Thermal Dynamics CutMaster 75 Operating Manual
  1. Manuals
  2. Brands
  3. Thermal Dynamics Manuals
  4. Welding System
  5. CutMaster 75
  6. Operating manual
Thermal Dynamics CutMaster 75 Operating Manual

Thermal Dynamics CutMaster 75 Operating Manual

Plasma cutting power supply
Hide thumbs
Table of Contents

Advertisement

Quick Links

Plasma Cutting
Power Supply
CutMaster™ 75
A-02991
Operating Manual
March 22, 2004
Manual No. 0-2868

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CutMaster 75 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Thermal Dynamics CutMaster 75

Summary of Contents for Thermal Dynamics CutMaster 75

  • Page 1 Plasma Cutting Power Supply CutMaster™ 75 A-02991 Operating Manual March 22, 2004 Manual No. 0-2868...
  • 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 CutMaster™ 75 Operating Manual Number 0-2868 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2001 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 1.07 Declaration of Conformity ................1-4 1.08 Statement of Warranty .................. 1-5 SECTION 2: INTRODUCTION .......................
  • 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 ................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) ..........

  • 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 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.

  • Page 10: 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 11: 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 12 GENERAL INFORMATION January 27, 2004...

  • Page 13: Introduction

    This manual contains descriptions, operating instructions CutMaster 75, 208/230-Volt, 400-Volt, and basic maintenance procedures for the Thermal Dy- and 460-Volt Power Supply Duty Cycle namics CutMaster 75 Plasma Cutting Power Supply only. 104° F 104° F 104° F Ambient Servicing of this equipment is restricted to properly (40°...

  • Page 14: Power Supply Options And Accessories

    2.04 Power Supply Options and Accessories Refer to Section 6, Parts Lists, for catalog numbers and ordering information. A. Single Stage Air Line 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 15: Installation

    SECTION 3: 3.03 Unpacking INSTALLATION The product is packaged and protected to prevent dam- age during shipping. 1. Unpack each item and remove any packing material. 3.01 Introduction 2. Locate the packing list(s) and use the list(s) to iden- This Section describes installation of the Power Supply tify and account for each item.
  • Page 16 For 400-VAC, 460-VAC, or 600-VAC Three-Phase op- 5. Strip back the insulation on the individual wires eration: and connect as follows: 1. Remove the Power Supply cover per section 5.05. • Line 1 (Live) wire to main input contactor ter- minal L1.

  • Page 17: Gas Connections

    C. Connecting Gas Supply to Unit 3.06 Gas Connections The gas supply connects to the Regulator/Filter Assem- A. Gas Requirements bly on the rear of the unit. The connection is the same for compressed air or high pressure gas cylinders. If an op- tional air line filter is to be installed, refer to procedures WARNING in subsection 3.06-D.
  • Page 18 D. Installing Optional Air Filter Kits 2. Optional Two-Stage Air Filter Kit This optional two-stage air line filter is also for use Additional filtering is recommended when using air from on compressed air shop systems. Filter removes mois- a compressor to insure that moisture and debris from the ture and contaminants to at least 5 microns.

  • Page 19: Torch Connections

    E. Using High Pressure Gas Cylinders A. Hand Systems Refer to the following when using high pressure gas cyl- inders as the gas supply: WARNING CAUTION Disconnect primary power at the source before dis- assembling the torch or torch leads. Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.
  • Page 20 5. Connect the torch Negative/Plasma Lead to the B. Machine Systems (Unshielded Leads) bulkhead connection inside the Power Supply. 1. Remove the Cover of the Power Supply to gain ac- cess to the Torch Bulkhead Panel. See Section 5.05. 2. Remove the strain relief nut from the Strain Relief. Note: Actual Bulkhead configuration may differ from that shown.
  • Page 21 9. Check the torch for proper parts assembly per the torch manual. Adapter CAUTION Negative/Plasma Connector Lead Connection The torch parts must correspond with the type of Power Supply Adapter operation. Refer to the appropriate torch manual Control Circuit for proper parts selection. Remote Connectors Pendant...
  • Page 22 D. Remote Pendant Control (Optional) In machine type operations the Power Supply has an Adapter Connector Adapter with a cable connector supplied at each end Negative/Plasma Adapter of the Adapter. One end is connected at the factory Lead Connection (Supplied With to the mating connector on the Power Supply Bulk- Power Supply) head area.

  • Page 23: Ground Connections For Mechanized Applications

    6 - 8 ft (1.8 - 2.4 m) into the earth so that the For Thermal Dynamics components it is recommended rod contacts moist soil over most of its length. Depend- to use a minimum of 10 AWG (European 6 mm...
  • Page 24 D. Routing Of Torch Leads 1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive mo- 115VAC: 3.0 VAC tors, control cables, or primary power lines. If cables 230VAC: 1.5 VAC have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in paral- lel with the torch leads in power tracts.

  • Page 25: Operation

    B. Control Panel Features SECTION 4: OPERATION 4.01 Introduction This section describes the power supply operating con- trols and procedures, identifies the front and rear com- ponents, and describes the operating procedures. 4.02 Product Features This subsection describes the power supply operating controls and indicators.

  • Page 26: Preparations For Operating

    4.03 Preparations For Operating GAS Indicator This procedure should be followed at the beginning of Green LED indicator comes ON when the input gas each shift: pressure is set to 35 psi (2.4 bar) or higher. Indicator is OFF when the pressure falls below 35 psi (2.4 bar). WARNING DC Indicator Green LED indicator comes ON while the torch switch...

  • Page 27: Sequence Of Operation

    E. Torch Connection Place RUN / SET switch to RUN (up) position. Check that the torch is properly connected. a. Gas flow stops; GAS Indicator turns OFF. F. Power On Protect eyes and activate torch. On the Power Supply place the ON / OFF switch to the ON (up) position.
  • Page 28 OPERATION Manual 0-2868...

  • Page 29: Service

    Compress the spring on the spool. Screw the filter SECTION 5: element and spool, with the baffle ring in place SERVICE (teeth facing downward) into the Regulator body. Tighten firmly by hand. 5.01 Introduction This section describes basic maintenance procedures per- formable by operating personnel.
  • Page 30 C. Optional Single-Stage Filter Element D. Optional Two-Stage Filter Element Replacement Replacement The Power Supply shuts down automatically when the The Two-Stage Air Filter has two Filter Elements. When Filter Element becomes completely saturated. The Filter the Filter Elements become dirty the Power Supply will Element can be removed from its housing, dried, and re- continue to operate but cut quality may become unaccept- used.

  • Page 31: Common Faults

    Follow all instructions as listed and complete each d. Improper cutting current section in the order presented. e. Non-Genuine Thermal Dynamics parts used This guide is set up in the following manner: 4. Short Torch Parts Life X. Symptom (Bold Type) a.
  • Page 32 3. Actual input voltage does not correspond to voltage of D. No cutting output; Torch activated; AC Power unit indicator ON; Gas flows; Fans operate a. Verify that the input line voltage is correct. Re- 1. Torch not properly connected to power supply fer to Appendix 1, Input Wiring Requirements.

  • Page 33: Power Supply Basic Parts Replacement

    3. Air flow obstructed (TEMP indicator ON) 5.05 Power Supply Basic Parts Replacement a. Check for obstructed air flow around the unit and correct condition. WARNING 4. Gas pressure too low (GAS indicator OFF when torch switch is activated) Disconnect primary power to the system before dis- a.
  • Page 34 Loosen, but do not remove, the lower screws. Care- fully pull the Cover up and away from the unit. Reinstall the cover as follows: a. Reconnect the ground wire, if necessary. b. Place the cover onto the frame so that it rests on the lower screws.

  • Page 35: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable com- ponents. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 Replacement Parts Section 6.05 Options and Accessories NOTE Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

  • Page 36: Power Supply Replacement

    The following items are included with the replacement power supply: work cable & clamp, gas pressure regulator/ filter, and operating manual. Description Catalog # CutMaster 75 Power Supply 208/230VAC, Single-Phase, with input power cable and plug 3-1050-1 400VAC, Three-Phase, with input power cable...

  • Page 37: Appendix 1: Input Wiring Requirements

    APPENDIX 1: INPUT WIRING REQUIREMENTS CutMaster 75 Input Wiring Requirements Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph...

  • Page 38: Appendix 2: Sequence Of Operation (Block Diagram

    APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET RUN/SET switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops. Gas solenoid open, seconds then steady on.

  • Page 39: Appendix 3: Torch Control Cable Wiring Diagram

    APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM This diagram applies to mechanized systems only. Torch Control Cable Control Connector Plug with Connectors Torch Control Connectors Control Shield Connector Torch Lead Lead Shield A-02801 Assembly Connectors only on Connector Shielded Leads Mate &...

  • Page 40: Appendix 4: Maintenance Schedule

    APPENDIX 4: 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 41 Notes: Manual 0-2868 APPENDIX...

  • Page 42: Appendix 5: System Schematic, 208/230-Volt Units

    APPENDIX 5: SYSTEM SCHEMATIC, 208/230-VOLT UNITS INPUT DIODE IGBT PCB ASSEMBLY 19X1756 ASSEMBLY 19X1755 E12A E17A GATE 208/230V DRIVE COPPER SINGLE PHASE STRAP INPUT (78) GATE DRIVE (33) E19A E21A INRUSH +12VDC CHASSIS IGBT PCB ASSEMBLY 19X1756 E12B FILTERING +18V E17B GATE DRIVE...
  • Page 43 INDUSTRIAL PARK No. 2 Scale Supersedes W EST LEBANON, NH 03784 603-298-5711 Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, May 15, 2001 Not For Release, Reproduction, or Distribution without Written Consent. Drawn: References NOTE: Unless Otherwise Specified, Resistors are in Ohms 1/4W 5%.

  • Page 44: Appendix 6: System Schematic, 400-V And 460-V Units

    APPENDIX 6: SYSTEM SCHEMATIC, 400-V and 460-V UNITS INPUT DIODE IGBT PCB ASSEMBLY 19X1756 ASSEMBLY 19X1811 E12A E17A GATE DRIVE 460VAC 3 PHASE INPUT 460VAC GATE DRIVE 1 PHASE INPUT E19A E21A INRUSH +12VDC IGBT PCB ASSEMBLY 19X1756 CHASSIS FILTER E12B CHASSIS 400V CE...
  • Page 45 WEST LEBANON, NH 03784 ECO 3CE2 603-298-57 11 ECO 100397 11/05/02 Date: Infor mati on Pr opr i etar y to THERMAL DYNAMICS CORPORATION. Tuesday, May 15, 2001 Not For Rel ease, Repr oducti on, or Distribution without Written Consent. Drawn: References NOTE: Unl ess Other wi se Speci fi ed, Resistors are in Ohms 1/4W 5%.

  • Page 46: Appendix 7: System Schematic, 600-Volt Units

    APPENDIX 7: SYSTEM SCHEMATIC, 600-VOLT UNITS INPUT DIODE IGBT PCB ASSEMBLY 19X1815 ASSEMBLY 19X1811 E 1 2 A E 1 7 A GATE DRIVE 600VAC 3 PHASE INPUT GATE DRIVE E 1 9 A E 2 1 A INRUSH + 1 2 VD C IGBT PCB ASSEMBLY 19X1815 CHASSIS E12B...
  • Page 47 MAIN CONTACTOR R e v R e vi s ions D a te P C B N o : THERMAL DYNAMICS A s s y N o : E C O 1 00032 G C W 0 4 /16/02 I N D USTRIAL PARK No. 2...

Table of Contents

Save PDF