1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
“The Wizard”
By
5’x10’ Plasma Cutter
INSTALLATION INSTRUCTIONS
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Air Supply & Filter Requirements
Tin Knocker recommends the following Ingersoll Rand compressor.
Ingersoll Rand 2340N5-V 230V-1Ph 2-stage Compressor, 80 gal
available through Tractor supply or similar
Specifications for
2340N5-V
Description
Air outlet size
0.5 inch
Amperage
28A
Brand
Ingersoll
Rand
CARB Compliance
Compliant
Volume flow rate at 40
psi
15 cfm
Volume flow rate at 90
psi
14.8 cfm
Drain system
Manual
Duty cycle
100%
Maximum Pressure
175 psi
Filter
• A filter on the air supply line will extend the life of the torch and consumables.
• Supply air should be 99.995% clean, dry, and oil vapor free.
• For safe operation, a shut off valve and a pressure regulator on the air supply line
must be installed prior to the filter.
Tin Knocker recommends the following minimum requirements for a three-layered filter:
Layer
Rating
First
5 microns
Second
0.03 microns
Third
oil vapor
absorption
The air supply line requires two additional hardware components after the filter for
proper operation:
• 1/4” NPT Tee
o to feed both the plasma supply and the pneumatic torch lifter
• 8’ Neoprene (1/4” diameter) hose with 1/4” NPT male end
o for plasma inlet.
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Exhaust Requirements
• The customer is responsible for providing an exhaust system.
• The customer’s system should be able to exhaust at a rate between 3,000 and 5,000
cfm at 1 inch of static pressure
• Tin Knocker recommends cutting out a 12” diameter exhaust hole from the bottom of
the table. (no more than two holes are necessary)
Recommended Exhaust Fans
Fan Model No
Seller Information
“Spread-All” SA-
12075
Grain System Distribution / Ripco Ltd (815)625-2838
www.ripcosystems.com
“Spread-All” SA-
12100
Grain System Distribution / Ripco Ltd (815)625-2838
www.ripcosystems.com
Dayton 7HP74
Grainger
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Electrical Requirements from Hypertherm Powermax45XP
Powermax 45XP
Specifications
Input Voltages
(± 10%)
CSA
CE
200 – 240 V, 1-PH, 50-60 Hz
230 V, 1-PH, 50-60 Hz
400 V, 3-PH, 50-60 Hz
Input Current
@5.95 kW
CSA
CE
200/230 V, 1-PH, 34/28 A
230 V, 1-PH, 30 A
380/400 V, 3-PH, 10.5/10 A
Output current
20 - 45 A
Rated output
voltage
132 VDC
Duty cycle @ 40°C
(104°F)
CSA
CE
CE
50% @ 45 A, 200 – 240 V, 1-PH
60% @ 41 A, 200 – 240 V, 1-PH
100% @ 32 A, 200 – 240 V, 1-PH
50% @ 45 A, 230 V, 1-PH
60% @ 41 A, 230 V, 1-PH
100% @ 32 A, 230 V, 1-PH
50% @ 45 A, 380/400 V, 3-PH
60% @ 41 A, 380/400 V, 3-PH
100% @ 32 A, 380/400 V, 3-PH
Open circuit
voltage (OCV)
275 VDC
Dimensions with
handles
16.75" (426 mm) D; 6.75" (172 mm) W;
13.7" (348 mm) H
Weight with 20' (6.1
m) torch
CSA
CE
37 lbs. (17 kg)
35 lbs. (16 kg)
Gas Supply
Clean, dry, oil-free air or nitrogen
Recommended gas
inlet
flow rate / pressure
Cutting: 360 scfh; 6 cfm (170 l/min) @ 80 psi (5.5
bar)
Gouging: 360 scfh; 6 cfm (170 l/min) @ 60 psi (4.1
bar)
Input power cable
length
10' (3 m)
Power supply type
Inverter - IGBT
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Grounding Requirements
IMPORTANT GROUNDING TEST
VERIFY BEFORE OPERATING THE PLASMA CUTTER
To avoid possible damage to electronic components, motors or the PC, it is imperative
that good grounding be verified prior to operating the plasma generator. Failure to
properly ground the machine will void the warranty and may cause costly damage to the
drive system.
The plasma arc produced by this plasma torch on this machine is controlled
lightning. Proper grounding serves as a lightning rod to provide a predetermined and
safe path for electrostatic discharge. Improper grounding may result in electronic
component failure, electric shock, and possibly death.
Tin Knocker strongly recommends that the customer install a ground rod into the earth
within 12 feet of the machine.
After Installing the ground rod run a large (#6) ground wire from the plasma leads and
table frame to the ground rod. Use a ground lead (at least #12) for the 110 circuit that
drives the PC and control system to this same ground. See illustration.
All grounding wires should be short in length and larger than 8 awg wire.
Preferred grounding procedure is shown on the next page.
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
GROUND TEST PROCEDURE
Connect a 100 W bulb to the ground rod and AC hot. Measure AC voltage with a meter
between the ground rod and the AC neutral. Voltage must be below 0.75 VAC. See
diagram below
The test described should be accomplished by a certified, licensed electrician. Do not
attempt the test yourself as potentially fatal level voltages are involved.
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Machine Layout - NOT TO SCALE
Exhaust cutout in a one-hole configuration
Diameter: 12” diameter
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Hardware Installation & Set Up
• #5 and #7 both plug into the Powermax 45XP
5. Powermax 45XP Torch power
cable
6. Gantry power supply
7. 6-pin interface cable
8. computer power cable
1. Laptop computer with
charging cables & Label
Printer (not shown)
2. Mouse
3. Mach3 Instruction cards
4. Powermax 45XP with
consumable starter kit
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
• The ground clamp plugs into the front of the Powermax 45 and clamps to ground
Ground Cable
Powermax 45XP
Torch power cable
Powermax 45XP
& manual
Ground clamp
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
• The compressor has a Tee that splits to provide air to the plasma torch as well as
the pneumatic Z axis control (up, down)
• The air supply line to the Powermax 45XP is a 3/8 inch hose with a water separator
(left) and a filter (right)
• The Powermax 45XP needs about 100 psi of air pressure to operate optimally
6-pin interface cable
Water Separator
Filter
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
• Air is supplied to the pneumatic height adjustment and typically is set to
approximately 45 psi.
Height Adjustment line
Regulator set to
approximately 45 psi
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
• The tray arm is installed on the leg with a pin.
• The black computer power cable is plugged in on the same leg
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
• The computer tray simply sits on the arm
• Plug in gantry data cable (ethernet) to computer
1550 Simpson Way, Escondido CA 92029 Toll Free: 800-640-0746 Email: info@taagind.com
Powermax 45XP Operating Instructions
“Hypertherm Says”
• Set the Powermax 45XP to output amps of 45 or 40 (DON’T ADJUST)
• The configuration shown is optimal for cutting
• Optimal Torch Height is between 0.06 and 0.25 inches from the surface of the work
• Optimal Torch speed is between 200 and 400 inches per minute for best cut
• Powermax 45XP recommends 100 psi of clean dry air pressure to the machine
• Consumables (spell check) should be changed as a pair, Nozzle (Part No 220941)
AND Electrode (Part No 220842). These consumables should be checked regularly.
• Check and replace the swirl ring (Part No 220857) every six to eight months
• For more information read Powermax 45XP manual
