Thermal Dynamics CE CutMaster 50 Operating Manual Download

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Plasma Cutting

Power Supply

CutMaster™ 50

A-02766

Operating Manual

April 21, 2003 Manual No. 0-2805

Summary of Contents for CE CutMaster 50

Page 1: ...Plasma Cutting Power Supply CutMaster 50 A 02766 Operating Manual April 21 2003 Manual No 0 2805 ...

Page 2: ...hermal 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 ...

Page 3: ...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...

Page 4: ... 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 ...

Page 5: ... 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 met als which may contain one or more of the follow ing Antimony Chromium Mercury...

Page 6: ... this manual 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 hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear ...

Page 7: ...re 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 CSAStandard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario ...

Page 8: ...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 associ ated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac turing ...

Page 9: ...s 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 fol...

Page 10: ...GENERAL INFORMATION 1 6 May 14 2002 ...

Page 11: ...2 04 for a list of power supply op tions and accessories A 02766 CutMaster 50 Power Supply 2 03 Specifications Design Features 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 in put power 208 230 VAC Single Phase 60 Hz 400VAC Three Phase 50 60 Hz 460VAC Three Phase 50 60 Hz 46...

Page 12: ... 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 contami nants to at least 5 microns The filter assembly is pre assembled at the factory and ne...

Page 13: ...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 con trols CAUTION Operation without proper air flow will inhibit proper cooling and reduce duty cycle 3 03 Unpacking The product is packaged and protected to prevent dam age during shipping 1 Unpack each item and remove an...

Page 14: ...iring requirements 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 5 Connect the input power cable or close the main disconnect switch to supply power to the system C 460 Volt Single Phase Operation The 460 Volt...

Page 15: ... 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 com plete torch failure Contaminants may cause poor cutting performance and rapid electrode wear C Connecting Gas Supply to Unit The gas supply connects to the Regulator Filter Assem bly locat...

Page 16: ...Other fittings may be used Install the fittings and tighten A 03000 Regulator Filter Assembly Inlet Port Bowl 1 4 NPT Hose Fitting 1 4 6 mm Gas Supply Hose Hose Clamp Optional Single Stage Filter Installation 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 mois ture and contaminants to at least 5 microns Conn...

Page 17: ...break off and block the small gas passages in the torch 3 07 Torch Connections Equipment ordered as a system will have the Torch fac tory 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...

Page 18: ...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 Re lief Strain Relief Nut Strain Relief Torch Leads Assembly A 03609 Remove Tie Wrap Remove Insulator Disconnect Wires Strain Relief Nut Removal 3 The Adapter suppli...

Page 19: ... 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 Remot...

Page 20: ...ed to use a minimum of 10 AWG European 6 mm2 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 pro tection 3 The cutting machine frame is then connected to th...

Page 21: ...r should be as follows For 115VAC 3 0 VAC For 230VAC 1 5 VAC A 02971 _ Meter set to VAC setting Machine Earth Ground Neutral Line Hot 100W Light Bulb 115 or 230VAC WARNING Use extreme caution This test uses live voltage 115VAC 3 0 VAC 230VAC 1 5 VAC V V VR COM A Ground Testing 2 Increasing the ground rod length beyond 20 30 ft 6 1 9 1 m does not generally increase the effective ness of the ground ...

Page 22: ...INSTALLATION 3 10 Manual 0 2805 ...

Page 23: ... 2 3 4 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 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 sup ply cover S...

Page 24: ...mperature sensors detect temperatures above normal limits The unit should be allowed to cool before continuing operation 6 GAS Indicator Green indicator will come ON when the input gas pressure is set to 35 psi 2 4 bar or higher Indicator will be OFF when the pressure falls below 35 psi 2 4 bar 7 DC Indicator Green indicator will come ON while the torch is acti vated Indicates DC output circuit is...

Page 25: ...he RUN SET switch to the SET position Gas will flow Adjust gas pressure control to 70 psi 4 8 bar 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 Re mote Pendant There is a 2 second pre ...

Page 26: ... during post flow the pi lot 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 in dicator 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 disco...

Page 27: ... will be visible and still attached to the main body of the Regula tor 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 5 The filter element and spool with the baffle ring in p...

Page 28: ...lement 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 3 Loosen the two bolts on the top of the Filter Assem bly enough to allow the Filter Elements to move freely First Second Stage Cartridges as mar...

Page 29: ...in the order presented For major troubleshooting and parts replacement proce dures 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 ...

Page 30: ...RENT control a Check and adjust to proper setting 2 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual F Limited output with no control 1 Poor input or output connections a Check all input and output connections 2 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual G Erratic or improper cutting outpu...

Page 31: ...power supply This section describes procedures for basic parts replace ment 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 t...

Page 32: ...Locate the internal fuse on the left side of the cen ter chassis 3 Replace the fuse Refer to Section 6 04 for proper fuse specification 4 Reinstall the cover by reversing the steps in para graph A above A 02957 Fuse Location Internal Fuse Location This completes the parts replacement procedures ...

Page 33: ...OTE 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 authori zation 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 ...

Page 34: ...nt Element 9 4414 1 Fuse 1 2A 250V for 208 230 Volt units 9 6395 1 2A 600V for 400 Volt and 460 Volt units 9 8110 6 05 Options and Accessories Qty Description Catalog 1 Single Stage Filter Kit includes Filter Hose 7 7507 1 Replacement Filter Body 9 7740 1 Replacement Filter Hose 9 7742 2 Replacement Filter Element 9 7741 1 Two Stage Filter Kit includes Hose Mounting Screws 7 7500 1 Bracket Filter ...

Page 35: ...d on National Electric Code and Canadian Electric Code 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 temperatu...

Page 36: ...ch 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 RESULT Power to system ACTION RUN SET switch to SET RESULT Gas solenoid open gas flows to set pressure GAS indicator on ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc aut...

Page 37: ...d Shield Connector Connectors only on Shielded Leads 2 1 3 4 12 14 13 Torch Control Cable Connector Remote Pendant CNC Cable Connector Control OK To Move 3 4 12 14 13 A 02821 Torch Leads Torch Head PIP Pin PIP Pin Shield Cup Mate Lock Connectors Mate Lock Connectors Pendant Ground Shield Return Power Supply Control OK To Move Relay APPENDIX 3 TORCH CONTROL CABLE WIRING DIAGRAM This diagram applies...

Page 38: ... 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 caus...

Page 39: ...Manual 0 2805 A 5 APPENDIX Notes ...

Page 40: ...APPENDIX A 6 Manual 0 2805 A 03269 APPENDIX 5 SYSTEM SCHEMATIC FOR 208 230V UNITS ...

Page 41: ...Manual 0 2805 A 7 APPENDIX A 03269 ...

Page 42: ...APPENDIX A 8 Manual 0 2805 APPENDIX 6 SYSTEM SCHEMATIC FOR 400 460V UNITS A 02967 ...

Page 43: ...Manual 0 2805 A 9 APPENDIX A 02967 ...

Page 44: ...APPENDIX A 10 Manual 0 2805 ...

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