Thermal Dynamics PAK MASTER 75XL PLUS, 75XL Operating Manual

Air Plasma Cutting
Power Supply
A-02464
Operating Manual
August 23, 1999
Manual No. 0-2746
WARNING
WARNING
While the information contained in this Operating Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use.
®
Pak Master
75XL Plus Air Plasma Cutting Power Supply
Operating Manual Number 0-2746 Published by:
Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711
Copyright 1999 by Thermal Dynamics Corporation
All rights reserved. Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
®
omission in the Pak Master
75XL Plus Air Plasma Cutting Power Supply Operating Manual, whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
August 1999
Record Serial Numbers For Warranty Purposes
Purchase Date
Power Supply
Torch
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et A v ertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 7
1.08 Statement of W arr anty................................................................................... 8
SECTION 2:
INTRODUCTION ................................................................................................................. 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description of System ...................................................................... 9
2.03 Specifications/Design Features ..................................................................... 9
2.04 Po wer Supply Options and Accessories ...................................................... 10
SECTION 3:
INST ALLATION PROCEDURES ........................................................................................ 11
3.01 Introduction.................................................................................................. 11
3.02 Site Selection............................................................................................... 11
3.03 Unpacking ................................................................................................... 11
3.04 Lifting Options.............................................................................................. 11
3.05 Input Po wer Connections............................................................................. 12
3.06 Input Voltage Selection ................................................................................ 12
3.07 Primary Input Power Cab le Connections ..................................................... 13
3.08 Gas Connections......................................................................................... 14
3.09 Connecting Torch Leads .............................................................................. 16
3.10 W ork Cable And Ground Connections......................................................... 17
3.11 Tip Sa v er/Drag Cut Sensing Circuit ............................................................. 18
SECTION 4:
OPERATION ...................................................................................................................... 19
4.01 Introduction.................................................................................................. 19
4.02 Functional Overview .................................................................................... 19
4.03 Operating Controls ...................................................................................... 19
4.04 Sequence of Operation................................................................................ 21
4.05 Preparations for Operating........................................................................... 22
4.06 Cut Quality................................................................................................... 24
SECTION 5:
CUSTOMER/OPERATOR SER VICE.................................................................................. 25
5.01 Introduction.................................................................................................. 25
5.02 General Maintenance .................................................................................. 25
5.03 Common Operating Problems ..................................................................... 26
5.04 Troubleshooting Guide ................................................................................. 27
5.05 Pow er Supply Parts Replacement ............................................................... 29
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS.....................................................................................................................31
6.01 Introduction.................................................................................................. 31
6.02 Ordering Information.................................................................................... 31
6.03 Complete Po wer Supply Replacement......................................................... 32
6.04 Replacement Parts ...................................................................................... 32
6.05 Options and Accessories............................................................................. 32
APPENDIX I: INPUT WIRING REQ UIREMENTS ...................................................................... 33
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:
Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium
• 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: 6/22/99 1 GENERAL 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 Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12 400 - 800* 10 14
* 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 INFORMATION 2 Date 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: 6/22/99 3 GENERAL 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:
antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium
• 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 INFORMATION 4 Date 6/22/99
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12 400 - 800* 10 14
* 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: 6/22/99 5 GENERAL 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 INFORMATION 6 Date 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: 6/22/99 7 GENERAL 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 & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
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 INFORMATION 8 Date 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 0-2746 9 SECTION 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 ODUCTION 10 Manual 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.
Manual 0-2746 11 SECTION 3: INSTALLATION PR OCEDURES
• 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.
SECTION 3: INSTALLA TION PR OCEDURES 12 Manual 0-2746
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.
AC Input Power
Cable Strain Relief
L3
L2
L1
A-02670
Unused Jumper L3 to L3 (storage)
AC Input Power Cable
Input Contactor
GND
Figure 3-4 Primary Power Cable Connections -
Three-Phase Operation
A-00912
AC Input
Power Cable
Figure 3-3 AC Input Power Cable Strain Relief
Manual 0-2746 13 SECTION 3: INSTALLATION PR OCEDURES
Single-Phase Operation
Single-phase operation requires a 2-conductor cable with ground.
a. Locate the single-phase jumper wire connected
between the two L3 terminal lugs on the input contactor .
b. Move one end of the jumper wire from termi-
nal lug L3 to L2 at the contactor.
NOTE
The jumper wire from L1 to L4 must not be re­moved.
Input Contactor
L3
L2
Input Contactor
L2
L1
A-00915
GND
AC Input
Power Cable
Figure 3-6 Primary Power Cable Connections -
Single-Phase Operation
3.08 Gas Connections
A. Gas Requirements
A-00914
Single Phase
Jumper Wire
(L2 to L3)
Figure 3-5 Single Phase Jumper Wire Installation
c. Locate the ground stud and remove the top nut
and washer . d. Install a lug terminal on the ground wire. e. Place the ground wire onto the ground stud
and secure with the nut and washer. f. Insert the other two wires into the L1 and L2
terminals on the contactor . g. Tighten all set screws.
WARNING
This unit not to be used with oxygen (O2).
Gases: Compressed Air or Nitr ogen (N2) Only Pressure: 60 psi (4.1 bar)
CAUTION
Maximum input gas pressure must not exceed 125 psi (8.6 bar)
Flow: Cutting - 300 scfh (142 lpm)
Gouging - 300 scfh (142 lpm)
SECTION 3: INSTALLA TION PR OCEDURES 14 Manual 0-2746
B. Checking Air Quality
D. Optional Air Line Filter Installation
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.
1/4 NPT to #4 (6mm)
Regulator/Filter
Assembly
Hose Fitting
Hose Clamp
A-00916
#4 (6mm) Gas
Supply Hose
Figure 3-7 Gas Connection To Regulator/Filter
Assembly
Figure 3-8 Gas Connection to Optional Dry Air
Filter Assembly
A-00917
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm) Gas
Supply Hose
Two Stage Filter
Assembly
Figure 3-9 Gas Connection To Optional Two Stage
Filter Assembly
Manual 0-2746 15 SECTION 3: INSTALLATION PR OCEDURES
E. Using High Pressure Gas Cylinders
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.
SECTION 3: INSTALLA TION PR OCEDURES 16 Manual 0-2746
Strain Relief Nut
A-02514
Figure 3-11 Torch Strain Relief Nut
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
Manual 0-2746 17 SECTION 3: INSTALLATION PR OCEDURES
Figure 3-13 Power Supply Work Cable Connection
3.11 Tip Saver/Drag Cut Sensing Circuit
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.
SECTION 3: INSTALLA TION PR OCEDURES 18 Manual 0-2746
SECTION 4:
OPERATION
4.01 Introduction
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 0-2746 19 SECTION 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: OPERATION 20 Manual 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 0-2746 21 SECTION 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: OPERATION 22 Manual 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 0-2746 23 SECTION 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
Nitrogen Good Good Good
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.
SECTION 4: OPERATION 24 Manual 0-2746
Fair - Excessive bevel (over 10°), wide kerf (over 2-1/2 x
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 0-2746 25 SECTION 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 VICE 26 Manual 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 0-2746 27 SECTION 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 VICE 28 Manual 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 0-2746 29 SECTION 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 VICE 30 Manual 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 0-2746 31 SECTION 6: PARTS LISTS
6.03 Complete Power Supply Replacement
Power supply includes: Work cable and clamp, pressure regulator/air filter, and operating manual.
Description Qty Catalog #
PAK MASTER 75XL PLUS Power Supply
208/230VAC, Single-Phase With 50 Amp Input Plug and Cable 1 3-7556-1 460VAC, Three-Phase Without Input Plug and Cable 1 3-7556-2
6.04 Replacement Parts
Qty Description Catalog #
1 Fuse (0.8 amp, 600V) 9-7526 1 220V Single-Phase Input Power Cable 9-7512
6.05 Options and Accessories
Qty Description Catalog #
1 Smart Cart 7-7777 1 575V Transformer 9-7500 1 Filter Kit “Dry Air” – Includes Filter And Hose - Optional 7-7507 1 Replacement Filter Body “Dry Air” 9-7740 2 Replacement Filter Element “Dry Air” 9-7741 1 Replacement Filter Hose “Dry Air” 9-7742 1 Bracket, Laman Filter Mounting - Optional 9-7535 1 Two Stage Air Line Filter Kit - Optional 7-7500 1 Dual Stage Air Filter Assembly 9-7527 1 Replacement First Stage Filter 9-1021 1 Replacement Second Stage Filter 9-1022
Computer Control Cable (CNC) 1 25 Foot (7.6 M) 8-5557 1 50 Foot (15.2 M) 8-5558
Housing
Filter
Element
Spring
Cover
Barbed
Fitting
Assembled Filter
A-02476
Optional Dry Air Filter Kit
SECTION 6: PARTS LISTS 32 Manual 0-2746
APPENDIX I: INPUT WIRING REQUIREMENTS
Input P ow er Input Current Input Recommended Sizes (See Notes)
Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) W ire (AWG) Wire (Canada)
(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50/60 12.5 11.2 60 31.1 70 40 4 8 4 8 230 50/60 12.5 11.3 54.1 28.3 70 35 4 8 4 8 240 50/60 12.6 11.4 52.3 27.5 60 35 6 8 6 8 380 50/60 13.9 12.4 36.5 18.9 45 25 8 10 8 10 415 50/60 13.9 12.6 33.4 17.5 40 25 8 12 8 12 460 50/60 13.9 12.7 30.1 16 35 25 8 12 8 12
575 Requir es Transformer Module
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 0-2746 33 APPENDIX
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.
APPENDIX 34 Manual 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 0-2746 35 APPENDIX
APPENDIX III: SYSTEM SCHEMATIC
A-02503
9
13 16
J21
J20
J19
GAS SOL
GAS
INRUSH
INRUSH
APPENDIX 36 Manual 0-2746
OK TO MOVE
OK
Manual 0-2746 37 APPENDIX
8/11/99
A-02503
APPENDIX 38 Manual 0-2746
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