Everlast Power plasma 50 wiring to Bulltear CNC plasma table

[MC]

This is a quick tutorial to wire up a Everlast Power Plasma 50 (50amp) plasma cutter to a Bulltear CNC plasma table for digital torch height control. Because space is very limited inside the unit the DTHC card will be mounted outside the unit in a steel box. To allow the DTHC to work we must first get divided volts so we are using a current transformer for this. This allows the DTHC to sense the current coming into the plasma cutter for monitoring and changes for Z axis adjustment. The Current transformer will fit inside the unit and can be fixed into position using either hot glue or industrial velcro tape. On top of the Current transformer is a "sandbox" resistor that wont allow too much current to flow in the resistor. Failure to use this will ruin your current transformer (they are very cheap though (under $20)).





The blue circle indicates the second leg of the 220v power coming in to the unit



Here we show the current transformer wired up. Because we will be sensing 50 amps and less we want to go through the center of the current transformer twice to pickup amperage settings below 35amps.



Here we show the loops and the resistor wired up. On the Current transformer the two white wires will connect to the DTHC card and this will give us our divided volts. Note we had to extend our red power wire by soldering it into the yellow wire which we will hook up to our power switch located on the back of the unit.



Here is our power switch. You will need to remove 4 small screws holding the switch onto the back of the unit and remove the lower red wire. This wire is what we used to loop through the Current transformer and we tied the yellow wire into. After that you want to take the wire you soldered into the red wire and screw it back into the spot on the switch that the origial red wire came out from. You will definately need to tape up the joint where you spliced the two together to avoid contact. We do it this way instead of putting a new wire into the unit due to the vast amount of solder used on these units and the heat required to remove the wire could damage the main board. This is why we splice into the existing red wire.



Here we have mounted a box to the top of the unit and drilled a hole in the top of the sheetmetal allowind the six wires to come through onto the DTHC card.





The other 4 wires are



1. Tip volts(negative) which are wired into the torch lead screw inside the unit (torch side)

2. Tip volts (Positive) work clamp which are wired into the work clamp screw inside the unit (clamp side)

3. Torch switch (pin 1 or 9) easily spliced into on the back of the torch plug

4. Torch switch (pin 1 or 9) easily spliced into on the back of the torch plug

[johndjmix]

mc, I would apreciate it if you could shoot me an email. Im using the power plasma50 on my CNC table, and have a few questions for you.....I have it operating but was curious if you are having the same issues as me.

Just send me a PM, and ill send you my #...

--John