Tweco 150XLCE User Manual

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PLASMA CUTTING

POWER SUPPLY

CE PAK Master® 150XL

Without Latch Circuit

T M

A-02072

™

Operating Manual

June 14, 2001 Manual No. 0-2727

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 Master150XL Without Latch Circuit Operating Manual Number 0-2727

Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711

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: June 14, 2001

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMA TION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.0 2 Important Safety Precautions....................................................................... 1 - 1

1.03 Publications.................................................................................................. 1-2

1.0 4 Note, Attention et Avertissement.................................................................. 1- 3

1.0 5 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference............................................................................. 1-5

1.0 7 Declaration of Conformity ............................................................................. 1- 7

1.0 8 Statement of W arranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION & DESCRIPTION ................................................................................... 2-1

2.0 1 Scope of Manual .......................................................................................... 2-1

2.0 2 Pow er Supply General Description ................................................................ 2- 1

2.0 3 Specifications/Design Features .................................................................... 2 -2

2.0 4 Po wer Supply Options and Accessories ....................................................... 2- 3

2.0 5 Theory Of Operation ..................................................................................... 2 -4

SECTION 3:

INST ALLATION PROCEDURES ........................................................................................ 3-1

3.01 Introduction................................................................................................... 3-1

3.0 2 Site Selection ............................................................................................... 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Transporting Options..................................................................................... 3-1

3.0 5 Input Pow er Cable Connections .................................................................... 3-2

3.0 6 Gas Connections .......................................................................................... 3- 2

3.07 Connecting T orch Leads ................................................................................ 3-5

3.0 8 Ground Connections For Mechanized Applications ....................................... 3 -7

3.0 9 Filling Pow er Supply Coolant......................................................................... 3-9

SECTION 4:

OPERATION...................................................................................................................... 4-1

4.01 Introduction................................................................................................... 4-1

4.02 Operating Controls........................................................................................ 4-1

4.03 Sequence of Operation ................................................................................. 4-3

4.04 Preparations for Operating ............................................................................ 4-4

4.0 5 Cut Quality ................................................................................................... 4- 5

4.0 6 System Operation......................................................................................... 4- 6

4.0 7 Optional Pow er Supply Settings.................................................................... 4- 7

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE.................................................................................. 5-1

5.01 Introduction................................................................................................... 5-1

5.02 General Maintenance.................................................................................... 5-1

5.03 Common Operating F aults ............................................................................ 5-2

5.04 Common Operating Problems ....................................................................... 5-3

5.05 T roub leshooting Guide .................................................................................. 5-4

5.0 6 Pow er Supply Parts Replacement................................................................. 5- 7

SECTION 6:

PARTS LISTS ................................................................................................................... 6-1

6.01 Introduction................................................................................................... 6-1

6.02 Ordering Information ..................................................................................... 6-1

6.0 3 System Replacement ................................................................................... 6- 2

6.04 P ower Supply Replacement .......................................................................... 6-2

6.0 5 Basic Replacement Parts ............................................................................. 6- 2

6.0 6 Options and Accessories.............................................................................. 6 - 3

APPENDIX 1: INPUT WIRING REQUIREMENTS..................................................................... A-1

APPENDIX 2: SEQ UENCE OF OPERATION BLOCK DIAGRAM ............................................. A-2

APPENDIX 3: GROUNDING DIAGRAM.................................................................................... A-3

APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE ............................................................ A-4

APPENDIX 5: PO WER SUPPLY CNC INTERF A CE DIA GRAM ................................................A-5

APPENDIX 6: SCHEMATIC DIAGRAM..................................................................................... A-6

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 pr ocedure which, if not properly followed, may cause damage to the equipment.

WARNING

A pr ocedure 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.

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 1-603298-571 1 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. You 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: May 1, 2000 1-1 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. Trapped 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. You must protect your ears from loud noise to prevent permanent loss of hearing.

• T o protect 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 injur e 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, 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 FACE 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 fr om the American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-2 Date: Ma y 1, 2000

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. A WS Standard A6.0, WELDING AND CUTTING CONT AINERS 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 Standar d 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 W1 17.2, 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 AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBST ANCES, obtainable fr om the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute pr océdur 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 RESPIRATOR Y 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: May 1, 2000 1-3 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 + 603-298-571 1 ou votre 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 1-4 Date: Ma y 1, 2000

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

RAYONS D’ARC DE PLASMA

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 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 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 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

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.

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 AY ANT 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, Batterymarch Park, Quincy, MA 02269

Date: May 1, 2000 1-5 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, Batterymar ch 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, RECOMMANDA TIONS DE PRA TIQUES SURES POUR LA PRÉP ARA TION 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, PRA TIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-6 Date: Ma y 1, 2000

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2

W est Lebanon, New Hampshir e 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 Dir ective.

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 r equirements among them ar e:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Ar c welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-cir cuit boards used.

* CENELEC EN50199 EMC Product Standard for Ar c 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 pr oduct is safe, when used according 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: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: May 1, 2000 1-7 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 ther eof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standar d industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or r eplacement, 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 P AR 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 fr om 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 fr om 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 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 Y ear 1 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year PCH/M-62 & PCH/M-102 Torches 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 1, 2000

GENERAL INFORMATION 1-8 Date: Ma y 1, 2000

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and basic maintenance procedures for the PAK Master 150XL Plasma Cutting Power Supply (CE). Service of this equipment is restricted to properly 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 Power Supply General

Description

Power Supply is designed to cut most metals up to 1-1/2 inches (38 mm) using air, nitrogen, or argon/hydrogen as the plasma gas. This system is also capable of satisfying many gouging applications. The Power Supply is ideal for hand applications and can also be used in mechanized applications.

A-02072

Figure 2-1 Pak Master 150XL System

The Standard Coolant supplied with the Power Supply can be used in ambient temperatures down to 10° F (-12° C). If the ambient temperature will be below 10° F (-12° C) then Super Coolant should be used. This coolant can be used in areas where the ambient temperature dr ops to -34° F (-36° C).

A. Typical System

A typical system configuration will contain the following:

The Power Supply provides 120 amp maximum output current and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle and a 20 ft (6.1 m) work cable with clamp.

The torch used with the Power Supply is available in the following configurations:

• 70° or 90° Hand Torch Head (PCH)

• 180° Machine Torch Head (PCM) with 1-3/8 inch

(34 mm) diameter Mounting Tube with Rack and Pinion Assembly

Machine torch systems with unshielded leads include a Remote Hand ON/OFF Pendant; machine torches with shielded leads include a CNC Interface Cable.

NOTES

The power supply can be ordered in various configurations with various options factory installed.

Refer to the supplied Tor ch Instruction Manual for more information on the Torch.

Refer to Section 2.04 for list of Power Supply Options and Accessories.

• CE Power Supply

• 20 ft (6.1 m) Work Cable with Clamp

• Torch with Leads (torch type and leads length as

ordered)

• Torch Spare Parts Kit

• CNC Interface Cable or Remote Pendant Control

(depending on type of torch leads ordered)

• Standard Thermal Arc Coolant - 3 gallons (11.4 liters)

NOTE

Refer to Section 2.04 for complete list of Power Supply Options and Accessories.

B. Requirements to Complete System

To complete the system, the user needs to provide the following:

• Primary Input Power Cable Plug

• Gas Supplies

Manual 0-2727 2-1 INTRODUCTION & DESCRIPTION

2.03 Specifications/Design Features

A. Power Supply Specifications

The following specifications apply to the Power Supply only:

9. CNC Interface Signals

Start/Stop and OK-To-Move

10. Coolant Pressure

Internal Service Adjustable (Factory Only)

1. Front Panel Controls

• ON/OFF and RUN/SET Switches

• Output Current Control

• Work Cable Connection

• Torch Leads Connection

2. Front Panel LED Indicators

• AC

• TEMP

• GAS Pressure/Coolant Flow

• DC Output

3. Rear Panel

• Primary Input Power Cable with Filtering Beads and Strain Relief

• Plasma Gas Regulator/Filter Assembly with Gas Pressure Gauge and Pressur e Adjustment

• Secondary Gas Regulator/Filter Assembly with Gas Pressure Gauge and Pressur e Adjustment

• Two Stage Air Line Filter Assembly

• EMI Filter Assembly

4. Input Power (see NOTES)

380-415 VAC (±10%), 50/60 Hz, Three-Phase

NOTE

Refer to Appendix 1 for suggested input wiring size, current ratings and circuit protection r equirements.

5. Output Power

Continuously variable from 30 to 120 amps (±5%)

6. Duty Cycle

60% @ 128 vdc output at 120 amps

7. Cut Capacity on Carbon Steel

130 psi (8.8 bar) at zero flow 120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)

11. Coolant Flow Rate

0.5 gpm (1.9 lpm) with 150 feet (45.7 m) of total torch and torch leads at 70°F (21°C)

NOTE

The flow rate varies with lead length, torch configuration, ambient temperature, amperage level, etc.

12. Cooling Capacity

4,000 to 10,000 BTU

NOTE

Maximum value based on “free flow” condition.

13. Coolant Reservoir Capacity

2 gallons (Use Thermal Arc® coolant only) Capable of handling a total of 150 feet (45.7 m) of torch

lead length

14. Overall Dimensions

Height: 45-3/8 inches (1.2 m) Width: 24-1/2 in (0.6 m) Depth: 35 inches (0.9 m)

15. Weight

Power Supply with Torch: 275 lbs (125 kg) Shipping Weight: 350 lbs (158.8 kg)

16. Used With Torch

• PCH-120 Hand Torch

• PCM-120 Machine Torch

• Genuine Cut Capacity: 1-1/2 inch (38 mm)

• Severance Cut: 1- 3/4 inch (44 mm)

• Pierce Rating: 5/8 inch (15.9 mm)

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2727

B. Gas Regulator/Filter Assembly

Specifications

The following specifications apply to the Gas Regulator/ Filter Assembly only:

1. Gas Regulator Maximum Gauge Pressure

Plasma: 160 psi (11.3 bar) Secondary: 160 psi (11.3 bar)

2.04 Power 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 the Power Supply:

2. Maximum Input Gas Pressure

125 psi (8.6 bar)

3. Filter

Coalescent type filter

C. Gas Requirements

1. Plasma

Gases: Compressed Air, Nitrogen, Argon/Hydrogen Operating Pressure: 65 psi (4.5 bar) Cold Flow:

Cutting: 50 - 78 scfh (23.6 - 36.8 lpm) Gouging: 85 - 95 scfh (40.1 - 44.8 lpm)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

2. Secondary

Gases: Compressed Air, Carbon Dioxide (C02), Nitrogen

Operating Pressure: 60 psi (4.1 bar) Cold Flow:

A. High Pressure Regulators

High pressure regulators are available for air, nitrogen, and argon-hydrogen. The regulators ar e used to set the proper pressure for the type of gas being used.

B. CNC Interface Cable

NOTE

Accessory is for use with Shielded PCM Torch & Leads.

The CNC 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.

C. Work Cable Kit

Power Supply is supplied with attached 20 ft (6.1 m) work cable and clamp. Longer cables are available as a user installed kit.

D. Remote Pendant Control

NOTE

Accessory is for use with Unshielded PCM Torch & Leads.

Control used to manually start and stop cutting operations from a location up to 25 ft. (7.6 m) from the

Plasma Power Supply. Cutting: 340 scfh (160.4 lpm) Gouging: 235 scfh (110.9 lpm)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.6 bar).

Manual 0-2727 2-3 INTRODUCTION & DESCRIPTION

2.05 Theory Of Operation

A. Plasma Arc Cutting and Gouging

Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma gas to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away by the flow of gas.

With a simple change of torch parts, the system can also be used for plasma arc gouging. Plasma arc gouging uses the same process to remove material to a controlled depth and width.

B. Input and Output Power

The unit converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead, and the positive output connects to the workpiece through the work cable.

C. Pilot Arc

When the torch is activated there is a 2 second (service adjustable) gas pre-flow, followed by an uninterrupted pulsed DC pilot arc established between the electrode and tip. The pilot arc is initiated by a momentary high frequency pulse from the Power Supply. The pilot creates a path for the main arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated.

1. Parts-In-Place (PIP) Interlock

The Power Supply has a built-in parts-in-place interlock that prevents accidental torch starting when torch parts are not properly installed. A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly. If not satisfied, the switch interrupts power to the tip and electrode.

2. Gas Pressure Interlock

A pressure switch acts as an interlock for the plasma gas supply . If the plasma gas supply pr essure falls below minimum requirements the pr essure switch will open, shutting off the power to the contactors, and the GAS indicator will go out. When adequate plasma supply pressure is available the pressure switch will close, allowing power to be resumed for cutting.

NOTE

There is no gas pressure interlock for secondary gas.

D. Main Cutting Arc

The power supply converts the AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead. The positive output is connected to the workpiece via the work cable and clamp connection.

E. RF Shielding

Machine torch systems using CNC Interface Cables are shielded to minimize radio frequency (RF) interference which results from the high frequency ar c initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads. The CNC control signals are filtered on an internal PC Board.

F. Interlocks

The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the fault condition must be remedied and the system recycled using the applicable control device.

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2727

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 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 components.

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.

1. Unpack each item and remove all packing material.

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 Transporting Options

a. Input power b. Internal power selection c. Work cable b. Gas connections d. T orch Installation e. Connecting auxiliary devices

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 in Section 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 (0.6 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.

• Do NOT lift by handle (see NOTES).

NOTES

Use the lifting eye located in the Top Panel to lift the Power Supply with cable and hook.

Power Supplies with revision letter 'I' or earlier have the Handle only.

Power Supplies with revision letter 'J' or later have the Lifting Eye and Handle.

The revision letter is the letter at the end of the serial number on the Power Supply data tag.

• Do NOT pull power supply by torch leads. Use the handle and wheels to move the power supply.

Manual 0-2727 3-1 INST ALLATION PROCEDURES

NOTE

WARNING

FALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.

3.05 Input Power Cable Connections

WARNING

Disconnect primary power at the source before connecting the primary power cable to the power supply.

The primary input power cable (see CAUTION) is supplied and must be connected by the user to the primary power source. Power Supply is factory wired for 380415 VAV, thr ee-phase power.

CAUTION

The primary input power cable must not be modified in any way as shielding is installed on the cable.

The power source must conform to local and national electric codes. Recommended circuit protection and wiring requirements are shown in Appendix 1.

Connect the primary input power cable to the customer power source per the following procedur e:

Refer to subsection 3.08 for procedures on installing an earth ground for the power supply and work cable.

3.06 Gas Connections

The Power Supply provides the liquid cooling and gases to support operation of the Torch.

NOTE

Refer to the Torch Instruction Manual for information on plasma and secondary gas selection and requirements.

The following are available gases that can be used with this System:

• Plasma Gases

Compressed Air , Nitrogen, Argon/Hydr ogen

• Secondary Gases

Compressed Air, Carbon Dioxide (CO2), Nitrogen

Gas requirements vary depending on the application. The gases are connected to the rear panel connections of the power supply. Depending on the options installed and the source of the gases will determine the installation of connections, filters and regulators.

This sub-section includes information for connecting the gas supplies to the Power Supply. The information is grouped in paragraphs for different types of gases and options per the following:

1. At the free end of the input power cable, cut back the insulation on the individual wires approximately 1/8 - 3/16 inch (3 - 5 mm).

2. Connect the ends of the individual wires to a customer supplied plug per the following:

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 (Power

Ground)

• Input Cable Shield Connector to Ground (Power Ground)

A. Using Shop Air Only B. Using Plasma Shop Air and Secondary High

Pressure Gas Cylinder

C. Using High Pressure Gas Cylinders Only

A. Using Shop Air Only

Each Air Line Regulator on the r ear of the power supply has a built-in Air Line Filter. Filtering is required when using an air compressor to insure that moisture and debris from the supply hose does not enter the torch.

CAUTION

When using shop air , 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.

INSTALLATION PROCEDURES 3-2 Manual 0-2727

The following procedure is the recommended shop air connection method:

1. Connect the PLASMA Shop Air to the Two Stage Filter on the rear of the unit per the following:

1. Remove the factory installed plug fitting from the end of the Fitting in the input port (IN) of the Two Stage Air Line Filter Assembly.

2. Locate the 1/4 NPT to #4 (6 mm) barbed hose fitting shipped inside the Torch Spare Parts Kit.

3. Install the barbed fitting into the input port (IN) of the Two Stage Air Filter.

A-02085

Barbed

Hose

Clamp

Gas Supply Hose

Fitting

Two Stage

Filter

Assembly

Figure 3-1 Shop Air Connection

a. Locate the 1/4 NPT to #4 (6 mm) barbed hose

fitting located inside the T or ch Spare Parts Kit.

b. Install the barbed fitting into the input port (IN)

of the Two Stage Air Line Filter. c. Tighten the barbed fitting. d. Connect the PLASMA air supply hose (see

NOTE) to the barbed fitting and secure with a

customer supplied hose clamp.

NOTE

The customer supplied hose must be at least a #4 hose (1/4 in or 6 mm I.D.) to provide adequate air flow.

Plasma Air Regulator

Barbed Hose

Fitting

Hose

Clamp

Gas Supply Hose

to Shop Air

Two Stage

Filter

Assembly

A-02333

Secondary Air Regulator

Gas Supply Hose to Gas Cylinder

4. Tighten the barbed fitting.

5. Connect the air supply hose (see NOTE) to the barbed fitting and secure with a customer supplied hose clamp.

NOTE

The customer supplied hose must be at least a #4 hose (1/4 inch or 6 mm I.D.) to provide adequate air flow .

B. Using Plasma Shop Air and Secondary

High Pressure Gas Cylinder

NOTES

Refer to the manufacturer’s specifications for installation and maintenance procedures. Refer to sales literature for a listing of available high-pressure regulators and accessories.

Do not use an air line filter with high pressure regulators.

Figure 3-2 Shop Air and Gas Cylinder Connections

2. Connect the SECONDARY gas supply to the rear of the Power Supply per the following:

a. Remove the Secondary Hose from the Inert-B

Fitting at the Secondary air regulator of the Power Supply.

b. Connect the customer supplied gas cylinder

supply hose from the secondary gas source to the Inert-B Fitting on the SECONDARY air regulator of the Power Supply.

c. Disconnect the unused Secondary gas supply

hose from the T-Fitting and install a customer supplied 1/4 NPT plug fitting.

Manual 0-2727 3-3 INST ALLATION PROCEDURES

C. Using High Pressure Gas Cylinders Only

NOTES

Refer to the manufacturer’s specifications for installation and maintenance procedures. Refer to sales literature for a listing of available high-pressure regulators and accessories.

Do not use an air line filter with high pressure regulators.

d. Reconnect the Plasma Hose to the Plasma

Regulator/Filter Assembly Inert-B Fitting.

e. Reconnect the Secondary Hose to the Secodary

Regulator/Filter Assembly Inert-B Fitting.

f. Install a 1/4 NPT-Insert B (right-hand) Adapter

Fitting (see NOTE) into the end of the T-Fitting.

NOTE

1. 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.

WARNING

Do not stand in front of valve outlet when opening.

2. Each cylinder must be equipped with an adjustable high-pressure regulator capable of outlet pr essures up to 100 psi (6.9 bar) maximum and flows of up to 400 scfh (188.7 lpm).

CAUTION

Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator.

3. When using gas cylinders as the plasma and secondary gas supplies the connections will depend on the number of cylinders used. Refer to one of the following procedures and make the gas connections.

Adapter Fitting must be supplied by the customer .

g. Connect the customer supplied gas regulator

supply hose directly to the Adapter Fitting.

A-02948

T-Fitting

Gas Regulator

Supply Hose

1/4 NPT - Inert B, R.H

Fitting

Figure 3-3 Connection Using Single Gas Cylinder

• Using Single Gas Cylinder for Plasma and Secondary Gas

If the Plasma and Secondary gas source are to be the same and will use the same high pressure cylinder , connect the gas regulator supply hose fr om the gas cylinder to the Power Supply per the following:

a. Remove the Plasma and Secondary Hoses from

the Inert-B Fitting at the Plasma and Secondary Regulator/Filter Assemblies of the Power Supply.

b. Remove the factory installed Two Stage Air

Line Filter Assembly and gas supply hoses from the Power Supply.

c. On the Two Stage Air Line Filter remove the

two hoses and the T-Fitting at the output port (OUT).

• Using Seperate Gas Cylinders for Plasma and Secondary Gas

If the Plasma and Secondary gases will be different or two separate high pressure cylinders are to be used, connect the gas regulator supply hoses to the Power Supply per the following:

a. Remove the Plasma and Secondary Hoses from

the Inert-B Fitting at the Plasma and Secondary Regulator/Filter Assemblies of the Power Supply.

b. Connect the customer supplied gas cylinder

supply hose from the plasma gas source directly to the input fitting at the PLASMA air regulator of the Power Supply.

c. Connect the customer supplied gas cylinder

supply hose from the secondary gas source directly to the input fitting at the SECONDARY air regulator of the Power Supply..

INSTALLATION PROCEDURES 3-4 Manual 0-2727

Inert B Fittings

Plasma Air Regulator Assemby

Plasma Gas Supply Hose From Gas Cylinder

A-02331

Secondary Air Regulator Assembly

Secondary Gas Supply Hose From Gas Cylinder

Figure 3-4 Connection Using Two Gas Cylinders

3.07 Connecting T orch Leads

WARNING

Disconnect primary power at the source before assembling or disassembling the power supply, tor ch parts, or torch and leads assembly.

The instructions for connecting the Torch Leads to the Power Supply are different depending on the type of leads. This sub-section covers connecting the Torch for the following applications:

A. Hand Systems B. Machine Systems (Unshielded Leads) C. Machine Systems (Shielded Leads) D. Remote Pendant Control (Optional)

The T or ch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory installed, make all torch connections to the Torc h Bulkhead Panel for the desired application.

NOTE

Screw Latches

Access Panel

Torch Leads Shield Stud

Bulkhead

A-02684

Figure 3-5 Access Panel

2. Lift up on the Access Panel to gain access to the Torch Bulkhead Panel.

A. Hand Systems

Connect the Hand Torch to the Power Supply using the following procedure:

1. Open the Access Panel to gain access to the Torch Bulkhead Panel.

2. Feed the end of the Torch Leads through the rubber boot on the front panel in the following order (see NOTE):

• Control Cable Connector

• Torch Coolant and Gas Leads

NOTE

Feed the Control Cable through the rubber boot first as there will not be enough space inside the rubber boot for the connector if the Coolant and Gas Leads have been fed through the rubber boot first.

Equipment ordered as a system will have the Torch factory connected to the Power Supply.

Connecting the T or ch Leads to the Power Supply requires gaining access to the Torch Bulkhead Panel in the Power Supply per the following procedure:

1. Turn the two screw latches securing the Access Panel to the power supply front panel.

Manual 0-2727 3-5 INST ALLATION PROCEDURES

Secondary

A-02950

Secondary

Gas

Plasma (+)

Gas

Remote Hand

Pendant Control

Cable

Coolant

Return

Coolant

Supply (-)

Control Cable

Connector

Gas

Plasma (+)

Gas

Connect the Remote Hand Pendant and Torch Leads to the Power Supply using the following procedure:

1. Open the Access Panel to gain access to the Torch Bulkhead Panel.

Coolant

Supply (-)

A-02949

Control Cable

Connector

Coolant

Return

Control

Cable

Figure 3-6 Hand Torch Leads Connections

3. Connect torch coolant and gas leads to connectors on the Torch Bulkhead Panel.

4. Close the access panel and turn the two latching screws.

5. Check the torch for proper parts assembly.

B. Machine Systems (Unshielded Leads)

Systems ordered with Unshielded Machine Torch will include a Remote Hand Pendant. The Remote Hand Pendant allows the operator to start the cutting operation from a remote location.

2. Feed the connector on the end of the Remote Hand Pendant Control Cable through the rubber boot on the front panel of the Power Supply (see NOTE).

NOTE

3. Connect the Remote Hand Pendant Control Cable connector to the Control Cable connector on the Torch Bulkhead Panel.

4. Feed the end of the Torch Leads through the rubber boot.

Remote Pendant/CNC

Cable Connector

Control

OK-To-Move

12 14 13

3 4

PIP

Circuit

Torch Control

Cable Connector

2 3

4 12 14 13

A-01366

Figure 3-7 Remote Pendant Connector Diagram

NOTE

Equipment ordered as a System will have the Control Cable and Torch Leads factory connected to the Power Supply.

Figure 3-8 Unshielded Machine Torch Connections

5. Connect torch coolant and gas leads to connectors on the Torch Bulkhead Panel.

6. Close the Access Panel and turn the two latching screws.

7. Check the torch for proper parts assembly.

C. Machine Systems (Shielded Leads)

Systems ordered with Shielded Machine Torch will include a Computer Control (CNC) Control Cable. The CNC Control Cable allows the Power Supply to interface with a computer or other control device.

NOTE

Refer to Appendix 5 for CNC Control Cable Interface Signal Diagram.

INSTALLATION PROCEDURES 3-6 Manual 0-2727

Connect the CNC Control Cable and Torch Leads to the Power Supply using the following procedure:

1. Open the Access Panel to gain access to the Torch Bulkhead Panel.

3.08 Ground Connections For Mechanized Applications

A. Electromagnetic Interference (EMI)

2. Feed the connector on the end of the CNC Control Cable through the rubber boot on the front panel of the Power Supply (see NOTE).

NOTE

3. Connect the CNC Control Cable connector to the Control Cable connector on the Torch Bulkhead Panel.

4. Feed the end of the Torch Leads through the rubber boot.

Plasma (+)

Gas

Secondary

Gas

Coolant

Supply (-)

A-02113

Torch Leads

Shield Stud

Control Cable

Connector

Coolant

Return

CNC Control

Cable

Shield Wire

With Ring Lug

Pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. T o minimize RF interfer ence, follow these grounding procedures when installing mechanized systems:

B. Grounding

1. The preferred gr ounding arrangement is a single point or “Star” ground. The single point, usually on the cut- ting table, is connected with 1/0 (42 mm2) or larger wire to a good earth ground (refer to paragraph ‘C’, Creating An Earth Ground). The ground r od must be placed as close as possible to the cutting table. Ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible. Wires of long length will have increased r esistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better.

2. Components that are mounted on the cutting machine; CNC controller, plasma remote controls, height controllers, remote arc starters, etc., should be gr ounded to the cutting machine frame (chassis) with at least a 12 AWG (4 mm2) wire. Flat copper braid works even better.

3. The cutting machine frame is then connected to the

Figure 3-9 Shielded Machine Torch Connections

5. Connect the Torch Leads Shield Wire per the following procedure:

a. Remove one nut and star washer from the torch

leads shield stud on the T or ch Bulkhead Panel.

b. Place the ring lug from the Torch Leads Shield

Wire over the shield stud.

c. Secure the wire with the nut and star washer.

6. Connect torch coolant and gas leads to connectors on the Torch Bulkhead Panel.

“Star” point using AWG 6 (13.3 mm2) or larger wire.

4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.

NOTE

Do Not connect the work cable directly to the ground rod.

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare

7. Close the Access Panel and turn the two latching screws.

8. Check the torch for proper parts assembly.

metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended.

9. Connect the other end of the CNC Control Cable to the desired equipment.

Manual 0-2727 3-7 INST ALLATION PROCEDURES

6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.

When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.

NOTE

It is recommend that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 mm) of the cutting table, if possible.

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interference than with no shield at all.

C. Creating An Earth Ground

A-02971

Meter set to VAC setting

WARNING

Use extreme caution. This

test uses live voltage.

Neutral

115 VAC

Line (Hot)

Light Bulb

100W

3.0

COM

Earth Ground

Machine

1. To create a solid, low r esistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground 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. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 (53.5 mm2) or greater, between the ground rod and the star ground point on the cutting table.

NOTE

Ideally, a properly installed gr ound rod will have a resistance of three ohms or less.

T o test for a proper earth gr ound using 1 15 VAC, refer to the following diagram. Ideally, the r eading on the multimeter should be 3.0 VAC or less.

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the ef fective- ness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference.

INSTALLATION PROCEDURES 3-8 Manual 0-2727

3.09 Filling Power Supply Coolant

The ambient temperature of the environment where the Power Supply will be located determines the coolant to be used. The Standard Torch Coolant supplied with the system can be used in ambient temperatures down to 10° F (-12° C).

Optional Super Torch Coolant should be used in areas where the ambient temperature drops down to -34° F (-36° C).

CAUTION

Use only Thermal Arc Torch Coolant. Use of any other coolant can result in torch damage, insufficient thermal protection, and/or pilot arc interference.

1. Locate the coolant deionizer bag and remove from the plastic shipping bag.

2. Remove the coolant filler cap from the reservoir at the rear of the Power Supply.

3. Carefully pour enough of the supplied Thermal Arc Torch Coolant into the reservoir to fill it.

6. Remove the filler cap, re-fill the reservoir, place the deionizer bag into the basket in the coolant reservoir and re-install the filler cap.

4. Reinstall the reservoir coolant filler cap.

5. After the complete system has been installed do the following procedure to make sur e the coolant has been pumped through the system (see NOTE):

NOTE

Depending on the length of the torch leads ordered with the system more coolant may need to be added after turning ON the system for the first time.

a. Place the ON/OFF Switch to ON. b. After about 10 seconds the system will shut

down (see NOTE).

NOTE

DO NOT allow the pump to operate for more than 10 seconds the first time the system is turned ON.

c. Place the ON/OFF switch to OFF. d. After 10 seconds place the ON/OFF switch to

ON again.

e. Repeat steps ‘b’ through ‘d’ until the system

no longer shuts down. Depending on the length of the torch leads this sequence may need to be done three to five times.

f. After the system stays operational allow the

pump to operate for ten minutes to properly purge any air from the coolant lines before using the system.

Manual 0-2727 3-9 INST ALLATION PROCEDURES

INSTALLATION PROCEDURES 3-10 Manual 0-2727

SECTION 4:

RUN

OFF

TEMP GAS DC

120

100

CURRENT

OPERATION

4.01 Introduction

This section provides a description of the CE Power Supply operating controls and procedures. Identification of the Front and Rear Panel components is followed by operating procedures.

2. Access Panel

A panel to gain access to the bulkhead area containing the torch connections.

3. Torch Leads Input

Rubber Boot and 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).

4.02 Operating Controls

This subsection provides specific functional descriptions of the Power Supply operating controls and indicators.

A. Front and Access Panel

1. Control Panel

All operator controls, except gas pressure adjustment, are located on this panel and include:

• Power ON/OFF and RUN/SET switches

• CURRENT control

• LED indicators for AC Power , TEMP, GAS/

Coolant, and DC.

5. Lifting Eye

Used to lift the Power Supply with cable and hook.

B. Control Panel

1. Current Control

Adjustment to set the desired output current between 30-120 amps. For drag cutting applications set the control between 30 - 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.

CURRENT

120

100

AC TEMP GAS DC

A-02079

OFF

RUN

SET

A-02078

Figure 4-2 Control Panel

Figure 4-1 Front and Access Panels

Manual 0-2727 4-1 OPERA TION

3. RUN/SET Switch

5. Torch Lead Shield Stud (see NOTE)

RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.

4. AC Power Indicator

Once ON/OFF power switch is set to ON, green LED indicator will blink ON then OFF for approximately

eight seconds and then stay ON. Indicates

operating power is present in the unit.

5. TEMP Indicator

Normally OFF. Yellow LED indicator will come ON when the internal temperature sensors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation.

6. GAS/Coolant Flow OK Indicator

This LED is both a gas pressure and coolant flow indicator.

A green LED indicator ON means the input gas pressure is set to 40 psi (2.8 bar) or higher, and there is adequate coolant flow of greater than 0.5 gpm

Stud used to secure the torch lead shield ring lug.

NOTE

Used with Shielded Torch Leads only.

6. Control Cable Connector

Connector used to interface the Torch Control Cable to the unit. In Hand Torch applications interfaces the Torch Switch to the unit. In Machine T orch applications interfaces either Remote Hand Pendant Control Cable (unshielded Torch Leads) or CNC Control Cable (shielded Torch Leads).

The Indicator will be OFF when the pressure falls below 40 psi (2.8 bar) or there is not enough coolant flow (less than 0.5 gpm) caused by damaged hose(s), clogged filter(s), etc.

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. Plasma (+) Gas Lead Connection

Left-hand thread fitting to connect the torch plasma lead to the unit.

2. Secondary Gas Lead Connection

Fitting to connect the torch secondary lead to the unit.

3. Coolant Supply (-) Lead Connection

Fitting to connect the torch coolant supply lead to the unit.

4. Coolant Return Lead Connection

Left-hand thread fitting to connect the torch coolant return lead to the unit.

A-02881

Figure 4-3 Torch Bulkhead Panel

D. Rear Panel

1. Primary Power EMI Input Filter, Cable and Strain Relief

The factory installed EMI Input Filter Assembly is mounted to the rear panel of the power supply. A strain relief is supplied to secure the shielded primary input AC power cable to the EMI Input Filter Assembly. The input cable is routed through the strain relief and is connected to input terminals of an input filter. The shielded input power cable requires two ground connections outside of the Power Supply:

• Power ground for the cable

• Shielded cable cover ground

OPERATION 4-2 Manual 0-2727

2. Plasma Gas Pressure Regulator/Filter Assembly

5. Gas Input

Pressure Regulator to adjust the plasma input gas pressure to the Power Supply. The Pressure Regulator has a built-in air line filter.

A-02297

Input connections for plasma and secondary gases. Acceptable gases are as follows:

Plasma Gases - Air, Nitr ogen, Argon Hydrogen Secondary Gases - Air, Nitr ogen, Carbon Dioxide

WARNING

This unit not to be used with oxygen (O2).

6. Two Stage Air Line Filter

Two Stage Air Line Filter Assembly will remove moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least 5 microns.

4.03 Sequence of Operation

The following is a typical sequence of operation for this cutting system. Refer to Appendix 2 for a block diagram.

1. Close main power source disconnect. a. AC power is available at the Power Supply .

Figure 4-4 Rear Panel

3. Secondary Gas Pressure Regulator/Filter Assembly

Pressure Regulator to adjust the secondary input gas pressure to the Power Supply. The Pressure Regulator has a built-in air line filter.

4. Coolant Reservoir

The coolant reservoir supplies the system with coolant to cool the torch and torch parts during operation. The maximum capacity of the reservoir is two gallons of coolant.

Inside the reservoir, in the filler hole, is a basket and deionizer bag. The bag removes charged particles from the coolant after it is returned to the reservoir and prevents the coolant from becoming conductive. If the coolant becomes conductive it must be replaced (see NOTE).

NOTE

Refer to Section 5.02, General Maintenance, subsections 'E' and 'F' for procedures on checking and replacing coolant.

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. Fan turns ON. b. Coolant Pump turns ON. c. AC Power indicator LED blinks ON and OFF

for eight seconds then stays ON.

d. Start-up pre-purge of gas.

4. Place RUN/SET switch to SET mode. a. Gas Solenoid opens and gas flows to set pres-

sure.

b. GAS indicator turns ON.

NOTE

GAS indicator will not come ON if the gas pressure is set below 40 psi (2.8 bar) at the Regulator/ Filter Assembly or if coolant flow switch is not satisfied.

5. Place RUN/SET switch to RUN mode. a. Gas flow stops. b. GAS indicator turns OFF.

Manual 0-2727 4-3 OPERA TION

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)

4.04 Preparations for Operating

Follow this set-up procedure each time the system is operated:

a. Power Supply enabled. b. DC indicator turns ON.

8. Pilot arc is established.

9. Move T orch within transfer distance of workpiece. a. Main arc transfer. b. Pilot arc OFF.

10. To rch is ready to cut. Complete cutting operation.

NOTE

If the torch is lifted from the workpiece while still having the torch switch activated, the main arc will stop and the pilot arc will automatically restart.

11. Release or deactivate the tor ch switch. a. Main arc stops.

NOTE

If the torch is activated during post-flow, pilot arc will immediately restart.

If the torch is within 3/8 inch (9.5 mm) transfer distance of workpiece, main arc will transfer.

12. Gas will flow for 20 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.

WARNING

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

A. Coolant Level Inspection

Check the coolant level at the coolant reservoir at the rear of the unit. If the coolant is down from the top of the reservoir more than 2 inches (50 mm), add coolant.

NOTE

The label on the coolant reservoir indicates the level at which coolant should be added.

B. Deionizer Bag Inspection

Check the condition of the deionizer bag in the reservoir basket. If the bag is a yellowish brown (straw color) then replace the bag.

C. Torch Parts Selection

Check the torch for proper parts assembly. Install proper torch parts for the application (refer to Torch Instruction Manual).

D. Primary Input Power Source

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, Specifications/Design Features.

Connect the input power cable (or close the main disconnect switch) to supply power to the system.

E. Plasma Gas Supply Selection

Select desired plasma gas. Make sure gas sources meet requirements (refer to Torch Instruction Manual). Check connections and turn plasma gas supply on.

F. Secondary Gas Supply Selection

Select desired secondary gas. Make sure gas sources meet requirements (refer to Torch Instruction Manual). Check connections and turn secondary supply on.

G. Work Cable Connection

Check for a solid and clean work cable connection to the workpiece. The area must be free from paint and rust.

OPERATION 4-4 Manual 0-2727

A-02081

Figure 4-5 Work Cable Connection to Workpiece

H. Torch Connection

Check that torch is properly connected.

I. Plasma Gas Purge (Pre-Flow)

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 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 gas purge process.

J. Current Output Level Selection

Select the desired current output level for the operation.

• 30-120 amps for standoff cutting and gouging

• 30 - 35 amps for drag cutting

K. Set Operating Pressure

Move the RUN/SET switch to SET position. Set plasma and secondary pressures. Adjust the gas pressure to 65 psi (4.5 bar) for plasma and 60 psi (4.1 bar) for secondary.

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. 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 dif ficulties if the material is welded after the cutting process.

Kerf Width

Cut Surface Bevel Angle

Top

Spatter

L. Ready for Operation

Top Edge

Return the RUN/SET switch to RUN position. The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram of the Sequence of Operation.

4.05 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

Cut quality will vary on different types of and material thicknesses. The table shows the cut quality that can be expected from this equipment for materials with a thickness from gage to 1-1/2 inches (38.1 mm):

Dross

Build-Up

Cut Surface

Drag Lines

Figure 4-6 Cut Quality Characteristics

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 4-6:

Manual 0-2727 4-5 OPERA TION

Rounding

A-00007

Cut Qua li ty on Va rious Materials

Types of Mate rial

Type of Gases Material Thi ckness Carbon Steel Stainl ess Aluminum

Air Plasma and

Air S econdary

Nitrogen Pl asma

and Air or CO2

Sec ondary

Gage (0.5 mm)

Gage t o 1 inch ( 0.5 mm - 25.4 mm)

1 to 1 - 1/2 inch (25. 4 mm - 38.1 mm)

Gage (0.5 mm)

Gage to 1/ 2 inch (0.5 mm - 12.7 mm)

1/2 to 1-1/2 inc h (12.7 mm - 38.1

Excellent Good-Excellent Good-Excellent Excellent Good Good Excellent Good Good

NR Good-Excellent Good-Excellent NR Good-Excellent Good-Excellent NR Good-Excellent Good-Excellent

Ar/ H2 Pl asma and

N2 or CO2

Sec ondary

Gage to 1/ 4 inch (0.5 mm - 6.4 mm)

1/4 to 1-1/4 inc h (6.4 mm - 31.8 mm)

1/2 to 1-1/2 inc h (12.7 mm - 38.1

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.

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.

NR NR NR NR Good Excellent NR Good Excellent

4.06 System Operation

NOTE

Frequently review the safety precautions at the fr ont of this manual.

This section contains operating information which is specific to the power supply. Detailed operating information for torches can be found in the appropriate Torch Instruction Manual.

WARNINGS

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.

It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.

A. Operational Suggestions

The suggestions below should be followed in all cutting and gouging operations:

1. Wait five minutes befor e setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run to dissipate operating heat from the power supply.

2. For maximum parts life, do not operate the pilot arc any longer than necessary.

3. Use care in handling torch leads and protect them fr om damage.

OPERATION 4-6 Manual 0-2727

4. In continuous cutting applications using CO2, it is often necessary to manifold four to six cylinders together to maintain adequate flow at operating pressures.

B. Fold Back Feature

Should the torch tip contact the workpiece or molten slag, the output current will immediately drop to 35 amps to minimize potential tip damage.

4.07 Optional Power Supply

Settings

The following functions can be used to tailor a system for special application requirements or unique user preferences. These functions are controlled by DIP switches located on the Logic Control PC board in the power supply.

Remove the left side panel and locate the Logic Control PC Board near to top center of the unit. Set the function as required.

A. High/Low Speed Auto-Restart Function

(SW5)

The Plasma Power Supply is always in the Auto-Restart mode. This means that at the end of the cut, if the ST ART signal is still on, the pilot will restart automatically.

Logic PC Board

A-02258

SW5

Figure 4-7 High/Low Speed Auto-Restart Switch

SW5 Location

Select the desired function as shown in the following chart:

An immediate pilot restart, when cutting over holes or expanded metal at relatively slow speeds, may cause the arc to transfer back to the piece just cut. This happens because the torch has not had time to be moved away from the cut piece and results in extra starts and unnecessary parts wear.

The High/Low Speed Auto-Restart switch, SW5, has two settings as follows:

• Low Speed - adds a one-tenth second delay to the pilot restart to prevent arc back conditions.

• High Speed - no delay required as it may delay starting on the next edge.

High/Low Speed Auto-Restart Function

Speed SW5-1 SW5-2

High 0 (OF F) 0 (OFF)

Low * 1 (ON) 1 (ON)

* = F a ct ory Se t t in g

NOTE

The ON position is in the direction of the arrow on the PC Board next to the switch.

B. Gas Pre-Flow Delay (SW3)

The pre-flow delay allows time for gases to flow to the torch when the torch is activated. Pre-flow is immediately followed by pilot arc initiation. Gas Pre-Flow Delay is set depending on the total torch lead length used in the system. All power supplies ar e factory set at 2 seconds and must be reset either to 3.4 or 4 seconds as required if total torch lead length in the system is over 60 ft (18.3 m).

Manual 0-2727 4-7 OPERA TION

Logic PC Board

A-02288

SW3

Figure 4-8 Gas Pre-Flow Delay Switch SW3

Location

Select the proper gas pre-flow time for the total torch lead length as shown in the following chart:

Pre-Flow

(Sec ond s)

2 *

3.4

Gas Pre-Flow Delay Function

Total Torch

Lead Length

0 - 60 ft

(0 - 18. 3 m)

61 - 85 ft

(18.6 - 25.9 m)

86 - 125 ft

(26.2 - 38.1 m)

SW3-1 SW3-2

1 (ON) 1 (ON)

1 (ON) 0 (OFF)

0 (OFF) 0 (OFF)

* = F a cto ry Se tti n g

OPERATION 4-8 Manual 0-2727

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

This section describes maintenance procedures, basic troubleshooting and service performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.

5.02 General Maintenance

A. Routine Maintenance

NOTE

C. Coolant Filter Assembly Cleaning

The Coolant Filter Screen should be cleaned periodically. T o gain access to the Coolant Filter Assembly, remove the right side panel when viewed from front of unit. Remove the Filter Screen by unscrewing the filter holder from the Coolant Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before reinstalling in the Coolant Filter Assembly.

Refer to Appendix 4 for a recommended maintenance schedule for water cooled plasma cutting systems.

Routine maintenance for the Power Supply should include an occasional thorough cleaning and inspection. The frequency depends on the usage and the operating environment.

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.

B. Power Supply Cleaning

To clean the unit, open the 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.

WARNING

Filter

Filter Holder

A-02152

Figure 5-1 Coolant Filter Assembly

D. In-Line Coolant Filter Assembly Cleaning

The In-line Coolant Filter Screen should be cleaned periodically. To gain access to the In-Line Coolant Filter Assembly remove the right side panel (when viewed from the front of unit). Remove the Filter Screen by unscr ewing the Filter Holder from the In-Line Coolant Filter Assembly. Clean the Filter Scr een by rinsing with hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before re-installing in the InLine Coolant Filter Assembly.

Do NOT blow air into the power supply during cleaning; make sure to always blow air out of the unit. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damge to the unit.

While the unit is open, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected.

Manual 0-2727 5-1 CUSTOMER/OPERATOR SER VICE

2. Disconnect the coolant input hose to the Coolant Filter Assembly .

3. Carefully lower the hose out the right side of the Power Supply and drain the coolant into an acceptable container.

CAUTION

Filter

Filter Holder

A-02153

Figure 5-2 In-Line Filter Assembly

E. Coolant Level and Conductivity

1. Coolant Level

The coolant level should be checked every day at the rear panel coolant gauge. If the coolant in the reservoir is more than 2 inches (50 mm) from the top of the reservoir then add Torch Coolant.

2. Coolant Conductivity

The coolant conductivity level should be checked if the pilot doesn't start.

Handle and dispose of the used coolant per recommended procedures.

Coolant Filter Assembly

Place hose in bucket to drain

Coolant Reservoir

Coolant Input Hose

Check the condition of the deionizer bag in the reservoir basket, if the bag is yellowish brown (straw color) replace the bag and coolant (see NOTE).

NOTE

To accurately measure the coolant conductivity it is recommended to use a Conductivity Sensor such as Thermal Dynamics Model TDS-73 (Catalog # 7-2844).

F. Draining and Replacing Coolant

Remove the old coolant from the Power Supply reservoir per the following procedure:

1. Remove the right side panel from the Power Supply.

A-02154

Figure 5-3 Draining Coolant From Reservoir

4. Reconnect the hose to the Coolant Filter Assembly.

5. Remove Coolant Reservoir lid and install new coolant and deionizer bag.

6. Reinstall the right side panel.

5.03 Common Operating Faults

Listed below are common cutting problems followed by probable causes of each. If the problems are caused by a torch problem, refer to the appropriate Torch Manual.

CUSTOMER/OPERATOR SERVICE 5-2 Manual 0-2727

1. Insufficient Penetration

5. Poor Pilot Starting

a. Cutting speed too fast b. Torch tilted too much c. Incorrect Gas Settings d. Metal too thick e. Worn torch parts f. Cutting current too low g. Non-Genuine Thermal Dynamics Parts

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 f. Non-Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current

a. Non-Genuine Thermal Dynamics Parts b. High coolant conductivity

5.04 Common Operating Problems

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

Frequently review the Important Safety Precautions in Section 1 of this Manual. 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. e. Improper gas selection on settings f. Non-Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in gas source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Starting or finishing off the workpiece e. Gas flow too low (incorrect pressure or flow setting) f. Improperly assembled torch g. Output current too high for parts being used h. Torch tip contacting workpiece i. Improper gas selection for parts being used j. Damaged or loose torch head components k. Restricted coolant flow l. Non-Genuine Thermal Dynamics Parts

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.

Manual 0-2727 5-3 CUSTOMER/OPERATOR SER VICE

D. Direction of Cut

In the 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. Viewed along the direction of travel, the right side of the cut is more square than the left (Refer to Figure 5-4). 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.

Left Side

Cut Angle

Right Side Cut Angle

A-00512

Figure 5-4 Side Characteristics Of Cut

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 troubleshoot-

ing techniques.

B. Basic Tr oubleshooting

This manual covers a basic level of troubleshooting that requires limited dissasembly and measurements. 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 r efer to CE PAK Master 150XL Power Supply Service Manual 0-2728.

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.

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 required 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.

5.05 Troubleshooting Guide

A. General

T roubleshooting and r epairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic T ype)

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 LED 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 Cable Connections)

3. Actual input voltage is not within the specified range. This unit is designed to be operated from 380-415V, 3Phase input power.

a. Check actual line voltage

CUSTOMER/OPERATOR SERVICE 5-4 Manual 0-2727

4. Customer's main power line fuse(s) blown

a. Check main power panel fuse(s) and replace

as required.

D. AC Power LED ON; Fans operating; No cutting

output

1. Torch not properly connected to power supply

5. Unit internal fuse blown or loose

a. If blown, double check input voltage and re-

place fuse per Subsection 5.06-C. If fuse blows again, return unit to an authorized service center.

6. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

B. AC Power LED ON; TEMP indicator ON

1. 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.

2. Airflow obstructed

a. Check for obstructed air flow and correct con-

dition.

3. Fan(s) blocked

a. Check and correct condition

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.

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.

3. Poor input or output connections

a. Check all input and output connections.

F. Erratic or improper cutting output

4. Input line voltage is below 75% of rated level

a. Check and connect to proper input power line

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 switch in SET position

a. Move switch to RUN position.

2. Switch activated during 8 second inrush time

a. Release switch and wait until AC LED stops

flashing before 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 plasma gas pressure to 65 psi (4.5 bar) and

secondary gas to 60 psi (4.1bar).

5. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

1. Poor input or output connections

a. Check all input and output connections.

2. Faulty torch parts.

a. Replace with new torch parts.

G. AC Power LED indicator ON; Cutting output

available; Fan(s) 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.

H. AC POWER LED indicator ON; Fans operate; No

gas flow

1. Gas not connected or pressure too low

a. Check source for at least 100-125 psi (68.9- 86.2

bar).

2. Faulty components in unit

a. Return for repair or have qualified technician

repair per Service Manual.

Manual 0-2727 5-5 CUSTOMER/OPERATOR SER VICE

I. Torch cuts but not adequately

M. Leaking torch connection

1. Current set too low

a. Increase current setting.

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Instruction

Manual supplied with torch).

3. 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)

4. Defective torch parts

a. Replace defective parts.

J. GAS LED indicator OFF

1. Gas pressure set too low

a. Adjust pressure

2. Faulty power supply

a. Return for repair or have qualified technician

repair per Service Manual.

3. No coolant flow.

a. Return for repair or have qualified technician

repair per Service Manual.

K. GAS LED indicator OFF, plasma and/or secondary

gas does not flow

1. Low plasma pressure

a. Check plasma pressure

2. Secondary supply turned OFF (or cylinder empty)

1. Loose torch connection

a. Check connection making sure connector is

fully seated.

N. Weak or sputtering pilot; CD stays on during

pilot

1. Plasma gas pressure too high

a. Adjust pressure

2. Low OCV (normal 290-350 VDC) caused by improper input voltage selection

a. Check input voltage connections

3. Faulty power supply

a. Return for repair or have qualified technician

repair per Service Manual.

O. Pilot arc ON; No main arc transfer (torch brought

within range of work)

1. Work cable not connected

a. Connect work cable securely

2. Faulty power supply

a. Return for repair or have qualified technician

repair per Service Manual.

P. AC LED indicator ON; GAS LED Indicator light

on when torch switch pressed; DC LED Indicator light blinks

1. Shorted torch.

a. Return for repair or have qualified technician

repair per Service Manual.

a. Check secondary supply

3. Blocked torch

a. Check torch parts.

4. Faulty power supply

a. Return for repair or have qualified technician

repair per Service Manual.

L. GAS LED Indicator flashing ON and OFF

1. Air in coolant lines

a. Check for proper coolant level at rear panel

gauge

b. Run pump for ten minutes to purge air from

the coolant lines before using the system.

CUSTOMER/OPERATOR SERVICE 5-6 Manual 0-2727

2. Faulty power supply.

a. Return for repair or have qualified technician

repair per Service Manual.

5.06 Power Supply Parts Replacement

7. To reinstall the Side Panel do the following: a. Reconnect the ground wire to the Side Panel, if

disconnected.

WARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply .

A. Left or Right Side Panel Removal

1. Remove input power from the unit.

2. Loosen the two bottom screws in the slotted holes of the desired Side Panel (viewed from the front of the unit).

3. Remove the remaining screws which secure the Side Panel to the Power Supply.

4. Pull the top of the Side Panel out and then lift up to remove the panel from the Power Supply a short distance (see NOTE).

NOTE

There is a ground wire connection to the Side Panel on the inside of the unit.

5. Remove the nut securing the ground wire to the side panel and remove the ground wire.

6. Remove Side Panel from unit and set aside.

b. Place the Side Panel onto the frame and slide the

top edge under the lip on the Top Panel.

c. Reinstall all the screws to secure the Side Panel.

B. Fuse Replacement

The Fuse is located inside the Power Supply behind the Left Side Panel as viewed from front of the Power Supply.

1. Remove the Left Side Panel per paragraph 'A' above far enough to gain access to the Fuse (see NOTE).

NOTE

The ground wire connection to the Side Panel on the inside of the unit need not be disconnected to gain access to the Fuse.

2. Locate the internal fuse on the Center Chassis inside the unit.

3. Replace the Fuse.

4. Reinstall the Left Side Panel.

A-02951

NOTE:

Art may differ

from actual unit.

Fuse

Figure 5-6 Internal Fuse Location

C. Coolant Filter Assembly Replacement

The Coolant Filter Assembly is located inside the Power

A-02952

Figure 5-5 Left Side Panel Removal

Manual 0-2727 5-7 CUSTOMER/OPERATOR SER VICE

Supply behind the Right Side Panel as viewed from front of the Power Supply.

1. Remove the Right Side Panel from the Power Supply per paragraph 'A' above.

2. Remove the two Coolant Hose connections to the Coolant Filter Assembly.

Coolant Filter

Assembly

Bracket

Elbow Fitting

Coolant Hose

To Pump Assembly

(Filter Output)

Flow Switch

Assembly

In-line Coolant

Filter Assembly

Coolant Hose

(Filter Input)

A-02155

Figure 5-7 Coolant Filter Replacement

3. Remove the two elbow fittings on each side of the Coolant Filter Assembly and remove the damaged assembly from the bracket.

4. Clean the old thread sealer from the threads of the elbow fittings.

5. Apply a thin coating of liquid teflon thread sealer to the threads of the elbow fittings.

6. Place the replacement Coolant Filter Assembly in the bracket with the arrow pointing to the left and reinstall the two elbow fittings.

7. Reconnect the two Coolant Hoses to the Coolant Filter Assembly making sure that the hose to the Pump Assembly is on the output of the Coolant Filter Assembly (left side as viewed from the side of unit).

8. Reinstall the Right Side Panel.

D. In-Line Coolant Filter Assembly

Replacement

Coolant Hose

From

Radiator Assembly

A-02156

Figure 5-8 In-Line Coolant Filter Replacement

3. Disconnect the Flow Switch Assembly at the top of the In-Line filter Assembly.

4. Clean the old thread sealer from the threads of the hoses and the fittings.

5. Apply a thin coating of liquid teflon thread sealer to the threads of the fittings.

6. Reconnect the Coolant Hose from the Radiator Assembly to the bottom of the In-Line Filter Assembly . Reconnect the top of the In-Line Filter Assembly to the Flow Switch Assembly.

7. Reinstall the Right Side Panel.

The In-Line Coolant Filter Assembly is located inside the Power Supply behind the Right Side Panel as viewed from the front of the Power Supply.

1. Remove the right side panel from the Power Supply per paragraph 'A' above.

2. Locate the In-Line Coolant Filter and remove the Coolant Hose connection at the bottom of the InLine Filter Assembly.

CUSTOMER/OPERATOR SERVICE 5-8 Manual 0-2727

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 System Replacement Section 6.04 Power Supply Replacement Section 6.05 Basic Replacement Parts Section 6.06 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 product must be returned for service, contact your authorized distributor. Materials returned 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. Address all inquiries to your authorized distributor.

Manual 0-2727 6-1 PAR TS LISTS

6.03 System Replacement

Includes: CE Power Supply with Input Power Cable, EMI Filter Assembly, Work Cable & Clamp, Coolant, Torch & Leads (as ordered), Torch Spare Parts Kit, and Operating Manual.

Qty Description Catalog #

CE PAK Master 150XL 380-415V Units:

With PCH 70° Hand Torch 1 25 ft (7.6 m) Lead Length 1-1870-3 1 50 ft (15.2 m) Lead Length 1-1871-3

With PCH 90° Hand Torch 1 25 ft (7.6 m) Lead Length 1-1890-3 1 50 ft (15.2 m) Lead Length 1-1891-3

With PCM Machine Torch (Unshielded Leads & Remote Pendant) 1 25 ft (7.6 m) Lead Length 1-1880-3 1 50 ft (15.2 m) Lead Length 1-1881-3

With PCM Machine Torch (Shielded Leads & CNC Cable) 1 25 ft (7.6 m) Lead Length 1-1882-3 1 50 ft (15.2 m) Lead Length 1-1883-3

6.04 Power Supply Replacement

Includes: CE Power Supply with Input Power Cable, EMI Filter Assembly, Work Cable & Clamp, Coolant, and Operating Manual.

Qty Description Catalog #

1 CE PAK Master 150XL Power Supply, 380-415V 3-1800-3

6.05 Basic Replacement Parts

Qty Description Catalog #

1 Fuse, 5 Amp, 600V, Delay 10-2274 1 In-Line Coolant Filter 8-3460 1 Coolant Filter 8-4276 1 Torch Coolant - 1 gal (3.78 liters)

Standard 25/75 Mix for Ambient Temperatures to +10°F (-12°C) 7-2850

Super 50/50 Mix for Ambient Temperatures to -34°F (-36°C) 7-2959 1 Deionizer Bag 8-3312 1 Two Stage Air Line Filter Kit 7-7502

Replacement Elements 1 First Stage 9-1021 1 Second Stage 9-1022

1 CE Shielded Primary Input Power Cable 9-7890

PAR TS LISTS 6-2 Manual 0-2727

6.06 Options and Accessories

Qty Description Catalog #

CNC Interface Control Cable - Used With Shielded PCM Machine Torch 1 25 ft (7.6 m) 8-5557 1 50 ft (15.2 m) 8-5558

1 Torch Guide/Circle Cutting Attachment 7-7505 1 Locking Caster Kit (2 Casters) 9-7868 1 Remote Pendant Contr ol - Used With Unshielded PCM Machine Torch

25 ft (7.6 m) 7-3114

Manual 0-2727 6-3 PAR TS LISTS

PAR TS LISTS 6-4 Manual 0-2727

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input Current Suggested Sizes (See N ote s )

Volta g e Freq . 3-Ph 3-Ph Fus e (A m p s )

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

380 50/60 29.0 44 60 10 415 50/60 29.5 41 60 10

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

Wire (mm

)

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. 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 0-2727 A-1 APPENDIX

APPENDIX 2: 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 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-02324

APPENDIX A-2 Man ual 0-2727

APPENDIX 3: GROUNDING DIAGRAM

Power

3-Phase

Input

Supply

Work Cable

Workpiece

NOTES

Earth

Ground

Work Cable must connect directly to workpiece. DO NOT connect Work Cable to earth ground and then to workpiece.

Shielded input power cable must be grounded to earth ground at plug end.

A-02330

Earth

Ground

Manual 0-2727 A-3 APPENDIX

APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE

This schedule applies to all types of 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.

Daily Operational Checks or Every Six Arc Hours:

1. Check torch parts, replace if damaged.

2. Check plasma and secondary supply and pressure/flow.

3. Purge plasma gas line to remove any moisture build-up.

4. Check deionizer bag/cartridge, replace if color is predominantly yellow.

5. Check coolant pressure (100 - 120 psi).

Weekly or Every 30 Arc Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or 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 Arc Hours:

1. Remove and clean in-line filter screens.

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.

4. Check all pillow blocks and bearings, clean and lubricate if necessary.

5. Check fan, pump and pulley belts for wear or cracking, replace if necessary.

Twelve Months or Every 1500 Arc Hours:

1. Drain coolant, fill with distilled water , turn on main power switch and let machine run for approximately 30 minutes.

WARNING

DO NOT energize the Torch.

Drain distilled water and replace with Thermal Ar c Coolant. Use Standard Mix Coolant (Catalog # 7-2850) or Super Mix Coolant (Catalog # 7-2959) for environments below +10° F (-12° C).

2. Check radiator fins, clean and comb out if necessary.

3. Repeat six month maintenance.

APPENDIX A-4 Man ual 0-2727

APPENDIX 5: POWER SUPPLY CNC INTERFACE DIAGRAM

Cutting Machine CNC Cable

START/STOP

Start Motion (OK-To-Move)

Shield must be terminated

at the Cutting Machine

Shield

Red

Black

Blue

Orange

White Green

J22

4 10 11 12 14

Power Supply

Source 15 vdc, 10ma

Not Used Not Used

2A, 125 VAC

28 vdc

A-02259

Manual 0-2727 A-5 APPENDIX

APPENDIX 6: SCHEMATIC DIAGRAM

A-02329

APPENDIX A-6 Man ual 0-2727

A-02329

Manual 0-2727 A-7 APPENDIX

APPENDIX A-8 Man ual 0-2727

Tweco 150XLCE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.01 Scope of Manual

2.03 Specifications/Design Features

2.04 Power Supply Options and Accessories

2.05 Theory Of Operation

3.01 Introduction

3.03 Unpacking

3.04 Transporting Options

3.02 Site Selection

3.05 Input Power Cable Connections

3.06 Gas Connections

3.07 Connecting T orch Leads

3.08 Ground Connections For Mechanized Applications

3.09 Filling Power Supply Coolant

4.01 Introduction

4.02 Operating Controls

4.03 Sequence of Operation

4.04 Preparations for Operating

4.05 Cut Quality

4.06 System Operation

5.01 Introduction

5.02 General Maintenance

5.03 Common Operating Faults

5.04 Common Operating Problems

5.05 Troubleshooting Guide

5.06 Power Supply Parts Replacement

6.01 Introduction

6.02 Ordering Information

6.03 System Replacement

6.04 Power Supply Replacement

6.05 Basic Replacement Parts

6.06 Options and Accessories

APPENDIX 1: INPUT WIRING REQUIREMENTS

APPENDIX 3: GROUNDING DIAGRAM

APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE

APPENDIX 5: POWER SUPPLY CNC INTERFACE DIAGRAM

APPENDIX 6: SCHEMATIC DIAGRAM