Thermal Dynamics CE CutMaster 50 Operating Manual

Plasma Cutting

Power Supply

CutMaster™ 50

A-02766

Operating Manual

April 21, 2003 Manual No. 0-2805

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

CutMaster 50

Operating Manual Number 0-2805

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711 www.thermal-dynamics.com

Copyright 2000 by

Thermal Dynamics Corporation

All rights reserved.

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: April 21, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

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

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

1.07 Declaration of Conformity ............................................................................. 1-4

1.08 Statement of Warranty .................................................................................. 1-5

SECTION 2:

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

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

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

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

2.04 Power Supply Options and Accessories ....................................................... 2-2

SECTION 3:

INSTALLATION ................................................................................................................. 3-1

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

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

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

3.04 Lifting Options .............................................................................................. 3-1

3.05 Primary Input Power Connections ................................................................ 3-2

3.06 Gas Connections ......................................................................................... 3-3

3.07 Torch Connections ....................................................................................... 3-5

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

SECTION 4:

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

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

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

4.03 Preparations For Operating .......................................................................... 4-2

4.05 Sequence of Operation ................................................................................ 4-3

SECTION 5:

SERVICE .......................................................................................................................... 5-1

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

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

5.03 Common Faults ............................................................................................ 5-2

5.04 Basic Troubleshooting Guide ........................................................................ 5-3

5.05 Power Supply Basic Parts Replacement ...................................................... 5-5

TABLE OF CONTENTS (continued)

SECTION 6:

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

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

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

6.03 Power Supply Replacement ......................................................................... 6-2

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

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

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

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM) .......................................................................................................... A-2

APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM ................................................ A-3

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

APPENDIX 5: SYSTEM SCHEMATIC FOR 208 / 230V UNITS ................................................ A-6

APPENDIX 6: SYSTEM SCHEMATIC FOR 400 / 460V UNITS ................................................ A-8

SECTION 1:

GENERAL INFORMATION

GASES AND FUMES

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 background information which requires additional emphasis or is helpful in efficient operation of the system.

A procedure which, if not properly followed, may cause damage to the equipment.

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

CAUTION

WARNING

WARNINGS

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 1-603-298-

5711 or your local distributor if you have any questions.

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony

Arsenic

Barium

Beryllium

Cadmium

Chromium

Cobalt

Copper

Lead

Manganese

Mercury

Nickel

Selenium

Silver

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.”

May 14, 2002 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. Trapped hydrogen gas that is ignited will cause an explosion.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding 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:

Arc Current

Minimum Protective

Shade No.

Suggested

Shade No.

Less Than 300*

300 - 400*

400 - 800*

1.03 Publications

8

9

10

9

12

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.

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.

• To protect your hearing from loud noise, wear protective 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.

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C.

20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding 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 OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, 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 May 14, 2002

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 Standard A6.0, WELDING AND CUTTING CON-

TAINERS 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 PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018


1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’

(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

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

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

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing 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


1.08 Statement of Warranty

LIMITED WARRANTY:

Thermal Dynamics

®

Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

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

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

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

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

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

PAK Units, Power Supplies

Parts

XL Plus &

CutMaster Series

Parts

Cougar/Drag-Gun

Parts

All Others Labor

Main Power Magnetics

Original Main Power Rectifier

Control PC Board

All Other Circuits And Components Including,

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat

Exchanges, And Accessory Equipment

3 Years

3 Years

3 Years

1 Year

1 Year

1 Year

1 Year

1 Year

1 Year

2 Years

2 Years

2 Years

1 Year

1 Year

1 Year

1 Year

1 Year

1 Year

1 Year

Torch And Leads

Maximizer 300 Torch

SureLok Torches

All Other Torches

1 Year

180 Days 180 Days

1 Year

1 Year

180 Days

1 Year

1 Year

180 Days

Repair/Replacement Parts

90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001



SECTION 2:

INTRODUCTION

2.03 Specifications & Design

Features

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the CutMaster 50

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 Torch Manual provided with this Power

Supply for torch and cutting information.

2.02 General Description

The power supply provides 40 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, primary input power cable (with plug on 208 / 230V units only), and work cable & clamp.

NOTE

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. Input Power (See Note)

The CutMaster 50 is available for the following input power:

• 208 / 230 VAC, Single - Phase, 60 Hz

• 400VAC, Three - Phase, 50 / 60 Hz

• 460VAC, Three - Phase, 50 / 60 Hz

• 460VAC, Single - Phase, 50 / 60 Hz

NOTE

Refer to Appendix 1 for input wiring requirements.

2. Output Power

Continuously variable from 20 to 40 amps maximum.

3. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher than shown in the chart.

208 / 230Volt Power Supply Duty Cycle:

208/230 Volt Power Supply Duty Cycle

Ambient

Temperature

Duty Cycle

104° F

(40° C)

40%

104° F

(40° C)

60%

104° F

(40° C)

100%

Current

39 Amps 33 Amps 20 Amps

DC Voltage

110 vdc 105 vdc 100 vdc

400 - Volt and 460 - Volt Power Supply Duty Cycle:

A-02766

CutMaster 50 Power Supply

400V, 460V Power Supply Duty Cycle

Ambient

Temperature

Duty Cycle

104° F

(40° C)

40%

104° F

(40° C)

60%

104° F

(40° C)

100%

Current

40 Amps 33 Amps

DC Voltage

110 vdc 105 vdc n/a n/a

4. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

Manual 0-2805 2-1 INTRODUCTION

5. Weight

52 lbs (23.6 kg)

Weight includes Power Supply with Input Cable (and plug, on 208 / 230V units), Work Lead, and Torch &

Leads.

6. Overall Dimensions (incl. handles)

Length:

Width:

22-1/2 inches (572 mm)

10-3/4 inches (273 mm)

Height: 16-3/8 inches (416 mm)

7. Gas Filter / Regulator Assembly Specifications

The following specifications apply to the standard Gas

Filter / Regulator Assembly only:

• Operating Pressure (Output): 70 psi (4.8 bar)

• Maximum input gas pressure: 125 psi (8.6 bar)

• Filter: Particulate Type Filter (to 20 microns)

2.04 Power Supply Options and

Accessories

D. Wheel Kit

A kit with easy - rolling 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. Top shelf is 12 " (305 mm) x 20 (508 mm). Steel handle is 30" (762 mm) high.

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 compressed 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 pre

- assembled at the factory and need only be attached to the power supply.

C. Extended Work Cable with Clamp

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

INTRODUCTION 2-2 Manual 0-2805

SECTION 3:

INSTALLATION

CAUTION

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

3.01 Introduction

3.03 Unpacking

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. Torch Leads d. Work cable

4. Grounding

5. Operator training

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.

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-energized supply line before moving unit.

FALLING EQUIPMENT

can cause serious personal injury and equipment damage.

HANDLE

is not for mechanical lifting.

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 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.

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

• Lift unit by the handle, using two hands.

• Install optional wheel kit or use hand 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.

Manual 0-2805 3-1 INSTALLATION

3.05 Primary Input Power

Connections

Check your power source for correct voltage before plugging in or connecting the unit. See Appendix 1, Input

Wiring Requirements.

A. 208 / 230 Volt Units

This power supply includes a factory-installed input power cable and plug.

1. Check your power source for correct voltage before plugging in the unit.

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

CAUTION

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

(refer to table in Appendix 1).

B. 400-Volt and 460-Volt Three-Phase Units

These Power Supplies are equipped with a three-phase, four conductor, input power cable. Connect the input power cable to the customer's power source as follows:

1. Remove the Power Supply cover per section 5.05.

2. The cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable.

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

C. 460-Volt Single-Phase Operation

The 460-Volt Power Supply is equipped with a four-conductor input power cable for 460VAC, Three-Phase input power. The Power Supply will accept 460VAC,

Single-Phase input power with a change of input power cable.

For 460-VAC, Single-Phase operation:

1. Remove the Power Supply cover per section 5.05.

2. Disconnect the original input power cable from the main input contactor and the chassis ground connection.

3. Loosen the strain relief on the back panel of the power supply. Pull the original power cable out of the power supply.

4. Pass a customer-supplied three-conductor input power cable through the access opening in the back panel of the power supply. Refer to Appendix 1 for power cable specifications. Tighten the strain relief to secure the power cable.

CAUTION


(refer to table in Appendix 1).

CAUTION


(refer to table in Appendix 1). All the input cable wires must be connected for three-phase operation.

• L1 wire to Line 1

• L2 wire to Line 2

• L3 wire to Line 3, refer to Caution above.

• Ground wire to Ground (Earth).

4. Replace the Power Supply cover.


L1

L3

Ground Wire with Ring

Terminal

Input Cable

A-03041

Main Input

Contactor

L1 L2 L3

Input Power Connections, 460VAC, Single-Phase

INSTALLATION 3-2 Manual 0-2805

5. Strip back the insulation on the individual wires and connect as follows:

• Line 1 wire to main input contactor terminal

L1.

• Line 3 wire to main input contactor terminal

L3.

• Ground wire to Ground (Earth). The Ground wire connection requires a ring terminal.

6. Replace the Power Supply cover.


3.06 Gas Connections

A. Gas Requirements

C. Connecting Gas Supply to Unit

The gas supply connects 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.

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

1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten.

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.

Regulator/Filter

Assembly

WARNINGS

This unit is not to be used with oxygen (O

2

).

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

Gases: Single Gas - Plasma / Secondary

Compressed Air or Nitrogen (N2) Only

Pressure: 70 psi (4.8 bar)

Flow: Cutting - 200 scfh (standard cubic feet / hr) (94.4

lpm)

Gouging - 230 scfh (standard cubic feet / hr) (108.5

lpm)

B. Checking Air Quality

To test the quality of air, place the RUN / SET switch to

SET position, place a welding filter lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens. Do not initiate an arc!

CAUTION

Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.

Inlet Port

Bowl

1/4 NPT to 1/4"

(6mm) Fitting

Hose Clamp

A-02999

Gas Supply

Hose

Gas Connection to Regulator / Filter Assembly


D. Installing Optional Air Filter Kits

Additional filtering is recommended when using air from a compressor to ensure that moisture and debris from the supply hose does not enter the torch. Although the Regulator has a filter, optional filter kits are recommended for improved filtering.

1. Optional Single-Stage Air Filter Kit

This optional in-line air filter kit 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 the maker'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

Regulator / Filter Assembly inlet port as shown.

b. Attach the Single-Stage Filter Assembly to the filter hose.

c. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten.

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.

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 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.

b. Install the two stage filter hose in the inlet port of the Regulator / Filter Assembly, as shown below.

c. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten.

Regulator/Filter

Assembly

Regulator Inlet Port

2-Stage Filter

Inlet Port (IN)

Regulator/Filter

Assembly

Bowl

Inlet Port

Hose

Clamp

Outlet Port

(OUT)

Two Stage

Filter

Assembly

1/4" (6 mm) Gas

Supply Hose) 1/4 NPT

Hose Fitting

A-03004

Optional Two-Stage Filter Installation

1/4 NPT Hose Fitting

Hose Clamp

1/4" (6 mm) Gas Supply Hose

A-03000

Optional Single-Stage Filter Installation


E. Using High Pressure Gas Cylinders

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.

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 pressures up to 100 psi (6.9 bar) maximum and flows of up to 200 scfh (94.3 lpm).

4. Use customer-supplied fitting(s) to connect 1/4"

(6 mm) inside diameter gas supply hose to the cylinder.

NOTE

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

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.

3.07 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 Torch Leads must be properly installed to the Power

Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the Torch

Bulkhead Panel for the desired application.

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

1. Remove the Cover of the Power Supply for access to the Torch Bulkhead Panel. See Section 5.05.

2. Remove the retaining nut from the Strain Relief.

Torch Leads

Assembly

WARNING

Strain Relief

Negative /

Plasma Lead

A-03607

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.


Note: Actual Bulkhead configuration may differ from that shown.

Negative/Plasma

Lead Connection

Adapter

Control Circuit

Connectors

Adapter

Connector

Torch Lead

Assembly

Pilot Lead Stud

Pilot Lead

Negative/Plasma

Lead

A-03608

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 Torch Leads.

10. Check the torch for proper parts assembly.

CAUTION

The torch parts must correspond with the type of operation. Refer to the appropriate torch manual for proper parts selection.

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

Supply.

B. Machine Systems (Unshielded Leads)

1. Remove the Cover of the Power Supply to gain access to the Torch Bulkhead Panel. See Section

5.05.

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

Remove Tie Wrap,

Remove Insulator,

Disconnect Wires

Torch Leads

Assembly

Strain Relief

Strain Relief

Nut

A-03609

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 secure the

Strain Relief to the Power Supply.

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


Negative/Plasma

Lead Connection

Power Supply Adapter

Remote

Pendant

Adapter

Control Circuit

Connectors

Open

Adapter

Connector

Open

Pilot Lead

Pilot Lead

Stud

Negative/Plasma

Lead

Torch Lead

Assembly

A-03610

Torch Lead Connections To Bulkhead

Power Supply Adapter

Control Circuit

Connectors

Open

Torch Lead

Assembly

Open

Pilot Lead

Negative/Plasma

Lead

A-03611

Torch Lead Connections To Bulkhead - Detail

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

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.

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. Reinstall 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 Torch Assembly.

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

NOTE

Refer to Appendix 3, Torch Control Cable Wiring

Diagram For Mechanized Systems, for detailed schematic of the Adapter.


Remote Pendant/CNC

Cable Connector

Control

3

4

PIP

Circuit

Torch Control

Cable Connector

2

3

4

OK-To-Move

12

14

13

12

14

13

A-01366

Remote Pendant Connector Diagram

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 mm

2

) 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.

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 AWG (European 6 mm

2

) wire or flat copper braid with cross section equal to or greater than 10 AWG 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 mm 2 ) 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.

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.


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 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 mm

2

) 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.

To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be as follows:

• For 115VAC: 3.0 VAC

• For 230VAC: 1.5 VAC

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.

115VAC: 3.0 VAC

230VAC: 1.5 VAC

V

~

Meter set to

VAC setting

WARNING

Use extreme caution. This test uses live voltage.

V

~

+

VR COM A

_

Neutral

115 or 230VAC

100W

Light Bulb

Line (Hot)

A-02971

Machine

Earth Ground

Ground Testing



SECTION 4:

OPERATION


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

4.02 Product Features

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

A. Front 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; LED indicators for AC Power, TEMP, GAS, and DC.

4. Roll Handle / Torch Leads Wrap

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

5. Torch Bulkhead Panel

The torch bulkhead panel is under the power supply cover. See Section 5.05 for cover removal directions.

A. Pilot Lead Stud

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

B. Control Cable Connector

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

C. Gas / Power Lead Connection

Connects the torch gas / negative lead to the unit.

2

4

1

A-02772

3

Front Panel Features

2. Torch Leads Input

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

3. Work Cable and Clamp

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

Manual 0-2805 4-1 OPERATION

B. Control Panel Features

3

1

25

20

A

30

40

35

4

5

6

7

2

6.

GAS Indicator

7.

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).

DC Indicator

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

C. Rear Panel Features

1. Gas Input Port

Connection for gas input.

A-03641

WARNING

Operating Controls

This unit is not to be used with oxygen (O

2

).

1. ON / OFF Power Switch

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

1

2. RUN / SET Switch

3

RUN position is used for general torch operation.

Torch switch must be held. SET position used for setting gas pressure and purging lines.

3. Current Control (A)

4.

Adjustment to set the desired output current between

20-40 amps.

AC Power Indicator

Green indicator will blink ON-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.

2

A-03042

Rear Panel

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.

2. Primary Input Power Cable / Strain Relief

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

3. Gas Pressure Filter / Regulator Assembly

Pressure regulator to adjust the input gas pressure to the Power Supply. The pressure regulator has its own built-in filter.

Factory installed.

For improved filtering, other filtering packages are available as options.

OPERATION 4-2 Manual 0-2805

4.03 Preparations For Operating

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.

I.

Prepare to Cut

Return the RUN / SET switch to RUN position. Gas will not flow until the Torch Trigger is pressed.

The system is now ready for operation. Activate the torch (press torch switch on the handle, send START signal from CNC or press the torch switch on the Remote Pendant). There is a 2 second pre-flow before the arc starts.

4.05 Sequence of Operation

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 electrode) must correspond 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.


C. Gas Selection

Select desired single gas supply. Make sure gas source meets requirements (refer to subsection 3.06A, Gas

Requirements). Check connections and turn gas supply on.

D. Work Cable Connection

Check for a solid work cable connection to the workpiece.

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 position.

G. Select Current Output Level

On the Control Panel, set the desired current output level between 20-40 amps for cutting or gouging.

H. Set Operating Pressure

Place the RUN / SET switch to the SET position. Gas will flow. Adjust gas pressure control to 70 psi (4.8

bar).

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 mode.

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

a. AC Power Indicator blinks ON and OFF for eight seconds then stays ON. Fan turns on.

NOTE

Gas comes on if Torch 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 mode.

a. Gas solenoid opens and gas flows to set pressure. Gas Pressure Regulator / Filter Assembly should be set to 70 psi (4.8 bar). 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 mode.

a. Gas flow stops. GAS Indicator turns OFF.

6. Protect eyes and activate torch.

a. Gas pre-flow starts (approximately 2 seconds).

GAS Indicator turns ON.

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

8. Pilot arc is established

Manual 0-2805 4-3 OPERATION

9. Move Torch within transfer distance of workpiece.

a. Main arc transfers. 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. Release or deactivate the torch switch.

a. Main arc stops. Pilot arc stops.

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

OPERATION 4-4 Manual 0-2805

SECTION 5:

SERVICE

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

Regulator/Filter

Assembly

Baffle

Ring

Filter

Element

WARNING

Spring

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

Spool

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, Parts List, for replacement filter element catalog number. The Regulator / Filter Assembly may vary; the replacement element and the replacement procedure are the same for both types of Regulator / Filter.

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

2. Unscrew the 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

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.

Bowl

A-02995

Regulator / Filter Element Replacement

6. Reinstall the bowl.

7. Turn on the air supply.

C. Optional Single-Stage Filter Element

Replacement

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, Parts List, for replacement filter element catalog number.

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 from barbed fitting.

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

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

Manual 0-2805 5-1 SERVICE

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

Housing

Filter

Element

(Cat. No. 9-7741)

Spring

O-ring

Assembled Filter

Cover

Barbed

Fitting

A-02476

First & Second

Stage

Cartridges

(as marked)

Optional Single-Stage Filter Element Replacement

A-02942

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

7. Replace Housing on Cover.

8. Reattach gas supply hose to barbed fitting.

NOTE

If unit leaks between housing and cover, inspect the

"O" Ring for cuts or other damage.

D. Optional Two-Stage Filter Element

Replacement

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

The Two-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, Parts List, for replacement filter element catalog number.

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.

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.

5.03 Common 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

SERVICE 5-2 Manual 0-2805

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 used

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 used

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 Basic Troubleshooting Guide

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.

A. Basic Troubleshooting: Overview

This guide 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.

For major troubleshooting and parts replacement procedures refer to Power Supply Service Manual 0-2806.

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 (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.

C. 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

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 correct. Refer to Appendix 1, Input Wiring Requirements.

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 ON

1. Airflow obstructed

a. Check for obstructed air flow around the unit and correct condition.

2. Fan blocked

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.



C. Torch 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 (refer to Instruction Manual supplied with torch).

3. Gas pressure too high or too low

a. Set pressure to 70 psi (4.8 bar).



D. No cutting output; Torch activated; AC Power indicator ON; Gas flows; Fan operates

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. Refer to the torch manual for details.



4. Faulty Torch

a. Return for repair or have qualified technician repair per Torch Manual.

E. Low cutting output

1. Incorrect setting of CURRENT control

a. Check and adjust to proper setting.



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.

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 at 70 psi (4.8 bar); adjust as needed.



I. No gas flow; AC POWER indicator ON; Fan operates

1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 bar).

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.




J. 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 Torch 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).

5.05 Power Supply Basic Parts

Replacement

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

Upper screws

Lower screws

Ground wire

WARNING

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.

A. Cover Removal

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

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.

A-02776

Cover Removal

3. To reinstall the cover, complete the following: 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

This completes the parts replacement procedures.


SECTION 6:

PARTS LISTS


A. Parts List Breakdown

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

Section 6.03 Complete Power Supply Replacement

Section 6.04 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. Address all inquiries to your authorized distributor.

Manual 0-2805 6-1 PARTS LISTS

6.03 Power Supply Replacement

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

Qty Catalog #

1

1

1

Description

CutMaster 50 Power Supply

208 / 230VAC, Single Phase, 60Hz, with input power cable and plug

400VAC, Three Phase, 50 / 60Hz, with input power cable (only)

460VAC, Three Phase, 50 / 60Hz, with input power cable (only)

3-5230

3-5230-3

3-5230-2

6.04 Replacement Parts

Qty

1

1

Description

Filter / Regulator Assembly Replacement Element

Fuse

1/2A, 250V (for 208 / 230 Volt units)

1/2A, 600V (for 400 Volt and 460 Volt units)

6.05 Options and Accessories

Qty

1

1

1

1

1

2

1

1

1

1

1

1

Description

Single Stage Filter Kit (includes Filter & Hose)

Replacement Filter Body

Replacement Filter Hose

Replacement Filter Element

Two Stage Filter Kit (includes Hose & Mounting Screws)

Bracket, Filter Mounting (not shown)

Two Stage Air Filter Assembly

First Stage Cartridge

Second Stage Cartridge

Extended Work Cable (50 ft / 15.2 m) with Clamp

Wheel Kit

Multi Purpose Cart

Catalog #

9-4414

9-6395

9-8110

Catalog #

7-7507

9-7740

9-7742

9-7741

7-7500

9-7535

9-7527

9-1021

9-1022

9-8529

9-8510

7-8888

First & Second

Stage

Cartridges

(as marked)

A-02942

Optional Two Stage Filter Kit

PARTS LISTS 6-2

A-02958

Wheel Kit, installed

Manual 0-2805

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input Current Input Suggested Sizes (See Notes)

Voltage Freq.

1-Ph 3-Ph 1-Ph 3-Ph

Fuse (Amps)

(Volts) (Hz.) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph

208

230

60

60

9

9

42

37

60

60

400

400

460

50

60

60 14

8

8.5

17.5

11

12

25

15

15

460

460

460

60

50

50

8 10 15

Wire (AWG)

1-Ph

10

10

12

3-Ph

12

12

12

14 17.5

25 12

8 9.5

15

Line Voltages with Suggested Circuit Protection and Wire Sizes

12

Based on National Electric Code and Canadian Electric Code

Wire (Canada)

1-Ph

10

10

3-Ph

12

12

12

12

12

12

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 0-2805 A-1 APPENDIX

APPENDIX

APPENDIX 2: SEQUENCE OF OPERATION

(BLOCK DIAGRAM)

ACTION

Close external disconnect switch.

RESULT

Power to system.

ACTION

ON/OFF switch to ON.

RESULT

AC indicator blinks for 8 seconds then steady on.

Fans on.

Pilot relay closes.

Power circuit ready.

ACTION

RUN/SET switch to SET.

RESULT

Gas solenoid open,

gas flows to set pressure.

GAS indicator on.

ACTION

RUN/SET switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Protect eyes and

activate torch.

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot arc established

ACTION

Torch deactivated (by torch switch release or by remote device).

RESULT

Main arc stops.

(Power supply enable signal removed)

Gas flows (10 seconds)

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

If torch is within transfer distance

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

will transfer.

After post-flow:

Gas solenoid closes, gas flow stops.

GAS indicator off.

PILOT ARC

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.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

ON/OFF switch to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Open external disconnect.

RESULT

No power to system

A-03568

A-2 Manual 0-2805

APPENDIX 3: TORCH CONTROL CABLE WIRING

DIAGRAM

This diagram applies to mechanized systems only.

To Torch

Control Device

Torch Control

Cable

Torch Control

Connectors

Control Connector

Plug with Connectors

To Power Supply

Control Connector

Torch Lead

Assembly

Control Shield

Connector

Lead Shield

Connector

Connectors only on

Shielded Leads

A-02801

A-02821

Shield

Return

Power Supply

Control

OK-To-Move

Relay

12

14

13

3

4

2

1

Torch Control

Cable Connector

Mate & Lock

Connectors

Torch Leads

Mate & Lock

Connectors

Torch Head

PIP Pin

Shield Cup

PIP Pin

12

14

3

4

13

OK-To-Move

Pendant Ground

Remote Pendant/CNC

Cable Connector

Control


APPENDIX 4: 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, replace if necessary.

APPENDIX A-4 Manual 0-2805

Notes:


APPENDIX 5: SYSTEM SCHEMATIC FOR 208 / 230V UNITS

A-03269


Manual 0-2805 A-7

A-03269

APPENDIX

APPENDIX 6: SYSTEM SCHEMATIC FOR 400 / 460V UNITS

A-02967


Manual 0-2805 A-9

A-02967

APPENDIX


No results