Tweco 15XCCE User Manual
PLASMA CUTTING
SYSTEM
CE Merlin® PAK® 15XC™
Instruction Manual
August 19, 2005 Manual No. 0-2529
W ARNINGS
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 System
CE Merlin P AK 15XC
Instruction Manual No. 0-2529
Published by:
Thermal Dynamics Corporation
82 Benning Street
W est Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 1996 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in this
Manual, whether such error results from negligence, accident, or any
other cause.
Printed in the United States of America
Publication Date: August 19, 2005
Record the following information for W arranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
T or ch Serial #: _______________________________________
TABLE OF CONTENTS
GENERAL INFORMATION.............................................................................................................i
Notes, Cautions and Warnings ..................................................................................i
Important Safety Precautions ....................................................................................i
Publications..............................................................................................................ii
Note, Attention et Av ertissement ............................................................................. iii
Precautions De Securite Importantes...................................................................... iii
Documents De Reference ....................................................................................... v
Declaration of Conformity....................................................................................... vii
Statement of W arranty........................................................................................... viii
SECTION 1: INTR ODUCTION & DESCRIPTION..................................................................... 1-1
1.1 SYSTEM DESCRIPTION .............................................................................. 1-1
1.2 POWER SUPPLY SPECIFICATIONS ............................................................ 1-2
1.3 TORCH SPECIFICATIONS ........................................................................... 1-3
1.4 OPTIONS AND ACCESSORIES................................................................... 1-5
1.5 THEORY OF OPERATION............................................................................ 1-6
SECTION 2: INSTALLATION .................................................................................................... 2-1
2.1 UNPACKING THE SYSTEM .......................................................................... 2-1
2.2 LOCATION .................................................................................................... 2-2
2.3 PLASMA AND SECONDARY CONNECTIONS............................................. 2-2
2.4 ELECTRICAL CONNECTIONS..................................................................... 2-6
2.5 WORK AND GR OUND CONNECTIONS....................................................... 2-8
2.6 COOLANT INSTALLATION ........................................................................... 2-9
2.7 AUXILIARY CONNECTIONS ...................................................................... 2-10
2.8 LIFTING THE PO WER SUPPLY.................................................................. 2-12
SECTION 3: OPERATION ........................................................................................................ 3-1
3.1 OPERATING CONTROLS............................................................................. 3-1
3.2 PRE-OPERATION SET-UP ........................................................................... 3-4
3.3 TORCH PARTS SELECTION ........................................................................ 3-5
3.4 GAS SELECTION FOR PLASMA CUTTING................................................. 3-8
3.5 PLASMA CUTTING OPERATION ............................................................... 3-12
3.6 HAND T ORCH OPERATION ....................................................................... 3-16
3.7 MACHINE TORCH OPERATION ................................................................. 3-18
3.8 PIERCING................................................................................................... 3-21
3.9 GOUGING OPERATION ............................................................................. 3-22
3.10 COMMON OPERATING ERRORS............................................................ 3-25
3.11 CUTTING SPEEDS................................................................................... 3-26
3.12 SEQUENCE OF OPERATION................................................................... 3-38
TABLE OF CONTENTS (continued)
SECTION 4: SERVICE ............................................................................................................. 4-1
4.1 T ORCH MAINTENANCE............................................................................... 4-1
4.2 HAND TORCH HEAD REPLACEMENT ........................................................ 4-2
4.3 MACHINE TORCH HEAD REPLACEMENT.................................................. 4-4
4.4 HAND T ORCH SWITCH REPLACEMENT .................................................... 4-6
4.5 HAND T ORCH LEADS REPLACEMENT ...................................................... 4-7
4.6 MACHINE TORCH LEADS REPLACEMENT ................................................ 4-9
4.7 LEADS EXTENSION KITS - HAND TORCH ............................................... 4-11
4.8 LEADS EXTENSION KITS - MACHINE TORCH ......................................... 4-13
4.9 POWER SUPPLY MAINTENANCE ............................................................. 4-16
4.10 TR OUBLESHOO TING THEORY ............................................................... 4-17
4.11 TROUBLESHOOTING GUIDE ................................................................... 4-21
4.12 SERVICE AND TEST PROCEDURES ...................................................... 4-27
SECTION 5: PARTS LISTS....................................................................................................... 5-1
5.1 ABOUT THE PARTS LIST ............................................................................. 5-1
5.2 SYSTEM COMPONENTS AND ACCESSORIES.......................................... 5-2
5.3 ACCESS PANEL COMPONENTS................................................................. 5-4
5.4 FRONT PANEL/CHASSIS COMPONENTS................................................... 5-5
5.5 REAR PANEL COMPONENTS ..................................................................... 5-6
5.6 BASE COMPONENTS .................................................................................. 5-8
5.7 UPPER CHASSIS COMPONENTS............................................................. 5-10
5.8 MAIN HEATSINK COMPONENTS .............................................................. 5-12
5.9 TORCH COMPONENTS ............................................................................. 5-14
5.10 TORCH ACCESSORIES ........................................................................... 5-16
SECTION 6: ADDITIONAL INFORMATION .............................................................................. 6-1
6.1 LADDER DIAGRAM - 120 V AC ...................................................................... 6-1
6.2 LADDER DIAGRAM - 15 VDC........................................................................ 6-2
6.3 DIGITAL CURRENT CONTROL INTERFACE ................................................ 6-3
6.4 CNC INTERF ACE ......................................................................................... 6-4
6.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE................. 6-5
6.6 REMOTE CONTROL CHASSIS SCHEMATIC .............................................. 6-6
6.7 ROUTINE MAINTENANCE SCHEDULE....................................................... 6-7
6.8 SYSTEM SCHEMATIC .................................................................................. 6-8
GENERAL INFORMATION
GASES AND FUMES
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 background information which requires additional emphasis or is
helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
Important Safety Precautions
W ARNINGS
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.
Gases and fumes produced during the plasma cutting process
can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep
your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the
metal, and the different processes. Y ou must be very
careful when cutting or welding any metals which may
contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an ar ea 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
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: January 27, 2004 i GENERAL INFORMA TION
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or
damp.
• Install and maintain equipment according to NEC code,
refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service
or repairs.
• Read and follow all the instructions in the Operating
Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the
plasma arc.
• Be sure there is no combustible or flammable material in
the workplace. Any material that cannot be removed
must be protected.
• V entilate 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. Y ou must protect
your ears from loud noise to prevent permanent loss of hearing.
• T o protect your hearing from 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 RA YS
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 protected.
• T o protect your eyes, always wear a welding helmet or
shield. Also always wear safety glasses with side shields,
goggles or other protective eye wear .
• W ear 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.
Publications
Refer to the following standards or their latest revisions for
more information:
1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF
CUTTING AND WELDING PROCESSES, obtainable from
American National Standards Institute, 1430 Broadway,
New Y ork, NY 10018
7. AWS 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
GENERAL INFORMA TION ii Date: January 27, 2004
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, NA TIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy , MA 02269
10 . NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, 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 Standar d 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 Welding Society Standar d A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA TOR Y
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
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 :
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.
Precautions De Securite
Importantes
A VERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
NOTE
Toute opération, procédure ou renseignement
FUMÉE et GAZ
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
ATTENTION
• Eloignez toute fumée et gaz de votre zone de respiration.
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
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.
Date: January 27, 2004 iii GENERAL INFORMA TION
• 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 différents pr océdés. 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
• 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.
• 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
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
RAYONS D’ARC DE PLASMA
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque ou un
écran de soudeur . Portez toujours des lunettes de sécurité
munies de parois latérales ou des lunettes de protection ou
une autre sorte de protection oculaire.
GENERAL INFORMA TION iv Date: January 27, 2004
• 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 1 2
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontr er que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. V ous dú4ez vous pr otéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE
COUPE ET DE SOUDAGE, disponible auprès de la Société
Américaine de Soudage (American W elding Society), 550
N.W . LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New Y ork, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA TIONAL,
disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy , MA 02269
10. Norme 51B de la NFP A, LES PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy , MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE
DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès
de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway , Suite 501, Ar lington, V A 22202
Date: January 27, 2004 v GENERAL INFORMA TION
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 W elding Supply Association), 1900 Arch Str eet, Philadelphia, P A 19103
14. Norme A WSF4.1 de l’Association Américaine de Soudage,
RECOMMANDA TIONS DE PRATIQUES SURES POUR
LA PRÉP ARA TION À LA COUPE ET AU SOUDAGE DE
CONTENEURS ET TUY AUX A Y ANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de la American W elding Society , 550 N.W . LeJeune Rd., Miami, FL
33126
15 . Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRA TOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway , New Y ork, NY
10018
GENERAL INFORMA TION vi Date: January 27, 2004
Declaration of Conformity
S
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the
enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European
Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and
date of manufacture.
National Standard and T echnical 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 Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* CENELEC EN50199 EMC Product Standard for Arc W elding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the
when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product 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 product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible repr esentative: Steve W ard
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley , Lancashire,
England PR6 7BX
mark conform to EN50192
Date: January 27, 2004 vii GENERAL INFORMA TION
Statement of Warranty
LIMITED W ARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal
shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s
specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or
accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by
Thermal to be defective.
THIS W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR
PURPOSE.
LIMIT A TION 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 fr om 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 her ein,
exceed the price of the goods upon which such liability is based.
THIS W ARRANTY BECOMES INV ALID IF REPLACEMENT P ARTS OR ACCESSORIES ARE USED WHICH MA Y IMP AIR 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 DRAGGUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such
distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of sale to an
authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations
on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized
distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two
(2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Y ear 2 Y ears 1 Year
Original Main Power Rectifier 3 Years 1 Y ear 2 Years 1 Year
Control PC Board 3 Years 1 Y ear 2 Y ears 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited T o, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMA TION viii Date: January 27, 2004
SECTION 1: INTRODUCTION & DESCRIPTION
1.1 SYSTEM DESCRIPTION
PAK 15XC Power Supply
Work Cable
Figure 1-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging System
The Merlin PAK 15XC
System Includes:
NOTE
Torch Leads
PCM-150 Machine Torch
• PAK 15XC 150 Amp Power Supply
with Running Gear and Handle
• PCH-150 90° or 70° Hand Torch
(or) PCM-150 Machine Torch with Mounting Assembly
• 25 ft (7.6 m) or 50 ft (15.2 m) Torch Leads
• PCH/M-150 Spare Parts Kit
• 25 ft (7.6 m) Work Cable and Clamp
• Running Gear and Handle
• Air Line Filter Assembly (or) High Pressure Regulators
System options and accessories are listed on page 1-5.
Remote Control Panel
A-00875
Spare Parts Kit
Manual 0-2529 1 - 1 INTRODUCTION & DESCRIPTION
1.2 POWER SUPPLY SPECIFICATIONS
Shipping Weight
Enclosure Only:
Input Power
Output Power
Duty Cycle
A-00876
Voltage Frequency Phase Amperage
380 50 or 60 Hz 3 44
415 50 or 60 Hz 3 40
Table 2-A (page 2-7) contains information on power input,
current ratings, circuit protection, and wire sizes.
Continuously adjustable from 50 to 150 amps
100% duty cycle.
Approximate Shipping Weight - 678 lbs (308 kg)
34.25 in
24.12 in
(0.61 m)
(0.87 m)
Figure 1-B Power Supply Dimensions
38.38 in
(0.98 m)
Fully Assembled:
Width: 28.50 in (0.72 m)
Height: 43.38 in (1.10 m)
Depth: 43.75 in (1.11 m)
INTRODUCTION & DESCRIPTION 1 - 2 Manual 0-2529
1.3 TORCH SPECIFICATIONS
Torch Configurations
Torch Leads Lengths
Current Rating
Cutting Range
Gas Requirements
• PCH-150 90° Hand Torch
• PCH-150 70° Hand Torch
• PCM-150 Machine Torch
Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m).
Extendable in increments of 25 ft or 50 ft up to a maximum
of 150 ft (45.7 m) with available leads extension packages
(see Options and Accessories, page 1-5)
150 Amps Maximum, Direct Current Straight Polarity
Hand and Machine Torch rated at 100% Duty Cycle
Most materials up to 2.0 in (50.8 mm)
Plasma
Gases
• Compressed Air
• Oxygen (O
2)
• Argon/Hydrogen
(Ar/H
• Nitrogen (N
2)
2)
Pressure
50 psi
(3.4 bar)
Hot Flow *
For Cutting:
22-28 scfh
(10.4-13.2 lpm)
For Gouging:
22-43 scfh
(10.4-20.3 lpm)
Secon-
dary
• Compressed Air
• Nitrogen (N
2)
• Carbon Dioxide
(CO
2)
• Water
50 psi
(3.4 bar)
Min.50 psi
(3.4 bar)
For Cutting or
Gouging:
220 scfh
(103 lpm)
8 gph
(30.3 lph)
NOTE
* Hot flow is measured with the main arc activated. When
pressure is set correctly the plasma gas flow rate is
significantly higher until the arc is initiated.
PCH-150 90° Hand Torch (without Leads) - 1.0 lb (.45 kg)Weight
Manual 0-2529 1 - 3 INTRODUCTION & DESCRIPTION
PCH-150 90o Hand Torch
13.31 in
(338 mm)
1.62 in
(41 mm)
3.81 in
(97 mm)
1.38 in
(35 mm)
PCH-150 70
o
Hand Torch
13.87 in
(352 mm)
3.96 in
(101 mm)
1.62 in
(41 mm)
PCM-150 Machine Torch With Rack
And Pinion Mounting Assembly
6.75 in (171 mm) Min.
16.75 in (425 mm) Max.
17.65 in (448 mm)
Figure 1-C PCH/M-150 Torch Dimensions
1.62 in
(41 mm)
A-02685
INTRODUCTION & DESCRIPTION 1 - 4 Manual 0-2529
1.4 OPTIONS AND ACCESSORIES
Power Supply Options
and Accessories
NOTE
Torch Options
and Accessories
• Remote Control Panel - For machine torch systems, the
low profile operator control panel allows system control
from a remote location with 25 or 50 ft (7.6 or 15.2 m)
cable included.
• Remote Pendant Control - Hand-held remote contactor
control device for machine torch systems.
• Computer Control Cable Kits - For interfacing the
power supply with a computer or auxiliary control
device. Available in 5 or 10 ft (1.5 or 3.0 m) lengths.
• SC-5 Standoff Control - For machine torch systems, the
SC-5 automatically finds height and maintains torch
standoff with a high speed torch lifter motor.
• High Pressure Regulators - Available for air, oxygen,
argon/hydrogen, nitrogen, CO
2, and water.
See System Components and Accessories (page 5-2) for
ordering information.
• Spare Parts Kits - Kits contain replacement front-end
torch parts and tools. Spare parts kits are available for
air cutting with hand or machine torch, multi-gas
cutting with hand or machine torch, or for gouging.
NOTE
• Leads Extension Packages - Available in 25 ft (7.6 m) or
50 ft (15.2 m) lengths. For extending leads up to a
maximum of 150 ft (45.7 m).
• Metal Shield Cup - For durability in hand cutting.
See Torch Components (page 5-14) and Torch Accessories
(page 5-16) for ordering information.
Manual 0-2529 1 - 5 INTRODUCTION & DESCRIPTION
1.5 THEORY OF OPERATION
;
Plasma Arc Cutting and
Gouging
Plasma Gas Flow
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 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. The Thermal Arc Merlin PAK 15XC is
a high performance plasma cutting system designed to cut
most metals up to two inches thick.
With a simple change of torch parts, the system can also be
used for plasma arc gouging. Plasma arc gouging is used
to remove material to a controlled depth and width.
The Thermal Arc torch uses a cool plasma gas such as
compressed air, nitrogen, argon/hydrogen, or oxygen.
The plasma gas flows into the torch through the plasma
torch lead and is channelled into Zone A (Figure 1-D),
where a pilot arc between the torch electrode and tip heats
and ionizes the gas. The main cutting arc transfers to the
workpiece through the column of plasma gas as it flows
out through the torch tip orifice.
Power Supply
(+)
(-)
Zone D
Zone C
Figure 1-D Theory of Operation
Zone A
Zone B
Workpiece
Coolant
Plasma Gas
Secondary Gas
A-00900
INTRODUCTION & DESCRIPTION 1 - 6 Manual 0-2529
Plasma Gas Flow
(continued)
By forcing the plasma gas and arc through a consrticted
orifice, the torch delivers a high concentration of heat to a
small area. The stiff, constricted plasma arc is shown in
Zone B (Figure 1-D). Direct current (DC) straight polarity
is used for plasma cutting, as shown in the illustration.
Secondary Flow
Coolant Flow
Pilot Arc
The torch also uses a secondary gas (or water) which
assists the high velocity plasma gas in blowing molten
metal from the area of the cut to create a fast, slag-free cut.
The secondary flow (Zone C, Figure 1-D) also cools the
torch and minimizes heat input to the workpiece. The
secondary flows into the torch through the secondary lead,
down around the outside of the torch liner, and out between the tip and shield cup around the plasma arc.
Compressed air, supplied by either a cylinder or plant air
system, nitrogen, CO
2, or water can be used as the secon-
dary. An exception to this is oxygen plasma operation,
which requires no secondary.
The torch is liquid-cooled by an internal closed cooling
system. De-ionized coolant is distributed from a reservoir
in the power supply through the coolant supply lead. At
the torch, the coolant is circulated around the torch tip and
electrode (Zone D, Figure 1-D), where the extra cooling
effect helps to increase parts life. The coolant then flows
back to the power supply through the return lead.
When the torch is started, a DC pilot arc is established
between the electrode and cutting tip after a two-second
pre-flow delay. The pilot arc is initiated by a momentary
high frequency pulse. The pilot arc creates a path for the
main cutting 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.
Main Cutting Arc
The PAK 15XC accepts 380/415 VAC, 50 or 60 Hz, threephase, line input. The power supply 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. The positive output is connected to
the workpiece via the work cable and clamp connection.
RF Shielding
All machine torch systems are shielded to minimize radio
frequency (RF) interference which results from the high
frequency arc initiation. These shielded systems are designed with features such as a wire for establishing an
earth ground and shielded torch and control leads.
Manual 0-2529 1 - 7 INTRODUCTION & DESCRIPTION
Interlocks
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down the
system, the torch switch (or control device) must be used
to restart the system.
Parts-In-Place Interlock
Gas Pressure Interlock
Thermal Interlock
The torch 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.
Pressure switches act as an interlock for the gas supplies. If
supply pressure falls below minimum requirements the
pressure switches will open, shutting off the power to the
contactors, and the GAS indicator will go out. When
adequate supply pressure is available the pressure
switches close, allowing power to be resumed for cutting.
Thermal overload sensors are located in the transformer
and main heatsink in the power supply. If one of these
components is overheated the appropriate switch will
open up, causing the temperature light to turn from green
to red and shutting off power to the main contactor. When
the overheated component cools down the switch will
close again and allow operation of the system.
INTRODUCTION & DESCRIPTION 1 - 8 Manual 0-2529
SECTION 2: INSTALLATION
2.1 UNPACKING THE SYSTEM
The power supply is skid-mounted and protected with a
carton and padding material to prevent damage during
shipment. The power supply, work cable, torch, and torch
leads are factory-assembled and packaged together. Also
packed with the system are:
1. Remove all packing material.
2. Locate the packing list. Use the list to identify and
3. Inspect each item for possible shipping damage. If
The unit is mounted on the skid with two brackets. To
remove the unit from the skid, refer to Figure 2-A and:
• Spare parts kit for the torch
• Coolant de-ionizing cartridge
• Air filter assembly (for air systems)
account for each item.
damage is evident, contact your distributor before
proceeding with system installation.
Shipping Brackets
A-00953
4. Remove the six bolts connecting the brackets to the
base of the unit.
5. Roll the unit off the skid backwards (rear wheels first).
Shipping Pallet
Three Bolts
(Each Side)
Figure 2-A Unpacking the System
Manual 0-2529 2 - 1 INSTALLATION
2.2 LOCATION
Choosing the Location
Select a clean, dry location with good ventilation and
adequate working space around all components.
The power supply is air cooled and air flow through the
front, rear, and side panels must not be obstructed. At least
two feet (0.61 m) of clearance should be provided on all
sides.
CAUTION
Operation without proper air flow will inhibit proper
cooling and reduce duty cycle.
Review Operating Precautions (page iv) to be sure that the
selected location meets all safety requirements.
2.3 PLASMA AND SECONDARY CONNECTIONS
Plasma Gas Requirements
Compressed air, oxygen (O2), nitrogen (N2), or argon/
hydrogen (Ar/H
2).
Pressure 50 psi (3.5 bar)
Secondary Gas
Requirements
Secondary Water
Requirements
NOTE
CAUTION
Flow 22 - 28 scfh (10.4 - 13.2 lpm) For Cutting
22 - 43 scfh (10.4 - 20.3 lpm) For Gouging
Compressed Air, nitrogen (N
2), or carbon dioxide (CO2).
Pressure 50 psi (3.5 (bar)
Flow 220 scfh (103 lpm) For Cutting or Gouging
Tap Water
Pressure Min. 50 psi (3.5 bar)
Flow 8 gph (30.3 lph) For Cutting
See Gas Selection for Plasma Cutting (page 3-8) for detailed information on operation with various plasma and
secondary options.
Maximum input gas pressure to the power supply's
internal regulator must not exceed 125 psi (8.6 bar).
INSTALLATION 2 - 2 Manual 0-2529
Input Gas Connections
(Air Operation)
Systems that are set up for operation with shop air require
installation of the air line filter on the plasma input fitting
on the rear panel. These systems are shipped with the
following components:
(1) Air Line Filter Assembly (For Plasma Line)
(2) Hex Nipples
(1) 90° Female Elbow
(1) 90° Street Elbow
(1) Y-Hose Assembly
Air Line Filter Installation
Refer to Figure 2-B and:
1. Thread the first hex nipple into the 90° female elbow.
2. Thread the other end of the hex nipple into the outlet
3. Thread the second hex nipple into the fitting on the
4. Thread the 90° street elbow into the inlet side of the air
Plasma Gas
Fitting
Female Elbow
of the air filter assembly. Tighten both sides securely.
rear panel marked PLASMA.
filter assembly.
Secondary Gas
Fitting
Y-Hose
Assembly
Hex Nipple
Hex Nipple
Street Elbow
Air Filter Assembly
(Plasma Line Only)
From Supply
A-00902
Figure 2-B Air Line Filter Installation
Manual 0-2529 2 - 3 INSTALLATION
Air Line Filter Installation
(continued)
5. Connect one side of the Y-hose assembly into the other
side of the 90° street elbow.
6. Thread the 90° female elbow onto the other end of the
second hex nipple. Fasten both sides securely.
7. Connect the other side of the Y-hose assembly to the
fitting on the rear panel marked SECONDARY.
8. Connect the supply line from the source to the Y-hose
assembly. The supply hose must be 3/8 in (10 mm)
min. inside diameter to provide adequate air flow.
Input Gas Connections
(Multi-Gas Operation)
WARNING
CAUTION
1. Examine the cylinder valves to be sure they are clean
and free of oil, grease or any foriegn material. Momentarily open each cylinder valve to blow out any dust
which may be present.
Do not stand in front of the valve outlet when opening.
2. Each cylinder must be equipped with an adjustable
high-pressure regulator capable of pressures up to 125
psi (8.6 BAR) maximum and flows of up to 220 scfh
(103 lpm) for cutting or 470 scfh (222 lpm) for gouging.
Maximum input pressure to the power supply's internal
regulator must not exceed 125 psi (8.6 bar).
Refer to the regulator manufacturer's specifications for
installation and maintenance procedures. Refer to
System Components and Accessories (page 5-2) for a
listing of available high-pressure regulators.
3. Connect the plasma supply hose (black) to the plasma
gas cylinder and to the input fitting on the rear panel
marked PLASMA.
4. Connect the secondary supply hose (yellow) to the
secondary gas cylinder and to the input fitting on the
rear panel marked SECONDARY.
NOTE
A typical 50 lb. CO
2 cylinder can deliver a continuous flow
rate of 35 scfh (16.5 lpm). To obtain the required flow rate
for the torch, it may be necessary to manifold several CO2
cylinders. Continuous flow requirements will depend on
the specific application and duty cycle.
INSTALLATION 2 - 4 Manual 0-2529
Secondary Water
Connections
1. The water source must be capable of delivering a
minimum water pressure of 50 psi (3.5 bar) and flow of
8 gph (30.3 lph).
2. Connect the secondary water supply hose to the rear
panel fitting marked SEC. WATER.
NOTE
Secondary Water
Plasma Gas
The water source does not need to be deionized, but in
water systems with extremely high mineral content a
water softener is recommended.
Secondary Gas
High Flow
Water Shield
Remote Interface
Connection
A-00874
Figure 2-C Rear Panel Connections
Manual 0-2529 2 - 5 INSTALLATION
2.4 ELECTRICAL CONNECTIONS
Electrical Requirements
Electrical Connections
WARNING
The PAK 15XC power supply is designed to accept a an
input voltage of 380/415 VAC.
The electrical power source must conform to local electric
code and the following recommended circuit protection
and wiring requirements (see Table 2-A, page 2-7).
1. Check the three-phase electrical power source for line
voltage and proper circuit protection and wiring (see
Table 2-A, page 2-7).
Disconnect primary power at the source before connecting the primary power cable to the power supply.
Refer to Figure 2-D (page 2-7) and:
2. Remove the left side panel of the power supply (as
viewed from the front).
3. Check the bus bar configuration (factory installed) on
the input voltage terminal board . The bus bar configuration must correspond with the 380 VAC line
voltage.
4. Insert the primary power cable (customer supplied)
through the strain relief in the rear panel of the power
supply.
WARNING
5. Locate the four input connectors, flat washers, conical
spring washers, and hex locking nuts supplied with
the power supply.
6. Install the input connectors, supplied, onto each of the
input power line leads of the power cable.
7. Connect the input power connectors to the EMI Input
Power Filter PC Board input studs with the supplied
hex locking nuts, conical spring washers, and flat
washers as follows:
• Input ground wire to G1.
• LI input line to X1.
• L2 input line to Y1.
• L3 input line to Z1.
8. Tighten the nuts being careful not to over-tighten.
Refer to the following WARNING.
Do Not over tighten the nuts securing the iput power
cable connectors as damage to the PC Board can occur.
INSTALLATION 2 - 6 Manual 0-2529
Voltage Power Input Current Frequency Phase Recommended
(Volts) (kVA) (Amps) (Hz) Fuse Size Wire Size
380 29 44 50 3 50 amps AWG 8
415 29 40 50 3 45 amps AWG 8
Table 2-A Line Voltages, Circuit Protection and Recommended Wire Size
(Based on Table 310-16, 1987 National Electric Code).
PC Board
Power Stud
Flat Washer
Input
Connector
A-00908
Slotted Screw
Input Power Cable
(One Line)
Input Voltage Connector
Installation Detail
Conical Spring
Washer
Hex Locking
Nut
Input Power
Filter PC Board
and Bracket
Input Ground
Connection
INPUT
VOLTAGE
380/415
VAC
BUS BAR
CONNECTIONS
L1-3, 1-2
L2-8, 6-7
L3-13, 11-12
380/
415VAC
L3
L2
L1
Primary Power
Cable
L3
L2
L1
Strain Relief
Fitting
A-00896
Figure 2-D Input Voltage Connections and Bus Bar Configuration
Manual 0-2529 2 - 7 INSTALLATION
2.5 WORK AND GROUND CONNECTIONS
Machine torch systems are equipped with shielded torch
leads to minimize RF interference from high frequency
pilot arc initiation. Follow these grounding procedures
when installing machine torch systems:
1. Connect the ground wire (from the front panel) to a
solid earth ground, which is created by driving a
copper rod approximately 7 ft (2 m) into the earth.
Locate the rod as close as possible to the power supply.
Cut the ground wire to the appropriate length.
2. The power supply and work table should be grounded
to the same earth ground. The control device should be
grounded separately to a similar earth ground.
3. To minimize RF interference, torch leads should be run
as far as possible from any CNC components, control
lines, or primary power lines.
4. Connect work ground cables as shown (Figure 2-E).
3-Phase
Input
Earth
Ground
Power
Supply
Power Supply
Remote Panel
CNC Control
Earth
Ground
Work
Cable
Standoff Control
Console
Green Cable
(Work Ground)
Standoff Control
Remote Panel
Workpiece
Work Ground
A-00880
Figure 2-E Proper Work and Ground Cable Connections
INSTALLATION 2 - 8 Manual 0-2529
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