Thermal Dynamics CE CutMaster 100 Operating instructions

Brand: Thermal Dynamics

Model: CE CutMaster 100

Category: Welding System

Type: Operating instructions

Operating Manual

Plasma Cutting

Power Supply

CutMaster™ 100

March 22, 2004 Manual No. 0-2859

A-02991

Plasma Cutting Power Supply

CutMaster™ 100

Operating Manual Number 0-2859

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

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: March 22, 2004

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.

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.07 Declaration of Conformity ............................................................................. 1-4

1.08 Statement of Warranty .................................................................................. 1-5

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description ...................................................................................... 2-1

2.03 Specifications/Design Features .................................................................... 2-1

2.04 Power Supply Options and Accessories ....................................................... 2-2

SECTION 3:

INSTALLATION 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 .......................................................................................... 3-3

3.07 Torch Connections ........................................................................................ 3-5

3.08 Ground Connections For Mechanized Applications ....................................... 3-8

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 Replacement Parts ....................................................................................... 6-2

6.05 Options and Accessories.............................................................................. 6-2

APPENDIX 1: INPUT WIRING REQUIREMENTS ..................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... A-2

APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM.................................................. A-3

APPENDIX 4: MAINTENANCE SCHEDULE ............................................................................. A-4

APPENDIX 5: SYSTEM SCHEMATIC, 208/230 VOLT UNITS .................................................. A-6

APPENDIX 6: SYSTEM SCHEMATIC, 400 and 460 V UNITS.................................................. A-8

APPENDIX 7: SYSTEM SCHEMATIC, 600 VOLT UNITS....................................................... A-10

January 27, 2004 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. Persons who

work near plasma arc cutting applications should

consult their medical health professional and the

manufacturer of the health equipment to determine

whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and instruc-

tions before using the equipment. Call 1-603-298-

5711 or your local distributor if you have any ques-

tions.

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, pro-

duces 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 January 27, 2004

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any ser-

vice 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 mate-

rial 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 underwa-

ter or while using a water table. DO NOT cut alu-

minum alloys underwater or on a water table un-

less the hydrogen gas can be eliminated or

dissipated. Trapped hydrogen gas that is ignited

will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc 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 workpiece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C.

20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding 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. Government

Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National 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

January 27, 2004 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

GENERAL INFORMATION 1-4 January 27, 2004

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.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit

and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* 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: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

January 27, 2004 1-5 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in

workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation

charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall

be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001

GENERAL INFORMATION 1-6 January 27, 2004

Manual 0-2859 2-1 INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions

and basic maintenance procedures for the Thermal Dy-

namics CutMaster 100 Plasma Cutting Power Supply

only. Servicing of this equipment is restricted to prop-

erly trained personnel; unqualified personnel are strictly

cautioned against attempting repairs or adjustments not

covered in this manual, at the risk of voiding the War-

ranty.

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 for torch and cutting

information.

2.02 General Description

The power supply provides 80 amp maximum output and

includes all control circuitry, electrical and gas inputs and

outputs, pilot circuitry, primary input power cable, and

work cable & clamp.

Section 2.04 lists power supply options and accessories.

2.03 Specifications/Design Features

1. Input Power (See Note)

Available for the following input power:

• 208 / 230VAC (±10%), Single-Phase, 50/60 Hz

• 400VAC (±10%), Three-Phase, 50/60 Hz

• 460VAC (±10%), Three-Phase, 60 Hz

• 460VAC (±10%), Single-Phase, 60 Hz

• 600VAC, (517-632 VAC), Three-Phase, 60 Hz

NOTE

Refer to Appendix 1 for input wiring requirements.

Units ordered as 208/230V, single-phase, have an

input cable and plug factory installed.

2. Output Power

Continuously variable from 20 to 80 amps maximum.

3. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary input

voltage (AC) is low or the DC voltage is higher

than shown in the chart.

CutMaster 100, 208/230-Volt and 460-Volt Duty Cycle:

Ambient

Tem

erature 104° F

(40° C) 104° F

(40° C)

Duty Cycle 40% 60% 100%

Current 78 Amps 68 Amps 45 Amps

DC Voltage 120 vdc 111 vdc 98 vdc

CutMaster 100 208/230-Volt

and 460-Volt Power Su

Dut

cle

Cutmaster 100, 400-Volt Power Supply Duty Cycle:

Ambient

Tem

erature 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

CutMaster 100 400-Volt

Power Supply Duty Cycle

Cutmaster 100, 600-Volt Power Supply Duty Cycle:

Ambient

Tem

erature 104° F

(40° C) 104° F

(40° C)

Duty Cycle 35% 60% 100%

Current 78 Amps 68 Amps 43 Amps

DC Voltage 120 vdc 111 vdc 97 vdc

CutMaster 100 600-Volt

Power Supply Duty Cycle

4. Pilot Circuitry

Capacitive Discharge (CD), Ignition DC Pilot

5. Weight

83 lbs (37.6 kg)

Weight includes Power Supply w/Input Cable, Work

Lead, and Torch & Leads.

INTRODUCTION 2-2 Manual 0-2859

6. Overall Dimensions (including handles)

• Length: 27.5 inches (696 mm)

• Width: 12.4 inches (315 mm)

• Height: 17.3 inches (439 mm)

7. Gas Regulator/Filter Assembly Specifications

• Operating Pressure (Output): 70 psi (4.8 bar)

• Maximum input gas pressure: 125 psi (8.6 bar)

• Filter: Coalescent type filter

2.04 Power Supply Options and

Accessories

Refer to Section 6, Parts Lists, for catalog numbers and

ordering information.

A. Single Stage Air Filter Kit

For use with compressed air shop systems. Filters

moisture and particulate matter from the air stream

to at least 0.85 microns.

B. Two Stage Air Filter Kit

For use on compressed air shop systems. Filters mois-

ture and particulate matter from the air stream to at

least 5.0 microns.

C. High Pressure Regulators

High pressure regulators are available. The regula-

tors are used to set the proper pressure for the type gas

being used.

NOTE

Regulators should not be installed with In-Line Air

Filters.

D. Extended Work Cable with Clamp

As an alternative to the standard 20 ft (6.1 m) work

cable & clamp on the power supply, a 50 ft (15.2 m)

work cable with clamp is available.

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 0-2859 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; in-

stallation 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 in-

structions 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. 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.

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 (61 cm) in the rear

and at least 6 inches (152 mm) on each side for clearance.

Provide a minimum of 6 inches (or 152 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.

• Only persons of adequate physical strength should

lift the unit.

• Lift unit by the handle, using two hands.

• Use hand cart or similar device of adequate capac-

ity to move unit.

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

porting with a fork lift or other vehicle.

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.

INSTALLATION PROCEDURES 3-2 Manual 0-2859

3.05 Primary Input Power

Connections

Check the power source for correct voltage before con-

necting the unit.

A. 400-Volt, 460-Volt, or 600-Volt Power Supply

These Power Supplies are equipped with a four-conduc-

tor input power cable for three-phase input power. The

460-Volt Power Supply will accept 460-VAC, Single-Phase

input power with a change of input power cable.

For 400-Volt 460-Volt, or 600-Volt Three-Phase op-

eration:

1. Remove the Power Supply cover per section 5.05.

2. The cable's outer covering is stripped back at the

factory to expose the individual wires at the free

end of the cable.

3. Connect the ends of the individual wires to a cus-

tomer supplied plug or main disconnect as fol-

lows:

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). All the input cable

wires must be connected for three-phase operation.

• L1 wire to Line 1.

• L2 wire to Line 2.

• L3 wire to Line 3, refer to Caution above.

• Ground wire to Ground.

4. Replace the Power Supply cover.

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

disconnect switch) to supply power to the system.

For 460-VAC, Single-Phase operation:

1. Remove the Power Supply cover per section 5.05

2. Disconnect the original input power cable from

the main input contactor and the chassis ground

connection.

3. Loosen the strain relief on the back panel of the

power supply. Pull the original power cable out

of the power supply.

4. Pass a customer-supplied, three-conductor input

power cable through the access opening in the

back panel of the power supply. Refer to Appen-

dix 1 for power cable specifications. Tighten the

strain relief to secure the power cable.

CAUTION

The primary power source and power cable must

conform to local electrical code and the recom-

mended circuit protection and wiring requirements

(refer to table in Appendix 1).

5. Strip back the insulation on the individual wires.

6. Connect to main input contactor as follows:

• Line 1 wire to terminal L1.

• Line 3 wire to terminal L3.

7. Connect the ground wire to Ground (Earth). The

Ground wire connection requires a ring terminal.

A-03041

L1 L3

Ground Wire

with Ring

Terminal

Main Input

Contactor

Input Cable

L1 L2 L3

Input Power Connections, 460VAC, Single-Phase

8. Replace the Power Supply cover.

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

disconnect switch) to supply power to the system.

Manual 0-2859 3-3 INSTALLATION PROCEDURES

B. 208/230-Volt Power Supply

This power supply includes a factory-installed input

power cable and plug.

1. Check your power source for correct voltage before

plugging in the unit.

2. Connect the input power cable (or close the main dis-

connect switch) to supply power to the system.

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).

3.06 Gas Connections

A. Gas Requirements

WARNING

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

Gases: Single Gas - Plasma/Secondary

Compressed Air Only

Pressure: 70 psi (4.8 bar)

CAUTION

Maximum pressure at inlet must not exceed 125 psi

(8.6 bar)

Flow: Cutting - 400 scfh (190 lpm)

Gouging - 400 scfh (190 lpm)

scfh = standard cubic feet per hour.

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 to Power Supply

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

procedures in subsection 3.06-D.

Connect the gas supply as follows:

1. Use customer-supplied fittings to connect the gas line

to the Regulator/Filter. Typical fittings are shown;

other fittings may be used.

Art # 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

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.

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 has its own filter, the optional fil-

ter kits 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.

INSTALLATION PROCEDURES 3-4 Manual 0-2859

Art # 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

NOTE

For a secure seal, apply thread sealant to the fitting

threads, according to manufacturer's instructions.

Do Not use Teflon tape as a thread sealer as small

particles of the tape may break off and block the

small gas passages in the torch. Connect the gas

supply as follows:

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

lator/Filter Assembly inlet port as shown.

b. Attach the Single-Stage Filter Assembly to the

filter hose.

c. Use customer-supplied fittings to connect the

gas line to the Filter. A 1/4 NPT to 1/4" hose

barbed fitting is shown as an example.

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 bracket to the back

of the power supply per instructions supplied

with the filter assembly.

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.

b. Connect the two stage filter outlet hose to the

inlet port of the Regulator/Filter Assembly.

c. Use customer-supplied fittings to connect the

gas line to the Filter. A 1/4 NPT to 1/4" hose

barbed fitting is shown as an example.

Art # 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 adjust-

able high-pressure regulator capable of outlet

pressures up to 100 psi (6.9 bar) maximum and

flows of up to 400 scfh (190 lpm).

4. Use customer-supplied fittings to connect the gas

line to the cylinder.

NOTE

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

Manual 0-2859 3-5 INSTALLATION PROCEDURES

3.07 Torch Connections

NOTE

Equipment ordered as a system will have the Torch

factory connected to the Power Supply.

The instructions for connecting the Torch Leads to the

Power Supply are different depending on the type of

leads. This sub-section covers connecting the Torch for

the following applications:

A. Hand Systems

B. Machine Systems (Unshielded Leads)

C. Machine Systems (Shielded Leads)

D. 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 for ac-

cess to the Torch Bulkhead Panel. See Section 5.05.

2. Remove the retaining nut from the Strain Relief.

3. Feed the torch lead ends and the Strain Relief into

the hole in the front of the unit.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-03607

Negative /

Plasma Lead

Pilot Lead

Retaining Nut Removal

4. Secure the Strain Relief with the retaining nut re-

moved earlier.

5. Connect the Negative/Plasma Lead to the bulk-

head connection inside the Power Supply.

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma

Lead Connection

A-03608

Note: Actual Bulkhead

configuration may

differ from that shown.

Adapter

Control Circuit

Connectors

Torch Lead Connections To Bulkhead

6. Connect the Control 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. Reinstall the Power Supply Cover on the Power

Supply.

INSTALLATION PROCEDURES 3-6 Manual 0-2859

B. Machine Systems (Unshielded Leads)

1. Remove the Cover of the Power Supply for access

to the Torch Bulkhead Panel. See Section 5.05.

2. Remove the strain relief nut from the Strain Relief.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-03609

Remove Tie Wrap,

Remove Insulator,

Disconnect Wires

Strain Relief Nut Removal

3. Install the Torch Adapter 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.

5. If not previously done, remove the tie wrap from

the two mated and joined wires on the torch leads.

Disconnect the joined wires. Connect the Con-

trol Circuit Connectors to the mating connectors

on the Adapter supplied on the Power Supply.

Two wires on the Torch Leads remain unused.

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.

Power Supply Adapter

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Negative/Plasma

Lead Connection

A-03610

Control Circuit

Connectors

Remote

Pendant

Adapter Open

Open

Adapter

Connector

Pilot Lead

Stud

Torch Lead Connections To Bulkhead

A-03611

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Control Circuit

Connectors

Open

Power Supply Adapter

Wiring Connection Detail

8. Tighten the Strain Relief onto the Torch Leads.

9. Check the torch for proper parts assembly per the

torch manual.

CAUTION

The torch parts must correspond with the type of

operation. Refer to Section 4.04-A, Torch Parts

Selection.

10. Reinstall the Power Supply Cover.

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Thermal Dynamics CE CutMaster 100 Operating instructions

Brand: Thermal Dynamics

Model: CE CutMaster 100

Category: Welding System

Type: Operating instructions

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Thermal Dynamics CE CutMaster 100 Operating instructions

Thermal Dynamics CE CutMaster 100 Operating instructions

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