Thermal Dynamics CE CutMaster 101 Operating Manual
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Thermal Dynamics CE CutMaster 101 Operating Manual

Plasma cutting, power supply
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Plasma Cutting
Power Supply
CE CutMaster™ 101
A-03661
Operating Manual
January 6, 2004
Manual No. 0-2992

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Summary of Contents for Thermal Dynamics CE CutMaster 101

  • Page 1 Plasma Cutting Power Supply CE CutMaster™ 101 A-03661 Operating Manual January 6, 2004 Manual No. 0-2992...
  • Page 3 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™ 101 Operating Manual Number 0-2992 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2003 by Thermal Dynamics Corporation All rights reserved.

  • Page 4: Table Of Contents

    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 ................
  • Page 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 Parts ..............6-1 6.05 Options and Accessories ................6-2 6.06 Torch Parts ....................6-3 APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ......... A-1 APPENDIX 2: DATA TAG INFORMATION ................

  • Page 7: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 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.

  • Page 13: Declaration Of Conformity

    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.

  • Page 14: Statement Of Warranty

    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.

  • Page 15: Introduction

    This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dy- namics CE CutMaster 101 Plasma Cutting Power Supply only. Servicing of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not cov- ered in this manual, at the risk of voiding the Warranty.

  • Page 16: Input Wiring Specifications

    6" 6" 12.4 in / 150 mm 150 mm 315 mm A-03379 A-03572 2.03 Input Wiring Specifications CE CutMaster 101 Input Wiring Specifications Input Suggested Sizes (See Notes) Power Input Current Input Voltage Frequency 3-Ph 3-Ph Fuse (Amps) Wire (mm...

  • Page 17: Power Supply Features

    2.04 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-03578 Work Cable and Clamp Gas Pressure Regulator / Filter Assembly Gas Inlet Port Ports for Optional Automation Interface Cable Gas Pressure Gauge Art # A-03738 Input Power Cord Manual 0-2992 INTRODUCTION...

  • Page 18: Power Supply Options And Accessories

    2.05 Power Supply Options and Accessories Section 6, Parts Lists, provides 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.

  • Page 19: Section 3: Installation

    SECTION 3: INSTALLATION Unpacking 1. Use the packing lists to identify and account for each item. 2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or shipping company before proceeding with the installation. 3.

  • Page 20: Primary Input Power Connections

    Primary Input Power Connections CAUTION Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2.03.

  • Page 21: Air Connections

    Air Connections A. Connecting Air Supply to Unit Use only compressed air with this power supply. The connection is the same for compressed air from a compressor from high pressure cylinders. Refer to subsection 3.4-B or 3.4-C if an optional air line filter is to be installed. 1.
  • Page 22 B. Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port. 2.
  • Page 23 C. Installing Optional Two - Stage Air Filter Kit This optional two - stage air line filter is also for use on compressed air shop systems. Filter removes moisture and contaminants to at least 5 microns. Connect the air supply as follows: a.
  • Page 24 D. Using High Pressure Air Cylinders When using high pressure air cylinders as the air supply: 1. Refer to the manufacturer’s specifications for installation and maintenance procedures for high pressure regula- tors. 2. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foreign material. Briefly open each cylinder valve to blow out any dust which may be present.

  • Page 25: Torch Connections

    Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL60 or SL100 Torch (with ATC connector) to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
  • Page 26 B. Check Air Quality To test the quality of air: 1. Put the ON / OFF switch in the ON (up) position. 2. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position. 3. Place a welding filter lens in front of the torch and turn on the air. Any oil or moisture in the air will be visible on the lens.

  • Page 27: Section 4: Operation

    SECTION 4: OPERATION 4.01 Product Features A. Front Panel Controls and Indicators A) Output Current Control AC Indicator Sets the desired output current. Output settings up Steady light indicates power supply is ready to 40 Amps may be used for drag cutting (with the for operation.

  • Page 28: Preparations For Operating

    Power Supply (80 amps maximum). Refer to the Torch Manual. B. Torch Connection Check that the torch is properly connected. Only Thermal Dynamics model SL60 or SL100 Torches may be connected to this Power Supply. C. Check Primary Input Power Source 1.
  • Page 29 F. Power On Place the Power Supply ON / OFF switch to the ON (up) position. AC indicator turns on. Gas indicator turns on if there is sufficient air pressure for power supply operation. NOTE Minimum pressure for power supply operation is lower than minimum for torch operation. Art # A-03580 Manual 0-2992 OPERATION...
  • Page 30 Art # A -03577 2. Adjust air pressure per the settings chart. 70 - 75 psi / 4.5 - 5.2 bar Pressure Control Knob / Bouton De Contrôle CE CutMaster 101 de Pression Air Pressure Settings SL100 Leads (Hand Torch or...
  • Page 31 H. Select Current Output Level 1. Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Air flow stops. 2. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece), or up to 80 amps for standoff cutting.
  • Page 32 K. Postflow Release the trigger to stop the cutting arc. Air continues to flow for approximately 6 seconds. During post - flow, if the user moves the trigger release to the rear and presses the trigger, the pilot arc starts. The main arc transfers to the workpiece if the torch tip is within transfer distance to the workpiece.

  • Page 33: Service

    SECTION 5: SERVICE 5.01 General Maintenance A. O-Ring Lubrication An o-ring on the Torch ATC Male Connector requires lubrication on a regular basis, depending on how frequently the torch is disconnected and re-connected. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis.
  • Page 34 B. Filter Element Replacement The Regulator/Filter Assembly is on the rear panel. For better system performance, the Regulator/Filter Assembly filter element should be checked per the Maintenance Schedule (Appendix 3), and either cleaned or replaced. Remove power from the power supply; turn off the gas supply and bleed down the system. Unscrew the bowl on the bottom of the Regulator/Filter Assembly.
  • Page 35 C. Optional Single-Stage Filter Element Replacement These instructions apply to power supplies where the optional Single-Stage Filter has been installed. The Power Supply shuts down automatically when the Filter Element becomes completely saturated. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry. Refer to Section 6, Parts List, for replacement filter element catalog number.
  • Page 36 D. Optional Two-Stage Filter Element Replacement The Two-Stage Air Filter has two Filter Elements. When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable. Refer to Section 6, Parts List, for replacement filter element catalog number.

  • Page 37: Common Faults

    Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current e. Non - Genuine Thermal Dynamics parts used Incorrect gas pressure 4. Short Torch Parts Life a. Oil or moisture in air source b.

  • Page 38: Basic Troubleshooting Guide

    5.03 Basic Troubleshooting Guide WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. A. Basic Troubleshooting: Overview This guide covers basic troubleshooting.
  • Page 39 6. Unit internal fuse blown or loose a. If blown, double-check input voltage and replace fuse per Section 5.04-C. If fuse blows again, return unit to an authorized service center. 7. Actual input voltage does not correspond to voltage of unit a.
  • Page 40 G. Torch will not pilot; no gas flow; AC indicator ON, GAS indicator ON, DC indicator 1. Starter cartridge missing from torch a. Shut off power supply. Remove shield cup, install starter cartridge. Reinstall torch tip and shield cup. Turn power supply ON / OFF switch to ON (up).
  • Page 41 I. Torch cannot be activated; AC indicator flashing; Gas indicator ON; Temp indicator OFF; DC indicator 1. System is in protective interlock mode. (User held torch trigger while turning on ON / OFF switch.) a. Release torch trigger. 2. System is in protective interlock mode. (Torch parts are missing or loose.) a.
  • Page 42 6. Excessive oil or moisture in torch a. Put RUN / RAPID AUTO RESTART / SET switch in SET (down) position. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch). If there are contami- nants in the gas, additional filtering may be needed.

  • Page 43: Power Supply Basic Parts Replacement

    5.04 Power Supply Basic Parts Replacement WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. This section describes procedures for basic parts replacement. For more detailed parts replacement procedures, refer to the Power Supply Service Manual. A.
  • Page 44 B. Cover Installation Reconnect the ground wire, if necessary. 2. Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws. 3. Tighten lower screws. 4. Reinstall and tighten the upper screws. C.

  • Page 45: Parts Lists

    CE CutMaster 101 Power Supply 400VAC,Three - Phase, 50 Hz, with input power cable 3-1320-4 6.04 Replacement Parts Description Catalog # Fuse for CE CutMaster 101 Power Supply 9-8602 Regulator / Filter Assembly Replacement Element 9-4414 Manual 0-2852 PARTS LISTS...

  • Page 46: Options And Accessories

    6.05 Options and Accessories Description Catalog # Single-Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Two-Stage Filter Kit (includes Hose & Mounting Screws) 7-7500 Bracket, Filter Mounting (not shown) 9-7535 Two-Stage Air Filter Assembly 9-7527...

  • Page 47: Torch Parts

    6.06 Torch Parts Shield 9-8207 (40A) 9-8218 8-3487 8-3486 Shield Cap, Drag O-Ring O-Ring Shield 9-8236 (70-100A) Cup Body 9-8237 9-8211 (80A) 9-8243 Starter Electrode Shield Shield Cap, Deflector Cartridge 9-8215 9-8213 9-8218 Shield Art # A-03796 Cup Body 9-8225 - A (40A) 9-8237 9-8241 9-8226 - B...
  • Page 48 PARTS LISTS Manual 0-2852...

  • Page 49: Appendix 1: Sequence Of Operation (Block Diagram

    APPENDIX 1: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION: ACTION: ACTION: ACTION: RUN / ON / OFF switch to ON Close external RUN / Rapid Auto Restart / SET disconnect switch. Rapid Auto Restart / RESULT: switch to RUN SET switch RESULT: AC indicator to SET...

  • Page 50: Appendix 2: Data Tag Information

    APPENDIX 2: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Date of Mfr: Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor...

  • Page 51: Appendix 3: Maintenance Schedule

    APPENDIX 3: MAINTENANCE SCHEDULE This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment. Daily Operational Checks or Every Six Cutting Hours: 1.

  • Page 52: Appendix 4: Torch Pin - Out Diagrams

    APPENDIX 4: TORCH PIN - OUT DIAGRAMS A. Hand Torch Pin - Out Diagram ATC Female Receptacle ATC Male Connector Front View Front View Negative / Negative / Plasma Plasma 8 - Open 8 - Ground 4 - Green / Switch 4 - Switch 3 - Switch...

  • Page 53: Appendix 5: Connection Diagrams

    APPENDIX 5: CONNECTION DIAGRAMS A. Hand Torch Connection Diagram Torch: SL60 / SL100 Hand Torch Leads: Torch Leads with ATC Connector Power Supply: with ATC Receptacle Male ATC Leads ATC Female Receptacle Power Connector Torch Torch Supply Head Leads Black To Power Supply Switch Circuitry...

  • Page 54: Appendix 6: System Schematic

    APPENDIX 6: SYSTEM SCHEMATIC E12A E17A GATE DRIVE 400/460V 400/460V 1 PHASE 3 PHASE INPUT INPUT E11A GATE DRIVE E19A E21A INP UT DIODE A S S Y 19X1811 IGB T BOARD A S S Y 19X1815 CHASSIS 400V 3 PHASE E12B INPUT GATE...
  • Page 55 Date: E CO 101 0 5/07/03 I n f o r m a t i o n Proprietary to THERMAL DYNAMICS CORPORATION. Tu e s day, May 15, 2001 POW ER OUTPUT BOARD ASSY 19X1914 N o t F o r R e l e ase, Reproduction, or Distribution without Written Consent.

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