Thermal Dynamics CE CutMaster 50 Operating Manual
Plasma cutting power supply
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Also See for CE CutMaster 50:
- Operating manual (44 pages) ,
- Instruction manual (90 pages) ,
- Service manual (88 pages)
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Summary of Contents for Thermal Dynamics CE CutMaster 50
- Page 1 Plasma Cutting Power Supply CE CutMaster CE CutMaster CE CutMaster A-02766 Operating Manual March 22, 2004 Manual No. 0-2844...
- Page 3 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 Copyright 2001 by Thermal Dynamics Corporation All rights reserved.
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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 6.05 Options and Accessories ................6-2 APPENDIX 1: INPUT WIRING REQUIREMENTS ..............A-1 APPENDIX 2A: SEQUENCE OF OPERATION (BLOCK DIAGRAM - CE CutMaster 50) ..A-2 APPENDIX 2B: SEQUENCE OF OPERATION (BLOCK DIAGRAM - CE CutMaster 75, CE CutMaster 100) ......................A-3 APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM ..........
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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.
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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.
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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
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. -
Page 16: Power Supply Options And Accessories
1. Operating Pressure (Output) CE CutMaster 50 Power Supply: 70 psi (4.8 bar) 2. Maximum input gas pressure CE CutMaster 50 Power Supply Duty Cycle 125 psi (8.6 bar) Ambient 104° F 104° F 104° F 3. -
Page 17: Installation Procedures
• Lift unit by the handle, using two hands. Select a clean, dry location with good ventilation and ad- • Install optional wheel kit (CE CutMaster 50 only) or use multi-purpose cart or similar device of ad- equate working space around all components. -
Page 18: Primary Input Power Connections
1. The outer covering of the cable is stripped back (Cutting) (Gouging) approximately 3 inches (76 mm) at the factory to 200 scfh 230 scfh CE CutMaster 50 70 psi (4.8 bar) expose the individual wires at the free end of the (94.4 lpm) (108.5 lpm) cable. CE CutMaster... - Page 19 C. Connecting Gas Supply to Unit D. Installing Optional Air Filter Kits The gas supply is connected to the Regulator/Filter As- Additional filtering is recommended when using air from sembly located on the rear of the unit. The connection is a compressor to insure that moisture and debris from the the same for compressed air or high pressure gas cylin- supply hose does not enter the torch.
- Page 20 Pressure Rate d. Attach the gas supply hose to the Two-Stage CE CutMaster 50 100 psi (6.9 bar) 200 scfh Filter Assembly. CE CutMaster 75 100 psi (6.9 bar) 400 scfh CE CutMaster 100 100 psi (6.9 bar) 400 scfh...
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Page 21: Torch Connections
3.07 Torch Connections Note: Actual Bulkhead Equipment ordered as a system will have the Torch fac- Adapter configuration may Pilot Lead Stud tory connected to the Power Supply. Connector differ from that shown. The instructions for connecting the Torch Leads to the Adapter Power Supply are different depending on the type of Plug... - Page 22 B. Machine Systems (Unshielded Leads) Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply. Remove the Cover of the Power Supply to gain ac- cess to the Torch Bulkhead Panel. See Section 5.05. Adapter Connector Negative/Plasma Remove the strain relief nut from the Strain Relief.
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Page 23: Ground Connections For Mechanized Applications
Remote Pendant Connector Diagram point locations. For Thermal Dynamics components it is recommended NOTE to use a minimum of 10 AWG (European 6 mm ) wire... - Page 24 5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connec- tion to the cutting table. The work and ground connec- tions must be free from rust, dirt, grease, oil and paint. 115VAC: 3.0 VAC 230VAC: 1.5 VAC If necessary grind or sand down to bare metal.
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Page 25: Operation
ON/OFF switch, RUN/SET switch; CURRENT control; indicators for AC Power, TEMP, GAS, and DC. A-03641 Operating Controls (CE CutMaster 50) A-02772 Front and Side Panel Features 2. Torch Leads Input Hole in the front panel to feed the torch leads through to the internal bulkhead connections. - Page 26 C. Rear Panel Features 1. ON / OFF Power Switch 1. Gas Input Port ON (up) position supplies AC power to activate all Connection for gas input. system control circuits. OFF (down) position deacti- vates control circuits. WARNING 2. RUN / SET Switch This unit is not to be used with oxygen (O...
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Page 27: Preparations For Operating
H. Set Operating Pressure 4.03 Preparations For Operating Place the RUN/SET switch to the SET (down) posi- This procedure should be followed at the beginning of tion. Gas will flow. Adjust gas pressure control to 70 each shift: psi / 4.8 bar. Prepare to Cut WARNING Return the RUN/SET switch to RUN (up) position. - Page 28 Protect eyes and press or activate torch switch. a. Gas pre-flow starts (approximately 2 seconds). b. GAS Indicator turns ON. After gas pre-flow: a. Power Supply enabled. b. DC indicator turns ON. c. Pilot Relay closes. Pilot arc is established. Move Torch within transfer distance of workpiece.
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Page 29: Customer/Operator Service
The filter element and spool, with the baffle ring in SECTION 5: place (teeth facing downward) can be screwed back CUSTOMER/OPERATOR into the Regulator body by compressing the spring on the spool. Tighten firmly by hand. SERVICE 5.01 Introduction This section describes basic maintenance procedures per- formable by operating personnel. -
Page 30: Common Faults
Cutting speed too fast Shut off air supply and bleed down system before b. Torch tilted too much changing Filter Elements. c. Metal too thick d. Worn torch parts e. Cutting current too low Non-Genuine Thermal Dynamics Parts used CUSTOMER/OPERATOR SERVICE Manual 0-2844... -
Page 31: Basic Troubleshooting Guide
Worn torch parts 1. Cause (Italic Type) d. Improper cutting current a. Check/Remedy (Text Type) e. Non-Genuine Thermal Dynamics Parts Locate your symptom, check the causes (easiest listed first), then remedies. Repair as needed being sure to 4. Short Torch Parts Life verify that unit is fully operational after any repairs. - Page 32 2. Fan(s) blocked E. Low cutting output a. Check and correct condition. 1. Incorrect setting of CURRENT (A) control 3. Unit is overheated a. Check and adjust to proper setting. a. Allow unit to cool down for at least 5 minutes. 2.
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Page 33: Power Supply Basic Parts Replacement
I. AC POWER indicator ON; Fan operating; A. Cover Removal No gas flow Remove the upper screws which secure the cover 1. Gas not connected or pressure too low to the main assembly. a. Check source for proper supply pressure. NOTE There is a ground wire connection to the inside of 2. - Page 34 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. c. Tighten lower screws. d. Reinstall and tighten the upper screws. B. Fuse Replacement Remove the unit cover per paragraph "A"...
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Page 35: Parts Lists
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 Basic Replacement Parts Section 6.05 Options and Accessories B. -
Page 36: Power Supply Replacement
The following items are included with the replacement power supply: work cable & clamp, gas pressure regulator/ air filter, input power cable, and operating manual. Description Catalog # CE CutMaster 50 Power Supply, 400VAC, Three-Phase 3-5830 CE CutMaster 75 Power Supply, 400VAC, Three-Phase 3-1850... -
Page 37: Appendix 1: Input Wiring Requirements
Fuse (Amps) Wire (mm (Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph CE CutMaster 50 50/60 11.5 CE CutMaster 75 11.1 CE CutMaster 100 13.9 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. -
Page 38: Appendix 2A: Sequence Of Operation (Block Diagram - Ce Cutmaster 50
APPENDIX 2A: SEQUENCE OF OPERATION (BLOCK DIAGRAM - CE CutMaster 50) 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. -
Page 39: Appendix 2B: Sequence Of Operation (Block Diagram - Ce Cutmaster 75, Ce Cutmaster 100
APPENDIX 2B: SEQUENCE OF OPERATION (BLOCK DIAGRAM - CE CutMaster 75, CE CutMaster 100) 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. -
Page 40: Appendix 3: Torch Control Cable Wiring Diagram
APPENDIX 3: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS 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 & Lock Torch Head Connectors A-02821 PIP Pin... -
Page 41: Appendix 4: Routine Maintenance Schedule
APPENDIX 4: ROUTINE 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: Check torch consumable parts, replace if damaged or worn. -
Page 42: Appendix 5: System Schematic (Ce Cutmaster 50
APPENDIX 5: SYSTEM SCHEMATIC (CE CutMaster 50) A-02967 APPENDIX Manual 0-2844... - Page 43 A-02967 Manual 0-2844 APPENDIX...
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Page 44: Appendix 6: System Schematic (Ce Cutmaster 75
APPENDIX 6: SYSTEM SCHEMATIC (CE CutMaster 75) 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 FILTERING... - 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%.
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Page 46: Appendix 7: System Schematic (Ce Cutmaster 100
APPENDIX 7: SYSTEM SCHEMATIC (CE CutMaster 100) INPUT DIODE IGBT PCB ASSEMBLY 19X1756 ASSEMBLY 19X1811 E 1 2 A E 1 7 A GATE DRIVE 460VAC 3 PHASE INPUT 460VAC GATE 1 PHASE DRIVE INPUT E 1 9 A E 2 1 A INRUSH + 1 2 VD C IGBT PCB ASSEMBLY... - Page 47 R e v R e vi s ions D a te P C B N o : THERMAL DYNAMICS 1 9 X 1 7 5 3 A s s y N o : E C O 3 7E2 H AS...
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Questions and answers
Have air flow at cutting nozzle but no arc.
The Thermal Dynamics CE CutMaster 50 could have airflow at the cutting nozzle but no arc due to several possible reasons:
1. Torch Not Within Transfer Distance – If the torch is not within 1/4 inch (6.4mm) of the workpiece, the main arc will not transfer.
2. Pilot Arc Not Established – If the pilot arc relay does not close or the pilot arc does not start, the main arc will not initiate.
3. Gas Flowing but No Arc Start – If gas flows for 2 seconds but the pilot arc does not establish, there may be an issue with the torch, electrode, or connection.
4. Power Circuit Not Ready – If the power circuit is not ready or the DC indicator is not on, the arc will not start.
5. Blocked or Contaminated Torch Components – If the torch tip or electrode is worn or contaminated, it may prevent arc initiation.
Checking these factors can help diagnose and resolve the issue.
This answer is automatically generated