Thermal Dynamics Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100 Manuel utilisateur

Marque: Thermal Dynamics

Modèle: Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100

Catégorie: Système de soudage

Taper: Manuel utilisateur

Plasma Cutting

Power Supply

CE CutMaster

100

A-02766

April 21, 2003 Manual No. 0-2844

Operating Manual

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.

Plasma Cutting Power Supply

CE CutMaster™ 50

CE CutMaster™ 75

CE CutMaster™ 100

Operating Manual Number 0-2844

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

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: April 21, 2003

Record the following information for Warranty purposes:

Where Purchased:_________________________________________

Purchase Date:____________________________________________

Model Number:____________________________________________

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

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference............................................................................ 1-5

1.07 Declaration of Conformity............................................................................. 1-7

1.08 Statement of Warranty.................................................................................. 1-8

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 PROCEDURES ....................................................................................... 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......................................................................................... 3-2

3.07 Torch Connections ....................................................................................... 3-4

3.08 Ground Connections For Mechanized Applications ...................................... 3-6

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 Product Features.......................................................................................... 4-1

4.03 Preparations For Operating .......................................................................... 4-2

4.04 Sequence of Operation ................................................................................ 4-3

SECTION 5:

CUSTOMER/OPERATOR 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 Basic 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: ROUTINE MAINTENANCE SCHEDULE...........................................................A-4

APPENDIX 5: SYSTEM SCHEMATIC (CE CutMaster 50) ........................................................A-6

APPENDIX 6: SYSTEM SCHEMATIC (CE CutMaster 75) ........................................................A-8

APPENDIX 7: SYSTEM SCHEMATIC (CE CutMaster 100) ....................................................A-10

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 follow-

ing:

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 in-

formation 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 com-

bustible 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 de-

fects 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 op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

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 ma-

terial 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 pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective 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 hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect 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

Date: November 15, 2001 1-3 GENERAL INFORMATION

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtain-

able 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, ob-

tainable 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.

GENERAL INFORMATION 1-4 Date: November 15, 2001

• 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 combus-

tibles 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 tra-

vail 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 tra-

vail 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 com-

bustibles 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

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

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

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

mark conform to EN50192

when used in conjunction with hand torches with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing 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 1-8 Date: November 15, 2001

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

Manual 0-2844 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions

and basic maintenance procedures for the CE CutMaster

Plasma Cutting Power Supply only. Servicing of this

equipment is restricted to properly trained personnel; un-

qualified personnel are strictly cautioned against attempt-

ing 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 equip-

ment 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 includes all control circuitry, electri-

cal and gas inputs and outputs, pilot circuitry, primary

input power cable, and work cable & clamp.

NOTE

Refer to Section 2.04 for a list of power supply op-

tions and accessories.

A-02766

CE CutMaster Power Supply

2.03 Specifications/Design Features

A. Power Supply Technical Specifications

The following specifications apply to the Power Supply

only:

1. Front Panel Features

• Main power ON/OFF switch

• RUN/SET switch

• output current control

• torch leads access

• work lead

2. Rear Panel Features

• Primary input power cable

• gas pressure regulator/filter assembly

• gas supply connection

• Grounding stud (CE CutMaster 75 & 100)

3. Front Panel LED Indicators

AC, TEMP, GAS, DC

4. Input Power (See Note)

400VAC (±10%), Three Phase. Power Supply includes

4-conductor input power cable with filtering beads.

NOTE

Refer to Appendix 1 for input wiring requirements.

5. Output Power

Continuously variable.

• CE CutMaster 50: from 20 to 40 amps maximum.

• CE CutMaster 75: from 15 to 60 amps maximum.

• CE CutMaster 100: from 20 to 80 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.

CE CutMaster 50 Power Supply:

Ambient

Tem

erature

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

Duty Cycle

40% 60%

100%

Current

40 Amps 33 Amps n/a Amps

DC Voltage

110 vdc 105 vdc

n/a vdc

CE CutMaster 50 Power Supply Duty Cycle

INTRODUCTION 2-2 Manual 0-2844

CE CutMaster 75 Power Supply:

Ambient

Tem

erature

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

Duty Cycle

50% 60%

100%

Current

60 Amps 60 Amps

45 Amps

DC Voltage

109 vdc 109 vdc

98 vdc

CE CutMaster 75 Power Supply Duty Cycle

CE CutMaster 100 Power Supply:

Ambient

Tem

erature

104° F

(40° C)

104° F

(40° C)

104° F

(40° C)

Duty Cycle

35% 60%

100%

Current

80 Amps 68 Amps

45 Amps

DC Voltage

112 vdc 111 vdc

98 vdc

CE CutMaster 100 Power Supply Duty Cycle

7. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

8. Overall Dimensions (incl. handles) and Weight

CE CutMaster 50 CE CutMaster 75, 100

Length: 22.5 in. (572 mm) 27.5 in (696 mm)

Width: 10.75 in (273 mm) 12.4 in (315 mm)

Height: 16.37 in ( 416 mm) 17.3 in (439 mm)

Weight: 54 lb (24.5 kg) 85 lb (38.5 kg)

CE CutMaster Dimensions and Weights

Weight includes Power Supply w/Input Cable, Work

Lead, and Torch & Leads.

B. Gas Regulator/Filter Assembly

Specifications

The following specifications apply to the standard Gas

Regulator/Filter Assembly only:

1. Operating Pressure (Output)

70 psi (4.8 bar)

2. Maximum input gas pressure

125 psi (8.6 bar)

3. 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 cata-

log 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 contami-

nants 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 factory installed 20 ft (6.1 m)

work cable & clamp on the power supply, a 50 ft

(15.2 m) work cable with clamp is available.

D. Wheel Kit (CE CutMaster 50 only)

A kit with easy-rolling wheels, for maximum portabil-

ity 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.

Manual 0-2844 3-1 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

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 informa-

tion.

This Section describes installation of the Power Supply

and connecting the Torch.

These instructions apply to the Power Supply only; in-

stallation procedures for the Torch, Options, and Acces-

sories 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

3.02 Site Selection

Select a clean, dry location with good ventilation and ad-

equate 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 con-

trols.

CAUTION

Operation without proper air flow will inhibit

proper cooling and reduce duty cycle.

3.03 Unpacking

The product is packaged and protected to prevent dam-

age during shipping.

1. Unpack each item and remove any packing material.

2. Locate the packing list(s) and use the list(s) to iden-

tify 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 instal-

lation.

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-ener-

gized supply line before moving unit.

HANDLE is not for mechanical lifting.

FALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.

• Only persons of adequate physical strength should

lift the unit.

• Lift unit by the handle, using two hands.

• Install optional wheel kit (CE CutMaster 50 only)

or use multi-purpose cart or similar device of ad-

equate capacity to move unit.

• Place and secure unit on a proper skid before trans-

porting with a fork lift or other vehicle.

INSTALLATION PROCEDURES 3-2 Manual 0-2844

3.05 Primary Input Power

Connections

The CE CutMaster

Power Supply operates on three

phase, 400VAC (± 10%), input power.

CAUTION

The primary power source and power cable must

conform to local electrical code and the recom-

mended circuit protection and wiring requirements

(refer to table in Appendix 1).

The Power Supply is equipped with a three-phase, four

conductor, input EMC power cable attached. Connect

the cable to the customer's power source as follows:

NOTE

The input power cable must not be modified in any

way as filtering beads are installed on the cable.

1. The outer covering of the cable is stripped back

approximately 3 inches (76 mm) at the factory 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 cus-

tomer supplied plug or main disconnect per the

following:

NOTE

All the input cable wires must be connected for

three-phase operation.

• Blue wire to Line 2 (Live)

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

• Brown wire to Line 1 (Live)

• Green/Yellow wire to Ground (Earth)

4. (CE CutMaster 75, CE CutMaster 100 only): Con-

nect a customer-supplied grounding cable to the

grounding stud on the rear panel as required by

applicable Local and National Codes or local au-

thority having jurisdiction. Grounding stud is

identified with this symbol:

5. Connect the input power cable (or close the main

disconnect switch) to supply power to the system.

3.06 Gas Connections

A. Gas Requirements

WARNING

This unit is not to be used with oxygen (O

Gases: Single Gas - Plasma/Secondary

Compressed Air or Nitrogen (N2) Only

CAUTION

Maximum pressure at inlet must not exceed 125

psi (8.6 bar)

Output Pressure

Flow

(Cutting)

Flow

(Gouging)

CE CutMaster 50 70 psi (4.8 bar)

200 scfh

(94.4 lpm)

230 scfh

(108.5 lpm)

CE CutMaster

75, 100

70 psi (4.8 bar)

400 scfh

(188.8 lpm)

400 scfh

(188.8 lpm)

CE CutMaster Gas Requirements

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!

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 com-

plete torch failure. Contaminants may cause poor

cutting performance and rapid electrode wear.

C. Connecting Gas Supply to Unit

The gas supply is connected to the Regulator/Filter As-

sembly located on the rear of the unit. The connection is

the same for compressed air or high pressure gas cylin-

ders.

Connect the gas supply as follows:

1. If an optional air line filter is to be installed, refer to

procedures in subsection 3.06-D.

2. Connect the gas line to the filter. A typical installa-

tion using a barbed fitting is illustrated; other fittings

may be used.

Manual 0-2844 3-3 INSTALLATION PROCEDURES

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. Connect the gas line to the Regulator/Filter Assem-

bly.

A-02999

Hose Clamp

1/4 NPT to 1/4"

(6mm) Fitting

Regulator/Filter

Assembly

Inlet Port

Gas Supply

Hose

Bowl

Gas Connection to Regulator/Filter Assembly

D. Installing Optional Air Filter Kits

Additional filtering is recommended when using air from

a compressor to insure that moisture and debris from the

supply hose does not enter the torch. Although the Regu-

lator/Filter Assembly does have its own filter, the op-

tional Single-Stage Air Filter Kit or optional Two-Stage

Air Filter Kit are recommended for improved filtering.

1. Optional Single-Stage Air Filter Kit

This optional in-line air filter for use on compressed

air shop systems is highly effective at removing mois-

ture and particulate matter from the air stream to at

least 0.85 microns.

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. Connect the

gas supply as follows:

a. Attach the Single-Stage Filter Hose to the Regu-

lator/Filter Assembly inlet port as shown be-

low.

b. Connect the gas line to the optional filter. A

typical installation using a barbed fitting is il-

lustrated; other fittings may be used.

c. Attach the gas supply hose to the Single-Stage

Filter Assembly.

A-03000

Regulator/Filter

Assembly

Inlet Port

Bowl

1/4 NPT Hose Fitting

1/4" (6 mm) Gas Supply Hose

Hose Clamp

Optional Single Stage Filter Installation

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 mois-

ture 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 barbed

fitting threads according to manufacturer's in-

structions. 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 be-

low.

c. Connect the gas line to the optional filter. A

typical installation using a barbed fitting is il-

lustrated; other fittings may be used.

d. Attach the gas supply hose to the Two-Stage

Filter Assembly.

INSTALLATION PROCEDURES 3-4 Manual 0-2844

A-03004

Regulator/Filter

Assembly

Hose

Clamp

1/4 NPT

Hose Fitting

1/4" (6 mm) Gas

Supply Hose)

2-Stage Filter

Inlet Port (IN)

Outlet Port

(OUT)

Regulator Inlet Port

Two Stage

Filter

Assembly

Optional Two-Stage Filter Installation

E. Using High Pressure Gas Cylinders

Refer to the following when using high pressure gas cyl-

inders as the gas supply:

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 in-

stallation 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 mate-

rial. 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

and flows as follows:

Maximum

Pressure

Flow

Rate

CE CutMaster 50 100 psi (6.9 bar) 200 scfh

CE CutMaster 75 100 psi (6.9 bar) 400 scfh

CE CutMaster 100 100 psi (6.9 bar) 400 scfh

CE CutMaster Cylinder Gas Requirements

4. Connect the gas supply hose to the cylinder valve.

NOTE

Supply hose must be at least 1/4 inch (6 mm) I.D.

3.07 Torch Connections

Equipment ordered as a system will have the Torch fac-

tory 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.

A. Hand Systems

WARNING

Disconnect primary power at the source before dis-

assembling the torch or torch leads.

1. Remove the Cover of the Power Supply to gain

access to the Torch Bulkhead Panel. See Section

5.05.

2. Remove the retaining nut from the Strain Relief.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-03529

Negative /

Plasma Lead

Pilot Lead

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 re-

moved earlier.

5. Connect the torch Negative/Plasma Lead to the

bulkhead connection inside the Power Supply.

Manual 0-2844 3-5 INSTALLATION PROCEDURES

Adapter

Plug

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma Lead

Connection

A-03527

Control Circuit

Connectors

Note: Actual Bulkhead

configuration may

differ from that shown.

Torch Lead Connections To Bulkhead

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.

B. Machine Systems (Unshielded Leads)

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 Re-

lief.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-03567

Negative /

Plasma Lead

Pilot Lead

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.

Adapter

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter Connector

Negative/Plasma

Lead Connection

A-03528

Control Circuit

Connectors

Remote

Cable

Connector

Not

Used

Not

Used

Torch Lead Connections To Bulkhead

INSTALLATION PROCEDURES 3-6 Manual 0-2844

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 must be taped out of the way to pre-

vent contacting the Negative/Plasma or Pilot

Leads.

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. Re-install 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 fac-

tory to the mating connector on the Power Supply

Bulkhead area. The other end allows connection of a

Remote Pendant. The remote pendant lead connec-

tor 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 con-

nector provided on the Adapter from the Power Sup-

ply.

Torch Control

Cable Connector

Remote Pendant/CNC

Cable Connector

PIP

Circuit

Control

OK-To-Move

A-01366

Remote Pendant Connector Diagram

NOTE

Refer to Appendix 3, Torch Control Cable Wiring

Diagram For Mechanized Systems, for detailed

schematic of the Adapter.

3.08 Ground Connections For

Mechanized Applications

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electro-

magnetic interference (EMI), commonly called RF noise.

This RF noise may interfere with other electronic equip-

ment such as CNC controllers, remote controls, height

controllers, etc. To minimize RF interference, follow these

grounding procedures when installing mechanized sys-

tems:

B. Grounding

1. The preferred grounding arrangement is a single point

or “Star” ground. The single point, usually on the

cutting table, is connected with 1/0 (42 mm

) or larger

wire to a good earth ground (refer to paragraph ‘C’,

Creating An Earth Ground). The ground rod must be

placed as close as possible to the cutting table. Ide-

ally this is 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.

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Thermal Dynamics Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100 Manuel utilisateur

Marque: Thermal Dynamics

Modèle: Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100

Catégorie: Système de soudage

Taper: Manuel utilisateur

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Thermal Dynamics Plasma Cutting Power Supply CE CutMaster™ 50 CE CutMaster™ 75 CE CutMaster™ 100 Manuel utilisateur

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