Cutting Machine

Grounding

General Guidelines
Article Number: 0560946064
Revision Date: January 7, 2011
Revision Number: 00
Language: ENG
2
Cutting Machine Grounding
The purchaser is responsible for the safe
operation and use of all products purchased,
including compliance with all applicable
standards in the country of use. See standard
ESAB terms and conditions of sale for a specifc
statement of ESABs responsibilities and
limitations on liability.
Information in this document is subject to change
without notice. This manual is for the convenience
and use of the cutting machine purchaser. It is not
a contract or any obligation on the part of ESAB
Cutting Systems.
ESAB Cutting Systems, 2010

Revision History:
00 - Original Release
3
Cutting Machine Grounding
Table of Contents
Introduction .......................................................................................................................................................................................... 5
Grounding Overview ......................................................................................................................................................................... 6
Basic Layout .................................................................................................................................................................................... 7
Elements of a Ground System......................................................................................................................................................... 8
Plasma Current Return Path ...................................................................................................................................................... 9
Plasma System Safety Ground................................................................................................................................................ 10
Cutting Machine Chassis Ground .......................................................................................................................................... 13
Rail System Safety Ground ...................................................................................................................................................... 14
Earth Ground Rod ............................................................................................................................................................................. 15
Ground Rod................................................................................................................................................................................... 15
Soil Resistivity ............................................................................................................................................................................... 15
Utility Power Electrical Ground .............................................................................................................................................. 16
Electrolytic Ground Rods ......................................................................................................................................................... 17
Multiple Ground Rods ............................................................................................................................................................... 18
Earth Ground Test ............................................................................................................................................................................. 19
Ground Cable Sizes ........................................................................................................................................................................... 21
Machine Grounding Schematic.................................................................................................................................................... 22
4
Cutting Machine Grounding
Spacer Page
MACHINE GROUNDING
5
Introduction
Introduction
The information in this booklet is designed to help
prepare for the installation of an ESAB cutting
machine. Machine grounding is an important part
of the installation process, which can be greatly
simplifed if prepared in advance. The most difcult
part of the grounding process is designing and
installing a low impedance Earth ground rod.
However, the better the Earth ground rod, the
less chance there is of having electromagnetic
interference problems after the installation is
complete.
Most national electric codes address grounding
for the purpose of fre prevention and short
circuit protection; they do not address equipment
protection and electromagnetic interference noise
reduction. Therefore, this manual presents more
stringent requirements for machine grounding.
WARNING
ElEctRIc Shock hAzARd.
Improper grounding can cause severe
injury or death.
Improper grounding can damage machine
electrical components.
Machine must be properly grounded
before putting it into service.
the cutting table must be connected to
machine earth grounding rod.
Grounding Overview
MACHINE GROUNDING
6
Grounding Overview
There are two parts to a ground system;
Component or "chassis" ground
Earth ground
Component grounding connects all pieces to a
single component, like the machine chassis, which is
then connected to a common point know as the star
point. This provides a safe current path in case of a
fault.
An earth ground provides a safe path for fault
current and electromagnetic interference (EMI) to
return to its source. Without a properly grounded
system, an unintended path through people or
sensitive equipment may be found, resulting in
serious injury, death, and/or premature equipment
failure.
This manual focuses on machines with a plasma
cutting system. Machines with plasma cutting
capability are particularly prone to electromagnetic
interference problems and often utilize dangerous
voltages and currents. All machines must have
electrical components grounded and attached to
an earth ground, regardless of process type (shape
cutting, marking, or other material preparation).
A common symbol used to identify
an earth ground on drawings.
A common symbol used to identify
a chassis ground on drawings.
MACHINE GROUNDING
7
Grounding Overview
Note: The three phase electrical input @
to the plasma power supply must include
an electrical ground.
The electrical ground layout is similar for both large
and small machines. The chassis ground @, plasma
positive electrical lead @ and the rail ground cables
@ are attached to a common point @ on the cutting
table. This common connection is referred to as
a star point (see illustration below). One cable @
connects the star point to the Earth ground rod
@. The size of ground cables is dependant on the
maximum current output of the plasma power
supply @. Specifcation of cable sizes is discussed
later in this manual. Some country standards or
directives require a separate ground rod @ for
the plasma power supply. Consult your machine
schematics for more information.
Basic Layout
This illustration demonstrates multiple ground
cables fastened with a single bolt to create a star
point @. The location of the star point on the
cutting table will vary.
8
Elements of a Ground System
MACHINE GROUNDING
8
Elements of a Ground System
The ground system consists of fve main
components:
plasma current return path
plasma system safety ground
utility power electrical ground
cutting machine chassis ground
rail system safety ground.
Ensure provisions are made during the installation
for each of these elements for creating a complete
ground system.
MACHINE GROUNDING
9
Elements of a Ground System
1
2
3
4
5
Plasma Current Return Path
The return path ground cable is the most important
element of the ground system. It completes the path
for the plasma current. Solid, low impedance, well
maintained electrical connections are a necessity.
The plasma cutting current is generated by the
plasma power supply @. A welding cable carries
this current from the negative (-) connection @ in
the plasma power supply through the x axis cable
chain @ to the torch. The current then arcs @ to the
work piece on the cutting table. The current path
must be closed so that the current can easily return
to its source. This is done by connecting the cutting
table to the positive (+) connection @ on the plasma
power supply. If the return path ground cable is not
connected, the plasma system will not work. There
will be no way for the arc to establish between the
torch and the work piece. If the cable is connected,
but the connections have a very high resistance, it
will limit the current of the arc, and cause dangerous
voltage levels between system components.
Elements of a Ground System
MACHINE GROUNDING
10
The only way to ensure that all components are at
the same voltage level (same potential), and thus
eliminate the possibility of being shocked, is to
ensure that all interconnections are making good
electrical contact. Good electrical contact requires
that connections are made with bare metal to metal
contact, the connections are very tight, and are
protected from rust and corrosion. Use a grinder or
wire wheel to clean all paint, rust, and dirt from the
surface when connecting cable lugs to any metal
surface. Use an electrical joint compound between
cable lugs and metal surfaces to prevent future rust
and corrosion. Use the largest size bolts, nuts, and
washers possible, and tighten fully. Use lock washers
to ensure that connections stay tight.
Plasma System Safety Ground
The plasma system safety ground (or ground rod)
serves several important purposes. It provides:
Frame voltage for personnel safety by ensuring
that there are no potential diferences between
system components and building components.
A stable signal reference for all digital and analog
electrical signals on the cutting machine.
Helps control electromagnetic Interference (or
EMI).
Provides a discharge path for short circuits and
high voltage spikes, such as those caused by
lightening strikes.
MACHINE GROUNDING
11
Elements of a Ground System
Misconception about Earth ground rods.
There are many misconceptions about the ground
rod, and the role it plays in reducing electromagnetic
interference. In theory, the ground rod is present to
eliminate possible potential diferences between
equipment and building structures. However many
people believe that the ground rod allows all radio
frequency noise @ to be absorbed and disappear
into the Earth. Experience has shown that a good
ground rod will eliminate radio frequency noise
problems.
1
Elements of a Ground System
MACHINE GROUNDING
12
In reality the ground rod is providing a low
impedance path by which noise currents @ may
return to their source @.
Earth ground rod reality.
1
2
MACHINE GROUNDING
13
Elements of a Ground System
Cutting Machine Chassis Ground
Since all electrical enclosures and shields on the
cutting machine are connected to the chassis, proper
function of the electronic systems on the cutting
machine depends on the chassis being grounded.
The cutting machine chassis ground connects the
chassis of the cutting machine gantry to the plasma
system star ground point. This usually consists of a
13.3mm
2
[6 gauge] stranded copper wire, connected
to the cutting table. This wire connects all electrical
and chassis grounds on the machine to the ground
rod. This wire is supplied with the cutting machine
and will be connected during machine installation.
Elements of a Ground System
MACHINE GROUNDING
14
Rail System Safety Ground
The rail system safety ground makes sure that the
entire rail is at ground potential, eliminating any
possible shock hazard, and providing backup for the
machine chassis ground in case of a plasma current
short circuit. All four corners of the rail system should
be connected to the cutting table.
MACHINE GROUNDING
15
Earth Ground Rod
Earth Ground Rod
The best way to make sure that your Earth ground
connection is optimized is to enlist the services of
a professional. There are a number of engineering
frms which specializes in designing and installing
Earth grounding systems. However, if this option
cannot be used, then there are several things which
can be done to ensure that your Earth ground
connection is good:
Ground Rod
The ground rod itself can be optimized in two ways:
length and diameter. The longer the grounding
rod, the better the connection. The same is true for
diameter: the larger the diameter, the better the
connection. However, if the soil resistance is very
low, then a ground rod longer than 3m [10 feet] does
not make a signifcant diference.

Since soil resistivity
is rarely as good as it could be, a standard grounding
rod should be 25mm [1 inch] in diameter and 6m [20
feet] long.
Soil Resistivity
Soil resistivity can be changed in two ways: by
altering the mineral content, the moisture content,
or both. The ideal solution to poor soil resistivity is
to excavate the immediate area and backfll with
conditioned soil additives. In extremely dry areas,
the moisture content can be improved by installing
a drip system which continually moisturizes the
soil surrounding the ground rod. A crude way of
afecting soil moisture and content is to use salt
water, or rock salt to condition the surrounding soil.
Earth Ground Rod
MACHINE GROUNDING
16
1
2
3
Utility Power Electrical Ground
The utility power electrical ground must accompany
all 3 phase and single phase power feeds. This
electrical ground provides the proper reference for
all incoming power. Failure to provide this ground
is a violation of most electrical codes, and a serious
safety hazard.
Depending on the 3 phase power arrangement
(either a Delta or a Y), the line to ground voltage
may be equal to, or less than the line to line voltage.
A problem exists any time the line to ground
voltage exceeds any individual line to line voltage
(diference in potential). Contact your local utility
company if you are not sure that your 3 phase power
has a proper electrical ground. Make sure that your
electrical contractor properly installs the electrical
ground wire with all 3 phase and single phase power
feeds.
The electrical ground must be connected to the
appropriate terminal inside of the plasma power
supply. Size wire according to local electrical codes.
Utility Power Electrical Ground
3 Phase Electrical Supply
Plasma Power Supply
1
2
3
MACHINE GROUNDING
17
Earth Ground Rod
Electrolytic Ground Rods
One solution that may be suggested by a grounding
expert is the use of an electrolytic ground rod, with
conditioned backfll. This option can be expensive,
but will give the best possible ground connection.
To install one of these rods, the ground must
be excavated or drilled, the rod installed, then
conditioned soil used to backfll around the rod. The
result is a very low impedance earth ground, which
will maintain itself for the lifetime of the cutting
machine. If the concrete slab on which your cutting
machine will be installed has not yet been poured,
then the electrolytic ground rod may be the best
option for your grounding system.
Earth Ground Rod
MACHINE GROUNDING
18
Multiple Ground Rods
There are a number of reasons why multiple ground
rods should not be used. While installing multiple
rods may improve a safety ground or lightening
ground, it ofers no advantage for electromagnetic
interference reduction, and can cause more
problems than it is worth.
The problem with multiple ground rods is that
each rod uses an interfacing Electromagnetic
Interference sphere @ of earth, having a radius of
1.1 times the length of the rod. Overlapping of these
Electromagnetic Interference spheres @ causes a
loss in grounding efectiveness proportional to the
amount of overlap.


2.5 l
Multiple ground points can also create undetectable
sneak pathways for radio frequency noise currents,
actually causing more interference! Instead of
considering multiple ground rods, take steps to
make the single ground rod as good a ground
connection as possible.
1.1l
l
1
2
Multiple ground rods should be avoided if possible.
However, if all other avenues have been explored
to lessen your systems electronic interferences,
multiple ground rods are an option.
Such a system should be installed by a professional
and the distance between the rods should exceed
2.5 times the length of the rods.
MACHINE GROUNDING
19
Earth Ground Test
Earth Ground Test
An Earth ground test should be conducted to test
the impedance of your system. A specialized tester
can be used. If necessary, contact a specialist to
conduct the test.
It is possible to create your own test circuit in North
America. This method may not be appropriate, or
even illegal in some countries. Check with local/
national codes or ordinances before proceeding.
Earth Ground Test
MACHINE GROUNDING
20
1
2
3
4
5
115 VAC HOT
110w light bulb
Ground rod
Voltmeter set to measure AC
AC NEUTRAL
1
2
3
4
5
Connect a 110 watt light bulb between standard AC
current (115 VAC HOT) and the cutting machines
grounding rod. Then connect a digital voltmeter
between AC NEUTRAL (from the same source) and
the grounding rod.
The meter will display the voltage between AC
NEUTRAL and the ground rod, which is equal to the
resistance in ohms between these two points.
The ideal condition is 3 ohms or less between
ground rod and electrical ground. However, this
value may be difcult to achieve. To reduce the
ground resistance, one of the following steps can be
taken:
Increase rod length and/or diameter.
Condition the soil surrounding the ground rod
by adding moisture and salt.
Use an electrolytic ground rod with conditioned
backfll.
WARNING
ElEctRIcAl Shock hAzARd
Under certain situations a dangerous
hazard may exist if anyone may contact
the ground rod during testing.
do not touch the ground rod while power
is being applied to the light bulb .
MACHINE GROUNDING
21
Ground Cable Sizes
Ground Cable Sizes
Cable sizes must be able to handle the largest
possible current fault on a machine. Since a plasma
torch usually requires the largest current, cable sizes
are dependent upon the size of plasma system. As a
general rule of thumb, plasma ground cables should
be at least half the size of plasma power cables. A
machine with only oxyfuel process might require
a star-to-rod cable with a size of 35mm
2
[2 AWG].
The same machine with an ESAB EPP-360 plasma
power supply and PT-36 torch will require a star-to-
rod cable with a cross-sectional area of 70mm
2
[00
AWG]. Check with an ESAB representative for more
information on ground cable size specifcations.
Machine Grounding Schematic
MACHINE GROUNDING
22
1
7
2
(+)
3
4
5
6
8
9
10
Machine Grounding Schematic
Main Control Enclosure
Component Enclosures
Maine Star Ground
Rails
Cutting Table
System Star Ground (on Table)
Earth Ground Rod
Plasma Power Supply
Plasma Power Supply Ground (required by EU
Standards)
Electrical System Ground
1
2
3
4
5
6
7
8
9
10
All electrical enclosures bolted to the
machine chassis
Machine chassis grounded to star point on
cutting table.
Rails grounded to cutting table
Plasma ground connected to star point on
cutting table
Earth ground rod connected to star point on
cutting table.
A separate ground rod is required for the
plasma power supply by some regulations
and directives. Check with local regulations
to determine if this additional ground rod is
required.
MACHINE GROUNDING
23
Machine Grounding Schematic
Spacer Page
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)
ESAB Welding and Cutting Products
PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
http://www.esab.com
ESAB Cutting Systems Canada
6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879
ESAB Cutting Systems GMBH
Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone +49-6039-400
Fax +49-6039-403-02
http://www.esab.de