Thermal Dynamics PakMaster 75XL Plus Operating Manual Download

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INSTALLATION

3-10

Manual 0-2746

3.10 Ground Connections for

Mechanized Applications

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electro-
magnetic interference (EMI), commonly called RF noise.
This RF noise may interfere with other electronic equip-
ment such as CNC controllers, remote controls, height
controllers, etc. To minimize RF interference, follow these
grounding procedures when installing mechanized 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 mm

) or larger wire to a good earth ground (refer

to paragraph ‘C’, Creating An Earth Ground). The
ground rod must be placed as close as possible to the
cutting table, ideally less than 10 ft (3.0 m), but no
more than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible.
Long wires will have increased resistance to RF
frequencies. Smaller diameter wire has increased
resistance to RF frequencies, so using a larger di-
ameter wire is better.

2. Grounding for components mounted on the cutting

table (CNC controllers, height controllers, plasma re-
mote controls, etc.) should follow the manufacturer’s
recommendations for wire size, type, and connection
point locations.

For Thermal Dynamics components it is recom-
mended to use a minimum of 10 AWG (European 6
mm

) 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 the

“Star” point using 1/0 AWG (European 50 mm

) or

larger wire.

4. The plasma power supply work cable (see NOTE) is

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 to keep the connections tight.
Using electrical joint compound to prevent corrosion
is also recommended.

6. The plasma power supply chassis is connected to the

power distribution system ground as required by elec-
trical codes. If the plasma supply is close to the cut-
ting table (see NOTE) a second ground rod is not usu-
ally needed, in fact it could be detrimental as it can
set up ground loop currents that cause interference.

When the plasma power supply is far away from the
ground rod and interference is experienced, it may
help to install a second earth ground rod next to the
plasma power supply. The plasma power supply
chassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supply
be within 20 - 30 ft (6.1 – 9.1 m) of the cutting
table, if possible.

7. The plasma control cable should be shielded with the

shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground
loop currents which may cause more interference than
with no shield at all.

C. Creating An Earth Ground

1. To create a solid, low resistance, earth ground, drive a

1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that
the rod contacts moist soil over most of its length.
Depending on location, a greater depth may be re-
quired to obtain a low resistance ground (see NOTE).
Ground rods, typically 10 ft (3.0 m) long, may be
welded end to end for greater lengths. Locate the rod
as close as possible to the work table. Install a ground
wire, 1/0 AWG (European 50 mm

) or greater, between

the ground rod and the star ground point on the cut-
ting table.

NOTE

Ideally, a properly installed ground rod will have a
resistance of three ohms or less.

To test for a proper earth ground, refer to the follow-
ing diagram. Ideally, the reading on the multimeter
should be as follows:

• For 115VAC: 3.0 VAC

• For 230VAC: 1.5 VAC