Page 1
Plasma Cutting
Power Supply
CE PAKMaster© 75 XL
A-02464
TM
Plus
Operating Manual
July 7, 2003 Manual No. 0-2782
Page 2
Page 3
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
CE Pak Master® 75XLTM Plus
Service Manual Number 0-2782
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 1999 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: July 7, 2003
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:____________________________________
Page 4
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and Warnings ..................................................................... 1-1
1.02 Important Safety Precautions .......................................................................1-1
1.03 Publications.................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes........................................................... 1-3
1.06 Documents De Reference ............................................................................ 1-5
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty.................................................................................. 1-8
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description of System..................................................................... 2-1
2.03 Specifications/Design Features .................................................................... 2-1
2.04 Power Supply Options and Accessories....................................................... 2-2
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Lifting Options .............................................................................................. 3-1
3.05 Input Power Cab le Connections ................................................................... 3-2
3.06 Gas Connections ......................................................................................... 3-2
3.07 Connecting Torch Leads ............................................................................... 3-4
3.08 Ground Connections For Mechanized Applications...................................... 3-9
3.09 Tip Saver/Drag Sensing Circuit .................................................................. 3-11
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 ........................................................................... 4-5
4.05 Cut Quality ................................................................................................... 4-6
Page 5
TABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Maintenance ................................................................................... 5-1
5.03 Common Operating Problems ...................................................................... 5-3
5.04 Troubleshooting Guide ................................................................................. 5-4
5.05 Power Supply Parts Replacement ................................................................ 5-6
SECTION 6:
PAR TS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 Complete Power Supply Replacement ......................................................... 6-2
6.04 Replacement Parts...................................................................................... 6-2
6.05 Options and Accessories ............................................................................. 6-2
APPENDIX 1: INPUT WIRING REQ UIREMENTS ....................................................................A-1
APPENDIX 2: SEQUENCE OF OPERATION w(BLOCK DIAGRAM) .......................................A-2
APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................A-3
APPENDIX 4: DATA TAG INFORMATION ................................................................................. A-4
APPENDIX 5: SYSTEM SCHEMATIC....................................................................................... A-6
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SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEAL TH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different pr ocesses. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
Date: No v ember 15, 2001 1-1 GENERAL INFORMATION
Page 8
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RA YS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New Y ork, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001
Page 9
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFP A Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard 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 Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédure pouvant résulter
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 RESPIRATO RY
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: No v ember 15, 2001 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 + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
Page 10
• 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: Nov ember 15, 2001
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
Page 11
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur . Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculair e.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New 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
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. V ous dú4ez vous pr otéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269
Date: No v ember 15, 2001 1-5 GENERAL INFORMATION
Page 12
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001
Page 13
1.07 Declaration of Conformity
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 Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements. 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 Ar c 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 S mark conform to EN50192
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 representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: No v ember 15, 2001 1-7 GENERAL INFORMATION
Page 14
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PAR TICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 1 Year
All Other To rches 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 INFORMATION 1-8 Date: Nov ember 15, 2001
Page 15
SECTION 2:
p
INTRODUCTION
2.01 Scope of Manual
The system provides a maximum 1 inch (25.4 mm) cut
capacity . Torch heads are available in various configurations. Torch leads are available in various lengths with
fittings for simple installation. Spare Parts Kits are available for the torches which provide an assortment of replacement torch parts.
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
75XL PLUS Air 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 General Description of System
The 75XL PLUS (CE) System includes a power supply,
torch & leads and work cable & clamp, and input power
cable.
The Power Supply provides 60 amp maximum output
and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle,
work cable with clamp, and input power cable.
The power supply can be ordered in various configurations with various options factory installed. Refer to Section 2.04 for list of power supply options and accessories.
2.03 Specifications/Design Features
®
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch, RUN/SET/LATCH Switch and
Output Current Control
2. Front Panel Indicators
AC , TEMP , GAS , DC
3. Rear Panel
Input Power Cable, Gas Connection, Gas Regulator/
Filter Assembly
4. Input Power
380/415 VAC (±10%), 50/60 Hz, Three-Phase
Supplied with a 10 ft. (3.1 m) 4-Conductor Input
Power Cable with filtering beads.
5. Output Power
Continuously variable from 15 to 60 Amps maximum
6. Duty Cycle (see NOTE)
XL PLUS Power Supply
The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher
than shown in the chart.
Power Supply Duty Cycle
Ambient
Tem
erature
A-02462
Work Cable and Clamp
Pak Master 75XL PLUS (CE) System
Manual 0-2782 2-1 INTRODUCTION
Torch and Leads
7. Cut Capacity (Mild Steel)
Duty Cy cle
Current
DC Voltage
3/4 inch (19.1 mm); 1 inch (25.4 mm) severance
NOTE
104° F
(40° C)
65% 100%
60 Amps 50 Amps
104 vdc 104 vdc
104° F
(40° C)
Page 16
8. Pilot Circuitry
C. High Pressure Regulators
Capacitive Discharge (CD), Pulsed DC
9. Weight
71 lbs (32 kg) withwork lead, input power cable
78 lbs (35.4 kg) withwork lead, torch & lead, input power
cable
10. Overall Dimensions
19" (482 mm) High x 13" (330 mm) Wide x 24.8" (630
mm) Long
Overall dimensions are with Handle, Lead Wrap
Bracket, and Gas Regulator/Filter Assembly installed.
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas regulator maximum gauge pressure
160 psi (11 bar)
2. Maximum input gas pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
2.04 Power Supply Options and
Accessories
The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for part numbers
and ordering information
A. Single Stage Air Line Filter Kit
High pressure regulators ar e available for air and nitrogen. The regulators are used to set the pr oper pressure for the type gas being used.
NOTE
Regulators should not be installed with options A
or B above.
D. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and
front-mounted swivel casters. Provides maximum
mobility for the power supply and can also serve as a
display cart. T op shelf is 12 " (305 mm) x 20 (508 mm).
Steel handle is 30" (762 mm) high.
E. Computer Control Cable (CNC)
NOTE
This accessory can be used only with the PCM-60
Torches.
The interface cable is available in two lengths, 25 ft
(7.6 m) and 50 ft (15.2 m). The cable is used to interface the power supply with an auxiliary control device to provide OK-To-Move and ON/OFF signals.
F. Remote Hand Pendant Control
The remote hand pendant control is available with a
20 ft. (6.1 m) cable. An extension cable of 25 ft. (7.6 m)
can be added to the standard hand pendant control to
produce a total length of 50 ft. (15.2 m).
G. Cutting Guide Kit
Easy add-on attachments to allow for straight line,
circle, or bevel cutting.
H. Standoff Cutting Guide
A Single Stage In-Line Air Filter for use with compressed air shop systems. Filters moisture and particulate matter from the air stream to at least 0.85 microns.
Simple, push-on guide attachment to allow for torch
dragging without risk of touching tip.
B. Two Stage Air Line Filter
A Two Stage In-Line Air Filter for use on compressed
air shop systems. Filters moisture and particulate matter from the air stream to at least 5.0 microns.
INTRODUCTION 2-2 Manual 0-2782
Page 17
SECTION 3:
3.03 Unpacking
INSTALLATION
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply Options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended that
all subsections be read for general information.
This section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; installation procedures for the Torch, Options, and Accessories
are given in Manuals specifically provided for those units.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Gas
c. Work cable
d. Tor ch Leads
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
l. Unpack each item and remove any packing material.
NOTE
The Cutting Spare Parts Kit is shipped in the T or ch
Leads Storage Area on the side of the Power Supply.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system installation.
3.04 Lifting Options
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
F ALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
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 (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 (0.61 m) in the rear and at
least 6 inches (150 mm) 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 150
mm).
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
This unit is equipped with one handle mounted onto the
top of the enclosure for hand carrying purposes.
• Lift unit with the handle on top of the enclosure.
• Only persons of adequate physical strength should
lift the unit.
• Use hand cart, optional Cart, or similar device of
adequate capacity.
• If using a fork lift vehicle, place and secure unit on
a proper skid before transporting.
• This unit has a handle mounted on top of the enclosure for hand lifting only. Be sure unit is lifted and
transported safely and securely.
WARNING
HANDLE is not for mechanical lifting.
Manual 0-2782 3-1 INST ALLATION
Page 18
3.05 Input Power Cable Connections
3.06 Gas Connections
The 75XL PLUS Power Supply operates on three phase,
380-415 VAC ± 10% 50/60 Hz input.
CAUTION
The primary power source, power cable, and plug
must all conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix 1).
The Power Supply is supplied with a three-phase, four
conductor, input EMC power Cable attached. Connect
the supplied input EMC power cable to the customer's
power source per the following procedur e:
NOTE
The input power cable must not be modified in any
way as filtering beads are installed onthe cable.
1. Strip back the outer covering approximately 3
inches (76 mm) to expose the individual wires at
the free end of the cable.
2. Cut back the insulation on the individual wires
approximately 1/8 - 3/16 inch (3-5 mm).
3. Connect the ends of the individual wires a customer supplied plug or main disconnect per the
following:
A. Gas Requirements
WARNING
This unit not to be used with oxygen (O2).
Gases: Compressed Air or Nitr ogen (N2) Only
Pressure: 60 - 75 psi (4.1 - 5.2 bar)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
Flow: Cutting - 300 scfh standard cubic feet/hour(142 lpm)
Gouging - 300 scfh (142 lpm)
B. Checking Air Quality
To test the quality of air, place the RUN/SET/LATCH
switch to SET position, place a welding filter lens in front
of the torch and turn on the gas. Any oil or moisture in
the air will be visible on the lens. Do not initiate an arc!
CAUTION
NOTE
All the input cable wires must be connected for
three-phase operation.
• Blue wire to Line 2 (Live)
• Black wire to Line 3 (Live), refer to Note above
• Brown wire to Line 1 (Live)
• Green/Yellow wire to Ground (Earth)
The air supply must be free of moisture, and other
contaminants. Excessive moisture may cause
double-arcing, rapid tip wear, or even complete
torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.
C. Gas Connections
The gas supply is connected to the Pressure Regulator/
Filter Assembly installed on the rear of the unit. The connection is the same for compressed air or high pressure
gas cylinders.
Connect the gas supply as illustrated. T ypical fittings are
shown as examples. Other fittings may be used.
1. If an optional air line filter is to be installed, refer to
subsection D.
NOTE
Filtering is required when using air from a compressor to ensure that moisture and debris fr om the
supply hose does not enter the torch. It is recommended to order the optional
INST ALLATION 3-2 Manual 0-2782
Page 19
Regulator/Filter
Assembly
Single-Stage Air Filter Kit or Two Stage Filter Kit Assembly
1/4 NPT to #4 (6 mm) Hose
Fitting
Hose Clamp
#4 (6 mm) Gas
3
A-01149
Supply Hose
Figure 3-1 Gas Connection To Regulator/Filter
Assembly
A-02607
Air Line Filter
Assembly
1/4 NPT to #4 (6mm)
Hose Fitting
Hose Clamp
#4 (6mm) Gas
Supply Hose
Figure 3-2 Gas Connection to Optional Single-Stage
Air Filter Assembly
D. Optional Air Line Filter Installation
Filtering is required when using air from a compr essor to
insure that moisture and debris from the supply hose does
not enter the torch. Although the Regulator does have its
own filter, it is recommended the optional Single-Stage
Filter or optional Two Stage Air Line Filter be installed
for improved filtering. Gas connections to optional filters are shown in Figures 3-2 and 3-3.
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm) Gas
Supply Hose
Two Stage Filter
Assembly
A-01150
Figure 3-3 Gas Connection To Optional Two Stage
Filter Assembly
Manual 0-2782 3-3 INST ALLATION
Page 20
E. Using High Pressure Gas Cylinders
1. Refer to the following when using high pressure gas
cylinders as the gas supply:
A. Hand Systems
WARNING
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
a. Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
b. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to blow
out any dust which may be present.
c. The cylinder must be equipped with an adjustable
high-pressure regulator capable of outlet pressur es
up to 100 psi (6.9 bar) maximum and flows of up
to 300 scfh (141.5 lpm).
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
3.07 Connecting T orch Leads
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. T urn the screw latch securing the fr ont access panel
to the power supply front panel.
Access
Panel
Screw
Latch
CAUTION
This system is designed for use with the PCH/M102, SL60, or SL100 torches only. Do not connect
any other torch to this power supply.
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)
The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.
NOTE
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
A-02467
Figure 3-4 Front Access Panel
2. Lift the access panel to gain access to the torch
bulkhead panel.
3. Remove the securing nut from the strain relief supplied on the end of the Torch Leads.
NOTE
The leads may include a pair of wires connected
together and covered with an insulating sleeve.
These wires must remain connected and insulated.
INST ALLATION 3-4 Manual 0-2782
Page 21
Torch Leads
Assembly
Strain Relief
A-02836
Retaining Nut
Figure 3-5a Torch Strain Relief Nut (Leads with
Two Control Wires)
Strain Relief
Torch Leads
Assembly
6. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
Adapter
Adapter
(Supplied With
Power Supply)
Control (PIP) Circuit
Connectors
Torch Lead
Assembly
Connector
Negative/Plasma
Lead
Pilot Lead Stud
Negative/Plasma Lead
Connection
Pilot Lead
A-02825
Figure 3-6a Torch Lead Connections (Leads with
Two Control Wires)
Negative /
Plasma Lead
A-03607
Pilot Lead
Strain Relief
Nut
Figure 3-5b Torch Strain Relief Nut (Leads with
Four Control Wires)
4. Feed the torch lead ends and the Strain Relief into
the hole in the unit.
5. Secure the Strain Relief with the retaining nut removed earlier .
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Adapter
Control Circuit
Connectors
Negative/Plasma
Lead Connection
Torch Lead
Assembly
Pilot Lead
Negative/Plasma
Lead
Connector
Pilot Lead Stud
A-03608
Figure 3-6b Torch Lead Connections (Leads with
Four Control Wires)
7. Connect the Control Cables to the mating connectors on the Adapter supplied on the Power Supply.
Manual 0-2782 3-5 INST ALLATION
Page 22
8. Remove the top nut and washer from the Pilot
Adapter
(Supplied With
Power Supply)
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Adapter Connector
Pilot Lead
Stud
Negative/Plasma
Lead Connection
A-02828
Control (PIP) Circuit
Connectors
Shield Connectors
(Not Used)
Remote
Cable
Connector
Stud.
9. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
10. Tighten the Strain Relief onto the Torch Leads.
11. Check the tor ch for proper parts assembly.
12. Close the access panel and turn the latching screw.
B. Machine Systems (PCM-62 Torch with
Unshielded Leads)
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. T urn the screw latch securing the fr ont access panel
to the power supply front panel.
c. Feed the end of the torch lead and the Strain
Relief into the hole in the unit while routing
the single black wire into the notch of the Strain
Relief.
d. Tighten the Strain Relief Nut to secure the
Strain Relief to the Power Supply.
2. Lift the access panel to gain access to the torch
bulkhead panel.
3. Remove the retaining nut from the Strain Relief.
Torch Leads
Assembly
Strain Relief
A-02827
Strain Relief
Figure 3-7 Strain Relief Nut Removal
4. The Adapter supplied with the Power Supply must
be installed per the following:
Nut
a. Inside the Power Supply Bulkhead area, route
the connector on the free end of the Adapter
through the Strain Relief Nut.
b. Continue routing the connector out the hole in
the front panel of the Power Supply.
Figure 3-8 Torch Lead Connections
5. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
6. Connect the Control (PIP) Circuit Connectors to
the mating connectors on the Adapter supplied on
the Power Supply (see Warning).
WARNING
The Adapter supplied with the Power Supply has
two additional Shield Connectors that are used for
Shielded Systems only. These two connectors are
not used and need to be taped out of the way to
prevent contacting the Negative/Plasma or Pilot
Leads.
7. Remove the top nut and washer from the Pilot
Stud.
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
9. Tighten the Strain Relief onto the Torch Leads.
INST ALLATION 3-6 Manual 0-2782
Page 23
10. Check the torch for proper parts assembly.
11. Close the access panel and turn the latching screw.
C. Machine Systems (PCM-62 Torch with
Shielded Leads)
WARNING
Disconnect primary power at the source before assembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. T urn the screw latch securing the fr ont access panel
to the power supply front panel.
2. Lift the access panel to gain access to the torch
bulkhead panel.
3. Remove the retaining nut from the Strain Relief.
Torch Leads
Strain Relief
Assembly
Adapter Connector
Adapter
(Supplied With
Power Supply)
Control (PIP) Circuit
Connectors
Shield Connectors
Negative/Plasma
Torch Lead
Assembly
Negative/Plasma
Lead Connection
Lead
Pilot Lead
Stud
Pilot Lead
A-02829
Figure 3-10 Torch Lead Connections
5. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
A-02826
Strain Relief
Nut
Figure 3-9 Strain Relief Nut Removal
4. The Adapter supplied with the Power Supply must
be installed per the following:
a. Inside the Power Supply Bulkhead area, route
the connector on the free end of the Adapter
through the Strain Relief Nut.
b. Continue routing the connector out the hole in
the front of the Power Supply.
c. Feed the end of the torch lead and the Strain
Relief into the hole in the unit while routing
the single black wire into the notch of the Strain
Relief.
6. Connect the PIP and Shield Cables to the mating
connectors on the Adapter supplied on the Power
Supply.
7. Remove the top nut and washer from the Pilot
Stud.
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
9. Tighten the Strain Relief onto the Torch Leads.
10. Check the torch for proper parts assembly.
11. Close the access panel and turn the latching screw.
d. Tighten the Strain Relief Nut to secure the
Strain Relief to the Power Supply.
Manual 0-2782 3-7 INST ALLATION
Page 24
D. Machine Systems (SL100 Torch)
Torches with O2B connectors connect directly to the
power supply bulkhead. Mechanized torch leads with
O2B connectors require a remote pendant adapter to accept a remote pendant.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
6. Connect the control cir cuit connectors on the T orch
Leads to the mating connectors on the Remote
Pendant Adapter and Power Supply Adapter (see
Warning).
WARNING
There are two additional connectors that are not
used and must be taped out of the way to prevent
contacting the Negative / Plasma or Pilot Leads.
1. Remove the Strain Relief Nut from the Strain Relief.
Torch Leads
Assembly or ATC Adapter
Remove Tie Wrap ,
Remove Insulator,
Disconnect Wires
A-03530
Strain Relief
Strain Relief
Nut
Strain Relief Nut Removal
2. The leads Assembly includes two wires joined with
mating connectors and covered with an insulating sleeve. Remove the tie wrap and insulating
sleeve. Disconnect the two joined wires.
7. Remove the top nut and washer from the Pilot Stud
on the power supply bulkhead.
8. Place the Torch Leads Pilot lead terminal on onto
the stud and secure with the nut and washer removed in the above Step.
Note: Actual Bulkhead
configuration may
differ from that shown.
Power Supply
Control Circuit
Connectors
Open
Negative/Plasma
Remote Pendant
Adapter Wire Harness
Adapter
Connector
Adapter
Lead
Torch Lead
Pilot Lead Stud
Open
Negative/Plasma
Lead Connection
Pilot Lead
Assembly
A-03675
3. Feed the end of the torch leads and the Strain Relief into the hole in the unit.
4. Route the wire harness on the Remote Pendant
Bulkhead Connection - Unshielded Machine Torch
with O2B Fittings and Remote Pendant Adapter
Adapter through the Strain Relief and Strain Relief Nut. Tighten the Strain Relief Nut to secure
the Strain Relief to the Power Supply.
9. Connect the Torch Leads connectors and the remote pendant adapter connector to the power supply adapter as shown.
5. Connect the Negative / Plasma lead to the bulkhead connection inside the power supply.
INST ALLATION 3-8 Manual 0-2782
Page 25
Power Supply
Control Circuit
Connectors
Open
Remote Pendant
Adapter Wire
Harness
Torch Lead
Assembly
Adapter
Open
Pilot Lead
Negative/Plasma
Lead
A-03676
Bulkhead Connection Detail - Unshielded Machine
Torch with O2B Fittings and Remote Pendant
Adapter
10. Tighten the Strain Relief onto the Torch Leads or
A TC Adapter Leads Assembly .
11. Connect the remote pendant to the remote pendant adapter.
12. Check the tor ch for proper consumable parts.
3.08 Ground Connections For Mechanized Applications
A. Electromagnetic Interference (EMI)
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 interference, 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
cutting table, is connected with 1/0 AWG (European
50 mm2) or larger wire to a good earth ground (refer
to paragraph ‘C’, Creating An Earth Ground). The
ground rod 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.
Long wires will have increased resistance to RF
frequencies. Smaller diameter wire has increased
resistance to RF frequencies, so using a larger diameter wire is better .
2. G rounding for components mounted on the cutting
table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s
recommendations for wire size, type, and connection
point locations.
For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (European 6
mm2) wire or flat copper braid with cross section equal
to or greater than 10 AWG connected to the cutting
table frame. The connection point must be clean bare
metal; rust and paint make poor connections. For all
components, wires larger than the recommended
minimum can be used and may improve noise protection.
3. The cutting machine frame is then connected to the
“Star” point using 1/0 AWG (European 50 mm2) or
larger wire.
Manual 0-2782 3-9 INST ALLATION
Page 26
4. The plasma power supply work cable (see NOTE) is
connected to the cutting table at the single point “Star”
ground.
To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter
should be as follows:
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
metal. Use lock washers to keep the connections tight.
Using electrical joint compound to prevent corrosion
is also recommended.
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 recommended that the Plasma Power Supply
be within 20 - 30 ft (6.1 – 9.1 m) 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
1. To create a solid, low resistance, earth gr ound, 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 A WG (European 50 mm2) or greater , between
the ground rod and the star ground point on the cutting table.
• For 115VAC: 3.0 VAC
• For 230VAC: 1.5 VAC
115VAC: 3.0 VAC
230VAC: 1.5 VAC
~
Meter set to
VAC setting
WARNING
Use extreme caution. This
test uses live voltage.
Neutral
115 or 230VAC
Line (Hot)
A-02971
100W
Light Bulb
V
~
V
VR COM A
_
+
Machine
Earth Ground
Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft
(6.1 – 9.1 m) does not generally increase the effectiveness 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.
NOTE
Ideally, a properly installed ground r od will have a
resistance of three ohms or less.
INST ALLATION 3-10 Manual 0-2782
Page 27
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.
3.09 Tip Saver/Drag Sensing Circuit
This power supply is equipped with a Tip Saver/Drag
Cut Sensing Circuit which reduces current to 35 amps if
the tip touches the workpiece. The purpose of this is to
prolong the life of the tip.
If the user does not want the current to be decreasedwhen
the tip touches the workpiece, the sensing circuit can be
defeated by closing switch SW1-1 on the Gate/Logic PC
Board. Slide top white toggle on SW1-1 to the right to
close circuit.
SW1
1 2
Gate/Logic PC Board
ON
A-02569
Figure 3-12 SW1 Switch Location
WARNING
Tip life will be considerably shortened if tip is repeatedly touched to the workpiece without the Tip
Saver/Drag Sensing Circuit feature active.
Manual 0-2782 3-11 INST ALLATION
Page 28
INST ALLATION 3-12 Manual 0-2782
Page 29
SECTION 4:
OPERATION
4.01 Introduction
This section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operating procedures.
4.02 Operating Controls
This subsection provides specific functional descriptions
of the Power Supply operating controls and indicators.
A. Front and Side Panel Features
5. Torch Leads and Spare Parts Kit Storage Area
Bracket connected to the side panel of the unit for use
in storing the torch, torch leads, work cable, and spare
parts kit when not in use. The spare parts kit fits into
the opening on the top of the bracket. The torch leads
and work cable wrap around the bracket for easy storage.
B. Control Panel Features
40
1
A
60
15
4
5
6
7
1. Control Panel
All operator controls, except gas pressure adjustment,
are located on this panel. Power ON/OFF and RUN/
SET/LA TCH switches; CURRENT control; indicators
for AC Power, TEMP, GAS, and DC.
1
2
3
5
A-02458
4
2
A-03625
Figure 4-2 Operating Controls
1. Current Control (A)
Adjustment to set the desired output current between
15-60 amps. For drag cutting applications set the control between 15 - 35 amps. The unit has an automatic
fold-back circuit that limits current to 35 amps during drag cutting.
2. ON /OFF Power Switch
ON position supplies AC power to activate all system control circuits. OFF position deactivates control
circuits.
3
3. RUN /SET /LATCH
Figure 4-1 Front and Side Panel Connections
Switch
2. Access Panel
A panel for access to the bulkhead area containing
the torch connections.
3. Torch Leads Input
Hole in the front panel to feed the torch leads through
to the internal bulkhead connections.
4. Work Cable and Clamp
Work cable with clamp (factory installed).
Manual 0-2782 4-1 OPERATION
RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.
LA TCH position is used for specific applications (torch
switch can be released after main arc transfer).
4. AC Power Indicator
Green indicator will blink ON then OFF for approximately eight seconds and then stay ON after the ON/
OFF power switch is set to ON. Indicates operating
power is present in the unit.
Page 30
5. TEMP Indicator
Normally OFF. Yellow indicator turns ON when the
internal temperature senors detect temperatures
above normal limits. The unit should be allowed to
cool before continuing operation.
6. GAS Indicator
Green indicator turns ON when the input gas pressure is set to 35 psi (2.4 bar) or higher. Indicator will
be OFF when the pressure falls below 35 psi (2.4 bar).
NOTE
Minimum pressure for power supply operation may
be lower than minimum for torch operation.
7. DC Indicator
Green indicator turns ON while the torch switch is
pressed.
C. Torch Bulkhead Panel
The torch bulkhead panel is located under the access
panel.
D. Rear Panel Features
1. Gas Input
Input connection for air or nitrogen (N2) input.
WARNING
This unit not to be used with oxygen (O2).
1
2
3
1. Pilot Lead Stud
Stud used to connect the Torch Leads Pilot Lead to
the Power Supply.
1
2
3
A-00923
Figure 4-3 Torch Panel Connections
2. Control Cable Connector
A-02605
Figure 4-4 Rear Panel
2. Primary Input Power Cable
Primary input power cable capable of handling the
input voltage designed for this unit.
3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pr essur e to
the Power Supply . An air line filter is supplied as part
of the pressure regulator.
Used to interface the Adapter (supplied with Power
Supply) to the Torch Leads Control Cable.
3. Negative/Plasma Lead Connection
Connects the torch negative/plasma lead to the unit.
OPERA TION 4-2 Manual 0-2782
Page 31
4. Optional Filters
b. Two Stage Air Line Filter
a. Single-Stage Air Filter Assembly
This in-line filter removes moisture and contaminants
from the air stream when using compressed air. The
filter is capable of filtering to at least 0.85 microns.
3
2
4
A-02965
1
This optional filter will also remove moisture and contaminants from the air stream when using compressed
air. Filters to 5.0 microns.
1
2
3
4
A-01152
Figure 4-5 Rear Panel Showing Optional Single-
Stage Air Filter
Figure 4-6 Rear Panel Showing Optional Two Stage
Air Filter
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.
2. Place RUN/SET/LATCH switch to RUN mode.
3. Place the ON/OFF power switch on the front panel
of the Power Supply to ON.
a. AC Power indicator blinks ON and OFF for
eight seconds then stays ON.
b. Fans turn on.
Manual 0-2782 4-3 OPERATION
Page 32
4. Place RUN/SET/LATCH switch to SET mode.
12. Release or deactivate the tor ch switch.
a. Gas solenoid opens and gas flows to set pres-
sure.
b. GAS indicator turns ON.
NOTE
Minimum pressure for power supply operation may
be lower than minimum for torch operation.
NOTE
GAS indicator will not come ON if the gas pressure is set below 35 psi (2.4 bar) at the Regulator/
Filter Assembly.
5. Place RUN/SET/LATCH switch to RUN mode.
a. Gas flow stops.
b. GAS indicator turns OFF .
6. Protect eyes and press or activate torch switch
a. Gas pre-flows starts.
b. GAS indicator turns ON.
7. After gas pre-flow (approximately 2 seconds)
a. Main arc stops.
b. Pilot arc stops (power supply enable signal re-
moved).
NOTE
If torch is activated during post-flow , pilot arc will
immediately restart.
If torch is within 3/8 in (9.5mm) transfer distance
of workpiece, main arc will transfer.
13. Gas will flow for 15 seconds (post-flow).
a. Gas solenoid closes
b. Gas flow stops.
c. GAS indicator turns OFF.
14. Place the ON/OFF power switch on the front panel
of the unit to OFF
a. AC Power indicator turns OFF.
b. Fans turn OFF .
15. Place the main power disconnect to open.
a. Power supply enabled.
b. DC indicator turns ON.
c. Pilot relay closes.
8. Pilot arc is established
9. Move Torch within transfer distance of workpiece.
a. Main arc transfer.
b. Pilot arc OFF.
10. Optional - Place RUN/SET/LATCH to LATCH
mode.
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc transfer.
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer . The torch r emains activated until the
main arc breaks from the workpiece.
a. Main AC power is removed from the system.
11. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece, while still
having torch switch activated, the main arc will
stop and the pilot arc will automatically restart.
OPERA TION 4-4 Manual 0-2782
Page 33
4.04 Preparations for Operating
E. Torch Connection
Follow this set-up procedure each time the system is operated:
WARNING
Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate fr ont
end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging). Refer to the Instruction Manual supplied with the T orch Assembly for proper parts selection.
B. Check primary power source as follows:
1. Check the power source for proper input voltage.
Make sure the input power source meets the power
requirements for the unit per Section 2.03-A, Specifications/Design Features.
2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.
Check that the torch is properly connected.
F. Power Supply On
Move the ON/OFF switch to ON position.
G. Select Output Current
Select the desired current output level for the operation:
• 15 to 60 amps for standoff cutting and gouging
• 15 to 35 amps for drag cutting
NOTE
At output settings over 35 amps, the power supply automatically reduces output current to 35
amps if the torch tip touches the workpiece.
H. Set Operating Pressure
Move the RUN/SET/LA TCH switch to SET position. Adjust the gas pressure to 60 - 75 psi (4.1 - 5.2 bar). Refer to
the Torch manual for specific pressure settings.
I. RUN/SET Switch
Set the RUN/SET/LA TCH switch to RUN position.
The system is now ready for operation.
C. Gas Selection
Select desired gas (air or nitrogen). Make sure gas sour ce
meets pressure and flow requirements (refer to Section
3.08, Gas Connections). Check connection and turn gas
supply on.
D. Work Cable Connection
Check for a solid and clean work cable connection to the
workpiece. The area must be free from paint and rust.
Make a solid work cable
connection to the workpiece or cutting table
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc transfer.
For specific applications, use the LATCH position
where the torch switch can be r eleased after the main
arc transfer . The torch r emains activated until the
main arc breaks from the workpiece.
A-00925
Figure 4-7 Work Cable Connection To Workpiece
Manual 0-2782 4-5 OPERATION
Page 34
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
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
below:
Cut Surface
The condition (smooth or rough) of the face of the cut.
Bevel Angle
The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.
Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.
Dross Build-up and Top Spatter
Dross is molten material which is not blown out of the
cut area and re-solidifies on the plate. T op spatter is dross
which accumulates on the top surface of the workpiece.
Excessive dross may require secondary clean-up operations after cutting.
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Figure 4-8 Cut Quality Characteristics
Cut quality will vary on different types of and material
thicknesses.
The following table shows the cut quality that can be expected from this equipment for materials with a thickness from gauge to 3/4 inch (19.1mm):
Type of M aterial
Gas
Air
Nitrogen Good Good Good
Carbon
Steel
G ood -
Excellent
S tain less
Steel
G ood -
Excellent
Alum inum
G ood -
Excellent
Kerf Width
The width of material removed during the cut.
Nitride Build-up
Nitride deposits which may remain on the surface of the
cut when nitrogen is present in the plasma gas stream.
Nitride buildups may create difficulties if the material is
welded after the cutting process.
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.
OPERA TION 4-6 Manual 0-2782
Page 35
SECTION 5:
SERVICE
5.01 Introduction
This section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly
trained personnel.
Regulator/Filter
Assembly
Baffle
Ring
For major troubleshooting and parts replacement procedures refer to PAK Master 75XL Plus Power Supply
Service Manual (CE) 0-2783.
5.02 General Maintenance
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
T o clean the unit, open the enclosure (refer to Section 5.05A, Opening Enclosure) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents for cleaning
electrical apparatus may be used.
Perform maintenance per Appendix 3, Maintenance
Schedule.
A. Filter/Regulator Element Replacement
The Filter/Regulator Assembly is on the rear panel. For
better system performance, the Filter/Regulator Assembly filter element should be checked per the Maintenance
Schedule, and either cleaned or replaced.
1. Remove power from the power supply; turn off
the gas supply.
2. Unscrew the plastic bowl on the bottom of the Filter/Regulator Assembly. The filter element will
be visible and still attached to the main body of
the Filter Regulator .
3. Grasp the filter element and unscrew it from the
Filter/Regulator body. The filter element will
come off with a spool and some additional pieces.
Filter
Element
Spring
Spool
Bowl
A-02988
Figure 5-1 Standard Filter Element Replacement
4. Note the correct assembly of the filter/spool then
remove the filter from the spool and either clean
it or replace it.
5. The filter element and spool, with the baffle ring
in place (teeth facing downward) can be screwed
back into the Regulator body by compressing the
spring on the spool. Tighten firmly by hand.
B. Optional Single-Stage Air Filter Element
Replacement
This part is an option and is not installed on all units. See
Section 6, Parts Lists, for replacement element catalog
number.
NOTE
The XL PLUS Power Supply shuts down automatically when the Filter Element becomes completely
saturated. The Filter Element can be removed from
its housing, dried out, and reused. Allow 24 hours
for Element to dry.
1. Remove power from power supply .
2. Shut off air supply and bleed down system before
disassembly to change Filter Element.
Manual 0-2782 5-1 SERVICE
Page 36
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Assembled Filter
C. Optional Two Stage Air Line Filter
Replacement
This part is an option and may not be installed on all units.
See Section 6 for replacement element catalog number.
1. Remove power from power supply .
2. Shut off air supply and bleed down system before
changing Filter Elements.
WARNING
Always turn off the air supply and bleed the system before disassembling the Filter Assembly as
injury could result.
Cover
Barbed
Fitting
A-02476
Figure 5-2 Optional Single-Stage Air Filter
Replacement
3. Disconnect gas supply hose.
4. Turn the Cover counterclockwise and remove it
from the Filter Housing. The Filter Element is located inside the housing.
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element cup side first, as shown
below.
7. Replace Housing on Cover.
8. Reattach gas supply hose.
NOTE
3. Loosen the two bolts on the top of the Filter Assembly enough to allow the Filter Elements to
move freely.
4. Note the location and orientation of the old Filter
Elements.
5. Slide out the old Filter Elements.
First & Second
Stage
Cartridges
(as marked)
A-02942
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.
Figure 5-3 Optional Two-Stage Air Filter
6. Slide the replacement Filter Elements into the Filter Assembly, with the same orientation as noted
in Step 4 above.
7. Hand tighten the two bolts evenly, then torque
each bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).
8. Slowly apply air pressure to the assembly, checking for leaks.
SERVICE 5-2 Manual 0-2782
Page 37
5.03 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 (Section 1). Be sure the operator is equipped
with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes
into contact with the workpiece while the torch is
activated.
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
Handle torch leads with care and protect them fr om
damage.
A. Piloting
Piloting is harder on parts life than actual cutting because
the pilot arc is directed from the electrode to the tip rather
than to a workpiece. Whenever possible, avoid excessive
pilot arc time to improve parts life.
B. Torch Standoff
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield
cup life. Standoff may also significantly affect the bevel
angle. Reducing standoff will generally result in a more
square cut.
Left Side
Cut Angle
Right Side
Cut Angle
A-00512
Figure 5-4 Side Characteristics Of Cut
E. Dross
Generally when dross is present on carbon steel, it is referred to as either "high speed or slow speed dross".
"High speed dross" usually forms a narrow bead along
the bottom of the cut edge and is very difficult to remove.
"Slow speed dross" will be in larger quantities but does
not adhere tightly to the cut edge and can be easily removed.
When cutting a troublesome steel, it is suggested that the
torch travel speed be reduced to produce "slow speed
dross". Any r equired cleanup can then be done by scrapping, not grinding.
Dross present on top of the plate (top spatter), is normally
caused by a slow torch travel speed or too high of a torch
standoff distance.
F. Common Cutting Faults
1. Insufficient Penetration
C. Edge Star ting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip at the edge of the workpiece where the cut is to start. When starting at the edge
of the plate, do not pause at the edge and force the arc to
"reach" for the edge of the metal. Establish the cutting arc
as quickly as possible.
D. Direction of Cut
In the 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 5-2). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clockwise direction.
Manual 0-2782 5-3 SERVICE
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting curr ent too low
f. Non-genuine thermal Dynamics parts used
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. W orn torch parts
f. Non-genuine thermal Dynamics parts used
Page 38
3. Excessive Dross Formation
C. How to use this Guide
a. Cutting speed too slow
b. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non-genuine thermal Dynamics parts used
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Impr operly assembled tor c h
f. Non-genuine thermal Dynamics parts used
5.04 Troubleshooting Guide
A. General
T roubleshooting and repairing this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
The following information is a guide to help the Customer/Operator determine the most likely causes for
various symptoms.
This guide is set up in the following manner:
X. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
unit is fully operational after any repairs.
A. Main power line fuses blow as soon as main
disconnect is closed
1. Input power cable not properly connected to customer's
main power panel
a. Check that input power cable is properly con-
nected (refer to Section 3.05, Input Power Connections.)
B. AC Power Indicator OFF
1. Switch at customer's main power panel in OFF position.
WARNING
There are extremely danger ous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
B. Basic Tr oubleshooting
This manual covers a basic level of troubleshooting that
requires limited disassembly and measurements. It is
helpful for solving many of the common problems that
can arise with this system.
If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
For major troubleshooting and parts replacement procedures refer to P AK Master 75XL PLUS Power Supply
Service Manual 0-2783.
a. Close main power panel switch
2. Customer's main power line fuse(s) blown
a. Check main power panel fuse(s) and replace
as required.
3. Unit internal fuse blown or loose
a. If blown, double check input voltage against
voltage selection (inside of unit) and replace
fuse per Section 5.05-B. If fuse blows again,
components inside the unit may be faulty.
4. Faulty components in unit
a. Return unit to an authorized service center for
repair or have qualified technician repair per
Service Manual.
C. AC Power indicator ON; TEMP indicator ON
1. Airflow obstructed
a. Check for obstructed air flow and correct con-
dition.
2. Fan blocked
a. Check and correct condition
SERVICE 5-4 Manual 0-2782
Page 39
3. Unit is overheated
G. Erratic or improper cutting output
a. Allow unit to cool down. Make sure the unit
has not been operated beyond duty cycle limit.
4. Input line voltage is below 75% of rated level
a. Check and connect to proper input power line
5. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
D. Torch will not pilot when torch switch is activated
1. RUN/SET/LATCH switch in SET position
a. Move switch to RUN position.
2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
fer to Instruction Manual supplied with torch).
3. Gas pressure too high or too low
a. Set pressure to 60 psi (4.1 bar).
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
E. No cutting output; AC Power indicator ON; Fans
operating
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached to
power supply.
2. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against
torch head (do not overtighten if screwed on).
3. Faulty components in unit
1. Poor input or output connections
a. Check all input and output connections.
2. Incorrect type and size cable on input or output
a. Use proper type and size cables.
H. Cutting output available; Fans not operating, AC
Power indicator ON
1. Fan blades blocked
a. Check and clear blades.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. No gas flow; Fans operate; AC POWER indicator
ON
1. Gas not connected or pressure too low
a. Check source for at least 70 psi (4.8 bar).
2. Gas supply pressure too high
a. Maximum of 125 psi inlet pressure
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
J. Torch cuts but not adequately
1. Drag circuit active
a. Lift tip from work piece.
2. Current set too low
a. Increase current setting.
3. T orch is being moved too fast across workpiece
a. Return for repair or have qualified technician
repair per Service Manual.
4. Faulty T orch
a. Return for repair or have qualified technician
repair per Torch Instruction Manual.
F. Low cutting output with no control
1. T orch tip touching workpiece, tip saver active
2. Incorrect setting of CURRENT control
a. Check and adjusted to proper setting.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
Manual 0-2782 5-5 SERVICE
a. Reduce cutting speed (refer to Instruction
Manual supplied with torch.)
4. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface
while purging and observe oil or moisture
buildup (do not activate torch).
Page 40
5.05 Power Supply Parts Replacement
B. Fuse Replacement
1. Remove the left side panel per paragraph "A"
above.
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
A. Left Side Panel Removal
1. Remove the screws which secure the left side panel
(viewed from front of unit) to the frame assembly.
Left Side
Panel
2. Locate the internal fuse above the input power contactor on the left side of the unit.
3. Replace the fuse. See Section 6, Parts Lists, for replacement fuse catalog number.
4. Reinstall the left side panel per paragraph "A"
above.
Internal Fuse
0.8 Amps, 600V
A-02613
A-02648
EMC Filter
Ground
Screws
(5 places)
Wire
Figure 5-5 Left Side Panel Removal
NOTE
There is a ground wire connection to the Left Side
Panel on the inside of the unit. There is no need to
disconnect the ground wire.
2. Carefully pull the Left Side Panel up and away
from the unit to gain access to the inside of the
unit.
3. To reinstall the left side panel do the following:
a. Place the left side panel onto the frame and
slide the top edge under the lip on the top of
the right side panel.
b. Reinstall all the screws to secure the left side
panel.
Figure 5-6 Internal Fuse Location
This completes the replacement procedur es.
SERVICE 5-6 Manual 0-2782
Page 41
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all r eplaceable components. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a product must be returned for service, contact your
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. Addr ess all inquiries to your authorized distributor .
Manual 0-2782 6-1 PARTS LISTS
Page 42
6.03 Complete Power Supply Replacement
Power supply includes: Work cable and clamp, pressure regulator/air filter, input power cable, and operating
manual.
Qty Description Catalog #
1 PAK MASTER 75XL PLUS Power Supply (CE), 380/415VAC, 3-7856
Three-Phase W ith EMC Input Cable (no plug)
6.04 Replacement Parts
Qty Description Catalog #
1 Fuse (0.8 amp, 600V) 9-7526
1 Filter/Regulator Assembly Replacement Element 9-8534
1 CE Input Power Cable, Thr ee Phase 9-7668
6.05 Options and Accessories
Qty Description Catalog #
1 Multi-Purpose Cart 7-8888
1 Cutting Guide Kit 7-8910
1 Standof f Cutting Guide 8-7575
1 Single-Stage Air Line Filter Kit – Includes Filter And Hose 7-7507
1 Filter Body 9-7740
2 Filter Element 9-7741
1 Filter Hose (not shown) 9-7742
1 Two Stage Air Line Filter Kit 7-7500
1 Bracket, Filter Mounting (not shown) 9-7535
1 T wo-Stage Air Filter Assembly 9-7527
1 First Stage Filter 9-1021
1 Second Stage Filter 9-1022
Computer Control Cable (CNC)
1 25 Foot (7.6 m) 8-5557
1 50 Foot (15.2 m) 8-5558
1 Hand Pendant Control with 20 Ft (6.1 m) cable 7-3460
1 Hand Pendant Extension Cable - 25 Ft (15.2 m) 7-7744
1 Metal Mounting Tube with Pinion Assembly 7-7745
Housing
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
Cover
Barbed
Fitting
Assembled Filter
A-02476
First & Second
Stage
Cartridges
(as marked)
A-02942
Optional Single-Stage Air Filter Kit Optional Two-Stage Air Filter Kit
PARTS LISTS 6-2 Manual 0-2782
Page 43
APPENDIX 1: INPUT WIRING REQUIREMENTS
(
)(Hz)(
)(Amps)
Input Power Input
Volta g e Freq. 3-Ph 3-Ph F us e (Amps ) Wire (mm
Volts
380 50/60 12.4 18.9 25 6
415 50/60 12.6 17.5 25 4
Line Voltages with Recommended Circuit Protection and Wire Sizes
kVA
Current Input Suggested Sizes
2
)
3-Ph 3-Ph
NOTES
The table above is based on the following output current and voltage: 130VDC @ 60A
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 0-2782 A-1 APPENDIX
Page 44
APPENDIX 2: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
LATCH
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
Protect eyes and
activate torch
RESULT
Gas flows (2 seconds).
After gas pre-flow:
DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
ON/OFF switch
to ON.
RESULT
AC indicator blinks for 8
seconds then steady on.
Fans on.
Power circuit ready.
RUN/SET/LATCH switch
gas flows to set pressure.
PILOT ARC
ACTION
to SET.
RESULT
Gas solenoid open,
GAS indicator on.
ACTION
RUN/SET/LATCH
switch to RUN.
RESULT
Gas flow stops.
GAS indicator off.
ACTION
Torch moved away
from work (while
still activated).
RESULT
Main arc stops.
Pilot arc automatically
restarts.
ACTION
Torch moved within
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.
transfer distance of workpiece.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
Open external
disconnect.
RESULT
No power to system.
ACTION
Torch Switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
A-02461
APPENDIX A-2 Man ual 0-2782
Page 45
APPENDIX 3: MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting 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 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.
Manual 0-2782 A-3 APPENDIX
Page 46
APPENDIX 4: DATA TAG INFORMATION
Type of Power
Supply (Note 1)
Plasma Cutting
Symbol
Input Power
Symbol
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Model:
1/3
Rated NoLoad V oltage
Degree of Protection
f
1
f
2
Output Current Type
U
0
X
I
=
U
2
Conventional
Load V oltage
U
1
Rated Supply
Voltage (Note 2)
West Lebanon, NH USA 03784
S/N
Made in USA
Duty Cycle Factor
Rated Maximum
Supply Current
1max 1eff
1
1Ø
I
3Ø
1
Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code
Regulatory Standard Covering
This Type of Power Supply
Output Range (Amperage/
Voltage)
Duty Cycle Data (Note 3)
I
3Ø1Ø
Maximum Effective
Supply Current
Manufacturer's Electrical
Schematic File Number
and Revision Level
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle values.
Second row: Rated cutting current values.
Third row: Conventional load voltage values.
Standard Symbols
AC
DC
Phase
Ø
A-03288
APPENDIX A-4 Man ual 0-2782
Page 47
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Manual 0-2782 A-5 APPENDIX
Page 48
APPENDIX 5: SYSTEM SCHEMATIC
A-02638
APPENDIX A-6 Man ual 0-2782
Page 49
A-02638
Manual 0-2782 A-7 APPENDIX
Page 50
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