Plasma Cutting Power Supply

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December 4, 2002 Manual No. 0-2724

Plasma Cutting Power Supply

CE CutMaster ^™ 80XL

Operating Manual

A-02218

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Plasma Cutting Power Supply CE Cut Master ^™ 80XL

Operating Manual Number 0-2724 Published by:

Thermal Dynamics Corporation 82 Benning Street

West Lebanon, New Hampshire, USA 03784 (603) 298-5711

Reproduction of this work, in whole or in part, without written per- mission 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: December 4, 2002

Record the following information for Warranty purposes:

Where Purchased:______________________________________

Purchase Date:_________________________________________

Power Supply Serial #:_________________________________

Torch Serial #:__________________________________________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper- ating, 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.

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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 Controls ... 4-1 4.03 Sequence Of Operation ... 4-3 4.04 Preparations for Operating ... 4-4 4.05 Cut Quality ... 4-4 SECTION 5:

CUSTOMER/OPERATOR SERVICE ... 5-1 5.01 Introduction ... 5-1 5.02 General Maintenance ... 5-1 5.03 Common Operating Problems ... 5-1 5.04 Troubleshooting Guide ... 5-2 5.05 Power Supply Parts Replacement ... 5-4

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TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS ... 6-1 6.01 Introduction ... 6-1 6.02 Ordering 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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Date: November 15, 2001 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high- lights are categorized as follows:

NOTE

An operation, procedure, or background informa- tion which requires additional emphasis or is help- ful 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 oper- ating 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. Per- sons who work near plasma arc cutting applica- tions should consult their medical health profes- sional 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 in- structions 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 met- als 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.”

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GENERAL INFORMATION 1-2 Date: November 15, 2001

• 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, Publica- tions.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operat- ing 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 under- water 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 dis- sipated. 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 deci- bels (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 work- piece.

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 Docu- ments, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding So- ciety, 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. Govern- ment 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 Stan- dards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri- can National Standards Institute, 1430 Broadway, New York, NY 10018

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Date: November 15, 2001 1-3 GENERAL INFORMATION 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 Associa- tion, 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 Associa- tion, 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

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 contribue à l’efficacité de fonctionnement du système.

ATTENTION Toute procédure pouvant résulter

l’endommagement du matériel en cas de non- respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au person- nel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

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• Eloignez toute fumée et gaz de votre zone de respira- tion. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer.

(La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser 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 soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou in- flammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons

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Date: November 15, 2001 1-5 GENERAL INFORMATION ultra-violets très forts. Ces rayons d’arc nuiront à vos

yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que 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 TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superin- tendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRA- VAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American Na- tional Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American Na- tional Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Pro- tection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la Na- tional Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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GENERAL INFORMATION 1-6 Date: November 15, 2001 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ 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 Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

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Date: November 15, 2001 1-7 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro- pean Council Directive 89/336/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.

* 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 to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* 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

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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: November 15, 2001

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Manual 0-2724 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the CutMaster 80XL Plasma Cutting Power Supply. Service of this equipment is restricted to Thermal Dynamics 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 understand- ing of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2.02 General Description

The power supply provides 60 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle and a work cable with clamp.

The power supply can be ordered in various configura- tions with various options factory installed. Refer to Sec- tion 2.04 for a list of power supply options and accessories.

A-02837

Power Supply

Torch and Leads

Work Cable With Clamp

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 Output Cur- rent Control

2. Front Panel LED Indicators AC, TEMP, GAS, DC 3. Rear Panel

Input power cable with strain relief, gas connection and Gas Regulator/Filter Assembly

4. Input Power

Available for the following input power:

208/230 VAC (±10%), 50/60 Hz, Three-Phase 380-415 VAC (±10%), 50/60 Hz, Three-Phase 460 VAC (±10%), 50/60 Hz, Three-Phase

Supplied with 4-conductor Input Power Cable with filtering beads.

5. Output Power

Continuously variable from 15 to 60 Amps maximum 6. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary in- put voltage (AC) is low or the DC voltage is higher than shown in the chart.

Ambient Temperature

104° F (40° C)

Duty Cycle 45% 60% 100%

Current 60 Amps n/a n/a

DC Voltage 120 vdc n/a n/a CutMaster 80XL Duty Cycle

7. Cut Capacity

7/8 inch (22.2 mm); 1-1/4 inch (31.8 mm) severance 8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

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INTRODUCTION 2-2 Manual 0-2724 9. Weight

72 lbs (32.7 kg) 10. Overall Dimensions

18.9" (480 mm) High x 10" (254 mm) Wide x 23.5"

(597 mm) Long

Overall dimensions are with handle installed.

B. Gas Regulator/Filter Assembly Specifications

The following specifications apply to the Gas Regu- lator/Filter Assembly only:

1. Maximum input gas pressure 125 psi (8.6 bar)

2. Filter

Coalescent type filter

2.04 Power Supply 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

A Two 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 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.

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Manual 0-2724 3-1 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION PROCEDURES

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 Acces- sories are given in Manuals specifically provided for those units.

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.

The complete installation consists of:

1. Site selection 2. Unpacking

3. Connections to Power Supply a. Input power

b. Gas c. Work cable d. Torch Leads 4. Grounding 5. Operator training

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 front panel to the rear panel. Air flow must not be ob- structed. Provide at least 2 feet (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 access 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 Torch are factory installed.

Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping.

A. Power Supply

Included with each power supply is Input Power Cable;

Work Cable and Clamp; Pressure Regulator/Filter As- sembly and connection hardware; Operating Manual.

B. Torch and Leads

Included with each Torch is Torch and Leads with Torch Handle Assembly, Shield Cup, Tip, Electrode, Gas Dis- tributor and all connectors installed; Torch Spare Parts Kit; and Instruction Manual.

C. Options and Accessories

Options and Accessories are packaged separately if not installed at the factory.

D. Unpacking Procedure

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list 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 system installation.

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INSTALLATION PROCEDURES 3-2 Manual 0-2724

3.04 Lifting Options

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-ener- gized supply line before moving unit.

FALLING EQUIPMENT can cause serious per- sonal injury and equipment damage.

HANDLE is not for mechanical lifting.

This unit is equipped with one handle mounted on top of the enclosure for hand carrying purposes only.

• Lift unit with the handle on top of the enclosure.

• Only persons of adequate physical strength should lift the unit.

• Use hand cart or similar device of adequate capacity.

• If using a fork lift vehicle, place and secure unit on a proper skid before transporting.

• Be sure unit is lifted and transported safely and se- curely.

3.05 Input Power Connections

The Power Supply accepts input voltages from 208 VAC to 460 VAC, 50/60 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 electric codes. Recommended circuit protection and wiring requirements are shown in Appendix 1.

C. Opening Power Supply Enclosure

The Cover of the Power Supply must be removed for access to the input power connections inside the unit.

WARNING

Disconnect primary power at the source before as- sembling or disassembling the Power Supply, torch parts, or torch and leads assemblies.

A-02220

Mounting Screws

Handle

Leads Wrap

Figure 3-1 Handle and Leads Wrap Removal 1. Remove the screws securing the Handle and the Leads

Wrap to the top of the Cover.

2. Remove the screws which secure the Cover to the frame assembly.

3. Carefully pull the Cover up and away from the unit to gain access to the inside of the unit.

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Manual 0-2724 3-3 INSTALLATION PROCEDURES Cover

Cover Screws (5 Places On Each Side)

A-02260

Figure 3-2 Cover Removal

3.06 Input Voltage Selection

The Power Supply has three voltage settings;

208/230VAC, 380-415VAC, or 460VAC. Power Supplies are factory-wired for 380-415VAC three-phase input. In- put voltage selection is accomplished by switching a wire harness connector inside the Power Supply.

WARNING

Disconnect primary power at the source before as- sembling or disassembling the power supply, torch parts, or torch and leads assemblies.

Move the Voltage Selection Plug to the desired Voltage Selection Connection for 208/230V, 380-415V, or 460V operation per the label attached to the panel.

Voltage Selection Plug 380-415 Volts 460 Volts

208/230 Volts

A-02261

Voltage Selection Connectors

Voltage Selection 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 power source, power cable, and plug all must conform to local electric code and the rec- ommended circuit protection and wiring require- ments (refer to Appendix 1).

1. Strip back the outer covering approximately 3 inches (76 mm) to expose the individual wires at the free end of the cable.

2. Cut back the insulation on the individual wires approximately 1/8 - 3/16 inch (3-5 mm).

3. Connect the ends of the individual wires to a customer supplied plug or main disconnect as follows:

• Brown wire to Line 1 (Live)

• Blue wire to Line 2 (Live)

• Black wire to Line 3 (Live), refer to Note above

• Green/Yellow wire to Ground (Earth)

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3.08 Gas Connections

A. Gas Requirements

WARNING

This unit not to be used with oxygen (O₂).

Gases: Compressed Air or Nitrogen (N2) Only Pressure: 60 psi (4.1 bar)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

Flow: Cutting and Gouging - 300 scfh (141.5 lpm) (scfh = standard cubic feet/hour)

B. Gas Connection

The gas supply is connected to the rear of the Power Sup- ply.

CAUTION

The 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.

Filtering is required when using air from a com- pressor to insure that moisture and debris from the supply hose does not enter the torch. It is recom- mended to order the Optional Two Stage Air Line Filter for air filtering.

1. Locate the 1/4 NPT hose barb fitting shipped inside the Torch Spare Parts Kit.

2. Depending on the options installed at the factory, install the supplied barb fitting into the gas connector 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 fit- ting threads, according to manufacturer's instruc- tions. 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. Tighten the barbed fitting.

4. Place an adjustable hose clamp (customer supplied) over the gas supply hose.

Regulator/Filter Assembly

1/4 NPT to #4 (6 mm) Hose Fitting

#4 (6 mm) Gas Supply Hose

Hose Clamp

A-01149

Figure 3-4 Gas Connection To Standard Air Filter Assembly

Two Stage Filter Assembly 1/4 NPT to

#4 (6mm) Hose Fitting

#4 (6mm) Gas Supply Hose Hose Clamp

A-01150

Figure 3-5 Gas Connection To Optional Two Stage Filter Assembly

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Manual 0-2724 3-5 INSTALLATION PROCEDURES 5. Refer to the following when using high pressure

gas cylinders as the gas supply:

CAUTION

Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.

Do not use an air line filter with high pressure gas cylinders.

a. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure gas regulators.

b. 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.

c. 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 300 scfh (141.5 lpm).

6. Slide the gas supply hose over the barb fitting installed in Step 2. Supply hose must be at least #4 hose (1/4 in or 6 mm I.D.).

7. Secure the gas supply hose in place with the adjustable hose clamp.

3.09 Connecting Torch Leads

CAUTION

This system is designed for use with the PCH/M- 102 torch only. Do not connect 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 torch leads were not factory-installed, make all torch connections to the Torch Bulkhead Panel for the desired application.

Equipment ordered as a system will have the Torch factory connected to the Power Supply.

A. Hand Systems

WARNING

1. Remove the Cover of the power supply for access to the torch bulkhead panel.

2. Remove the retaining nut from the strain relief supplied on the end of the Torch Leads.

Retaining Nut Strain Relief

Torch Leads Assembly

A-02836

Figure 3-6 Torch Strain Relief RetainingNut 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.

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INSTALLATION PROCEDURES 3-6 Manual 0-2724 Adapter

(Supplied With Power Supply)

Pilot Lead

Torch Lead Assembly

Negative/Plasma Lead Adapter

Connector Pilot Lead Stud

Negative/Plasma Lead Connection

A-02825

Control (PIP) Circuit Connectors

Figure 3-7 Torch Lead Connections

6. Connect the PIP Cables to the mating connectors on the Adapter supplied on the Power Supply.

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 the above Step.

9. Tighten the Strain Relief onto the Torch Leads.

10. Check the torch for proper parts assembly.

11. Re-install the Power Supply Cover.

B. Machine Systems (Unshielded Leads)

WARNING

2. Remove the strain relief nut from the Strain Re- lief.

Strain Relief Nut Strain Relief

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 Adapter through the Strain Relief Nut.

b. Continue routing the connector out the hole in the front panel 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.

Adapter (Supplied With Power Supply)

Pilot Lead

Torch Lead Assembly

Negative/Plasma Lead Adapter Connector

Pilot Lead Stud Negative/Plasma Lead Connection

A-02828

Control (PIP) Circuit Connectors

Shield Connectors (Not Used)

Remote Cable Connector

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Manual 0-2724 3-7 INSTALLATION PROCEDURES 4. Connect the torch Negative/Plasma Lead to the

bulkhead connection inside the Power Supply.

5. Connect the Control (PIP) Circuit Connectors to the mating connectors on the Adapter supplied on the Power Supply (see Warning).

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 need to be taped out of the way to prevent contacting the Negative/Plasma or Pilot Leads.

10. Re-install the Power Supply Cover.

C. Machine Systems (Shielded Leads)

WARNING

2. Remove the strain relief nut from the Strain Re- lief.

Strain Relief Nut

Strain Relief

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 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.

Adapter (Supplied With Power Supply)

Pilot Lead

Torch Lead Assembly

Negative/Plasma Lead Adapter Connector

Pilot Lead Stud Negative/Plasma Lead Connection

A-02829

Control (PIP) Circuit Connectors Shield Connectors

4. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.

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INSTALLATION PROCEDURES 3-8 Manual 0-2724 5. Connect the PIP and Shield Cables to the mating

connectors on the Adapter supplied on the Power Supply.

10. Re-install the Power Supply Cover on the Power Supply.

3.10 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 (42 mm²) 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. Ide- ally 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.

Wires of long length will have increased resistance to RF frequencies. Smaller diameter wire has in- creased resistance to RF frequencies, so using a larger diameter wire is better.

2. Components that are mounted on the cutting machine;

CNC controller, plasma remote controls, height controllers, remote arc starters, etc., should be grounded to the cutting machine frame (chassis) with at least a 12 AWG (4 mm²) wire. Flat copper braid works even better.

3. The cutting machine frame is then connected to the

“Star” point using AWG 6 (13,3 mm²) 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 recommend that the Plasma Power Supply be within 20 - 30 ft (6,1 – 9,1 mm) 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 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 (53,5 mm²) 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.

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Manual 0-2724 3-9 INSTALLATION PROCEDURES To test for a proper earth ground using 115 VAC, re-

fer to the following diagram. Ideally, the reading on the multimeter should be 3.0 VAC or less.

3.0

VR COM A A-02971

+ _

V~

Meter set to VAC setting

Machine Earth Ground Neutral

Line (Hot)

100W Light Bulb 115 VAC

WARNING Use extreme caution. This

test uses live voltage.

Figure 3-12 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 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 mo- tors, 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.

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Manual 0-2724 4-1 OPERATION

SECTION 4:

OPERATION

4.01 Introduction

This Section provides a description of the Power Supply operating controls and procedures. Identification of the Front and Rear Panel components is followed by operating procedures.

4.02 Operating Controls

This subsection provides specific functional descriptions of the Power Supply operating controls and indicators.

A. Front Panel

1. Control Panel

All operator controls, except gas pressure adjustment, are located on this panel. Power ON/OFF and RUN/

SET switches; CURRENT control; LED indicators for AC Power, TEMP, GAS, and DC.

A-02228

1 2

3 4

5

Figure 4-1 Front Panel Controls

2. Torch Leads Input

Torch leads boot and hole in the front panel to allow feeding the torch leads through to an internal bulkhead for connecting the torch leads.

3. Work Cable and Clamp

Work 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 ON RUN

OFF

A

CURRENT

15 60

35

A-02229

3 4

5 6 7

Figure 4-2 Operating Controls

1. Current Control

Adjustment to set the desired output current between 15-60 amps. For drag cutting applications set the control between 15 - 35 amps.

2. ON/OFF Power Switch

ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits.

3. RUN/SET Switch

RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.

4. AC Power Indicator

Green LED indicator will blink ON then 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.

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OPERATION 4-2 Manual 0-2724 5. TEMP Indicator

Normally OFF. Yellow LED indicator will come ON when the internal temperature sensors detect tem- peratures above normal limits. The unit should be allowed to cool before continuing operation.

6. GAS Indicator

Green LED indicator will come ON when the input gas pressure is set to 45 psi (3.1 bar) or higher. Indi- cator will be OFF when the pressure falls below 45 psi (3.1 bar).

7. DC Indicator

Green LED indicator will come ON while the torch switch is pressed.

8. CURRENT Control Knob Guards

Two guards used to prevent damage to the CUR- RENT Control Knob.

C. Torch Bulkhead Panel

The torch bulkhead panel area is located behind the Front Panel and requires removal of the Power Supply Cover for access.

1. Negative/Plasma Lead Connection

Connects the torch negative/plasma lead to the 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 4-4 Rear Panel With Standard Air Filter Installed

2. EMC Primary Input Power Cable and Strain Relief Supplied EMC primary input power cable and strain relief. Input power cable is capable of handling up to 460 VAC, three-phase, input power.

3. Gas Pressure Regulator/Filter Assembly

Pressure regulator to adjust the input gas pressure to the Power Supply. An air line filter is supplied as part of the Pressure Regulator.

4. Optional Two Stage Air Line Filter

The optional filter will remove moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least 5 microns.

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Manual 0-2724 4-3 OPERATION

A-01152

1

3

4

2

Figure 4-5 Rear Panel With Optional Two Stage Air Filter Installed

4.03 Sequence Of Operation

The following is a typical sequence of operation for this cutting system. Refer to Appendix 2 for a block diagram.

1. Close main power source disconnect.

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.

a. AC Power indicator LED blinks ON and OFF for eight seconds then stays ON.

b. Fans turn on.

4. Place RUN/SET switch to SET mode.

a. Gas solenoid opens and gas flows to set pressure.

b. GAS indicator turns ON.

NOTE

GAS indicator will not come ON if the gas pres- sure is set below 45 psi (3.1 bar) at the Regulator/

Filter Assembly.

5. Place RUN/SET switch to RUN mode.

a. Gas flow stops.

b. GAS indicator turns OFF.

6. 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, while still having torch switch activated, the main arc will stop and the pilot arc will automatically restart.

11. Release or deactivate the torch switch.

a. Main arc stops.

NOTE

If torch is activated during post-flow, pilot arc will immediately restart.

If torch is within 3/8 in (9.5 mm) transfer distance of workpiece, main arc will transfer.

12. Gas will flow for 15 seconds (post-flow).

a. Gas solenoid closes.

b. Gas flow stops.

c. 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.

b. Fans turn OFF.

14. Place the main power disconnect to open.

a. Main AC power is removed from the system.

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OPERATION 4-4 Manual 0-2724

4.04 Preparations for Operating

Follow this set-up procedure each time the system is operated:

WARNING

Disconnect primary power at the source before dis- assembling the power supply, torch, or torch leads.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate front end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging). Refer to the Instruction Manual supplied with the Torch Assembly for proper parts selection.

B. Check primary power source as follows:

1. Check the power source for proper input voltage.

Make sure the input power source meets the power requirements for the unit per Section 2.03-A-4, Speci- fications/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 gas (air or nitrogen). Make sure gas source meets pressure and flow requirements (refer to Section 3.08, Gas Connections). Check connection and turn gas supply on.

D. Work Cable Connection

Check for a solid and clean work cable connection to the workpiece. The area must be free from paint and rust.

Make a solid work cable connection to the workpiece or cutting table

A-00925

Figure 4-6 Work Cable Connection To Workpiece

E. Torch Connection

Check that the torch is properly connected.

F. Purge the System (Gas Pre-Flow)

Move the ON/OFF switch to ON position. To start 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 for drag cutting

H. Set Operating Pressure

Move the RUN/SET switch to SET position. Adjust the gas pressure to 60 psi (4.1 bar).

I. RUN/SET Switch

Set the RUN/SET switch to RUN position.

The system is now ready for operation.

4.05 Cut Quality

Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation.

The following cut quality characteristics are illustrated in Figure 4-7 below:

Cut Surface

The condition (smooth or rough) of the face of the cut.

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Dross Build-up and Top Spatter

Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece.

Excessive dross may require secondary clean-up opera- tions after cutting.

Plasma Cutting Power Supply

December 4, 2002 Manual No. 0-2724