Plasma Cutting Power Supply CutMaster 50 A-02766 Operating Manual April 21, 2003 Manual No. 0-2805
WARNINGS Read and understand this entire Manual and your employer s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutMaster 50 Operating Manual Number 0-2805 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2000 by Thermal 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 of America Publication Date: April 21, 2003 Record the following information for Warranty purposes: Where Purchased: Purchase Date: Power Supply Serial #: Torch Serial #:
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION... 1-1 1.01 Notes, Cautions and Warnings... 1-1 1.02 Important Safety Precautions... 1-1 1.03 Publications... 1-2 1.07 Declaration of Conformity... 1-4 1.08 Statement of Warranty... 1-5 SECTION 2: INTRODUCTION... 2-1 2.01 Scope of Manual... 2-1 2.02 General Description... 2-1 2.03 Specifications & Design Features... 2-1 2.04 Power Supply Options and Accessories... 2-2 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... 4-3 SECTION 5: SERVICE... 5-1 5.01 Introduction... 5-1 5.02 General Maintenance... 5-1 5.03 Common Faults... 5-2 5.04 Basic Troubleshooting Guide... 5-3 5.05 Power Supply Basic Parts Replacement... 5-5
TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS... 6-1 6.01 Introduction... 6-1 6.02 Ordering Information... 6-1 6.03 Power Supply Replacement... 6-2 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
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment. WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area. 1.02 Important Safety Precautions WARNINGS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN- GEROUS AND HAZARDOUS TO YOUR HEALTH. Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions. GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Keep all fumes and gases from the breathing area. Keep 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 metals which may contain one or more of the following: Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual. Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. Do not use the plasma torch in an area where combustible or explosive gases or materials are located. Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. Never touch any parts that are electrically live or hot. May 14, 2002 1-1 GENERAL INFORMATION
Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. Repair or replace all worn or damaged parts. Extra care must be taken when the workplace is moist or damp. Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. Disconnect power source before performing any service or repairs. Read and follow all the instructions in the Operating Manual. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc. Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. Ventilate all flammable or explosive vapors from the workplace. Do not cut or weld on containers that may have held combustibles. Provide a fire watch when working in an area where fire hazards may exist. Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion. NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace. Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels. For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in 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 helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. Use the shade of lens as suggested in the following per ANSI/ASC Z49.1: Minimum Protective Suggested Arc Current Shade No. Shade No. Less Than 300* 8 9 300-400* 9 12 400-800* 10 14 * These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece. 1.03 Publications Refer to the following standards or their latest revisions for more information: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU- PATION AND EDUCATIONAL EYE AND FACE PRO- TECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MEN S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 GENERAL INFORMATION 1-2 May 14, 2002
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CON- TAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. NFPA Standard 51B, CUTTING AND WELDING PRO- CESSES, obtainable from the National Fire 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. CSA Standard W117.2, CODE FOR SAFETY IN WELD- ING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 14. American Welding Society Standard AWSF4.1, RECOM- MENDED SAFE PRACTICES FOR THE PREPARA- TION FOR WELDING AND CUTTING OF CONTAIN- ERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 May 14, 2002 1-3 GENERAL INFORMATION
1.07 Declaration of Conformity Manufacturer: Address: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements. Among them are: * CSA (Canadian Standards Association) 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 associated accessories. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Giorgio Bassi Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy GENERAL INFORMATION 1-4 May 14, 2002
1.08 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal ) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal s sole option, of any components or parts of the product determined by Thermal to be defective. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser ) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT. THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The limited warranty periods for Thermal products shall be 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 follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below). The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below). Parts XL Plus & Parts Parts PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year Exchanges, And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 1 Year SureLok Torches 1 Year 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days Repair/Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer s risk and expense. This warranty supersedes all previous Thermal warranties. Effective August 6, 2001 May 14, 2002 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 May 14, 2002
SECTION 2: INTRODUCTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and basic maintenance procedures for the CutMaster 50 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed. NOTE Refer to the Torch Manual provided with this Power Supply for torch and cutting information. 2.02 General Description The power supply provides 40 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, primary input power cable (with plug on 208 / 230V units only), and work cable & clamp. NOTE Refer to Section 2.04 for a list of power supply options and accessories. 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 input power: 208 / 230 VAC, Single - Phase, 60 Hz 400VAC, Three - Phase, 50 / 60 Hz 460VAC, Three - Phase, 50 / 60 Hz 460VAC, Single - Phase, 50 / 60 Hz NOTE Refer to Appendix 1 for input wiring requirements. 2. Output Power Continuously variable from 20 to 40 amps maximum. 3. Duty Cycle (see NOTE) NOTE The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher than shown in the chart. 208 / 230Volt Power Supply Duty Cycle: 208/230 Volt Power Supply Duty Cycle Ambient Temperature 104 F (40 C) 104 F (40 C) 104 F (40 C) Duty Cycle 40% 60% 100% Current 39 Amps 33 Amps 20 Amps DC Voltage 110 vdc 105 vdc 100 vdc 400 - Volt and 460 - Volt Power Supply Duty Cycle: 400V, 460V Power Supply Duty Cycle Ambient Temperature 104 F (40 C) 104 F (40 C) 104 F (40 C) Duty Cycle 40% 60% 100% A-02766 Current 40 Amps 33 Amps n/a DC Voltage 110 vdc 105 vdc n/a CutMaster 50 Power Supply 4. Pilot Circuitry Capacitive Discharge (CD), Ignition DC Pilot Manual 0-2805 2-1 INTRODUCTION
5. Weight 52 lbs (23.6 kg) Weight includes Power Supply with Input Cable (and plug, on 208 / 230V units), Work Lead, and Torch & Leads. 6. Overall Dimensions (incl. handles) Length: Width: 22-1/2 inches (572 mm) 10-3/4 inches (273 mm) D. Wheel Kit A kit with easy - rolling wheels, for maximum portability for the power supply. E. Multi - Purpose Cart Rugged steel cart on easy - rolling rear wheels and front - mounted swivel casters. Provides maximum mobility for the power supply and can also serve as a display cart. Top shelf is 12 " (305 mm) x 20 (508 mm). Steel handle is 30" (762 mm) high. Height: 16-3/8 inches (416 mm) 7. Gas Filter / Regulator Assembly Specifications The following specifications apply to the standard Gas Filter / Regulator Assembly only: Operating Pressure (Output): 70 psi (4.8 bar) Maximum input gas pressure: 125 psi (8.6 bar) Filter: Particulate Type Filter (to 20 microns) 2.04 Power Supply Options and Accessories The following options and accessories are available for this power supply. Refer to Section 6, Parts Lists, for catalog numbers and ordering information. A. Single - Stage Air 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 contaminants to at least 5 microns. The filter assembly is pre - assembled at the factory and need only be attached to the power supply. C. Extended Work Cable with Clamp As an alternative to the standard 20 ft (6.1 m) work cable & clamp on the power supply, a 50 ft (15.2 m) work cable with clamp is available. INTRODUCTION 2-2 Manual 0-2805
SECTION 3: INSTALLATION 3.01 Introduction This Section describes installation of the Power Supply and connecting the Torch. These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those units. The complete installation consists of: 1. Site selection 2. Unpacking 3. Connections to Power Supply a. Input power b. Gas c. Torch Leads d. Work cable 4. Grounding 5. Operator training NOTES Depending on how the system was ordered, some Power Supply Options may already be installed. If option(s) have been factory installed some of the instructions may not apply. It is recommended that all sub-sections be read for general information. 3.02 Site Selection Select a clean, dry location with good ventilation and adequate working space around all components. NOTE Review Important Safety Precautions (Section 1) to be sure that the selected location meets all safety requirements. The power supply is fan cooled by air flow through the side panel to the front and rear panels. Air flow must not be obstructed. Provide at least 2 feet (0.6 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 controls. 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 damage during shipping. 1. Unpack each item and remove any packing material. 2. Locate the packing list(s) and use the list(s) to identify and account for each item. 3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation. 3.04 Lifting Options This unit is equipped with a handle designed for hand lifting only. Be sure unit is lifted and transported safely and securely. WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. HANDLE is not for mechanical lifting. Only persons of adequate physical strength should lift the unit. Lift unit by the handle, using two hands. Install optional wheel kit or use hand cart or similar device of adequate capacity to move unit. Place and secure unit on a proper skid before transporting with a fork lift or other vehicle. Manual 0-2805 3-1 INSTALLATION
3.05 Primary Input Power Connections Check your power source for correct voltage before plugging in or connecting the unit. See Appendix 1, Input Wiring Requirements. A. 208 / 230 Volt Units This power supply includes a factory-installed input power cable and plug. 1. Check your power source for correct voltage before plugging in the unit. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system. CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Appendix 1). B. 400-Volt and 460-Volt Three-Phase Units These Power Supplies are equipped with a three-phase, four conductor, input power cable. Connect the input power cable to the customer's power source as follows: 1. Remove the Power Supply cover per section 5.05. C. 460-Volt Single-Phase Operation The 460-Volt Power Supply is equipped with a four-conductor input power cable for 460VAC, Three-Phase input power. The Power Supply will accept 460VAC, Single-Phase input power with a change of input power cable. For 460-VAC, Single-Phase operation: 1. Remove the Power Supply cover per section 5.05. 2. Disconnect the original input power cable from the main input contactor and the chassis ground connection. 3. Loosen the strain relief on the back panel of the power supply. Pull the original power cable out of the power supply. 4. Pass a customer-supplied three-conductor input power cable through the access opening in the back panel of the power supply. Refer to Appendix 1 for power cable specifications. Tighten the strain relief to secure the power cable. CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Appendix 1). 2. The cable's outer covering is stripped back at the factory to expose the individual wires at the free end of the cable. 3. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows: CAUTION The primary power source and power cable must conform to local electrical code and the recommended circuit protection and wiring requirements (refer to table in Appendix 1). All the input cable wires must be connected for three-phase operation. L1 L3 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. Ground Wire with Ring Terminal Input Cable A-03041 Main Input Contactor L1 L2 L3 5. Connect the input power cable (or close the main disconnect switch) to supply power to the system. Input Power Connections, 460VAC, Single-Phase INSTALLATION 3-2 Manual 0-2805
5. Strip back the insulation on the individual wires and connect as follows: Line 1 wire to main input contactor terminal L1. Line 3 wire to main input contactor terminal L3. Ground wire to Ground (Earth). The Ground wire connection requires a ring terminal. 6. Replace the Power Supply cover. 7. Connect the input power cable (or close the main disconnect switch) to supply power to the system. 3.06 Gas Connections A. Gas Requirements C. Connecting Gas Supply to Unit The gas supply connects to the Regulator / Filter Assembly located on the rear of the unit. The connection is the same for compressed air or high pressure gas cylinders. If an optional air line filter is to be installed, refer to procedures in subsection 3.06-D. 1. Connect the gas line to the inlet port. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten. NOTE For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch. WARNINGS This unit is not to be used with oxygen (O 2 ). Maximum pressure at inlet must not exceed 125 psi (8.6 bar) Gases: Single Gas - Plasma / Secondary Compressed Air or Nitrogen (N2) Only Pressure: 70 psi (4.8 bar) Flow: Cutting - 200 scfh (standard cubic feet / hr) (94.4 lpm) Gouging - 230 scfh (standard cubic feet / hr) (108.5 lpm) B. Checking Air Quality To test the quality of air, place the RUN / SET switch to SET position, place a welding filter lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens. Do not initiate an arc! Inlet Port A-02999 Bowl 1/4 NPT to 1/4" (6mm) Fitting Hose Clamp Gas Supply Hose Regulator/Filter Assembly Gas Connection to Regulator / Filter Assembly 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 complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear. Manual 0-2805 3-3 INSTALLATION
D. Installing Optional Air Filter Kits Additional filtering is recommended when using air from a compressor to ensure that moisture and debris from the supply hose does not enter the torch. Although the Regulator has a filter, optional filter kits are recommended for improved filtering. 1. Optional Single-Stage Air Filter Kit This optional in-line air filter kit for use on compressed air shop systems is highly effective at removing moisture and particulate matter from the air stream to at least 0.85 microns. NOTE For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small gas passages in the torch. Connect the gas supply as follows: a. Attach the Single-Stage Filter Hose to the Regulator / Filter Assembly inlet port as shown. b. Attach the Single-Stage Filter Assembly to the filter hose. c. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten. 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 moisture and contaminants to at least 5 microns. Connect the gas supply as follows: a. Attach the Two Stage Filter to the back of the power supply per instructions supplied with the filter assembly. NOTE For a secure seal, apply thread sealant to the fitting threads according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch. b. Install the two stage filter hose in the inlet port of the Regulator / Filter Assembly, as shown below. c. The illustration shows typical fittings as an example. Other fittings may be used. Install the fittings and tighten. Regulator/Filter Assembly Regulator Inlet Port 2-Stage Filter Inlet Port (IN) Regulator/Filter Assembly Inlet Port Hose Clamp Outlet Port (OUT) Two Stage Filter Assembly Bowl 1/4" (6 mm) Gas Supply Hose) 1/4 NPT Hose Fitting A-03004 1/4 NPT Hose Fitting Hose Clamp 1/4" (6 mm) Gas Supply Hose A-03000 Optional Two-Stage Filter Installation Optional Single-Stage Filter Installation INSTALLATION 3-4 Manual 0-2805
E. Using High Pressure Gas Cylinders Refer to the following when using high pressure gas cylinders as the gas supply: A. Hand Systems WARNING CAUTION Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator. 1. Refer to the manufacturer s specifications for installation and maintenance procedures for high pressure gas regulators. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to blow out any dust which may be present. 3. The cylinder must be equipped with an adjustable high-pressure regulator capable of outlet pressures up to 100 psi (6.9 bar) maximum and flows of up to 200 scfh (94.3 lpm). 4. Use customer-supplied fitting(s) to connect 1/4" (6 mm) inside diameter gas supply hose to the cylinder. NOTE Supply hose must be at least 1/4 inch (6 mm) I.D. For a secure seal, apply thread sealant to the fitting threads, according to manufacturer's instructions. Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas passages in the torch. 3.07 Torch Connections Equipment ordered 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-section covers connecting the Torch for the following applications: A. Hand Systems B. Machine Systems (Unshielded Leads) C. Remote Pendant Control (Optional) The Torch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the Torch Bulkhead Panel for the desired application. Disconnect primary power at the source before disassembling the torch or torch leads. 1. Remove the Cover of the Power Supply for access to the Torch Bulkhead Panel. See Section 5.05. 2. Remove the retaining nut from the Strain Relief. Negative / Plasma Lead A-03607 Torch Leads Assembly Pilot Lead Strain Relief Strain Relief Nut 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 retaining nut removed earlier. 5. Connect the torch Negative / Plasma Lead to the bulkhead connection inside the Power Supply. Manual 0-2805 3-5 INSTALLATION
B. Machine Systems (Unshielded Leads) Note: Actual Bulkhead configuration may differ from that shown. Control Circuit Connectors Negative/Plasma Lead Connection Adapter Torch Lead Assembly Pilot Lead Negative/Plasma Lead Adapter Connector Pilot Lead Stud 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 Relief. Remove Tie Wrap, Remove Insulator, Disconnect Wires Strain Relief Torch Leads Assembly A-03608 Torch Lead Connections To Bulkhead A-03609 Strain Relief Nut 6. Connect the Control (PIP) Circuit Connectors to the mating connectors on the Power Supply Adapter. 7. Remove the top nut and washer from the Pilot Stud. 8. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed in Step 7. 9. Tighten the Strain Relief onto the Torch Leads. 10. Check the torch for proper parts assembly. CAUTION The torch parts must correspond with the type of operation. Refer to the appropriate torch manual for proper parts selection. 11. Re-install the Power Supply Cover on the Power Supply. 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 Adapter through the Strain Relief Nut. b. Continue routing the connector out the hole in the front of the Power Supply. c. Feed the end of the torch lead and the Strain Relief into the hole in the unit while routing the single black wire into the notch of the Strain Relief. d. Tighten the Strain Relief Nut to secure the Strain Relief to the Power Supply. 4. Connect the torch Negative / Plasma Lead to the bulkhead connection inside the Power Supply. INSTALLATION 3-6 Manual 0-2805
Negative/Plasma Lead Connection Adapter Connector 5. Connect the Control (PIP) Circuit Connectors to the mating connectors on the Adapter supplied on the Power Supply (see Warning). Power Supply Adapter Remote Pendant Adapter Control Circuit Connectors Open Open Pilot Lead Pilot Lead Stud WARNING The Adapter supplied with the Power Supply has two additional Shield Connectors that are used for Shielded Systems only. These two connectors are not used and must be taped out of the way to prevent contacting the Negative / Plasma or Pilot Leads. Torch Lead Assembly Negative/Plasma Lead A-03610 Torch Lead Connections To Bulkhead Torch Lead Assembly Control Circuit Connectors Open Power Supply Adapter Negative/Plasma Lead Pilot Lead A-03611 Open Torch Lead Connections To Bulkhead - Detail 6. Remove the top nut and washer from the Pilot Stud. 7. Place 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. Remote Pendant Control (Optional) In machine type operations the Power Supply has an Adapter that has a cable connector supplied at each end of the Adapter. One end is connected at the factory to the mating connector on the Power Supply Bulkhead area. The other end allows connection of a Remote Pendant. The remote pendant lead connector allows connection to a remote pendant or CNC cable while using Control (PIP) Circuit connections in the Torch Assembly. Connect the remote pendant control cable to the connector provided on the Adapter from the Power Supply. NOTE Refer to Appendix 3, Torch Control Cable Wiring Diagram For Mechanized Systems, for detailed schematic of the Adapter. Manual 0-2805 3-7 INSTALLATION
Remote Pendant/CNC Cable Connector Control OK-To-Move 3 4 12 14 13 PIP Circuit Torch Control Cable Connector 2 3 4 12 14 13 A-01366 Remote Pendant Connector Diagram 3.08 Ground Connections For Mechanized Applications A. Electromagnetic Interference (EMI) Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems: 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 2 ) 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 diameter wire is better. 2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer s recommendations for wire size, type, and connection point locations. For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (European 6 mm 2 ) 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 protection. 3. The cutting machine frame is then connected to the Star point using 1/0 AWG (European 50 mm 2 ) 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 properly 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 electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually 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. INSTALLATION 3-8 Manual 0-2805
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 required 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 2 ) or greater, between the ground rod and the star ground point on the cutting table. NOTE Ideally, a properly installed ground rod will have a resistance of three ohms or less. 2. Increasing the ground rod length beyond 20-30 ft (6.1 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. 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 resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good. D. Routing Of Torch Leads 1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts. 2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference. To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be as follows: For 115VAC: 3.0 VAC For 230VAC: 1.5 VAC 115VAC: 3.0 VAC 230VAC: 1.5 VAC V~ Meter set to VAC setting V~ WARNING Use extreme caution. This test uses live voltage. VR COM + _ A Neutral 115 or 230VAC 100W Light Bulb Line (Hot) A-02971 Machine Earth Ground Ground Testing Manual 0-2805 3-9 INSTALLATION
INSTALLATION 3-10 Manual 0-2805
4.01 Introduction SECTION 4: OPERATION This section identifies the front and rear components and describes the power supply operating controls and procedures. 4.02 Product Features This subsection provides specific functional descriptions of the power supply operating controls and indicators. A. Front Panel Features 1. Control Panel All operator controls, except gas pressure adjustment, are located on this panel: power ON / OFF switch, RUN / SET switch; CURRENT control; LED indicators for AC Power, TEMP, GAS, and DC. 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 supply cover. See Section 5.05 for cover removal directions. A. Pilot Lead Stud Connects the pilot control wire on the torch to the unit. B. Control Cable Connector Connects the torch switch to the unit. In machine torch applications connects the torch switch on the pendant to the unit. C. Gas / Power Lead Connection Connects the torch gas / negative lead to the unit. 2 4 1 A-02772 3 2. Torch Leads Input Front Panel Features 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. Manual 0-2805 4-1 OPERATION
B. Control Panel Features 6. GAS Indicator 3 25 20 A 30 40 35 4 5 6 7 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 activated. Indicates DC output circuit is active. C. Rear Panel Features 1 2 1. Gas Input Port Connection for gas input. Operating Controls 1. ON / OFF Power Switch A-03641 WARNING This unit is not to be used with oxygen (O 2 ). ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits. 1 2. RUN / SET Switch 3 RUN position is used for general torch operation. Torch switch must be held. SET position used for setting gas pressure and purging lines. 3. Current Control (A) Adjustment to set the desired output current between 20-40 amps. 4. AC Power Indicator Green indicator will blink ON-OFF for approximately eight seconds and then stay ON after the ON / OFF power switch is set to ON. Indicates operating power is present in the unit. 2 Rear Panel A-03042 5. TEMP Indicator Normally OFF. Yellow indicator will come ON when the internal temperature sensors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation. 2. Primary Input Power Cable / Strain Relief Primary input power cable with strain relief, capable of handling the input voltage for which this unit was designed. 3. Gas Pressure Filter / Regulator Assembly Pressure regulator to adjust the input gas pressure to the Power Supply. The pressure regulator has its own built-in filter. Factory installed. For improved filtering, other filtering packages are available as options. OPERATION 4-2 Manual 0-2805
4.03 Preparations For Operating This procedure should be followed at the beginning of each shift: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. A. Torch Parts Selection Check the torch for proper assembly and appropriate front end torch parts. The torch parts (shield cup, tip, gas distributor, and electrode) must correspond with the type of operation (cutting or gouging). Refer to the torch manual for proper parts selection. B. Check Primary Input Power Source 1. Check the power source for proper input voltage. Make sure the input power source meets the power requirements for the unit per subsection 2.03-A, Specifications / Design Features. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system. C. Gas Selection Select desired single gas supply. Make sure gas source meets requirements (refer to subsection 3.06A, Gas Requirements). Check connections and turn gas supply on. D. Work Cable Connection Check for a solid work cable connection to the workpiece. E. Torch Connection Check that the torch is properly connected. F. Power On On the Power Supply place the ON / OFF switch to the ON position. G. Select Current Output Level On the Control Panel, set the desired current output level between 20-40 amps for cutting or gouging. H. Set Operating Pressure Place the 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 Remote Pendant). There is a 2 second pre-flow before the arc starts. 4.05 Sequence of Operation The following is a typical sequence of operation for this power supply. Refer to Appendix 2 for block diagram. 1. Close main power source disconnect switch. a. AC power is available at the Power Supply. 2. Place RUN / SET switch to RUN mode. 3. Place the ON / OFF power switch on the front panel of the Power Supply to ON position. a. AC Power Indicator blinks ON and OFF for eight seconds then stays ON. Fan turns on. NOTE Gas comes on if Torch Trigger is pressed (although unit will not pilot until switch is released and reclosed after the light stops blinking). 4. Place RUN / SET switch to SET mode. a. Gas solenoid opens and gas flows to set pressure. Gas Pressure Regulator / 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 pressure is set below 35 psi (2.4 bar) at the Gas Pressure Regulator / Filter Assembly. 5. Place RUN / SET switch to RUN mode. a. Gas flow stops. GAS Indicator turns OFF. 6. Protect eyes and activate torch. a. Gas pre-flow starts (approximately 2 seconds). GAS Indicator turns ON. 7. After gas pre-flow: a. Power Supply enabled. DC indicator turns ON. Pilot Relay closes. 8. Pilot arc is established Manual 0-2805 4-3 OPERATION
9. Move Torch within transfer distance of workpiece. a. Main arc transfers. Pilot arc OFF. 10. Complete cutting operation. NOTE If the torch is lifted from the workpiece while the torch switch is activated, the main arc will stop and the pilot arc will automatically restart. 11. Release or deactivate the torch switch. a. Main arc stops. Pilot arc stops. If torch is activated during post-flow, the pilot 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 indicator 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 disconnect to open. a. Main AC power is removed from the system. For information on cutting techniques, cutting problems, cutting speeds, cut quality, etc., refer to the torch manual supplied with the torch. OPERATION 4-4 Manual 0-2805