manual 0-2844 A-9 APPENDIX

FUSE

FOR 460-VOLT UNITS: 1/4A 600V SLO-BLO, FNQ FOR 400-VOLT UNITS: 0.4A 500V SLO-BLO, FNQ

FUSE, 0.9A, RESETABLE OUTPUT INDUCTOR A 10 FAN, 4.5" 220VAC FAN, 4.5" 220VAC PILOT RELAY

SWITCH, ON/OFF SWITCH, RUN/SET MAIN TRANSFORMER

TEMP. SENSOR, IGBT HEATSINK TEMP. SENSOR, INDUCTOR MAIN CONTACTOR

DateByRevisionsRev

08/21/01GCWRELEASE ECO 3A16 ECO 3CE2 ECO 100397

Tuesday, November 05, 2002

GCW 11/13/01

11/05/02HAS

15:05:29

Information Pr opri etar y to THERMAL DYNAMICS CORPORATION.

Not For Rel eas e, R epr oducti on, or Distribution without Written Consent. NOTE:

TITLE:

C1 B1 C1 F3 F2 C1 D1 B7

E1 F1 F3,A2

THERMAL DYNAMICS INDUSTRIAL PARK No. 2 WEST LEBANON, NH 03784 603-298-5711

Unless Other wise Specif ied, Resistors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF)

SCHEMATIC,

CM75 400V 3PH/460V 3PH/1PH

PCB No:

Assy No:

SupersedesScale

Date:

Tuesday, May 15, 2001

Drawn: References

GCW

Chk: App:

Size

DWG No:

42X1099

Sheet

A-03222

APPENDIX 7: SYSTEM SCHEMATIC (CE CutMaster 100)

+12VDC

+18V

+18VDC

+18V

GATE DRIVE A

(22)

460VAC 3 PHASE INPUT

SOL1

J32

(38)

PILOT ON

FOR 460V ONLY

TIP SENSE

MAIN CONTACTOR

(37)

(23)

230V

P32

INRUSH DONE

+12VDC

CURRENT CONTROL

460V

W1 ON

(40)

OVERTEMP

+12V

POT LOW

OVTEMP

LOGIC BOARD

J14

GATE DRIVE

FILTERING

(5)

1010

CURRENT SENSE

(36)

(19)

OVERTEMP

GATE DRIVE A RTN

CURRENT SENSE RTN

(39)

J18

(3)

J29

(35)

CURRENT SENSE

+12VDC

(42)

CSR

230V

DC OK

(41)

P18

(20)

(26)

P29

CD ENABLE

IGB T PCB ASSEMBLY 19X1756

GAS ON

15 16

POT WIPER

GAS

POT HIGH

TO BIAS SUPPLY

(7)

GATE DRIVE

+12VDC

AC OK

GAS

CD ENABLE

J13

MAIN BOARD ASSEMBLY 400-VOLT: 19X1778 460-VOLT: 19X1753

GATE DRIVE

P24

PILOT ON

TORCH SW

ON/OFF SW

CHASSIS GND

J43

J27

P11

FAN1

(25)

PRESS GOOD

(24)

RUN/SET SW

GATE DRIVE B

LED PCB 19X1604

J11

GATE DRIVE B RTN

GAS SOLENOID

(12)

28VAC B

D21

(8)

D32

J12

P15

(6)

TEMP

FAN2

PRESS GOOD

(9)

IGB T PCB ASSEMBLY 19X1756

(1)

PILOT RELAY

FOR 400V ONLY

GATE DRIVE

J24

POT WIPER

P27

(13)

(21)

D37

J15

(4)

-OUT

PRESSURE SW

RUN/SET

(2)

POT HIGH

J23

28VAC A

400V

POT LOW

CURRENT SENSE RTN

CURRENT ADJUST 20 - 80

D20

INV ON

DRAG ON

CD ON

SW ON

(6)

(7)

3 4 5

INPUT DIODE

ASS EMBLY 19X1811

PCR

INRUSH

0.9A

EXTENDER BOARD

ASSEMBLY 19X1775

TEST CONNECTOR

28VAC A

MAIN CONTACTOR

GAS SOLENOID

SW1

SW2

TS1

PS1

(11)(10)

IGBT HEATSINK

TEMP

TS2

INDUCTOR TEMP

ASSEMBLY 19X1759

FAN

NTC

DC COM DC COM

DC COM

TORCH SW RTN

460VAC 1 PHASE INPUT

EMC

FILTER

ONLY

400V CE

400VAC 3 PHASE INPUT

CHASSIS GND

(SEE NOTES)

E13

E30

E22

E12B

E16

E17B

E17A

E19A

E21A

R78

12231314

24567

E23

FUSE

12231314

24567

E12A

RESETABLE

9 10

E20

E15

E14

E19B

E18

R29

LT1

1 2

E21B

Art # A-03093

APPENDIX A-10 Manual 0-2844

E9A

E11A

E11B

P25J25

J3A

212

P3A

E32

MAIN

E10

P7A

J7A

J3B

P3B

E9B

J7B

P7B

J30 P30

212

J31 P31

212

E27

P26J26

212

TIP SENSE

TORCH SW

TORCH SW RTN

CD ENABLE

-OUT

DC COM

+12VDC

CSR

PRI

J33

P33

1 2

2 3

5 6

6 7

7 8

(70) (71) (72) (73) (74) (75) (76) (77)

OUTPUT DIODE ASSEMBLY 19X1757

E50B

E45

E48B

E49

E53B

SEC

E54B

OUTPUT DIODE ASSEMBLY 19X1757

E50A

E47

E48A

E52

E53A E54A

P39

J39

1 2

2 3

4 5

COMP DESCRIPTION LOCATION

FOR 460-VOLT UNITS; 1/4A 500V SLO-BLO, FNQ

FOR 400-VOLT UNITS; 0.4A 500V SLO-BLO, FNQ

FUSE, 0.9A, RESETABLE L1E3OUTPUT INDUCTOR A10 M1

FAN, 4.5" 220VAC M2

FAN, 4.5" 220VAC PR

PILOT RELAY PS1 PRESSURE SWITCH SOL1 GAS SOLENOID SW1

SWITCH, ON/OFF SW2

SWITCH, RUN/SET

MAIN TRANSFORMER

T5 T10 CD TRANSFORMER C10

TEMP. SENSOR, IGBT HEATSINK

TS1

TEMP. SENSOR, INDUCTOR

TS2

MAIN CONTACTOR F3

ECO 38FA HAS 07/16/01

AB AC AD

EC O 1 00038 HAS 0 2 /26/02

AE AF

Last Modified:

Tu es da y, Ma rch 16, 2004

E34B

E36

POWER OUTPUT BOARD

ASSEMBLY 1 9X1754

E39B

E56B

E57

E60B

E34A

E37

E39A

E56A

E58

E60A

DateByRe vi s ionsRev

06 /08/01

HASEC O 3 7E2

11 /13/01GCWECO 3CE2

11 /05/02HASE C O 1 00397 03 /12/04HASE C O 1 01341

15:05:29

OUTPUT INDUCTOR

E32

E62

E35

E43

E64

E63

+12VDC

J40

CD ENABLE

E47

E45

CURRENT SENSE

DC COM

2 3 4 5 6 7 8

E61

J41

C1 B1 C1 F3 F2 C1 D1 B7

E1 F1

Information Proprietary to THERMAL DYNAMICS CORPORATION.

Not For Release, Reproduction, or Distribution without Written Consent.

NOTE:

Un l es s Oth erw is e Sp e cif ie d , Re s i s tors are in Ohms 1/4W 5%. Capacitors are in Microfarads (UF)

TITLE:

SCHEMATIC,

CM100 400V 3PH/460V 3PH/1PH

E(62)

E(35)

PILOT

THRU SCREW TERMINAL

CHASSIS GND

CD ASSEMBLY 19X1751

J28

P40

2 3 4

5 6 7

E(58)

J42

P41

(30)

(31)

THERMAL DYNAMICS IN D USTRIAL PARK No. 2 WE S T LEBANON, NH 03784 603-298-5711

(30)

(31)

T10

T O R C H

WORK

TORCH SWITCH

114X301

PCB No:

19X1753

Ass y No:

19X1778

Date:

Tuesday, May 15, 2001

Dr awn: R e fe re nces

GCW

Chk: App:

DWG No:

Size

42X1080

Art # A-03093

PCR

Su persedesScale

Sh eet

Manual 0-2844 A-11 APPENDIX

Thermal Dynamics CE CutMaster 50, CE CutMaster 75, CE CutMaster 100 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual