Thermal Dynamics CE CutMaster 100 Operating Manual Download

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Plasma Cutting

Power Supply

CE CutMaster

100

A-02766

March 22, 2004

Manual No. 0-2844

Operating Manual

Summary of Contents for CE CutMaster 100

Page 1: ...Plasma Cutting Power Supply CE CutMasterTM 50 CE CutMasterTM 75 CE CutMasterTM 100 A 02766 March 22 2004 Manual No 0 2844 Operating Manual...

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Page 3: ...hts reserved Reproduction of this work in whole or in part without written per mission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for...

Page 4: ...04 Power Supply Options and Accessories 2 2 SECTION 3 INSTALLATION PROCEDURES 3 1 3 01 Introduction 3 1 3 02 Site Selection 3 1 3 03 Unpacking 3 1 3 04 Lifting Options 3 1 3 05 Primary Input Power Con...

Page 5: ...UT WIRING REQUIREMENTS A 1 APPENDIX 2A SEQUENCE OF OPERATION BLOCK DIAGRAM CE CutMaster 50 A 2 APPENDIX 2B SEQUENCE OF OPERATION BLOCK DIAGRAM CE CutMaster 75 CE CutMaster 100 A 3 APPENDIX 3 TORCH CON...

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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: ...s 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 eyes...

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: ...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 S...

Page 13: ...ent 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 PT10 EN 60 974...

Page 14: ...ws 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...

Page 15: ...electri cal and gas inputs and outputs pilot circuitry primary input power cable and work cable clamp NOTE Refer to Section 2 04 for a list of power supply op tions and accessories A 02766 CE CutMaste...

Page 16: ...ssembly Specifications The following specifications apply to the standard Gas Regulator Filter Assembly only 1 Operating Pressure Output 70 psi 4 8 bar 2 Maximum input gas pressure 125 psi 8 6 bar 3 F...

Page 17: ...n 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 con trols CAUTION Operation...

Page 18: ...1 Live Green Yellow wire to Ground Earth 4 CE CutMaster 75 CE CutMaster 100 only Con nect a customer supplied grounding cable to the grounding stud on the rear panel as required by applicable Local an...

Page 19: ...air from a compressor to insure that moisture and debris from the supply hose does not enter the torch Although the Regu lator Filter Assembly does have its own filter the op tional Single Stage Air F...

Page 20: ...or Filter Assembly Hose Clamp 1 4 NPT Hose Fitting 1 4 6 mm Gas Supply Hose 2 Stage Filter Inlet Port IN Outlet Port OUT Regulator Inlet Port Two Stage Filter Assembly Optional Two Stage Filter Instal...

Page 21: ...s Assembly or ATC Adapter A 03529 Negative Plasma Lead Pilot Lead 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 r...

Page 22: ...the bulkhead connection inside the Power Supply Adapter Pilot Lead Torch Lead Assembly Negative Plasma Lead Adapter Connector Negative Plasma Lead Connection A 03528 Control Circuit Connectors Remote...

Page 23: ...d sys tems B Grounding 1 The preferred grounding arrangement is a single point or Star ground The single point usually on the cutting table is connected with 1 0 AWG European 50 mm2 or larger wire to...

Page 24: ...ds typically 10 ft 3 0 m long may be welded end to end for greater lengths Locate the rod as close as pos sible to the work table Install a ground wire 1 0 AWG European 50 mm2 or greater between the g...

Page 25: ...s 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 4 Roll Han...

Page 26: ...lowed to cool before continuing operation 6 GAS Indicator Green indicator will come ON when the input gas pressure is set to 35 psi 2 4 bar or higher Indicator will be OFF when the pressure falls belo...

Page 27: ...rent Output Level On the Control Panel set the desired current output level H Set Operating Pressure Place the RUN SET switch to the SET down posi tion Gas will flow Adjust gas pressure control to 70...

Page 28: ...rt 11 Deactivate the torch a Main arc stops b Pilot arc stops power supply enable signal re moved If torch is activated during post flow the pilot arc will immediately restart If torch is within 1 4 i...

Page 29: ...be visible andstillattachedtothemainbodyoftheFilterRegu lator 3 Grasp the filter element and unscrew it from the Filter Regulator body The filter element will come off with a spool and some additiona...

Page 30: ...eptable Refer to Section 6 for replace ment 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...

Page 31: ...ons as listed and complete each sec tion in the order presented For major troubleshooting and parts replacement proce dures refer to the Power Supply Service Manual B How to Use This Guide Thefollowin...

Page 32: ...have qualified technician repair per Service Manual 4 Faulty Torch a Return for repair or have qualified technician repair per Torch Manual E Low cutting output 1 Incorrect setting of CURRENT A contro...

Page 33: ...tput drops during operation CE CutMas ter 75 and 100 only 1 Torch tip touches work Tip Saver circuit active Cir cuitry in the Power Supply automatically reduces out put current to 40 amps if the torch...

Page 34: ...rews 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...

Page 35: ...c Replacement Parts Section 6 05 Options and Accessories B Returns If a product must be returned for service contact your distributor Materials returned without proper authori zation will not be accep...

Page 36: ...wer Cable CE 9 8553 6 05 Options and Accessories Qty Description Catalog 1 Single Stage Air Line Filter Kit includes Filter Hose 7 7507 1 Replacement Filter Body 9 7740 1 Replacement Filter Hose not s...

Page 37: ...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...

Page 38: ...t 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 ACTION Close external disconnect switch RES...

Page 39: ...y 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 ACTION Open external disconnect RES...

Page 40: ...l Device Torch Control Cable Control Shield Connector Lead Shield Connector Connectors only on Shielded Leads 2 1 3 4 12 14 13 Torch Control Cable Connector Remote Pendant CNC Cable Connector Control...

Page 41: ...sma 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...

Page 42: ...APPENDIX A 6 Manual 0 2844 APPENDIX 5 SYSTEM SCHEMATIC CE CutMaster 50 A 02967...

Page 43: ...Manual 0 2844 A 7 APPENDIX A 02967...

Page 44: ...ESS GOOD 23 22 9 24 RUN SET SW 20 GATE DRIVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 GATE DRIVE B RTN GAS SOLENOID 1 13 12 34 3 28VAC B 31 2 28VAC B S 3 27 D21 9 6 8 8 8 7 K4 21 2 12...

Page 45: ...T5 B7 TS1 TS2 E1 F1 GCW W1 MAIN CONTACTOR F3 A2 TEMP SENSOR IGBT HEATSINK TEMP SENSOR INDUCTOR MAIN CURRENT SENSE L1 PCR T10 CD L1 E3 OUTPUT INDUCTOR A10 MAIN TRANSFORMER T10 CD TRANSFORMER C10 08 21...

Page 46: ...5 8 5 P11 FAN1 14 8 16 15 5 25 1 1 PR ESS GOOD 23 22 9 24 RUN SET SW 20 G ATE D R IVE B 35 LED PCB 19X1604 27 J11 2 2 32 5 12 M2 7 4 8 W1 A 33 G ATE D R IVE B R TN GAS SOLENOID 1 13 12 34 3 28VAC B 3...

Page 47: ...O 6 3 CD ENABLE 1 1 2 E 62 6 C D EN ABLE C 6 3 T5 J7A CHASSIS GND J7B 12VDC E 35 J42 5 H 2 7 1 3 T OR C H SW 30 1 4 8 OUT 2 J3A 7 SEC 1 P7B E45 T OR C H SW R TN 8 3 8 8 R 4 PRI 3 2 C SR 7 2 3 8 P33 1...

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