APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 34
APPENDIX III: SYSTEM SCHEMATIC....................................................................................... 36
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
W ARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
• Always read the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: 6/22/991GENERAL INFORMA TION
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o pr otect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum ProtectiveSuggested
Arc CurrentShade No.Shade No.
Less Than 300*89
300 - 400*912
400 - 800*1014
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION2Date 6/22/99
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFP A Standar d 70, NA TIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
A VERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédur e pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
Date: 6/22/993GENERAL INFORMA TION
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
P AS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
RAYONS D’ARC DE PLASMA
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
GENERAL INFORMATION4Date 6/22/99
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance MinimumNuance Suggerée
Courant ArcProtective NuméroNuméro
Moins de 300*89
300 - 400*912
400 - 800*1014
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L ’ARC ET AU GAZ, disponible aupr ès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRA TIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American W elding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection 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. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W1 17.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
Date: 6/22/995GENERAL INFORMA TION
14. Norme A WSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION6Date 6/22/99
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address:Industrial Park #2
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used accor ding to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured pr oduct 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.
Manufacturers responsible repr esentative:Steve W ard
Director of Operations
Thermadyne UK
Chorley England
Date: 6/22/997GENERAL INFORMA TION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry prac tice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PA R TICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus Series &PartsParts
PAK Units, Power SuppliesCutMaster 80XLCougar/Drag-GunAll OthersLabor
Main Power Magnetics3 Years1 Year2 Years1 Year
Original Main Power Rectifier3 Years1 Year2 Years1 Year
Control PC Board3 Years1 Year2 Years1 Year
All Other Circuits And Components Including,1 Year1 Year1 Year1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat1 Year1 Year1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch1 Year1 Year
All Other Torches180 Days180 Days180 Days180 Days
Repair/Replacement Parts90 Days90 Days90 DaysNone
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. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 6, 1999
GENERAL INFORMATION8Date 6/22/99
SECTION 2:
INTRODUCTION
available in 25 ft (7.6 m), or 50 ft (15.2 m) lengths with
fittings for simple installation. Spare Parts Kits are available for the torches which provide an assortment of replacement torch parts.
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
75XL Plus Air Plasma Cutting Power Supply. Service of
this equipment is restricted to Thermal Dynamics trained
personnel; unqualified personnel are strictly cautioned
against attempting repairs or adjustments not covered in
this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
2.02 General Description of System
The 75XL PLUS System includes a power supply, PCH/
M-60 torch & leads and work cable & clamp.
The Power Supply provides 60 amp maximum output
and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle
and a work cable with clamp.
NOTE
Refer to Section 2.04 for list of power supply options and accessories.
®
2.03 Specifications/Design Features
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch, RUN/SET/LATCH Switch and
Output Current Control
2. Front Panel LED Indicators
AC, TEMP, GAS, DC
3. Rear Panel
Input Power Cable Strain Relief*, Gas Connection, Gas
Regulator/Filter Assembly
*208/230/240 units include input power cable
NOTE
The power supply can be ordered in various configurations with various options factory installed.
XL PLUS Power Supply
A-02462
Work Cable and Clamp
Torch and Leads
Figure 2-1 Pak Master 75XL Plus System
The PCH/M-60 torch provides a maximum 1 inch (25.4
mm) cut capacity. Hand torches are available in a 70°
and 90° torch head configuration, a machine torch is available in a 180° torch head configuration. Torch leads are
4. Input Power
Can be configured for the following:
208/230/240 V AC (±10%), 50/60 Hz, Single or Thr ee-
Phase
380/415 VAC (±10%), 50/60 Hz, Three-Phase
460 VAC (±10%), 50/60 Hz, Single or Three-Phase
5. Output Power
Continuously variable from 15 to 60 Amps maximum
6. Duty Cycle
65% Duty Cycle at an output of 104VDC/60 Amps
100% Duty Cycle at an output of 104 VDC/50 Amps
7. Cut Capacity (Mild Steel)
3/4 inch (19.1 mm); 1 inch (25.4 mm) severance
8. Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC
9. Weight
64 lbs (29 kg) w/work lead
71 lbs (32 kg) w/work lead and 25' Torch & Lead
Manual 0-27469SECTION 2: INTRODUCTION
10. Overall Dimensions
D. Smart Cart
19" (482 mm) High x 13" (330 mm) Wide x 24.8" (630
mm)Long
Overall dimensions are with Handle, Lead Wrap
Bracket, and Gas Requlator/Filter Assembly installed.
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas regulator maximum gauge pressure
160 psi (11 bar)
2. Maximum input gas pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
2.04 Power Supply Options and
Accessories
Steel cart on easy rolling 10" pneumatic tires to provide maximum mobility for the power supply . Handle
is 3/4" tubing with hooks for storage of torch leads.
A tie down strap is also included.
E. 575V Transformer
This step-down transformer allows the power supply to operate with 575 V AC thr ee-phase input power .
F. Computer Control Cable (CNC)
NOTE
This accessory can be used only with the PCM-60
Torches.
The interface cable is available in two lengths, 25 ft
(7.6 m) and 50 ft (15.2 m). The cable is used to interface the power supply with an auxiliary control device to provide OK-To-Move and ON/OFF signals.
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for this
power supply:
A. Dry Air Filter Kit
An optional in-line filter for use on compressed air
shop systems. highly effective at removing moisture
and particulate matter from the air stream to at least
.85 microns.
B. Two Stage Air Line Filter
An alternative to the Dry Air filter, this optional two
stage air line filter is for use on compressed air shop
systems. Filters moisture and contaminants to 5 microns. This filter assembly is pre-assembled at the factory and need only be attached to the power supply.
C. High Pressure Regulators
High pressure regulators ar e available for air and nitrogen. The regulators are used to set the pr oper pressure for the type gas being used.
NOTE
Regulators should not be installed with options A
or B above.
SECTION 2: INTR ODUCTION10Manual 0-2746
SECTION 3:
INSTALLATION
least 6 inches (0.2 m) on each side for clearance . Provide
sufficient clearance in front of the unit to allow access to
the front panel controls (minimum 6 inches or 0.2 m).
PROCEDURES
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply Options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all subsections be read for general information.,
This section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
l. Unpack each item and remove all packing material.
NOTE
The Cutting Spare Parts Kit is shipped in the T or ch
Leads Storage Area on the side of the Power Supply.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system installation.
3.04 Lifting Options
a. Input power
b. Gas
c. Work cable
d. Torch Leads
4. Grounding
5. Operator training
3.02 Site Selection
Select a clean, dry location with good ventilation and adequate working space around all components.
NOTE
Review Important Safety Precautions (page 1) to
be sure that the selected location meets all safety
requirements.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be obstructed. Provide at least 2 feet (0.61 m) in the rear and at
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
This unit is equipped with one handle mounted onto the
top of the enclosure for hand carrying purposes.
W ARNING
F ALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
• Lift unit with the handle on top of the enclosure.
• Persons only of adequate physical strength should
lift the unit.
• Use hand cart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
• This unit has a handle mounted on top of the enclosure for hand lifting only. Be sure unit is lifted and
transported safely and securely.
W ARNING
HANDLE is not for mechanical lifting.
Left Side
Panel
3.05 Input Power Connections
The Power Supply accepts input voltages from 208V to
460V. Input can be 50 or 60 Hz, single-phase or threephase.
The Power Supply is factory-wired for 230V single-phase
or 460V three-phase input depending on the order. For
any other input voltage, the Power Supply must be
changed using the procedure in Sections 3.06.
A. Electrical Connections
The power source must conform to local and national electric codes. Recommended circuit protection and wiring
requirements are shown in Appendix I.
B. Opening Power Supply Enclosure
The left side panel of the Power Supply must be removed
to gain access to the input power connections and the
input voltage selection.
WARNING
A-00910
Ground Wire
Screws
(5 Places)
Figure 3-1 Removing Left Side Panel
NOTE
There is a ground wire connection to the Left Side
Panel on the inside of the unit.
2. Carefully pull the Left Side Panel up and away from
the unit to gain access to the inside of the unit.
3.06 Input Voltage Selection
NOTE
For power supplies to use 575 VAC input power,
the unit must be setup for 460V three-phase operation and the 575V T ransformer Accessory must
be installed.
Disconnect primary power at the source before assembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
1. Using a phillips head screw driver remove the five
screws which secure the left side panel (viewed from
front of unit) to the frame assembly.
The Power Supply has three voltage settings; 208/230/
240VAC, 380/415VAC, or 460VAC. Power Supplies are
factory-wired for 230V single-phase or 460VAC threephase input depending on the order . Input voltage selection is accomplished by switching a wire harness connector inside the Power Supply . Also, a jumper wire must
be properly installed depending on the input used.
W ARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Move the power selection plug to the desired input
connection for 208/230/240V, 380/415V , or 460V operation per the label attached to the panel.
Voltage Selection
Label
460 Volts
380/415 Volts
208/230/240 Volts
Voltage Selection
Connector
Figure 3-2 Input Voltage Selection
A-00911
2. Connect the input cable inside the Power Supply for
the type of operation per the following:
Three-Phase Operation
Three-phase operation requires a 3-conductor cable
with ground.
a. Locate the ground stud and remove the top nut
and washer .
b. Install a lug terminal on the ground wire.
c. Place the ground wire onto the ground stud
and secure with the nut and washer.
d. Insert the other three wires into the L1, L2, and
L3 terminals on the contactor .
e. Tighten all set screws.
NOTE
The jumper wire from L1 to L4 must not be removed.
2. For three-phase 460VAC input, the jumper wire between L2 and L2 (storage) must be left in this storage
connection.
For single-phase operation the jumper wire must be
installed on the contactor as described in Section 3.07
for single-phase input voltage.
3.07 Primary Input Power Cable
Connections
Units ordered as 230V, single-phase, will have a six foot
power input cable and plug factory installed. For all other
units, a cable must be provided by the end user . Recommended cable sizes are specified in Appendix I.
1. Route the primary power cable through the strain relief fitting in the rear panel of the Power Supply and
tighten strain relief screws.
To test the quality of air, place the RUN/SET/LATCH
switch to SET position, place a welding filter lens in front
of the torch and turn on the gas. Any oil or moisture in
the air will be visible on the lens. Do not initiate an arc!
CAUTION
The air supply must be free of oil, moisture, and
other contaminants. Excessive oil and moisture
may cause double-arcing, rapid tip wear, or even
complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear .
C. Gas Connections
The gas supply is connected to the Pressure Regulator/
Filter Assembly installed on the rear of the unit. The connection is the same for compressed air or high pressure
gas cylinders.
Connect the gas supply as follows:
1. Locate the 1/4 NPT to #4 (6mm) hose barbed fitting
shipped inside the Torch Spare Parts Kit.
2. If an optional air line filter is to be installed, refer to
subsection D.
Filtering is required when using air from a compr essor to
insure that moisture and debris from the supply hose does
not enter the torch. Although the Regulator does have its
own filter , it is r ecommended the optional Dry Air Filter
or optional Two Stage Air Line Filter be installed for improved filtering. Gas connections to optional filters are
shown in Figures 3-8 and 3-9 below.
Dry Air Filter
Assembly
1/4 NPT to
#4 (6mm)
Hose Fitting
Hose Clamp
#4 (6mm)
Gas Supply
Hose
A-02469
3. Install the barbed fitting as shown below.
4. Tighten the barbed fitting
5. Place an adjustable hose clamp(customer supplied),
1/4" (6.5mm) to 5/8" (15.9mm)) over the gas supply
hose.
1. Refer to the following when using high pressure gas
cylinders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
a. Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
b. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to blow
out any dust which may be present.
Access
Panel
Screw
Latch
c. The cylinder must be equipped with an adjustable
high-pressure regulator capable of outlet pressur es
up to 100 psi (6.9 bar) maximum and flows of up
to 300 scfh (141.5 lpm).
2. Slide the gas supply hose over the barb fitting.
3. Secure the gas supply hose in place with the adjustable hose clamp.
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
3.09 Connecting Torch Leads
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
The T orch Leads must be pr operly installed to the Power
Supply for proper operation. Make all torch connections
to the Torch Bulkhead Panel per the following:
A-02467
Figure 3-10 Front Access Panel
2. Lift up on the access panel to gain access to the torch
bulkhead panel.
CAUTION
This system is designed for use with the PCH/M60 torch only. Do not connect any other torch to
this power supply.
3. Remove the Strain Relief Nut from the Strain Relief
supplied on the end of the Torch Leads.
Torch Leads
Strain Relief
Assembly
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
1. T urn the scr ew latch securing the front access panel to
the power supply front panel.
4. Feed the end of the torch leads through the hole in the
front panel in the following order:
• Control Cable
• Gas lead
• Pilot Lead
5. Place the Strain Relief Nut over the torch leads and
position it in the hole in the front panel.
6. Hold the Strain Relief Nut in position and tighten the
Strain Relief on the outside of the unit.
7. Connect the torch gas/power lead fitting onto the Gas/
Power Lead Connection.
Pilot Lead Stud
Control Cable
Connector
Control Cable
Pilot Lead
B. Creating an Earth Ground
1. Install a ground wire (not included) between the system and a solid earth ground (also called star ground).
T o create a solid earth gr ound, drive a 1/2 in (12 mm)
diameter copper rod at least 6 - 8 ft (1.8 - 2.4 m) into
the earth so that the rod contacts moist soil over most
of its length. The required depth will vary depending on location (see NOTE). Locate the rod as close as
possible to the power supply. The work table should
be connected to the same earth ground as the power
supply.
NOTE
A properly installed ground rod will have a resistance of one ohm or less.
2. Connect the control device (CNC) to a separate earth
ground similar to the ground rod described above.
The ground cable should be at least 12 gauge (4 mm2)
wire.
3. To minimize RF interference, position torch leads as
far as possible (at least 1 ft or 0.3 m) from any CNC
components, drive motors, control cables, or primary
power lines.
Gas/Power
Lead
Torch Lead
Assembly
Gas/Power Lead
Connection
A-00929
Figure 3-12 Torch Leads Connections
7. Connect the Torch Control Cable to the Torch Control
Connection.
8. Remove the top nut and washer from the Pilot Stud.
9. Place the lug on the Pilot Control Wire onto the stud
and secure with the nut and washer removed in Step
8.
10. Close the access panel and turn the latching screw .
3.10 Work Cable And Ground
Connections
A. Electromagnetic Interference (EMI)
Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.
This RF may interfere with other electronic equipment
such as CNC controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems:
4. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and increased chance of RF interference.
5. Make sure work cable and ground cables are pr operly
connected. The work cable must have a solid connection to the workpiece or cutting table. The connection must be free from dirt, gr ease, oil and paint
A-02459
Work Cable
And Clamp
Make a solid work cable
connection to the workpiece or cutting table
This power supply is equipped with a Tip Saver/Drag
Cut Sensing Circuit which cuts current back to 35 amps if
the tip touches the workpiece. The purpose of this is to
prolong the life of the tip.
If the user does not want the current to be decreasedwhen
the tip touches the workpiece, the sensing circuit can be
defeated by closing switch SW1-1 on the Gate/Logic PC
Board. Slide top white toggle on SW1-1 to the right to
close circuit.
SW1
1 2
Gate/Logic PC Board
ON
A-02569
Figure - SW1 Switch Location
WARNING
Tip life will be considerably shortened if tip is repeatedly touched to the workpiece without the Tip
Saver/Drag Sensing Circuit feature active.
This Section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operating procedures.
4.02 Functional Overview
The P AKMaster 75XL PLUS provides a degr ee of operating flexibility and the use of simple controls.
4.03 Operating Controls
This subsection provides specfic functional descriptions
of the Power Supply operating controls and indicators.
A. Front and Side Panel
1. Control Panel
All operator controls, except gas pressure adjustment,
are located on this panel. Power ON/OFF and RUN/
SET/LA TCH switches; CURRENT control; LED indicators for AC Power, TEMP, GAS, and DC.
3. Torch Leads Input
Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.
4. Work Cable and Clamp
Work cable with clamp (factory installed).
5. Torch Leads and Spare Parts Kit Storage Area
Bracket connected to the side panel of the unit for use
in storing the torch, torch leads, work cable, and spare
parts kit when not in use. The spare parts kit fits into
the opening on the top of the bracket. The torch leads
and work cable wrap around the bracket for easy storage.
B. Control Panel
5 6
AC
TEMP
GAS
DC
RUN
SET
LATCH
7
4
CURRENT
40
35
45
30
25
1
20
15
50
55
60
A
ON
2
OFF
1
2
3
5
A-02458
4
Figure 4-1 Front and Side Panel Connections
2. Access Panel
A panel to gain access to the bulkhead area containing the torch connections.
A-02456
3
Figure 4-2 Operating Controls
1. Current Control
Adjustment to set the desired output current between
15-60 amps. For drag cutting applications set the control between 15 - 35 amps. The unit has an automatic
fold-back circuit that limits current to 35 amps during drag cutting.
2. ON/OFF Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control
circuits.
3. RUN/SET/LATCH Switch
RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.
LA TCH position is used for specific applications (torch
switch can be released after main arc transfer).
Manual 0-274619SECTION 4: OPERATION
4. AC Power Indicator
3. Gas/Power Lead Connection
Green LED indicator will blink ON then OFF for approximately eight seconds and then stay ON after the
ON/OFF power switch is set to ON. Indicates operating power is present in the unit.
5. TEMP Indicator
Normally OFF. Yellow LED indicator will come ON
when the internal temperature senors detect temperatures above normal limits. The unit should be allowed
to cool before continuing operation.
6. GAS Indicator
Green LED indicator will come ON when the input
gas pressure is set to 35 psi (2.4 bar) or higher . Indicator will be OFF when the pressure falls below 35 psi
(2.4 bar).
7. DC Indicator
Green LED indicator will come ON while the torch
switch is pressed.
C. Torch Panel Bulkhead
The torch panel bulkhead is located under the access
panel.
1. Pilot Lead Stud
Connects the torch gas/negative lead to the unit.
D. Rear Panel
1. Gas Input
Input connection for air or nitrogen (N2) input.
WARNING
This unit not to be used with oxygen (O2).
1
3
Connects the pilot control wire on the torch to the unit.
1
2
3
A-00923
Figure 4-3 Torch Panel Connections
2. Control Cable Connector
Connects the torch switch to the unit. In machine torch
applications connects the torch switch on the pendant
to the unit.
2
A-00928
Figure 4-4 Rear Panel
2. Primary Input Power Cable Strain Relief
NOTE
Input power cable is supplied on units when ordered for 230V single-phase operation.
Primary input power cable strain relief for the primary power cable (see Note above) capable of handling the input voltage designed for this unit.
SECTION 4: OPERATION20Manual 0-2746
3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pr essur e to
the Power Supply . An air line filter is supplied as part
of the pressure regulator.
4. Optional Filters
a. Dry Air Filter Assembly
This optional in-line filter removes moisture and contaminants from the air stream when using compressed
air. The filter is capable of filtering to at least .85 microns.
3
4
1
3
4
2
A-00924
Figure 4-6 Rear Panel Showing Optional Two Stage
Air Filter
A-02460
2
1
Figure 4-5 Rear Panel Showing Optional Dry Air
Filter
b. Two Stage Air Line Filter
An alternative to the Dry Air Filter , this optional filter
will also remove moisture and contaminants from the
air stream when using compressed air. Filters to 5
microns.
4.04 Sequence of Operation
The following is a typical sequence of operation for this
cutting system. Refer to Appendix II for a block diagram.
1. Close main power source disconnect.
a. AC power is available at the Power Supply.
2. Place RUN/SET/LA TCH switch to RUN mode.
3. Place the ON/OFF power switch on the front panel
of the Power Supply to ON.
a. AC Power indicator LED blinks ON and OFF
for eight seconds then stays ON.
b. Fans turn on.
4. Place RUN/SET/LATCH switch to SET mode.
a. Gas solenoid opens and gas flows to set pres-
sure.
b. GAS indicator turns ON.
Manual 0-274621SECTION 4: OPERATION
NOTE
GAS indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Regulator/
Filter Assembly.
5. Place RUN/SET/LA TCH switch to RUN mode.
a. Gas flow stops.
b. GAS indicator turns OFF.
6. Protect eyes and press or activate torch switch
If torch is within 3/8 in (9.5mm) transfer distance
of workpiece, main arc will transfer.
13. Gas will flow for 15 seconds (post-flow).
a. Gas solenoid closes
b. Gas flow stops.
c. GAS indicator turns OFF.
14. Place the ON/OFF power switch on the front panel
of the unit to OFF
a. Gas pre-flows starts.
b. GAS indicator turns ON.
7. After gas pre-flow (approximately 2 seconds)
a. Power supply enabled.
b. DC indicator turns ON.
c. Pilot relay closes.
8. Pilot arc is established
9. Move T orch within transfer distance of workpiece.
a. Main arc transfer.
b. Pilot arc OFF.
10. Optional - Place RUN/SET/LATCH to LATCH
mode.
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc transfer.
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer . The tor ch remains activated until the
main arc breaks from the workpiece.
a. AC Power indicator turns OFF.
b. Fans turn OFF.
15. Place the main power disconnect to open.
a. Main AC power is removed from the system.
4.05 Preparations for Operating
Follow this set-up procedure each time the system is operated:
W ARNING
Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate fr ont
end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging).
11. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece, while still
having torch swicth activated, the main arc will
stop and the pilot arc will automatically restart.
12. Release or deactivate the torch switch.
a. Main arc stops.
b. Pilot arc stops (power supply enable signal re-
moved).
NOTE
If torch is activated during post-flow , pilot arc will
immediately restart.
SECTION 4: OPERATION22Manual 0-2746
Copper Shield Cup
Catalog No. 8-7496
Make a solid work cable
connection to the workpiece or cutting table
Standard Shield Cup
Catalog No. 8-7500
Standoff Cutting Tip
Air/N2, 60 Amp
Catalog No. 9-7726
Drag Cutting Tip
Air/N2, 35 Amp
Catalog No. 8-7503
Gas Distributor
Catalog No. 8-7501
Crown Shield Cup
Catalog No. 8-7507
Electrode
Catalog No. 8-7502
Gouging Tip, Air
Catalog No. 8-7506
Gouging Gas Distributor
Catalog No. 8-7508
A-02473
Figure 4-7 Parts Selection (PCH-60)
B. Check primary power source as follows:
1. Check the power source for proper input voltage. Make
sure the input power source meets the power requir ements for the unit per Section 2.03-A-4, Specifications/
Design Features.
A-00925
Figure 4-8 Work Cable Connection To Workpiece
E. Torch Connection
Check that the torch is properly connected.
F. Power Supply On
Move the ON/OFF switch to ON position.
G. Select Output Current
Select the desired current output level for the operation:
• 15 to 60 amps for standoff cutting and gouging
• 15 to 35 amps for drag cutting
H. Set Operating Pressure
Move the RUN/SET/LA TCH switch to SET position. Adjust the gas pressure to 60 psi (4.1 bar).
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
C. Gas Selection
Select desired gas (air or nitrogen). Make sure gas sour ce
meets pressure and flow requirements (refer to Section
3.08, Gas Connections). Check connection and turn gas
supply on.
D. Work Cable Connection
Check for a solid and clean work cable connection to the
workpiece. The area must be free from paint and rust.
Manual 0-274623SECTION 4: OPERATION
I. RUN/SET Switch
Set the RUN/SET/LA TCH switch to RUN position.
The system is now ready for operation.
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc transfer.
For specific applications, use the LATCH position
where the torch switch can be r eleased after the main
arc transfer . The tor ch remains activated until the
main arc breaks from the workpiece.
4.06 Cut Quality
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish cut
quality is desired to avoid a secondary cleaning operation.
The following cut quality characteristics are illustrated
in Figure 4-9 below:
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Cut Surface
The condition (smooth or rough) of the face of the cut.
Bevel Angle
The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.
Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.
Dross Build-up and Top Spatter
Dross is molten material which is not blown out of the
cut area and re-solidifies on the plate. T op spatter is dross
which accumulates on the top surface of the workpiece.
Excessive dross may require secondary clean-up operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Build-up
Nitride deposits which may remain on the surface of the
cut when nitrogen is present in the plasma gas stream.
Nitride buildups may create difficulties if the material is
welded after the cutting process.
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Figure 4-9 Cut Quality Characteristics
Cut quality will vary on different types of and material
thicknesses.
The following table shows the cut quality that can be expected from this equipment for materials with a thickness from gauge to 3/4 inch (19.1mm):
Type of Material
Gas
Air
NitrogenGoodGoodGood
Carbon
Steel
G ood -
E x c ellent
Stainless
Steel
G ood -
E x c ellent
Aluminum
G ood -
E x c ellent
Description of Cut Characteristics
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily removed), medium-smooth cut surface, slight top
edge rounding.
tip orifice diameter), medium to heavy dross, rough
cut surface, top edge rounding.
NOTES
Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and operator ability.
SECTION 5:
CUSTOMER/OPERATOR
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air
flow.
SERVICE
5.01 Introduction
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than Thermal
Dynamics T rained personnel.
For major troubleshooting and parts replacement procedures refer to PAK Master 75XL Plus Power Supply
Service Manual 0-2747.
5.02 General Maintenance
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
T o clean the unit, open the enclosure (refer to Section 5.05A, Opening Enclosure) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.
2. Vacuum dust and dirt out of the entire machine.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as
required
2. Check cables and hoses for leaks or cracks, replace
if necessary.
3. Check all contactor points for severe arcing or pits,
replace if necessary.
B. Optional Dry Air Filter Element
Replacement
NOTE
The XL PLUS Power Supply shuts down automatically when the Filter Element becomes completely
saturated. The Filter Element can be removed from
its housing, dried out, and reused. Allow 24 hours
for Element to dry.
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.
A. Maintenance Schedule
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged
or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/
flow .
4. Purge plasma gas line to remove any moisture
build-up.
5. Inspect input power cable for damage or exposed
wires, replace if necessary.
1. Remove power from power supply.
2. Shut off air supply and bleed down system before
disassembly to change Filter Element.
Manual 0-274625SECTION 5: SERVICE
Housing
Filter
Element
Make sure no part of the operator’s body comes into
contact with the workpiece while the torch is activated.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
Spring
Cover
Barbed
Fitting
Assembled Filter
A-02476
Figure 5-1 Optional Dry Air Filter Replacement
3. Disconnect gas supply hose from barbed fitting.
4. Turn the Cover counterclockwise and remove it
from the Filter Housing. The Filter Element is located inside the housing.
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element cup side first, as shown
below.
7. Replace Housing on Cover.
8. Reattach gas supply hose to barbed fitting.
NOTE
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.
5.03 Common Operating Problems
WARNINGS
NOTE
Handle torch leads with care and protect them fr om
damage.
A. Piloting
Piloting is harder on parts life than actual cutting because
the pilot arc is directed from the electrode to the tip rather
than to a workpiece. Whenever possible, avoid excessive
pilot arc time to improve parts life.
B. Torch Standoff
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield
cup life. Standoff may also significantly affect the bevel
angle. Reducing standoff will generally result in a more
square cut.
C. Edge Starting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip at the edge of the workpiece at the point where the cut is to start. When starting
at the edge of the plate, do not pause at the edge and
force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.
D. Direction of Cut
In the PCH/M-60 torches, the plasma gas stream swirls
as it leaves the torch to maintain a smooth column of gas.
This swirl effect results in one side of a cut being more
square than the other . V iewed along the direction of travel,
the right side of the cut is more square than the left (Refer
to Figure 5-2). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along
an outside diameter cut, the torch should travel in a clockwise direction.
Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.
Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with
proper gloves, clothing, eye and ear protection.
SECTION 5: SER VICE26Manual 0-2746
Left Side
Cut Angle
Right Side
Cut Angle
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
A-00512
Figure 5-2 Side Characteristics Of Cut
E. Dross
Generally when dross is present on carbon steel, it is referred to as either "high speed or slow speed dross".
"High speed dross" usually forms a narrow bead along
the bottom of the cut edge and is very difficult to remove.
"Slow speed dross" will be in larger quantities but does
not adhere tightly to the cut edge and can be easily removed.
When cutting a troublesome steel, it is suggested that the
torch travel speed be reduced to produce "slow speed
dross". Any r equired cleanup can then be done by scrapping, not grinding.
Dross present on top of the plate (top spatter), is normally
caused by a slow torch travel speed or too high of a torch
standoff distance.
F. Common Cutting Faults
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
5.04 Troubleshooting Guide
A. General
T roubleshooting and repairing this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
W ARNING
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.
B. Basic Troubleshooting
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
3. Excessive Dross Formation
a. Cutting speed too slow
This manual covers a basic level of troubleshooting that
requires limited dissasembly and measurements. It is
helpful for solving many of the common problems that
can arise with this system.
If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to P AK Master 75XL PLUS Power Supply
Service Manual 0-2747.
C. How to use this Guide
The following information is a guide to help the Customer/Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text T ype)
Manual 0-274627SECTION 5: SERVICE
1. Cause (Italic Type)
a. Check and connect to proper input power line
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
unit is fully operational after any repairs.
A. AC Power indicator OFF
1. Switch at customer's main power panel in OFF position.
a. Close main power panel switch
2. Input power not properly connected to customer's main
power panel
a. Check that input power is present and unit is
properly connected (refer to Section 3.05, Input
Power Connections.)
3. Customer's main power line fuse(s) blown
a. Check main power panel fuse(s) and replace as
required.
4. Actual input voltage does not correspond to voltage
selection inside unit
a. Check actual line voltage vs. voltage selection
(inside of unit).
5. Unit internal fuse blown or loose
a. If blown, double check input voltage vs. volt-
age selection (inside of unit) and replace fuse
per Section 5.05-B. If fuse blows again, components inside the unit may be faulty.
6. Faulty components in unit
a. Return unit to an authorized service center for
repair or have qualified technician repair per
Service Manual.
B. AC Power indicator ON; TEMP indicator ON
1. Airflow obstructed
a. Check for obstructed air flow and correct con-
dition.
2. Fan blocked
a. Check and correct condition
3. Unit is overheated
a. Allow unit to cool down for about 5 minutes.
Make sure the unit has not been operated beyond duty cycle limit.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
C. Torch will not pilot when torch switch is activated
1. RUN/SET/LATCH switch in SET position
a. Move switch to RUN position.
2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
3. Gas pressure too high or too low
a. Set pressure to 60 psi (4.1 bar).
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
D. AC Power indicator ON; Fans operating; No
cutting output
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply.
2. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against
torch head (do not overtighten if screwed on).
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
4. Faulty Torch
a. Return for repair or have qualified technician
repair per Torch Service Manual (0-2752).
E. Low cutting output with no control
1. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
F. Limited output with no control
1. Poor input or output connections
4. Input line voltage is below 75% of rated level
SECTION 5: SER VICE28Manual 0-2746
a. Check all input and output connections.
2. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
G. Erractic or improper cutting output
5.05 Power Supply Parts
Replacement
WARNING
1. Poor input or output connections
a. Check all input and output connections.
2. Incorrect type and size cable on input or output
a. Use proper type and size cables.
H. AC Power indicator ON; Cutting output avail-
able; Fans not operating,
1. Fan blades blocked
a. Check and clear blades.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. AC POWER indicator ON; Fans operate; No gas
flow
1. Gas not connected or pressure too low
a. Check source for at least 70 psi (4.8 bar).
2. Gas supply pressure too high
a. Maximum of 125 PSI inlet pressure
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
A. Left Side Panel Removal
1. Using a phillips head screw driver remove the five
screws which secure the left side panel (viewed
from front of unit) to the frame assembly.
Left Side
Panel
A-02468
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. Torch cuts but not adequately
1. Drag circuit active
a. Lift tip from work piece.
2. Current set too low
a. Increase current setting.
3. Torch is being moved too fast across workpiece
a. Reduce cutting speed (refer to Instruction
Manual supplied with torch.
4. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch).
Ground
Screws
Wire
(5 places)
Figure 5-1 Left Side Panel Removal
NOTE
There is a ground wire connection to the Left Side
Panel on the inside of the unit. There is no need to
disconnect the ground wire.
2. Carefully pull the Left Side Panel up and away
from the unit to gain access to the inside of the
unit.
3. To reinstall the left side panel do the following:
a. Place the left side panel onto the frame and
slide the top edge under the lip on the top of
the right side panel.
b. Reinstall all the screws to secure the left side
panel.
Manual 0-274629SECTION 5: SERVICE
B. Fuse Replacement
1. Remove the left side panel per paragraph "A"
above.
2. Locate the internal fuse above the input power contactor on the left side of the unit.
3. Replace the fuse (0.8 amp, 600V).
4. Reinstall the left side panel per paragraph "A"
above.
Internal Fuse
A-00919
0.8 Amps, 600V
Figure 5-2 Internal Fuse Location
SECTION 5: SER VICE30Manual 0-2746
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all r eplaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a Thermal Dynamics product must be returned for service, contact your Thermal Dynamics distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Addr ess all inquiries to your authorized Thermal Dynamics distributor .
Manual 0-274631SECTION 6: PARTS LISTS
6.03 Complete Power Supply Replacement
Power supply includes: Work cable and clamp, pressure regulator/air filter, and operating manual.
DescriptionQtyCatalog #
PAK MASTER 75XL PLUS Power Supply
208/230VAC, Single-Phase With 50 Amp Input Plug and Cable13-7556-1
460VAC, Three-Phase Without Input Plug and Cable13-7556-2
6.04 Replacement Parts
QtyDescriptionCatalog #
1Fuse (0.8 amp, 600V)9-7526
1220V Single-Phase Input Power Cable9-7512
6.05 Options and Accessories
QtyDescriptionCatalog #
1Smart Cart7-7777
1575V Transformer9-7500
1Filter Kit “Dry Air” – Includes Filter And Hose - Optional7-7507
1Replacement Filter Body “Dry Air”9-7740
2Replacement Filter Element “Dry Air”9-7741
1Replacement Filter Hose “Dry Air”9-7742
1Bracket, Laman Filter Mounting - Optional9-7535
1Two Stage Air Line Filter Kit - Optional7-7500
1Dual Stage Air Filter Assembly9-7527
1Replacement First Stage Filter9-1021
1Replacement Second Stage Filter9-1022
Line Voltages with Recommended Circuit Protection and Wire Sizes
(Based on Tabl e 310- 16, 1987 Nati onal El ectric Code) and Table 4, Canadian Electrical Code.
NOTES
The table above is based on the following output current and voltage: 130VDC @ 60A
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
Primary input power cable must have an outside diameter of 0.69 inches (17.5 mm) or greater.
Manual 0-274633APPENDIX
APPENDIX II: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
LATCH
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
Protect eyes and
activate torch
RESULT
Gas flows (2 seconds).
After gas pre-flow:
DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
ON/OFF switch
to ON.
RESULT
AC indicator blinks for 8
seconds then steady on.
Fans on.
Power circuit ready.
RUN/SET/LATCH switch
gas flows to set pressure.
PILOT ARC
ACTION
to SET.
RESULT
Gas solenoid open,
GAS indicator on.
ACTION
RUN/SET/LATCH
switch to RUN.
RESULT
Gas flow stops.
GAS indicator off.
ACTION
Torch moved away
from work (while
still activated).
RESULT
Main arc stops.
Pilot arc automatically
restarts.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
(Power supply enable signal removed.)
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
Gas solenoid closes, gas flow stops.
Main arc stops.
Gas flows (15 seconds)
NOTE - If torch is activated during
workpiece, main arc will transfer.
After post-flow:
GAS indicator off.
APPENDIX34Manual 0-2746
ACTION
ON/OFF switch
to OFF
RESULT
All indicators off.
Power supply fans off.
ACTION
Torch moved within
transfer distance of workpiece.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Open external
disconnect.
RESULT
No power to system.
ACTION
Torch Switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
A-02461
This Page Left Blank
Manual 0-274635APPENDIX
APPENDIX III: SYSTEM SCHEMATIC
A-02503
9
1316
J21
J20
J19
GAS
SOL
GAS
INRUSH
INRUSH
APPENDIX36Manual 0-2746
OK TO
MOVE
OK
Manual 0-274637APPENDIX
8/11/99
A-02503
APPENDIX38Manual 0-2746
Loading...
+ hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.