Thermal Dynamics CE CutMaster 80XL Operation Manual

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Plasma Cutting

Power Supply

CE CutMaster™ 80XL

December 4, 2002 Manual No. 0-2724

A-02218

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 Cut Master ™ 80XL Operating Manual Number 0-2724

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

www.thermal-dynamics.com

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: December 4, 2002

Record the following information for Warranty purposes:

Where Purchased:______________________________________

Purchase Date:_________________________________________

Power Supply Serial #:_________________________________

Torch Serial #:__________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION .................................................................................................. 1

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

1.02 Important Safety Precautions .......................................................................... 1

1.03 Publications..................................................................................................... 2

1.04 Note, Attention et Avertissement ..................................................................... 3

1.05 Precautions De Securite Importantes.............................................................. 3

1.06 Documents De Reference............................................................................... 5

1.07 Declaration of Conformity................................................................................ 7

1.08 Statement of W arranty..................................................................................... 8

SECTION 2:

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

2.01 Scope of Manual .......................................................................................... 2-1

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

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

2.04 P ow er Supply Options and Accessories....................................................... 2-2

SECTION 3:

INST ALLATION PROCEDURES ....................................................................................... 3-1

3.01 Introduction .................................................................................................. 3-1

3.02 Site Selection ............................................................................................... 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Lifting Options .............................................................................................. 3-2

3.05 Input P ow er Connections ............................................................................. 3-2

3.06 Input V oltage Selection................................................................................. 3-3

3.07 Input Po wer Cab le Connections ................................................................... 3-3

3.08 Gas Connections ......................................................................................... 3-4

3.09 Connecting T orch Leads............................................................................... 3-5

3.10 Ground Connections For Mechaniz ed Applications...................................... 3-8

SECTION 4:

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

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

4.02 Operating Controls ....................................................................................... 4-1

4.03 Sequence Of Operation................................................................................ 4-3

4.04 Preparations for Oper ating ........................................................................... 4-4

4.05 Cut Quality ................................................................................................... 4-4

SECTION 5:

CUSTOMER/OPERATOR SERVICE................................................................................. 5-1

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

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

5.03 Common Operating Problems...................................................................... 5-1

5.04 Troubleshooting Guide ................................................................................. 5-2

5.05 P ower Supply Parts Replacement ................................................................ 5-4

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction ................................................................................................. 6-1

6.02 Ordering Information ................................................................................... 6-1

6.03 Complete Pow er Supply Replacement ........................................................ 6-2

6.04 Basic Parts Replacement ............................................................................ 6-2

6.05 Options and Accessories............................................................................. 6-2

APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1

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

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................ A-3

APPENDIX 4: SYSTEM SCHEMATIC.......................................................................................A-4

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 processes. 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: No v ember 15, 2001 1-1 GENERAL INFORMATION

• 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 INFORMATION 1-2 Date: Nov ember 15, 2001

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. NFP A 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 RESPIRA TOR 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: No v ember 15, 2001 1-3 GENERAL INFORMATION

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 INFORMATION 1-4 Date: Nov ember 15, 2001

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 démontr er 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: No v ember 15, 2001 1-5 GENERAL INFORMATION

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, RECOMMANDA TIONS DE PRA TIQUES 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 INFORMATION 1-6 Date: Nov ember 15, 2001

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: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, 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, corr ect such defects by suitable r epair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 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 Year 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 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year SureLok T orches 1 Y ear 1 Y ear 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 INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

2.03 Specifications/Design Features

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the CutMaster 80XL Plasma Cutting Power Supply. Service of this equipment is restricted to Thermal Dynamics 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.

2.02 General Description

The power supply provides 60 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry , tor ch leads receptacle and a work cable with clamp.

The power supply can be ordered in various configurations with various options factory installed. Refer to Section 2.04 for a list of power supply options and accessories.

A. Power Supply Technical Specifications

The following specifications apply to the Power Supply only:

1. Front Panel Controls

ON/OFF Switch, RUN/SET Switch and Output Current Control

2. Front Panel LED Indicators

AC, TEMP, GAS, DC

3. Rear Panel

Input power cable with strain relief, gas connection and Gas Regulator/Filter Assembly

4. Input Power

Available for the following input power: 208/230 VAC (±10%), 50/60 Hz, Three-Phase 380-415 VAC (±10%), 50/60 Hz, Three-Phase 460 VAC (±10%), 50/60 Hz, Three-Phase Supplied with 4-conductor Input Power Cable with

filtering beads.

5. Output Power

Continuously variable from 15 to 60 Amps maximum

Power Supply

Torch and

Leads

A-02837

Work Cable With Clamp

Figure 2-1 CutMaster 80XL Power Supply

The power supply is designed to work with the Model PCH/M-102 Plasma T or ches. The torch includes a spar e parts kit which provides an assortment of replacement torch parts.

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.

CutMaster 80XL Duty Cycle

Ambient

Tem

erature

Duty Cy cle

Current

DC Voltage

7. Cut Capacity

7/8 inch (22.2 mm); 1-1/4 inch (31.8 mm) severance

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

104° F

(40° C)

45% 60% 100%

60 Amps n/a n/a

120 vdc n/a n/ a

104° F

(40° C)

104° F

(40° C)

Manual 0-2724 2-1 INTRODUCTION

9. Weight

72 lbs (32.7 kg)

10. Overall Dimensions

18.9" (480 mm) High x 10" (254 mm) Wide x 23.5" (597 mm) Long

Overall dimensions are with handle installed.

B. Gas Regulator/Filter Assembly

Specifications

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

1. Maximum input gas pressure

125 psi (8.6 bar)

2. Filter

Coalescent type filter

2.04 Power Supply Options and

Accessories

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

A. Two Stage Air Line Filter

A Two Stage In-Line Air Filter for use on compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 5.0 microns.

B. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels and front-mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf is 12 " (305 mm) x 20 (508 mm). Steel handle is 30" (762 mm) high.

INTRODUCTION 2-2 Manual 0-2724

SECTION 3:

CAUTION

INSTALLATION

PROCEDURES

3.01 Introduction

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

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

Depending on how the system was ordered, some Power Supply Options may already be installed.

If option(s) have been factory installed some of the instructions may not apply . It is r ecommended that all subsections be read for general information.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input power b. Gas c. Work cable d. Tor ch Leads

4. Grounding

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

3.03 Unpacking

Equipment that was ordered as a system is packaged in one shipping carton. All options and the Torch are factory installed.

Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping.

A. Power Supply

Included with each power supply is Input Power Cable; Work Cable and Clamp; Pressure Regulator/Filter Assembly and connection hardware; Operating Manual.

B. Torch and Leads

Included with each Torch is To r ch and Leads with Torch Handle Assembly, Shield Cup, Tip, Electrode, Gas Distributor and all connectors installed; Torch Spare Parts Kit; and Instruction Manual.

C. Options and Accessories

Options and Accessories are packaged separately if not installed at the factory.

D. Unpacking Procedure

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list to identify and account for each item.

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.

The power supply is fan cooled by air flow through the front panel to the rear panel. Air flow must not be obstructed. Provide at least 2 feet (0.61 m) in the rear and at least 6 inches (150 mm) on each side for clearance. Provide sufficient clearance in front of the unit to allow access to the front panel controls (minimum 6 inches or 150 mm).

Manual 0-2724 3-1 INST ALLATION PROCEDURES

3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping company before proceeding with system installation.

3.04 Lifting Options

WARNINGS

Mounting Screws

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

gized supply line before moving unit. F ALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage. HANDLE is not for mechanical lifting.

This unit is equipped with one handle mounted on top of the enclosure for hand carrying purposes only.

• Lift unit with the handle on top of the enclosure.

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

• Use hand cart or similar device of adequate capacity.

• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

• Be sure unit is lifted and transported safely and securely.

3.05 Input Power Connections

The Power Supply accepts input voltages from 208 VAC to 460 VAC, 50/60 Hz, three-phase power.

A. Input Voltage Selection

Handle

Leads Wrap

A-02220

Figure 3-1 Handle and Leads Wrap Removal

1. Remove the screws securing the Handle and the Leads Wrap to the top of the Cover.

The Power Supply is factory-wired for 380-415 V AC thr eephase input. For any other input voltage the Power Supply must be changed using the procedure in Sections 3.06, Input Voltage Selection.

B. Electrical Connections

The power source must conform to local and national electric codes. Recommended circuit protection and wiring requirements are shown in Appendix 1.

C. Opening Power Supply Enclosure

The Cover of the Power Supply must be removed for access to the input power connections inside the unit.

WARNING

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

INST ALLATION PROCEDURES 3-2 Manual 0-2724

2. Remove the screws which secure the Cover to the frame assembly.

3. Carefully pull the Cover up and away from the unit to gain access to the inside of the unit.

Cover Screws

(5 Places On Each Side)

Cover

460 V olts

380-415 V olts

208/230 V olts

Voltage Selection

Connectors

A-02261

A-02260

Figure 3-2 Cover Removal

3.06 Input V oltage Selection

The Power Supply has three voltage settings; 208/230VAC, 380-415VAC, or 460VAC. Power Supplies are factory-wired for 380-415VAC three-phase input. Input voltage selection is accomplished by switching a wire harness connector inside the Power Supply.

WARNING

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

Move the Voltage Selection Plug to the desired Voltage Selection Connection for 208/230V , 380-415V, or 460V operation per the label attached to the panel.

Voltage Selection

Plug

EMC Filter

Voltage Selection

Label

Figure 3-3 Input Voltage Selection

3.07 Input Power Cable Connections

The Power Supply is supplied with a 460V three-phase input EMC power cable attached. Connect the cable as follows:

CAUTION

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

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

The primary power source, power cable, and plug all must conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix 1).

1. Strip back the outer covering approximately 3 inches (76 mm) 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 as follows:

Manual 0-2724 3-3 INST ALLATION PROCEDURES

• Brown wire to Line 1 (Live)

• Blue wire to Line 2 (Live)

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

• Green/Yellow wire to Ground (Earth)

3.08 Gas Connections

A. Gas Requirements

WARNING

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

Gases: Compressed Air or Nitr ogen (N2) Only Pressure: 60 psi (4.1 bar)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

Flow: Cutting and Gouging - 300 scfh (141.5 lpm)

(scfh = standard cubic feet/hour)

B. Gas Connection

The gas supply is connected to the rear of the Power Supply.

Regulator/Filter

Assembly

1/4 NPT to #4 (6 mm) Hose

Fitting

Hose Clamp

#4 (6 mm) Gas

Supply Hose

A-01149

CAUTION

The 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 .

Filtering is required when using air from a compressor to insure that moisture and debris fr om the supply hose does not enter the torch. It is recommended to order the Optional Two Stage Air Line Filter for air filtering.

1. Locate the 1/4 NPT hose barb fitting shipped inside the Torch Spare Parts Kit.

2. Depending on the options installed at the factory, install the supplied barb fitting into the gas connector fitting input or the IN port of the Optional Two Stage Air Filter Assembly at the rear panel.

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. Tighten the barbed fitting.

4. Place an adjustable hose clamp (customer supplied) over the gas supply hose.

Figure 3-4 Gas Connection To Standard Air Filter

Assembly

1/4 NPT to

#4 (6mm) Hose

Fitting

Hose Clamp

#4 (6mm) Gas

Supply Hose

Two Stage Filter

Assembly

A-01150

Figure 3-5 Gas Connection To Optional Two Stage

Filter Assembly

INST ALLATION PROCEDURES 3-4 Manual 0-2724

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

A. Hand Systems

CAUTION

Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.

Do not use an air line filter with high pressure gas cylinders.

a. Refer to the manufacturer’s specifications for

installation and maintenance procedures for high pressure gas regulators.

b. Examine the cylinder valves to be sure they

are clean and free of oil, grease or any for eign material. Momentarily open each cylinder valve to blow out any dust which may be present.

c. The cylinder must be equipped with an ad-

justable high-pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows of up to 300 scfh (141.5 lpm).

6. Slide the gas supply hose over the barb fitting installed in Step 2. Supply hose must be at least #4 hose (1/4 in or 6 mm I.D.).

7. Secure the gas supply hose in place with the adjustable hose clamp.

WARNING

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

1. Remove the Cover of the power supply for access to the torch bulkhead panel.

2. Remove the retaining nut from the strain relief supplied on the end of the Torch Leads.

Torch Leads

Assembly

Strain Relief

A-02836

Retaining Nut

3.09 Connecting T orch Leads

CAUTION

This system is designed for use with the PCH/M102 torch only. Do not connect any other torch to this power supply.

The instructions for connecting the Torch Leads to the Power Supply are different depending on the type of leads. This sub-section covers connecting the Torch for the following applications:

A. Hand Systems B. Machine Systems (Unshielded Leads) C. Machine Systems (Shielded Leads)

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.

Equipment ordered as a system will have the Torch factory connected to the Power Supply.

Figure 3-6 Torch Strain Relief RetainingNut

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 0-2724 3-5 INST ALLATION PROCEDURES

Adapter

Adapter (Supplied With Power Supply)

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter Connector

Pilot Lead

Stud

Negative/Plasma Lead Connection

A-02828

Control (PIP) Circuit

Connectors

Shield Connectors

(Not Used)

Remote Cable Connector

(Supplied With Power Supply)

Control (PIP) Circuit

Connectors

Torch Lead

Assembly

Adapter

Connector

Negative/Plasma Lead

Pilot Lead

Negative/Plasma

Lead

Pilot Lead Stud

Connection

A-02825

Torch Leads

Assembly

Strain Relief

A-02827

Strain Relief

Nut

Figure 3-8 Strain Relief Nut Removal

3. The Adapter supplied with the Power Supply must be installed as follows:

Figure 3-7 Torch Lead Connections

6. Connect the PIP Cables to the mating connectors on the Adapter supplied on the Power Supply.

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 the above Step.

9. Tighten the Strain Relief onto the Torch Leads.

10. Check the torch for proper parts assembly.

11. Re-install the Power Supply Cover.

B. Machine Systems (Unshielded Leads)

WARNING

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

1. Remove the Cover of the power supply for access to the torch bulkhead panel.

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 panel of the Power Supply.

c. Feed the end of the torch lead and the Strain

Relief into the hole in the unit while routing the single black wire into the notch of the Strain Relief.

d. Tighten the Strain Relief Nut to secure the

Strain Relief to the Power Supply.

2. Remove the strain relief nut from the Strain Re-

INST ALLATION PROCEDURES 3-6 Manual 0-2724

lief.

Figure 3-9 Torch Lead Connections

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

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

Strain Relief

Torch Leads Assembly

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 need to 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.

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.

10. Re-install the Power Supply Cover.

C. Machine Systems (Shielded Leads)

WARNING

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

1. Remove the Cover of the power supply for access to the torch bulkhead panel.

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

A-02826

Strain Relief Nut

Figure 3-10 Strain Relief Nut Removal

3. The Adapter supplied with the Power Supply must be installed per the following:

a. Inside the Power Supply Bulkhead area, route

the connector on the free end of the Adapter through the Strain Relief Nut.

b. Continue routing the connector out the hole

in the front of the Power Supply.

c. Feed the end of the torch lead and the Strain

Relief into the hole in the unit while routing the single black wire into the notch of the Strain Relief.

d. Tighten the Strain Relief Nut to secure the

Strain Relief to the Power Supply.

Adapter Connector

Adapter (Supplied With Power Supply)

Control (PIP) Circuit

Connectors

Shield Connectors

Negative/Plasma Lead Connection

Pilot Lead

Stud

Pilot Lead

Manual 0-2724 3-7 INST ALLATION PROCEDURES

Negative/Plasma

Lead

Torch Lead

Assembly

A-02829

Figure 3-11 Torch Lead Connections

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

5. Connect the PIP and Shield Cables to the mating connectors on the Adapter supplied on the Power Supply.

4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.

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

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

8. Tighten the Strain Relief onto the Torch Leads.

9. Check the torch for proper parts assembly.

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

3.10 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. T o minimize RF interference, follow these grounding procedures when installing mechanized systems:

NOTE

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

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.

B. Grounding

1. The preferred gr ounding arrangement is a single point or “Star” ground. The single point, usually on the cutting table, is connected with 1/0 (42 mm2) or larger wire to a good earth ground (refer to paragraph ‘C’, Creating An Earth Gr ound). 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. Wires of long length will have increased r esistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better.

2. Components that are mounted on the cutting machine; CNC controller, plasma remote controls, height controllers, remote arc starters, etc., should be gr ounded to the cutting machine frame (chassis) with at least a 12 AWG (4 mm2) wire. Flat copper braid works even better.

3. The cutting machine frame is then connected to the “Star” point using AWG 6 (13,3 mm2) or larger wire.

NOTE

It is recommend that the Plasma Power Supply be within 20 - 30 ft (6,1 – 9,1 mm) of the cutting table, if possible.

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. To create a solid, low resistance, earth gr ound, 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 (53,5 mm2) or greater, between the ground rod and the star ground point on the cutting table.

NOTE

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

INST ALLATION PROCEDURES 3-8 Manual 0-2724

To test for a proper earth ground using 115 VAC, refer to the following diagram. Ideally, the reading on the multimeter should be 3.0 VAC or less.

A-02971

Meter set to VAC setting

WARNING

Use extreme caution. This

test uses live voltage.

Neutral

115 VAC

Line (Hot)

Light Bulb

Figure 3-12 Ground Testing

100W

3.0

COM

Earth Ground

Machine

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.

Manual 0-2724 3-9 INST ALLATION PROCEDURES

INST ALLATION PROCEDURES 3-10 Manual 0-2724

SECTION 4:

OPERATION

3. Work Cable and Clamp

Work cable with clamp (factory Installed).

4. Handle

4.01 Introduction

This Section provides a description of the Power Supply operating controls and procedures. Identification of the Front and Rear Panel components is followed by operating procedures.

4.02 Operating Controls

This subsection provides specific functional descriptions of the Power Supply operating controls and indicators.

A. Front Panel

1. Control Panel

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

Handle used to lift and transport the power supply.

5. Leads Wrap

Bracket connected to the Cover of the unit for storing the torch, torch leads and work cable when not in use. The torch leads and work cable wrap around the bracket for easy storage.

B. Control Panel

CURRENT

OFF

AC TEMP GAS DC

RUN

SET

A-02229

6 7

A-02228

Figure 4-1 Front Panel Controls

2. Torch Leads Input

T o r ch leads boot and hole in the fr ont panel to allow feeding the torch leads through to an internal bulkhead for connecting the torch leads.

Figure 4-2 Operating Controls

1. Current Control

Adjustment to set the desired output current between 15-60 amps. For drag cutting applications set the control between 15 - 35 amps.

2. ON/OFF Power Switch

ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits.

3. RUN/SET Switch

RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.

4. AC Power Indicator

Green LED indicator will blink ON then OFF for approximately eight seconds and then stay ON after the ON/OFF power switch is set to ON. Indicates operating power is present in the unit.

Manual 0-2724 4-1 OPERATION

5. TEMP Indicator

D. Rear Panel

Normally OFF . Yellow LED 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 LED indicator will come ON when the input gas pressure is set to 45 psi (3.1 bar) or higher. Indicator will be OFF when the pressure falls below 45 psi (3.1 bar).

7. DC Indicator

Green LED indicator will come ON while the torch switch is pressed.

8. CURRENT Control Knob Guards

Two guards used to prevent damage to the CURRENT Control Knob.

C. Torch Bulkhead Panel

The torch bulkhead panel area is located behind the Front Panel and requires removal of the Power Supply Cover for access.

1. Gas Input

Input connection for nitrogen (N2) or air input.

WARNING

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

1. Negative/Plasma Lead Connection

Connects the torch negative/plasma lead to the unit.

A-02230

Figure 4-3 Torch Bulkhead Panel Area

2. Control Cable Connector

Used to interface the Adapter (supplied with Power Supply) to the Torch Leads Control Cable.

3. Pilot Lead Stud

Stud used to connect the Torch Leads Pilot Lead to the Power Supply.

A-01151

Figure 4-4 Rear Panel With Standard Air Filter

Installed

2. EMC Primary Input Power Cable and Strain Relief

Supplied EMC primary input power cable and strain relief. Input power cable is capable of handling up to 460 VAC, three-phase, input power.

3. Gas Pressure Regulator/Filter Assembly

Pressure regulator to adjust the input gas pr essure to the Power Supply. An air line filter is supplied as part of the Pressure Regulator.

4. Optional Two Stage Air Line Filter

The optional filter will remove moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least 5 microns.

OPERA TION 4-2 Manual 0-2724

6. Protect eyes and press or activate torch switch.

a. Gas pre-flows starts. b. GAS indicator turns ON.

7. After gas pre-flow (approximately 2 seconds).

A-01152

Figure 4-5 Rear Panel With Optional Two Stage Air

Filter Installed

4.03 Sequence Of Operation

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

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

2. Place RUN/SET switch to RUN mode.

a. Power supply enabled. b. DC indicator turns ON. c. Pilot relay closes.

8. Pilot arc is established.

9. Move T orch 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 still having torch switch activated, the main arc will stop and the pilot arc will automatically restart.

11. Release or deactivate the torch switch. a. Main arc stops.

NOTE

If torch is activated during post-flow , pilot arc will immediately restart.

If torch is within 3/8 in (9.5 mm) transfer distance of workpiece, main arc will transfer.

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

a. AC Power indicator LED blinks ON and OFF

for eight seconds then stays ON.

b. Fans turn on.

4. Place RUN/SET switch to SET mode. a. Gas solenoid opens and gas flows to set pres-

sure.

b. GAS indicator turns ON.

NOTE

GAS indicator will not come ON if the gas pressure is set below 45 psi (3.1 bar) at the Regulator/ Filter Assembly.

5. Place RUN/SET switch to RUN mode. a. Gas flow stops. b. GAS indicator turns OFF .

12. Gas will flow for 15 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.

a. AC Power indicator turns OFF. b. Fans turn OFF.

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

Manual 0-2724 4-3 OPERATION

4.04 Preparations for Operating

E. Torch Connection

Follow this set-up procedure each time the system is operated:

WARNING

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate fr ont end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging). Refer to the Instruction Manual supplied with the T orch Assembly for proper parts selection.

B. Check primary power source as follows:

1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per Section 2.03-A-4, 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 gas (air or nitrogen). Make sure gas sour ce meets pressure and flow requirements (refer to Section

3.08, Gas Connections). Check connection and turn gas

supply on.

D. Work Cable Connection

Check for a solid and clean work cable connection to the workpiece. The area must be free from paint and rust.

Check that the torch is properly connected.

F. Purge the System (Gas Pre-Flow)

Move the ON/OFF switch to ON position. To start the pre-flow move the RUN/SET switch to SET position for a minimum of 20 seconds. The pre-flow gas purge will remove any moisture that may have accumulated in the torch and leads while the system was shut down. The torch cannot be activated during pre-flow.

G. Select Output Current

Select the desired current output level for the operation.

• 15 to 60 amps for standoff cutting and gouging

• 15 to 35 amps for drag cutting

H. Set Operating Pressure

Move the RUN/SET switch to SET position. Adjust the gas pressure to 60 psi (4.1 bar).

I. RUN/SET Switch

Set the RUN/SET switch to RUN position. The system is now ready for operation.

4.05 Cut Quality

Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation.

The following cut quality characteristics are illustrated in Figure 4-7 below:

Cut Surface

Make a solid work cable connection to the workpiece or cutting table

Figure 4-6 Work Cable Connection To Workpiece

OPERA TION 4-4 Manual 0-2724

A-00925

The condition (smooth or rough) of the face of the cut.

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Dross Build-up and Top Spatter

Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. T op spatter is dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary clean-up operations after cutting.

Kerf Width

Description of Cut Characteristics

The width of material removed during the cut.

Nitride Build-up

Nitride deposits which may remain on the surface of the cut when nitrogen is present in the plasma gas stream. Nitride buildups may create difficulties if the material is welded after the cutting process.

Kerf Width

Cut Surface Bevel Angle

Top

Spatter

Top Edge Rounding

Dross

Build-Up

Cut Surface

Drag Lines

A-00007

Figure 4-7 Cut Quality Characteristics

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x

tip orifice diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

tip orifice diameter), some dross (easily removed), medium-smooth cut surface, slight top edge rounding.

Fair - Excessive bevel (over 10°), wide kerf (over 2-1/2 x

tip orifice diameter), medium to heavy dross, rough cut surface, top edge rounding.

NOTES

Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Cut quality will vary on different types of and material thicknesses.

The following table shows the cut quality that can be expected from this equipment for materials with a thickness from gage to 7/8 inch (22.2 mm):

Type of Material

Gas

Air

Nitrogen Good Good Goo d

Carbon

Steel

Good -

Excellent

Stainless

Steel

Good -

Excellent

Aluminum

Good -

Excellent

Manual 0-2724 4-5 OPERATION

OPERA TION 4-6 Manual 0-2724

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

5.03 Common Operating Problems

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than Thermal Dynamics T rained personnel.

For major troubleshooting and parts replacement procedures refer to CutMaster 80XL Power Supply (CE) Service Manual 0-2725.

5.02 General Maintenance

WARNING

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

The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

Clean and maintain the power supply per Appendix 3, Maintenance Procedures.

Frequently review the Important Safety Precautions (Section 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated. Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

Handle torch leads with care and protect them fr om damage.

A. Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

B. Torch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally result in a more square cut.

T o clean the unit, open the enclosure (refer to Section 5.05A, Opening Enclosure) 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.

C. Edge Star ting

For edge starts, hold the torch perpendicular to the workpiece with the front of the tip at the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left (Refer to Figure 5-1). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Manual 0-2724 5-1 SERVICE

Left Side

Cut Angle

Right Side

Cut Angle

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current

3. Non-genuine Thermal Dynamics parts used.

A-00512

Figure 5-1 Side Characteristics Of Cut

E. Dross

Generally when dross is present on carbon steel, it is called either "high speed or slow speed dross".

"High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. "Slow speed dross" will be in larger quantities but does not adhere tightly to the cut edge and can be removed easily.

When cutting a troublesome steel, it is suggested that the torch travel speed be reduced to produce "slow speed dross". Any r equired cleanup can then be done by scrapping, not grinding.

Dross present on top of the plate (top spatter), is normally caused by a slow torch travel speed or too high of a torch standoff distance.

F. Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick 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

4. Short Torch Parts Life

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

5.04 Troubleshooting Guide

A. General

Troubleshooting and repairing this unit should be undertaken only by those familiar with high voltage high power electronic equipment.

WARNING

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.

B. Basic Tr oubleshooting

This manual covers a basic level of troubleshooting that requires 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.

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

c. Cutting current too high d. Work cable disconnected e. Worn torch parts f. Non-genuine Thermal Dynamics parts used.

SERVICE 5-2 Manual 0-2724

For major troubleshooting and parts replacement procedures refer to CutMaster 80XL Power Supply (CE) Service Manual 0-2725.

C. How to use this Guide

3. Unit is overheated

The following information is a guide to help the Customer/Operator determine the most likely causes for various symptoms.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

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.

A. AC Power indicator OFF

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

tion.

a. Close main power panel switch.

2. Input power not properly connected to customer's main

power panel

a. Check that input power is present and unit is

properly connected (refer to Section 3.05, Input Power Connections).

a. Allow unit to cool down for about 5 minutes.

Make sure the unit has not been operated beyond duty cycle limit.

4. Low input line voltage

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. Torch will not pilot when torch switch is activated

1. RUN/SET switch in SET position

a. Move switch to RUN position.

2. Torch switch activated during 2 second pre-flow

a. Release switch and wait at least 2 seconds be-

fore activating switch again.

3. Faulty torch parts

a. Inspect torch parts and replace if necessary (r e-

fer to Instruction Manual supplied with torch).

4. Gas pressure too high or too low

a. Set pressure to 60 psi (4.1 bar).

3. Actual input voltage does not correspond to voltage

phase selection inside unit

a. Check actual line voltage phase vs. voltage

phase selection (inside of unit).

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

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

as required.

5. Unit internal fuse blown

a. If blown, double check input voltage vs. volt-

age selection (inside of unit) and replace fuse per Section 5.05-B. If fuse blows again, return unit to an authorized service center.

6. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

B. AC Power indicator ON; TEMP indicator ON

1. Airflow obstructed

a. Check for obstructed air flow and correct con-

dition.

2. Fan blocked

a. Check and correct condition.

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

D. No cutting outputAC Power indicator ON; Fans

operating

1. Torch 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 (do not overtighten if screwed on)

3. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

E. Limited or low cutting output

1. Incorrect setting of CURRENT control

a. Check and adjust to proper setting.

2. Tip contacting workpiece

a. Drag cutting circuit limits current output, keep

tip off workpiece.

Manual 0-2724 5-3 SERVICE

3. Poor input or output connections

a. Check all input and output connections.

4. Faulty components in unit

5.05 Power Supply Parts Replacement

a. Return for repair or have qualified technician

repair per Service Manual.

F. Erratic or improper cutting output

1. Poor input or output connections

a. Check all input and output connections.

2. Incorrect type and size cable on input or output

a. Use proper type and size cables.

G. Fans not operating; AC Power indicator ON;

Cutting output available

1. Fan blades blocked

a. Check and clear blades.

2. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

H. No gas flow; AC POWER indicator ON; Fans

operate

1. Gas not connected or pressure too low

WARNING

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

A. Cover Removal

1. Remove the screws securing the Handle and the Leads Wrap to the top of the Cover .

Mounting Screws

Handle

Leads Wrap

a. Check source for at least 60 psi (4.1 bar).

2. Torch consumables not installed on torch

a. Install torch consumables.

3. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

I. Torch cuts but not adequately

1. Current set too low

a. Increase current setting.

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Instruction

Manual supplied with torch.

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).

A-02220

Figure 5-2 Handle and Leads Wrap Removal

2. Remove the screws which secure the Cover to the frame assembly.

3. Carefully pull the Cover up and away from the unit to gain access to the inside of the unit.

4. To reinstall the Cover reverse the above procedure.

SERVICE 5-4 Manual 0-2724

C. Regulator/Filter Element Replacement

Cover Screws

(5 Places On Each Side)

A-02260

Figure 5-3 Cover Removal

B. Fuse Replacement

Cover

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.

1. Remove power from the power supply; turn off the gas supply and bleed down the system.

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

Regulator/Filter

Assembly

Baffle Ring

Filter Element

1. Remove the Cover per paragraph "A" above.

2. Locate the internal fuse above and behind the EMC Filter Assembly on the left side of the unit.

3. Replace the fuse. See Section 6, Parts Lists, for replacement fuse catalog number.

4. Reinstall the Cover per paragraph "A" above.

Internal Fuse

0.8 Amps, 600V

Spring

Spool

Plastic Bowl

A-02988

Figure 5-5 Filter Element Replacement

3. Grasp the filter element and unscrew it from the Regulator/Filter 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.

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.

A-01547

EMC FIlter

Figure 5-4 Internal Fuse Location

Manual 0-2724 5-5 SERVICE

D. Optional Two-Stage Filter Element

Replacement

NOTES

These instructions apply to any power supply with the optional Two-Stage Filter 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.

1. Remove power from power supply .

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

WARNING

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)

Figure 5-6 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 torque each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

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

SERVICE 5-6 Manual 0-2724

A-02942

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provide a breakdown of all r eplaceable 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

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

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 in the parts list for each type item. Also include the model and serial number of the torch. Addr ess all inquiries to your authorized distributor .

Manual 0-2724 6-1 P A RTS LISTS

6.03 Complete Power Supply Replacement

Power supply includes: EMC Input Power Cable, Work cable, pressure regulator/filter , and operating manual.

Qty Description Catalog #

1 CutMaster 80XL Power Supply (CE) 3-8800

6.04 Basic Parts Replacement

Qty Description Catalog #

1 Fuse, 0.8A 600V 9-7526 1 Regulator/Filter Replacement Element 9-4414

6.05 Options and Accessories

Qty Description Catalog #

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

1 Second Stage Cartridge 9-1022

1 Torch Guide Kit (not shown) 7-8910

1 Multi-Purpose Cart 7-8888

PARTS LISTS 6-2 Manual 0-2724

First & Second Stage Cartridges (as marked)

A-02942

Optional Two-Stage Air Filter Kit

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Pow er Input Current Suggested Sizes (See Note)

V o ltag e Fr eq . 3-Ph 3-Ph Fuse (Amps)

(V o lts) (H z ) (kVA) (A m p s) 3- P h 3-P h

208 50/60 11.6 32.3 40 4 230 50/60 11.9 29.9 35 4 240 50/60 12 29 35 4 380 50/60 13.4 20.4 30 4 415 50/60 13.8 19.2 25 4 460 50/60 14.2 17.9 25 4

Line Voltages w i th S ug ges ted C i rc ui t Protection and Wir e Siz es

NOTES

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.

Wire (mm

)

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 0-2724 A-1 APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK

DIAGRAM)

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 deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed.)

post-flow, pilot arc will immediately restart. If torch is within transfer distance (3/8 in) of

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (15 seconds)

NOTE - If torch is activated during

workpiece, main arc 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-000926

APPENDIX A-2 Manual 0-2724

APPENDIX 3: 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, r eplace 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, replace if necessary.

Manual 0-2724 A-3 APPENDIX

APPENDIX 4: SYSTEM SCHEMATIC

A-02234

APPENDIX A-4 Manual 0-2724

Manual 0-2724 A-5 APPENDIX

B EC 8055 HAS C EC 8087 HAS

ECO 39F6

ECO 3AF2

HAS

11/23 12/18

09/15

2001

98 98

A-02234

Thermal Dynamics CE CutMaster 80XL Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual