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Thermadyne CE CutMaster 51, Operating Manual

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Thermadyne CE CutMaster 51 Operating Manual Download Page 17

Manual 0-2989

2-3

INTRODUCTION

2.04 Power Supply Features

Art # A-03578

Work Cable
and Clamp

Handle and Leads Wrap

Torch Leads Receptacle

Control Panel

Art # A-03738

Input Power Cord

Ports for Optional Automation 
Interface Cable

Gas Inlet Port

Gas Pressure Regulator / 

Filter Assembly

Gas Pressure Gauge

Summary of Contents for CE CutMaster 51

Page 1: ...Plasma Cutting Power Supply CE CutMaster 51 Operating Manual January 12 2004 Manual No 0 2989 A 03688...

Page 2: ......

Page 3: ...ermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the pub lisher is prohibited The publisher does not assume and hereby disclai...

Page 4: ...l 2 1 2 02 Power Supply Specifications 2 1 2 03 Input Wiring Specifications 2 2 2 04 Power Supply Features 2 3 2 05 Power Supply Options and Accessories 2 4 SECTION 3 INSTALLATION 3 1 3 1 Unpacking 3...

Page 5: ...lacement 6 1 6 04 Replacement Parts 6 1 6 05 Options and Accessories 6 2 6 06 Torch Parts 6 3 APPENDIX 1 SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 DATA TAG INFORMATION A 2 APPENDIX 3 MAINTENA...

Page 6: ......

Page 7: ...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...

Page 8: ...ns in this manual PLASMAARC RAYS PlasmaArc 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 eye...

Page 9: ...able 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 utilis s pour mettre e...

Page 10: ...er ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres pe...

Page 11: ...ue les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suiva...

Page 12: ...S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA...

Page 13: ...elding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 P...

Page 14: ...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 o...

Page 15: ...Rating TDC Rating Duty Cycle Current 40 Amps n a 25 Amps n a n a n a DC Voltage 96 vdc n a 90 vdc n a n a n a 400 VAC 360 440 VAC Three Phase 50 60 Hz NOTE The duty cycle will be reduced if the primar...

Page 16: ...Canadian Electric Code CE CutMaster 51 Input Wiring Specifications NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de rated...

Page 17: ...Features Art A 03578 Work Cable and Clamp Handle and Leads Wrap Torch Leads Receptacle Control Panel Art A 03738 Input Power Cord Ports for Optional Automation Interface Cable Gas Inlet Port Gas Press...

Page 18: ...ork cable clamp on the power supply a 50 ft 15 2 m work cable with clamp is available E Multi Purpose Cart Rugged steel cart on easy rolling rear wheels and front mounted swivel casters Provides maxim...

Page 19: ...ng Options The Power Supply includes a handle for hand lifting only Be sure unit is lifted and transported safely and securely WARNINGS Do not touch live electrical parts Disconnect input power cord b...

Page 20: ...eads for 400 Volt three phase input power 1 The input cable s outer covering is stripped back at the factory to expose the individual wires at the free end of the cable 2 Connect the ends of the indiv...

Page 21: ...r line to the inlet port The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to manufacturer s instructions Do not use Te...

Page 22: ...se 3 Connect the air line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s instructions D...

Page 23: ...ting 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 air passages in the torch b Connect the...

Page 24: ...hich 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 at least 300 scfh 141 5 lpm 4 Conn...

Page 25: ...he ATC male connector on the torch lead with the female receptacle Push the male connector into the female receptacle The connectors should push together with a small amount of pressure 2 Secure the c...

Page 26: ...e ON OFF switch in the ON up position 2 Put the RUN RAPID AUTO RESTART SET switch in the SET down position 3 Place a welding filter lens in front of the torch and turn on the air Any oil or moisture i...

Page 27: ...ally OFF Indicator is ON when internal temperature exceeds normal limits Shut unit OFF let the unit cool before continuing op eration GAS Indicator Indicator is ON when minimum input air pres sure for...

Page 28: ...e torch is properly connected Only Thermal Dynamics model SL60 or SL100 Torches may be connected to this Power Supply C Check Primary Input Power Source 1 Check the power source for proper input volta...

Page 29: ...ON OFF switch to the ON up position AC indicator turns on Gas indicator turns on if there is sufficient air pressure for power supply operation NOTE Minimum pressure for power supply operation is low...

Page 30: ...03690 1 2 2 Adjust air pressure to 65 85 psi 4 5 5 9 bar Refer to the chart for pressure setting details Leads Length SL60 Hand Torch SL100 Machine Torch Up to 25 7 6 m 75 psi 5 2 bar 65 psi 4 5 bar...

Page 31: ...ng the pilot arc With the switch in the Rapid Auto Restart middle position when the torch leaves the workpiece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot ar...

Page 32: ...trigger release to the rear and presses the trigger the pilot arc starts The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece L Shutdown Turn the ON O...

Page 33: ...a regular basis This can lead to potential performance problems It is recommended to apply a very light film of o ring lubricant Catalog 8 4025 to the o ring on a weekly basis NOTE DO NOT use other lu...

Page 34: ...ed 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...

Page 35: ...ff air supply and bleed down system before disassembling Filter to change Filter Element 3 Disconnect gas supply hose 4 Turn the Cover counter clockwise and remove it from the Filter Housing The Filte...

Page 36: ...ly as injury could result 3 Loosen the two bolts on the top of the FilterAssembly enough to allow the Filter Elements to move freely 4 Note the location and orientation of the old Filter Elements 5 Sl...

Page 37: ...rn 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 N...

Page 38: ...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...

Page 39: ...n torch switch is activated AC indicator ON 1 System is in SET mode a Change RUN Rapid Auto Restart SET switch to RUN up D No gas flow RUN Rapid Auto Restart SET switch in SET position Fans operate AC...

Page 40: ...ternal components may result 3 Upper O ring on torch head is in wrong position a Remove shield cup from torch check position of upper O ring Correct if necessary Lower O Ring Upper O Ring in Correct G...

Page 41: ...ut Torch pilots Gas flows Fans operate AC Gas and DC indicator ON TEMP indicator OFF 1 Work cable not connected to work piece or connection is poor a Make sure that work cable has a proper connection...

Page 42: ...cked TEMP indicator ON a Check and clear blades 3 Air flow obstructed TEMP indicator ON a Check for obstructed air flow around the unit and correct condition 4 Gas pressure too low GAS indicator OFF w...

Page 43: ...ment 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 t...

Page 44: ...e upper screws C 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 A replacement fuse is located insid...

Page 45: ...l 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 m...

Page 46: ...embly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 High Pressure Air Regulator 9 3022 1 Whee...

Page 47: ...s 9 8207 40A 9 8225 A 40A Starter Cartridge 9 8213 9 8241 9 8218 9 8237 8 3487 O Ring 8 3486 O Ring Art A 03816 Electrode 9 8215 Shield Cup Shield Cap Gouging Shield Cup Body A 03417 Electrode Starter...

Page 48: ...PARTS LISTS 6 4 Manual 0 2989...

Page 49: ...tem is ready for operation ACTION RUN Rapid Auto Restart SET switch to SET RESULT Gas flows to set pressure ACTION RUN Rapid Auto Restart SET switch to RUN for most applications or to Rapid Auto Resta...

Page 50: ...rer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 03288 D...

Page 51: ...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 f...

Page 52: ...1 Black PIP Negative Plasma 8 Ground ATC Male Connector Front View A 03701 B Mechanized Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma 3 W...

Page 53: ...4 3 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Rem...

Page 54: ...CONFIGURATION 400V CE VERSION INCLUDES IN LINE EMC FILTER 15 16 ISENSE CURRENT SENSE B CURRENT SENSE A RED 12V GATE DRIVE B RTN GATE DRIVE B GATE DRIVE A RTN GATE DRIVE A CSR ISENSE FILTERING R94 460...

Page 55: ...N TRANSFORMER T1 AUX TRANSFORMER REL ASSY 19X1721 J18 J19 P19 P18 WORK ASSY 19X1905 J28 PILOT BOARD DC COMMON T O R C H OUTPUT INDUCTOR IGBT BOARD NOTES UNLESS OTHERWISE SPECIFIED 1 DEPICTIONS OF CIRC...

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