Thermal Dynamics CE CutMaster 80XL Operation Manual Download

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December 4, 2002

Manual No. 0-2724

Plasma Cutting

Power Supply

CE CutMaster

™

80XL

Operating Manual

A-02218

Summary of Contents for CE CutMaster 80XL

Page 1: ...December 4 2002 Manual No 0 2724 Plasma Cutting Power Supply CE CutMaster 80XL Operating Manual A 02218 ...

Page 2: ......

Page 3: ... in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date December 4 2002 Record the following information for Warranty purposes Where Purchased ______________________________________ Purchase Date _________________________________________ Power Supply Serial _________________________________ Torch Serial _______...

Page 4: ...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 2 3 05 Input Power Connections 3 2 3 06 Input Voltage Selection 3 3 3 07 Input Power Cable Connections 3 3 3 08 Gas Connections 3 4 3 09 Connecting Torch Leads 3 5 3 10 Ground Connections For Mechanized Applications 3 8 SECTION 4 OPERATION 4 1 4 01 Introduction 4 1 4 02 Operating Con...

Page 5: ...ing Information 6 1 6 03 Complete Power Supply Replacement 6 2 6 04 Basic Parts Replacement 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 MAINTENANCE SCHEDULE A 3 APPENDIX 4 SYSTEM SCHEMATIC A 4 ...

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Page 7: ...p 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 met als which may contain one or more of the follow ing Antimony Chromium M...

Page 8: ...ons 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 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 w...

Page 9: ...American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilisés pour mettre en relief des informations à caractère important Ces mises en relief sont classifiées comme suit NOTE Toute opération procédure ou renseignement général sur lequel il importe d insister davantage ou qui contribu...

Page 10: ...lesser ou même tuer Le procédé au jet de plasma requiert et produit de l énergie électrique haute tension Cette énergie électrique peut produire des chocs graves voire mortels pour l opérateur et les autres personnes sur le lieu de travail Ne touchez jamais une pièce sous tension ou vive portez des gants et des vêtements secs Isolez vous de la pièce de travail ou des autres parties du circuit de s...

Page 11: ...ue les décibels le bruit ne dépassent pas les niveaux sûrs Pour des renseignements sur la manière de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles ci pour de plus amples renseignements 1 OSHA NORMES DE SÉCURITÉ DU TRAVAILET DE PROTECTION DE LA SANTÉ 29CFR 1910 disponible auprès du...

Page 12: ...ÉCURITÉ POUR LE SOUDAGE ET LA COUPE disponible auprès de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE disponible auprès de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Norme AWSF4 1 de l Association ...

Page 13: ...welding 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 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform...

Page 14: ...e 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 ...

Page 15: ...Figure 2 1 CutMaster 80XL Power Supply The power supply is designed to work with the Model PCH M 102 Plasma Torches The torch includes a spare parts kit which provides an assortment of replacement torch parts 2 03 Specifications Design Features A Power Supply Technical Specifications The following specifications apply to the Power Supply only 1 Front Panel Controls ON OFF Switch RUN SET Switch and...

Page 16: ...ply Options and Accessories The following accessories are available for this power supply Refer to Section 6 Parts Lists for part numbers and ordering information A Two Stage Air Line Filter ATwo Stage In Line Air Filter for use on compressed air shop systems Filters moisture and particulate matter from the air stream to at least 5 0 microns B Multi Purpose Cart Rugged steel cart on easy rolling r...

Page 17: ... 0 61 m in the rear and at least 6 inches 150 mm on each side for clearance Pro vide sufficient clearance in front of the unit to allow ac cess to the front panel controls minimum 6 inches or 150 mm CAUTION Operation without proper air flow will inhibit proper cooling and reduce duty cycle 3 03 Unpacking Equipment that was ordered as a system is packaged in one shipping carton All options and the ...

Page 18: ...60 Hz three phase power A Input Voltage Selection The Power Supply is factory wired for 380 415 VAC three phase input For any other input voltage the Power Sup ply must be changed using the procedure in Sections 3 06 Input Voltage Selection B Electrical Connections The power source must conform to local and national elec tric codes Recommended circuit protection and wiring requirements are shown i...

Page 19: ...ection Label EMC Filter Figure 3 3 Input Voltage Selection 3 07 Input Power Cable Connections The Power Supply is supplied with a 460V three phase input EMC power cable attached Connect the cable as follows CAUTION The input power cable must not be modified in any way as filtering beads are installed on the cable All the input cable wires must be connected for three phase operation The primary pow...

Page 20: ...to order the Optional Two Stage Air Line Filter for air filtering 1 Locate the 1 4 NPT hose barb fitting shipped in side the Torch Spare Parts Kit 2 Depending on the options installed at the factory install the supplied barb fitting into the gas con nector fitting input or the IN port of the Optional Two Stage Air Filter Assembly at the rear panel NOTE For a secure seal apply thread sealant to the...

Page 21: ...any other torch to this power supply The instructions for connecting the Torch Leads to the Power Supply are different depending on the type of leads This sub section covers connecting the Torch for the following applications A Hand Systems B Machine Systems Unshielded Leads C Machine Systems Shielded Leads The Torch Leads must be properly installed to the Power Supply for proper operation If the ...

Page 22: ...assemblies 1 Remove the Cover of the power supply for access to the torch bulkhead panel 2 Remove the strain relief nut from the Strain Re lief Strain Relief Nut Strain Relief Torch Leads Assembly A 02827 Figure 3 8 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 A...

Page 23: ...ower supply torch parts or torch and leads assemblies 1 Remove the Cover of the power supply for access to the torch bulkhead panel 2 Remove the strain relief nut from the Strain Re lief Strain Relief Nut Strain Relief Torch Leads Assembly A 02826 Figure 3 10 Strain Relief Nut Removal 3 The Adapter supplied with the Power Supply must be installed per the following a Inside the Power Supply Bulkhea...

Page 24: ...s 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 prop erly 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...

Page 25: ...ng 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 re quired to make sure the ground is still good D Routing Of Torch Leads 1 To minimize RF interference position torch leads as far as pos...

Page 26: ...INSTALLATION PROCEDURES 3 10 Manual 0 2724 ...

Page 27: ...ork cable with clamp factory Installed 4 Handle Handle used to lift and transport the power supply 5 Leads Wrap Bracket connected to the Cover of the unit for storing the torch torch leads and work cable when not in use The torch leads and work cable wrap around the bracket for easy storage B Control Panel 1 2 8 8 TEMP AC GAS DC SET RUN ON OFF A CURRENT 15 60 35 A 02229 3 4 5 6 7 Figure 4 2 Operat...

Page 28: ...he unit 1 2 3 A 02230 Figure 4 3 Torch Bulkhead Panel Area 2 Control Cable Connector Used to interface the Adapter supplied with Power Supply to the Torch Leads Control Cable 3 Pilot Lead Stud Stud used to connect the Torch Leads Pilot Lead to the Power Supply D Rear Panel 1 Gas Input Input connection for nitrogen N2 or air input WARNING This unit not to be used with oxygen O2 1 2 3 A 01151 Figure...

Page 29: ...Protect eyes and press or activate torch switch a Gas pre flows starts b GAS indicator turns ON 7 After gas pre flow approximately 2 seconds a Power supply enabled b DC indicator turns ON c Pilot relay closes 8 Pilot arc is established 9 Move Torch within transfer distance of workpiece a Main arc transfer b Pilot arc OFF 10 Complete cutting operation NOTE If the torch is lifted from the workpiece ...

Page 30: ...t the pre flow move the RUN SET switch to SET position for a minimum of 20 seconds The pre flow gas purge will remove any moisture that may have accumulated in the torch and leads while the system was shut down The torch cannot be activated during pre flow G Select Output Current Select the desired current output level for the operation 15 to 60 amps for standoff cutting and gouging 15 to 35 amps ...

Page 31: ...m this equipment for materials with a thick ness from gage to 7 8 inch 22 2 mm Type of Material Gas Carbon Steel Stainless Steel Aluminum Air Good Excellent Good Excellent Good Excellent Nitrogen Good Good Good Description of Cut Characteristics Excellent Minimum bevel 0 4 minimum kerf 2 x tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1 2 x...

Page 32: ...OPERATION 4 6 Manual 0 2724 ...

Page 33: ...piece while the torch is activated Sparks from the cutting process can cause damage to coated painted and other surfaces such as glass plastic and metal Handle torch leads with care and protect them from damage A Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive ...

Page 34: ...ics 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 3 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 N...

Page 35: ... ON 1 Airflow obstructed a Check for obstructed air flow and correct con dition 2 Fan blocked a Check and correct condition 3 Unit is overheated a Allow unit to cool down for about 5 minutes Make sure the unit has not been operated be yond duty cycle limit 4 Low input line voltage a Check and connect to proper input power line 5 Faulty components in unit a Return for repair or have qualified techn...

Page 36: ...orch consumables 3 Faulty components in unit a Return for repair or have qualified technician repair per Service Manual I Torch cuts but not adequately 1 Current set too low a Increase current setting 2 Torch is being moved too fast across workpiece a Reduce cutting speed refer to Instruction Manual supplied with torch 3 Excessive oil or moisture in torch a Hold torch 1 8 inch 3 mm from clean surf...

Page 37: ...edule and either cleaned or replaced 1 Remove power from the power supply turn off the gas supply and bleed down the system 2 Unscrew the plastic bowl on the bottom of the Regulator Filter Assembly The filter element will be visible and still attached to the main body of the Regulator Filter Regulator Filter Assembly Spool Plastic Bowl Spring Filter Element Baffle Ring A 02988 Figure 5 5 Filter El...

Page 38: ...n off the air supply and bleed the sys tem before disassembling the Filter Assembly as injury could result 3 Loosen the two bolts on the top of the Filter As sembly enough to allow the Filter Elements to move freely First Second Stage Cartridges as marked A 02942 Figure 5 6 Two Stage Filter Replacement 4 Note the location and orientation of the old Filter Elements 5 Slide out the old Filter Elemen...

Page 39: ...s 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 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 ea...

Page 40: ...atalog 1 Fuse 0 8A 600V 9 7526 1 Regulator Filter Replacement Element 9 4414 6 05 Options and Accessories Qty Description Catalog 1 Two Stage Air Filter Kit includes Hose Mounting Screws 7 7500 1 Bracket Filter Mounting not shown 9 7535 1 Two Stage Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Torch Guide Kit not shown 7 8910 1 Multi Purpose Cart 7 888...

Page 41: ...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 Input P ow er Input Current S uggested S izes S ee Note V oltage Freq 3 P h 3 P h Fuse Am ps W ire m m 2 V olts Hz kV A Am ps ...

Page 42: ...torch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to system 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 wh...

Page 43: ... 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 44: ...APPENDIX A 4 Manual 0 2724 APPENDIX 4 SYSTEM SCHEMATIC A 02234 ...

Page 45: ...Manual 0 2724 A 5 APPENDIX A 02234 B EC 8055 HAS 11 23 98 C EC 8087 HAS 12 18 98 AE ECO 39F6 ECO 3AF2 HAS 09 15 2001 ...

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