PLASMA CUTTING
POWER SUPPLY
CE PAK Master® 75XL
A-00909
September 25, 2001 Manual No. 0-2607
Operating Manual
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CE PAK Master® 75XL
Operating Manual Number 0-2607
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1997 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
this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: September 25, 2001
Record the following information for W arranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions and W arnings ........................................................................ 1
1.02 Important Safety Precautions .......................................................................... 1
1.03 Publications..................................................................................................... 2
1.04 Note, Attention et Avertissement ..................................................................... 3
1.05 Precautions De Securite Importantes.............................................................. 3
1.06 Documents De Reference ............................................................................... 5
1.07 Declaration of Conformity ................................................................................ 7
1.08 Statement of Warranty..................................................................................... 8
SECTION 2:
INTRODUCTION ................................................................................................................. 9
2.01 Scope of Manual ............................................................................................ 9
2.02 General Description........................................................................................ 9
2.03 Specifications/Design Features ...................................................................... 9
2.04 Pow er 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 .............................................................................................. 12
3.05 Input Pow er Connections.............................................................................. 12
3.06 Input Voltage Selection ................................................................................. 12
3.07 Input Pow er Cable Connections ................................................................... 13
3.08 Gas Connections.......................................................................................... 13
3.09 Connecting Torch Leads ............................................................................... 15
3.10 W ork Cable And Ground Connections.......................................................... 16
SECTION 4:
OPERATION ...................................................................................................................... 17
4.01 Introduction .................................................................................................. 17
4.02 Functional Overview..................................................................................... 17
4.03 Operating Controls ....................................................................................... 17
4.04 Sequence Of Operation................................................................................ 19
4.05 Preparations for Operating ........................................................................... 20
4.06 Cut Quality ................................................................................................... 20
SECTION 5:
CUSTOMER/OPERATOR SERVICE.................................................................................. 23
5.01 Introduction .................................................................................................. 23
5.02 General Maintenance ................................................................................... 23
5.03 Common Operating Problems ...................................................................... 23
5.04 Troubleshooting Guide.................................................................................. 24
5.05 Pow er Supply Parts Replacement ................................................................ 26
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS.....................................................................................................................29
6.01 Introduction .................................................................................................. 29
6.02 Ordering Information .................................................................................... 29
6.03 Complete Pow er Supply Replacement ......................................................... 30
6.04 Options and Accessories.............................................................................. 30
APPENDIX I: INPUT WIRING REQ UIREMENTS ...................................................................... 31
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 32
APPENDIX III: SYSTEM SCHEMATIC....................................................................................... 34
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.
WARNING
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
HEAL TH.
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.
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 pr ocesses. 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.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
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.”
Date: A ugust 6, 2001 1 GENERAL INFORMATION
• Wear 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 where
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 hydrogen 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. Yo u
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o protect your hearing from loud noise, wear pr otective 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 RA YS
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 HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
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, Washington, 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
GENERAL INFORMATION 2 Date: A ugust 6, 2001
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
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. NFPA Standard 70, NATIONAL 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 Standar d A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédur e pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
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.
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 :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: A ugust 6, 2001 3 GENERAL INFORMATION
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
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.
• 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.
• 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.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
• 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. (V oir 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.
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 PAS
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.
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.
GENERAL INFORMATION 4 Date: A ugust 6, 2001
RAYONS D’ARC DE PLASMA
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 oculair e.
• 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.
• 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.
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 TRA VAIL 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 auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL 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
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. V ous dú4ez vous pr otéger 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.
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 Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), 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, Batterymar ch Park,
Quincy, MA 02269
Date: A ugust 6, 2001 5 GENERAL INFORMATION
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 W117.2, 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.Livret 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
14. Norme AWSF4.1 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: A ugust 6, 2001
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.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/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) standar d C22.2 number 60 for Ar c welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* 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 product 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 representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: A ugust 6, 2001 7 GENERAL INFORMATION
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 practice,
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
PAR 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 Series , 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 Series 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 & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Y ear 2 Years 1 Year
All Other Circuits And Components Including, 1 Y ear 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 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 August 6, 2001
GENERAL INFORMATION 8 Date: A ugust 6, 2001
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
75XL Air Plasma Cutting Power Supply (EMC). 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.
Torches will provide a maximum 3/4 inch (19.05 mm)
cut capacity. Hand torches are available in 70° and 90°
configurations. Machine torches are available only in
Model PCM-75 and include a rack and pinion mounting
assembly. Torch leads are available in 25 ft (7.6 m), or 50
ft (15.2 m) lengths with fittings for simple installation.
The torch includes a spare parts kit which provides an
assortment of replacement torch parts.
®
Refer to Section 2.04 for list of power supply options and accessories.
NOTE
2.03 Specifications/Design Features
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
The power supply provides 55 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. Machine torch systems
also include a remote hand ON/OFF pendant.
NOTE
The power supply can be ordered in various configurations with various options factory installed.
Pak Master 75XL
Power Supply
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch, RUN/SET 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
4. Input Power
Available for the following input power:
208/230/240 VAC (±8%), 50/60 Hz, Three-Phase
380/415 VAC (±10%), 50/60 Hz, Three-Phase
460 VAC (±10%), 50/60 Hz, Three-Phase
Work Cable
With Clamp
PCH/M-75
Torch and Leads
Figure 2-1 Pak Master 75XL Power Supply
The power supply is designed to work with the Model
PCH/M-75 Plasma Torches.
Manual 0-2607 9 INTRODUCTION
A-01368
Supplied with 10 ft (3.05 m) 4-Conductor Input Power
Cable with filtering beads.
5. Output Power
Continuously variable from 15 to 55 Amps maximum
6. Duty Cycle
60% Duty Cycle @ 130V output with 60 Hz input
50% Duty Cycle @ 130V output with 50 Hz input
7. Cut Capacity
3/4 inch (19.05 mm); 1 inch (25.4 mm) severance
8. Pilot Circuitry
High Frequency (HF), Pulsed DC
9. Weight
D. Interface Cable
72 lbs (32.7 kg)
10. Overall Dimensions
18.9" (480 mm) High x 13" (330 mm) Wide x 23.5"
(597 mm) Long
Overall dimensions are with handle, lead wrap
bracket, and Gas Regulator/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 or 11.03 kPa)
2. Maximum input gas pressure
125 psi (8.6 BAR or 861 kPa)
3. Filter
Coalescent type filter
NOTE
This accessory can be used only with the PCM-75
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.
2.04 Po wer Supply Options and
Accessories
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. Two Stage Air Line Filter
An optional two stage air line filter is available. The
filter will remove moisture and contaminants from
the air stream when using compressed air. The filter
is capable of filtering to at least 5 microns. The filter
assembly is pre-assembled at the factory and need
only be attached to the power supply.
B. 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.
C. Smart Cart
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.
INTRODUCTION 10 Manual 0-2607
SECTION 3:
INSTALLATION
Provide sufficient clearance in front of the unit to allow
access to the front panel controls (minimum 6 inches or
0.15 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 sub-sections 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
NOTE
Equipment that was ordered as a system is packaged in one shipping carton. All options and the
Torch are factory installed.
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
A. Power Supply
Included with each power supply is Input Power Cable,
Work Cable and Clamp; Pressure Regulator/Filter Assembly and connection hardware; Operating Manual.
B. Torch and Leads
Included with each Torch is Torch and Leads with Torch
Handle Assembly, Shield Cup, Tip, Electrode, Gas Distributor and all connectors installed; Torch Spare Parts
Kit; Operating Manual.
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 least 6 inches (0.15 m) on each side for clearance .
Machine Torches also include Metal Rack and Pinion
Mounting Assembly, and Remote Control Hand Pendant.
C. Options and Accessories
Options and Accessories are packaged separately if not
installed at the factory.
D. Unpacking Procedure
1. Unpack each item and remove all packing material.
NOTE
The Spare Parts Kit is shipped in the Torch 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.
Manual 0-2607 11 INSTALLA TION PROCEDURES
3.04 Lifting Options
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-en-
ergized supply line before moving unit.
B. Electrical Connections
The power source must conform to local and national
electric codes. Recommended circuit protection and wir ing requirements are shown in Appendix I.
C. 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.
This unit is equipped with one handle mounted onto
the top of the enclosure for hand carrying purposes.
WARNING
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.
WARNING
HANDLE is not for mechanical lifting.
3.05 Input Po wer Connections
The Power Supply accepts input voltages from 208V to
460V. Input can be 50 or 60 Hz, three-phase. The Power
Supply is factory wired for 380/415V three-phase input.
For any other input voltage, the Power Supply must be
internally reset.
NOTE
WARNING
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.
Left Side
Panel
A-01562
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 far enough to gain access to the inside of the
unit.
Refer to Section 3.06, Input Voltage Selection for
procedure.
A. Input Voltage Selection
The Power Supply is factory-wired for 380/415V threephase input. For any other input voltage, the Power Supply must be changed using the procedure in Section 3.06.
INSTALLATION PROCEDURES 12 Manual 0-2607
3.06 Input Voltage Selection
The Power Supply has three voltage settings; 208/230/
240VAC, 380/415VAC, or 460VAC. Power Supplies are
factory-wired for 380/415VAC three-phase input. Input voltage selection is accomplished by switching a wire
harness connector inside the Power Supply.
WARNING
3. Connect the ends of the individual wires a cus-
tomer supplied plug or main disconnect per the
following:
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
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 V olts
380/415 V olts
208/230/240 V olts
NOTE
All the input cable wires must be connected for
three-phase operation.
• Blue wire to Line 2 (Live)
• Black wire to Line 3 (Live), refer to Note above
• Brown wire to Line 1 (Live)
• Green/Yellow wire to Ground (Earth)
CAUTION
The primary power source, power cable, and plug
all must conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix I).
3.08 Gas Connections
A. Gas Requirements
WARNING
Voltage Selection
A-01546
Connector
EMC Filter
Figure 3-2 Input Voltage Selection
3.07 Input Po wer Cable Connections
The Power Supply is supplied with a 460V three-phase
input EMC power cable attached. Connect the supplied
input EMC power cable per the following:
NOTE
The input power cable must not be modified in
any way as filtering beads are installed on the cable.
1. Strip back the outer covering approximately 3
inches (76 mm) to expose the individual wires at
the free end of the cable.
2. Cut back the insulation on the individual wires
approximately 1/8 - 3/16 inch (3-5 mm).
This unit not to be used with oxygen (O2).
Gases: Compressed Air or Nitrogen (N2) Only
Pressure: 60 psi (4.1 BAR or 414 kPa)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 BAR or 861 kPa)
Flow: Cutting - 300 scfh (141.5 lpm)
Gouging - 300 scfh (141.5 lpm)
CAUTION
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.
Manual 0-2607 13 INSTALLA TION PROCEDURES
B. Checking Air Quality
To test the quality of air, place the RUN/SET switch to
SET position, place a welding filter lens in front of the
torch and turn on the gas. Any oil or moistur e in the air
will be visible on the lens. Do not initiate an arc!
C. Gas Connection
The gas supply is connected to the rear of the Power
Supply. The connection is the same for compressed air
or high pressure gas cylinders.
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 .
An air line filter is supplied as part of the Pressure Regulator/Filter Assembly installed on the rear of the unit.
NOTE
Filtering is required when using air from a compressor to insure that moisture and debris from
the supply hose does not enter the torch. It is recommended to order the Optional Two Stage Air
Line Filter for improved air filtering.
Regulator/Filter
Assembly
1/4 NPT to #4 (6 mm) Hose
Fitting
Hose Clamp
#4 (6 mm) Gas
Supply Hose
A-01149
Figure 3-3 Gas Connection To Regulator/Filter
Assembly
1. Locate the 1/4 NPT to #4 (6 mm) hose barb fitting
shipped inside the Torch Spare Parts Kit.
NOTE
A barb fitting is provided for connection of the
gas supply hose to the rear of the Power Supply.
The fitting is placed in the Spare Parts Kit for
shipment.
2. Depending on the options installed at the factory, install the supplied barb fitting into the input of the
Regulator/Filter Assembly or the Optional T wo Stage
Air Filter Assembly.
3. Tighten the barb fitting.
4. Place an adjustable hose clamp, 1/4" (6.35mm) to 5/
8" (15.88mm), over the gas supply hose.
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm) Gas
Supply Hose
Two Stage Filter
Assembly
A-01150
Figure 3-4 Gas Connection To Optional Two Stage
Filter Assembly
INSTALLATION PROCEDURES 14 Manual 0-2607
5. 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 or 690
kPa) 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.
Access Panel
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.
c. The cylinder must be equipped with an adjustable
high-pressure regulator capable of outlet pressures up to 100 psi (6.9 BAR or 690 kPa) maximum and flows of up to 300 scfh (141.5 lpm).
6. Slide the gas supply hose over the barb fitting installed in Step 2.
7. Secure the gas supply hose inplace 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 T orch Leads
WARNING
Screw Latch
A-02319
Figure 3-5 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/M75 torch only. Do not connect any other torch to
this power supply.
3. Remove the securing nut from the strain relief supplied on the end of the Torch Leads.
Strain Relief
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:
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
1. Turn the screw latch securing the front access panel
to the power supply front panel.
Torch Leads
Assembly
Strain Relief
Nut
A-00930
Figure 3-6 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 into the hole and secure with
the nut removed in Step 3 above.
Manual 0-2607 15 INSTALLA TION PROCEDURES
6. Connect the torch gas/power lead fitting onto the
Gas/Power Lead Connection.
possible to the power supply. The work table should
be connected to the same earth ground as the power
supply.
Pilot Lead Stud
Control Cable
Connector
Control Cable
Pilot Lead
Gas/Power
Lead
Torch Lead
Assembly
Gas/Power Lead
Connection
A-00929
Figure 3-7 Torch Leads Connections
7. Connect the T o r ch Contr ol Cable to the Torch Control
Connection.
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 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.
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 properly connected.
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)
High frequency 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 procedur es
when installing mechanized systems:
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 approximately 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. Locate the rod as close as
A-02320
Work Cable
And Clamp
Make a solid work cable
connection to the workpiece or cutting table
Figure 3-8 Power Supply Work Cable Connection
INSTALLATION PROCEDURES 16 Manual 0-2607
SECTION 4:
TEMP
AC
GAS
DC
SET
RUN
ON
OFF
CURRENT
30
25
20
40
45
55
35
50
15
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 pr ovides a degree 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 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
4
CURRENT
35
30
40
25
1
20
15
ON
2
45
50
55
A
AC
TEMP
GAS
DC
RUN
5
6
7
3
Figure 4-1 Front and Side Panel Connections
2. Access Panel
A panel to gain access to the bulkhead area containing the torch connections.
OFF
1
2
Figure 4-2 Operating Controls
SET
A-02322
1. Current Control
3
Adjustment to set the desired output current between
15-55 amps. For drag cutting applications set the control between 15 - 35 amps.
A-02321
5
2. ON/OFF Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits.
4
3. RUN/SET Switch
RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.
4. AC Power Indicator
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..
Manual 0-2607 17 OPERATION
5. TEMP Indicator
D. Rear Panel
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 45 psi (3.1 BAR or 310 kPa) or
higher . Indicator will be OFF when the pressur e falls
below 45 psi (3.1 BAR or 310 kPa).
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 pilot control wire on the torch to the
unit.
1. Gas Input
Input connection for nitrogen (N2) or air input.
WARNING
This unit not to be used with oxygen (O2).
1
2
3
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.
A-01151
Figure 4-4 Rear Panel
2. EMC Primary Input Power Cable and Strain Relief
Supplied EMC primary input power cable and strain
relief. Input power cable is capable of handling up
to 460 VAC, three-phase, input voltage designed for
this unit.
3. Gas Pressure Regulator/Filter Assembly
Pressure requlator to adjust the input gas pressure
to the Power Supply. An air line filter is supplied as
part of the pressure regulator.
3. Gas/Power Lead Connection
Connects the torch gas/negative lead to the unit.
OPERATION 18 Manual 0-2607
4. Place RUN/SET switch to SET mode.
a. Gas solenoid opens and gas flows to set pres-
1
sure.
b. GAS indicator turns ON.
NOTE
GAS indicator will not come ON if the gas pressure is set below 45 psi (3.1 BAR or 310 kPa) at
the Regulator/Filter Assembly.
2
3
5. Place RUN/SET switch to RUN mode.
a. Gas flow stops.
b. GAS indicator turns OFF.
6. Protect eyes and press or activate torch switch
a. Gas pre-flows starts.
b. GAS indicator turns ON.
7. After gas pre-flow (approximately 2 seconds)
4
A-01152
Figure 4-5 Rear Panel With Optional Two Stage
Filter Installed
4. Optional Two Stage Air Line Filter
The optional filter will remove moisture and contaminants from the air stream when using compressed
air. The filter is capable of filtering to at least 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 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.
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. 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.
11. Release or deactivate the torch switch.
a. Main arc stops.
b. Pilot arc stops (power supply enable signal
removed).
NOTE
If torch is activated during post-flow , pilot arc will
immediately restart.
If torch is within 3/8 in (9.53mm) transfer distance of workpiece, main arc will transfer.
b. Fans turn on.
Manual 0-2607 19 OPERATION
12. Gas will flow for 15 seconds (post-flow).
a. Gas solenoid closes
b. Gas flow stops.
c. GAS indicator turns OFF.
13. Place the ON/OFF power switch on the front
panel of the unit to OFF
a. AC Power indicator turns OFF.
b. Fans turn OFF.
14. 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:
Make a solid work cable
connection to the workpiece or cutting table
A-00925
Figure 4-6 Work Cable Connection To Workpiece
E. Torch Connection
Check that the torch is properly connected.
F. Purge the System (Gas Pre-Flow)
WARNING
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
front end torch parts. The torch parts (shield cup, tip
and electrode) must correspond with the type of operation (cutting or gouging). Refer to the Instruction Manual
supplied with the Torch Assembly for proper parts selection.
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
requirements for the unit per Section 2.03-A-4, Specifications/Design Features.
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.
Move the ON/OFF switch to ON position. To start the
pre-flow move the RUN/SET switch to SET position for
a minimum of 20 seconds. The pre-flow gas purge will
remove any moisture that may have accumulated in the
torch and leads while the system was shut down. The
torch cannot be activated during pre-flow.
G. Select Output Current
Select the desired current output level for the operation.
• 15 to 55 amps for standoff cutting or gouging
• 15 to 35 amps for drag cutting
H. Set Operating Pressure
Move the RUN/SET switch to SET position. Adjust the
gas pressure to 60 psi (4.1 BAR or 414 kPa).
I. RUN/SET Switch
Set the RUN/SET switch to RUN position.
The system is now ready for operation.
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 4-7 below:
OPERATION 20 Manual 0-2607
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.
Type of M aterial
Gas
Air
Nitrogen Good G ood Good
Carbon
Steel
G ood -
Excellent
S tainless
Steel
G ood -
Excellent
Aluminum
G ood -
Excellent
Description of Cut Characteristics
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. Top 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.
Kerf Width
Cut Surface
Bevel Angle
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.
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.
Top
Spatter
Top Edge
Rounding
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Figure 4-7 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 gage to 3/4 inch (19.05mm):
Manual 0-2607 21 OPERATION
OPERATION 22 Manual 0-2607
SECTION 5:
CUST OMER/OPERATOR
SERVICE
5.03 Common Operating Problems
WARNINGS
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 Trained personnel.
For major troubleshooting and parts replacement procedures refer to P AK Master 75XL Power Supply (EMC)
Service Manual 0-2608.
5.02 General Maintenance
WARNING
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating environment.
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. 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.
NOTE
Handle torch leads with care and protect them fr om
damage.
A. Piloting
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.
To clean the unit, open the enclosure (refer to Section
5.05-A, 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.
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-75 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
Manual 0-2607 23 SERVICE
more square than the other. Viewed along the direction
of travel, the right side of the cut is more square than the
left (Refer to Figure 5-1). 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.
d. Work cable disconnected
e. Worn torch parts
3. Excessive Dross Formation
a. Cutting speed too slow
b. Torch standoff too high from workpiece
Left Side
Cut Angle
Right Side
Cut Angle
A-00512
Figure 5-1 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
1. Insufficient Penetration
a. Cutting speed too fast
b. To rch 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
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)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
5.04 T roubleshooting 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.
WARNING
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
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 Power Supply (EMC)
Service Manual 0-2608.
b. Torch standoff too high from workpiece
c. Cutting current too high
SERVICE 24 Manual 0-2607
C. How to use this Guide
3. Unit is overheated
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 Type)
1. Cause (Italic Type)
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. Actual input voltage does not correspond to voltage
selection inside unit
a. Check actual line voltage vs. voltage selection
(inside of unit)
4. Customer's main power line fuse(s) blown
a. Check main power panel fuse(s) and replace
as required.
5. Unit internal fuse blown or loose
a. If blown, double check input voltage vs. volt-
age selection (indide of unit) and replace fuse
per Section 5.05-B. If fuse blows again, return
unit to an authorized service center.
6. Faulty components in unit
a. Allow unit to cool down for about 5 minutes.
Make sure the unit has not been operated beyond duty cycle limit.
4. Input line voltage is below 75% of rated level
a. Check and connect to proper input power line
5. Input voltage of 460 VAC applied to 208/230/240 VAC
or 380/415 VAC Models
a. Check input line voltage and correct as re-
quired.
6. 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 acti-
vated
1. RUN/SET switch in SET position
a. Move switch to RUN position.
2. Switch activated during 2 second pre-flow
a. Release switch and wait at least 2 seconds be-
fore activating switch again
3. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
4. Gas pressure too high or too low
a. Set pressure to 60 psi (4.1 BAR or 414 kPa).
5. 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. To rch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply
a. Return 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
Manual 0-2607 25 SERVICE
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.
E. Low cutting output with no control
3. Excessive oil or moisture in torch
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
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
1. Poor input or output connections
a. Check all input and output connections.
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch)
5.05 Po wer Suppl y P arts
Replacement
WARNING
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.
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. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. Torch cuts but not adequately
1. Current set too low
a. Increase current setting.
2. Torch is being moved too fast across workpiece
Left Side
Panel
A-01562
Ground Wire
Screws
(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 far enough to gain access to the inside of the
unit.
a. Reduce cutting speed (refer to Instruction
Manual supplied with torch.
SERVICE 26 Manual 0-2607
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.
B. Fuse Replacement
1. Remove the left side panel per paragraph "A" above.
2. Locate the internal fuse above and behind the EMC
Filter PC Board 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
0.8 Amps, 600V
A-01547
EMC FIlter
Figure 5-2 Internal Fuse Location
Manual 0-2607 27 SERVICE
SERVICE 28 Manual 0-2607
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 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 Arc 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 0-2607 29 P A RTS LISTS
6.03 Complete Power Supply Replacement
Power supply includes: EMC Input Power Cable, W ork cable, pr essure r egulator/air filter, air hose and 1/4 NPT to
barb fittings, and operating manual.
Description Qty Catalog #
PAK MASTER 75XL Power Supply (EMC) 1 3-7850
6.04 Options and Accessories
Qty Description Catalog #
1 Two Stage Air Filter Kit 7-7500
Replacement Elements
1 First Stage 9-1021
1 Second Stage 9-1022
1 Smart Cart 7-7777
1 Circle Cutting Attachment 7-7501
Interface Cable - For Use With Machine Torches Only:
1 25 foot (7.62 m) 8-5557
1 50 foot (15.24 m) 8-5558
PARTS LISTS 30 Manual 0-2607
APPENDIX I: INPUT WIRING REQUIREMENTS
Input Power Input Current Suggested Sizes (See Note)
V o ltage Freq . 3-Ph 3-P h Fu se (A mp s)
(V olts) (H z) (kVA ) (Am p s) 3-P h 3-P h
208 50/60 7.5 38 45 10
230 50/60 7.5 33 40 10
245 50/60 7.5 31 40 10
380 50/60 7.5 20 25 10
415 50/60 7.5 18 25 10
460 50/60 7.5 16 20 10
Line V oltages w ith Suggested Circ uit P rotection and Wire Siz es
NOTES
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Cable size is de-rated based on the Duty Cycle of the equipment.
Wire (mm
2
)
The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations
refer to local or national codes.
Cable conductor temperature used is 167° F (75° C).
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.
Manual 0-2607 31 APPENDIX
APPENDIX II: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
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.
gas flows to set pressure.
PILOT ARC
ACTION
RUN/SET switch
to SET.
RESULT
Gas solenoid open,
GAS indicator on.
ACTION
RUN/SET
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.
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.
A-000926
APPENDIX 32 Manual 0-2607
Manual 0-2607 33 APPENDIX
APPENDIX III: SYSTEM SCHEMATIC
A-01544
APPENDIX 34 Manual 0-2607
Manual 0-2607 35 APPENDIX
A-01544
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