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Operating Manual

Plasma Cutting

Power Supply

CutMaster™ 75

March 22, 2004

Manual No. 0-2868

A-02991

Summary of Contents for CutMaster 75

Page 1: ...Operating Manual Plasma Cutting Power Supply CutMaster 75 March 22 2004 Manual No 0 2868 A 02991...

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Page 3: ...n in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date March 22 2004 Record the following information for Warr...

Page 4: ...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 1 3 06 Gas Connections 3 3 3 07 Torch Connec...

Page 5: ...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...

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Page 7: ...r 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...

Page 8: ...n 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...

Page 9: ...ire 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 Hig...

Page 10: ...2 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 applicab...

Page 11: ...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...

Page 12: ...GENERAL INFORMATION 1 6 January 27 2004...

Page 13: ...AC 10 Three Phase 460VAC 10 Single Phase 600 VAC 517 632 VAC Three Phase NOTE Refer to Appendix 1 for input wiring requirements Units ordered as 208 230V single phase have an input cable and plug fact...

Page 14: ...least 5 0 microns C High Pressure Regulators High pressure regulators are available The regulators are used to set the proper pressure for the type gas being used NOTE Regulators should not be install...

Page 15: ...e 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 shipp...

Page 16: ...mer supplied three conductor input power cable through the access opening in the back panel of the power supply Refer to Appen dix 1 for power cable specifications Tighten the strain relief to secure...

Page 17: ...ants 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 on the rear of the unit The connection is the...

Page 18: ...Filter Assembly inlet port as shown b Attach the Single Stage Filter Assembly to the filter hose c Use customer supplied fittings to connect the gas line to the Filter Typical fittings are shown as e...

Page 19: ...red 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 sect...

Page 20: ...ess to the Torch Bulkhead Panel See Section 5 05 2 Remove the strain relief nut from the Strain Relief Strain Relief Nut Strain Relief Torch Leads Assembly A 03609 Remove Tie Wrap Remove Insulator Dis...

Page 21: ...anual for proper parts selection 10 Reinstall the Power Supply Cover C Machine Systems Shielded Leads 1 Remove the Strain Relief Nut from the Strain Re lief Strain Relief Nut Strain Relief Torch Leads...

Page 22: ...endant Control Optional In machine type operations the Power Supply has an Adapter with a cable connector supplied at each end of the Adapter One end is connected at the factory to the mating connecto...

Page 23: ...5 Make sure work cable and ground cables are properly connected The work cable must have a solid connec tion to the cutting table The work and ground connec tions must be free from rust dirt grease oi...

Page 24: ...p 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 resis...

Page 25: ...ols 1 ON OFF Power Switch ON up position supplies AC power to activate all system circuits OFF down position deactivates con trol circuits 2 RUN SET Switch RUN up position is for general torch operati...

Page 26: ...edure should be followed at the beginning of each shift WARNING Disconnect primary power at the source before as sembling or disassembling power supply torch parts or torch and leads assemblies A Torc...

Page 27: ...as Pressure Regu lator 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 pres sure is set below 35 psi 2 4 bar at the Gas Pres sure...

Page 28: ...OPERATION 4 4 Manual 0 2868...

Page 29: ...egulator Filter As sembly filter element per the Maintenance Schedule and either clean or replace it Refer to Section 6 Parts List for replacement filter element catalog number 1 Shut off input power...

Page 30: ...it leaks between housing and cover inspect the O Ring for cuts or other damage D Optional Two Stage Filter Element Replacement The Two Stage Air Filter has two Filter Elements When the Filter Elements...

Page 31: ...ing techniques A Basic Troubleshooting Overview This guide covers basic troubleshooting that requires lim ited disassembly and measurements It is helpful for solv ing many of the common problems that...

Page 32: ...t a Return for repair or have qualified technician repair per Service Manual D No cutting output Torch activated AC Power indicator ON Gas flows Fans operate 1 Torch not properly connected to power su...

Page 33: ...h 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 surfa...

Page 34: ...wer screws c Reinstall and tighten the upper screws d Tighten lower 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 ch...

Page 35: ...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 p...

Page 36: ...or 600VAC Power Supply 9 8638 1 Regulator Filter Assembly Replacement Element 9 4414 6 05 Options and Accessories Qty Description Catalog 1 Single Stage Filter Kit includes Filter Hose 7 7507 1 Replac...

Page 37: ...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 Clas...

Page 38: ...h 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 RESULT No power to s...

Page 39: ...ch 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 OK To Move 3...

Page 40: ...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 41: ...Manual 0 2868 A 5 APPENDIX Notes...

Page 42: ...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 20 8 25 D32...

Page 43: ...OLENOID SWITCH ON OFF SWITCH RUN SET C1 F3 F2 C1 D1 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 INDUCTO...

Page 44: ...PRESS 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...

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: ...W 28 15 ON OFF SW CHASSIS GND J43 19 J27 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...

Page 47: ...2 3 72 E 58 J40 1 T 5 4 4 2 2 OUTPUT DIODE ASSEMBLY 19X1757 71 8 30 WORK 2 4 1 1 P3B P41 70 7 13 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...

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