Related Manuals for Thermal Dynamics CutMaster 151
Summary of Contents for Thermal Dynamics CutMaster 151
-
Page 1: Power Supply
Plasma Cutting Power Supply CutMaster™ 151 (CE) A-04517 Operating Manual May 5, 2005 Manual No. 0-4720... - Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, 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 CutMaster™...
-
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 5: SERVICE .......................... 5-1 5.01 General Maintenance ..................5-1 5.02 Common Faults .................... 5-5 5.03 Basic Troubleshooting Guide ................ 5-6 5.04 Power Supply Basic Parts Replacement ............5-11 SECTION 6: PARTS LISTS ........................6-1 6.01 Introduction ....................6-1 6.02 Ordering 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 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
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor. - Page 12 GENERAL INFORMATION March 2, 2004...
-
Page 13: Introduction
INTRODUCTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and basic maintenance procedures for the Thermal Dynamics® CE CutMaster™ 151 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 covered in this manual, at the risk of voiding the Warranty. -
Page 14: Input Wiring Specifications
24" 0.6 m 27.5 in / 696 mm 6" 12.4 in / 150 mm 315 mm A-03572 2.03 Input Wiring Specifications CE CutMaster 151 Input Wiring Specifications Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. 1-Ph 3-Ph... -
Page 15: Power Supply Features
2.04 Power Supply Features Handle and Leads Wrap Control Panel Torch Leads Receptacle Art # A-04507 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 0-4720 INTRODUCTION... -
Page 16: 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. This filter increases performance and improves consumables parts life. -
Page 17: 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 18: 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. A. -
Page 19: Gas Connections
Gas Connections A. Connecting Gas 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 20 B. Optional Air Filters 1. Connect the Filter as illustrated. Use only Synflex or equivalent grade hose. The illustrations show typical fittings as an example. NOTE For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions. Do Not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
-
Page 21: 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 22 B. Check Air Quality To test the quality of air: Put the ON / OFF switch in the ON (up) position. Put the RUN / RAPID AUTO RESTART / SET switch in the SET (down) position. 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. Do not start an arc! Art # A-04254 INSTALLATION...
-
Page 23: 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 to 40 Amps may be used for drag cutting (with the Steady light indicates power supply is ready torch tip contacting the workpiece). -
Page 24: Preparations For Operating
Power Supply (100 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. - Page 25 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 gas pressure for power supply operation. NOTE Minimum pressure for power supply operation is lower than minimum for torch operation. Art # A-04255 Manual 0-4720 OPERATION...
- Page 26 G. Set Operating Pressure Place the Power Supply RUN / Rapid Auto Restart / SET switch to the SET (down) position. Gas will flow. Art # A-04254 Adjust gas pressure per the settings chart. 70 - 75 psi / 4.5 - 5.2 bar Pressure Control Knob / Bouton De Contrôle CutMaster™...
- Page 27 H. Select Current Output Level Place RUN / Rapid Auto Restart / SET to RUN (up) or Rapid Auto Restart (center) position. Gas flow stops. Set the current output level, up to 40 amps for drag cutting (with the torch tip in contact with the workpiece), or up to 100 amps for standoff cutting.
- Page 28 K. Postflow Release the trigger to stop the cutting arc. Gas continues to flow for approximately 20 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 29: 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 30 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 31 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 32 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 33: 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 34: 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 35 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 36 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 37 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 38 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 39: 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 40 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 41: Parts Lists
The following items are included with the replacement power supply: work cable & clamp, input power cable, gas pressure regulator / filter, and operating manual. Description Catalog # CutMaster 151 Power Supply, 400V, Three Phase, CE 3-1720-4 6.04 Replacement Parts Description... -
Page 42: 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 43: Torch Parts
6.06 Torch Parts 9-8207 (40A) 9-8218 8-3487 8-3486 O-Ring O-Ring Joint torique Joint torique 9-8236 (70-100A) 9-8237 9-8215 9-8213 9-8243 9-8212 (100A) 9-8218 9-8281 9-8225 - A (40A) 9-8241 9-8237 9-8226 - B 9-8227 - C 9-8228 - D (100A) Art # A-04516 Worn Tip Good Tip... - Page 44 PARTS LISTS Manual 0-4720...
-
Page 45: 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 46: 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 47: 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 48: 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 49: 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 Supply Torch Head Leads Black To Power Supply Switch Circuitry... -
Page 50: Appendix 6: System Schematic
APPENDIX 6: SYSTEM SCHEMATIC E12A GATE E17A DRIVE 400/460V 400/460V 1 PHASE 3 PHASE INPUT INPUT E11A GATE DRIVE E19A E21A INPUT DIODE IGBT BOARD ASSY 19X1787 CHASSIS 400V 3 PHASE E12B INPUT GATE E17B (FILTERING) DRIVE 400V 'CE' VERSION INCLUDES IN-LINE EMC FILTER R29 (460/600V) - Page 51 603-298-5711 603-298-5711 603-298-5711 OUTPUT DIODE OUTPUT DIODE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. ASSEMBLY 19X2213 ASSEMBLY 19X2213 03/03/05 DC COMMON DC COMMON Not For Release, Reproduction, or Distribution without Written Consent.