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Summary of Contents for Thermal Dynamics PakMaster 75XL Plus
- Page 1 Plasma Cutting Power Supply ® PakMaster 75XL Plus A-02464 Operating Manual July 8, 2003 Manual No. 0-2746...
- Page 3 Manufacturer assumes no liability for its use. ® Plasma Cutting Power Supply PAKMaster 75 XL Plus Operating Manual Number 0-2746 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2000 by Thermal Dynamics Corporation All rights reserved.
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Page 4: Table Of Contents
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 1.07 Declaration of Conformity ................1-4 1.08 Statement of Warranty .................. 1-5 SECTION 2: INTRODUCTION ...................... - 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: PARTS LISTS ........................6-1 6.01 Introduction ....................
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Page 7: General Information
SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume. -
Page 8: Publications
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •... - Page 9 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CON- TAINERS WHICH HAVE HELD COMBUSTIBLES, ob- tainable from American Welding Society, 550 N.W.
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Page 10: Declaration Of Conformity
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. -
Page 11: Statement Of Warranty
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. - Page 12 GENERAL INFORMATION May 14, 2002...
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Page 13: Introduction
lengths with fittings for simple installation. Spare Parts SECTION 2: Kits are available for the torches which provide an as- INTRODUCTION sortment of replacement torch parts. 2.03 Specifications / Design 2.01 Scope of Manual Features This manual contains descriptions, operating instructions A. -
Page 14: Power Supply Options And Accessories
7. Cut Capacity (Mild Steel) 2.04 Power Supply Options and Accessories 3/4 inch / 19.1 mm ; 1 inch / 25.4 mm severance 8. Pilot Circuitry The following accessories are available for this power supply. Refer to Section 6, Parts Lists, for catalog num- Capacitive Discharge (CD), Pulsed DC bers and ordering information. -
Page 15: Installation
SECTION 3: CAUTION INSTALLATION Operation without proper air flow will inhibit proper cooling and reduce duty cycle. 3.01 Introduction 3.03 Unpacking NOTE Each component of the system is packaged and protected Depending on how the system was ordered, some with a carton and packing material to prevent damage Power Supply Options may already be installed. -
Page 16: Input Power Connections
2. Carefully pull the Left Side Panel up and away from 3.05 Input Power Connections the unit to gain access to the inside of the unit. The Power Supply accepts input voltages from 208V to 3.06 Input Voltage Selection 460V. Input can be 50 or 60 Hz, single - phase or three - phase. -
Page 17: Primary Input Power Cable Connections
For single - phase operation the jumper wire must be installed on the contactor as described in Section 3.07 Input for single - phase input voltage. Contactor 3.07 Primary Input Power Cable Connections Units ordered as 230V, single - phase, will have a six foot power input cable and plug factory installed. -
Page 18: Gas Connections
3.08 Gas Connections Input Contactor A. Gas Requirements WARNING This unit not to be used with oxygen (O Gases: Compressed Air or Nitrogen (N2) Only Pressure: Unshielded Leads: 70 psi / 4.8 bar Shielded Leads: 60 psi / 4.1 bar Single Phase A-00914 Jumper Wire... - Page 19 C. Gas Connections D. Optional Air Line Filter Installation The gas supply is connected to the Pressure Regulator / Filtering is required when using air from a compressor to Filter Assembly installed on the rear of the unit. The con- insure that moisture and debris from the supply hose does nection is the same for compressed air or high pressure not enter the torch.
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Page 20: Connecting Torch Leads
E. Using High Pressure Gas Cylinders 3.09 Connecting Torch Leads 1. Refer to the following when using high pressure gas cylinders as the gas supply: CAUTION CAUTION This system is designed for use with the PCH / M - 102 torch only. Do not connect any other torch to this power supply. - Page 21 A. Hand Systems 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 re- WARNING moved earlier. 6. Connect the torch Negative / Plasma Lead to the Disconnect primary power at the source before as- bulkhead connection inside the Power Supply.
- Page 22 B. Machine Systems (Unshielded Leads) Adapter Connector Negative/Plasma Lead Connection WARNING Power Supply Adapter Control Circuit Connectors Disconnect primary power at the source before as- Open sembling or disassembling the power supply, torch parts, or torch and leads assemblies. Open 1.
- Page 23 9. Place the lug on the Pilot Control Wire onto the d. Tighten the Strain Relief Nut to secure the stud and secure with the nut and washer removed Strain Relief to the Power Supply. in the above Step. 10. Tighten the Strain Relief onto the Torch Leads. Adapter Connector 11.
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Page 24: Ground Connections For Mechanized Applications
6 - 8 ft (1.8 - 2.4 m) into the earth so that For Thermal Dynamics components it is recom- the rod contacts moist soil over most of its length. mended to use a minimum of 10 AWG (European 6... -
Page 25: Tip Saver / Drag Cut Sensing Circuit
3.11 Tip Saver / Drag Cut Sensing Circuit 115VAC: 3.0 VAC This power supply is equipped with a Tip Saver / Drag 230VAC: 1.5 VAC Cut Sensing Circuit which cuts current back to 35 amps if the tip touches the workpiece. The purpose of this is to prolong the life of the tip. - Page 26 INSTALLATION 3-12 Manual 0-2746...
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Page 27: Operation
5. Torch Leads and Spare Parts Kit Storage Area SECTION 4: Bracket connected to the side panel of the unit for OPERATION 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. - Page 28 2. Control Cable Connector TEMP Indicator Used to interface the Adapter (supplied with Power Supply) to the Torch Leads Control Cable. Normally OFF. Yellow indicator turns ON when the internal temperature senors detect temperatures 3. Negative / Plasma Lead Connection above normal limits.
- Page 29 3. Gas Pressure Regulator / Filter Assembly b. Two - Stage Air Line Filter Pressure regulator to adjust the input gas pressure to A Two Stage In - Line Air Filter for use on compressed the Power Supply. An air line filter is supplied as air shop systems.
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Page 30: Sequence Of Operation
10. Optional - Place RUN / SET / LATCH to LATCH 4.03 Sequence of Operation mode. The following is a typical sequence of operation for this NOTE cutting system. Refer to Appendix 2 for a block diagram. For general cutting, use the RUN position which 1. -
Page 31: Preparations For Operating
Figure 4-7 Work Cable Connection To Workpiece 4.04 Preparations for Operating Follow this set - up procedure each time the system is E. Torch Connection operated: Check that the torch is properly connected. F. Power Supply On WARNING Move the ON / OFF switch to ON position. G. -
Page 32: Cut Quality
Cut quality will vary on different types of material and 4.05 Cut Quality thicknesses. Cut quality requirements differ depending on applica- The following table shows the cut quality that can be ex- tion. For instance, nitride build - up and bevel angle may pected from this equipment for materials with a thick- be major factors when the surface will be welded after ness from gauge to 3/4 inch / 19.1mm:... -
Page 33: Service
5. The filter element and spool, with the baffle ring SECTION 5: in place (teeth facing downward) can be screwed SERVICE back into the Regulator body by compressing the spring on the spool. Tighten firmly by hand. 5.01 Introduction This section describes basic maintenance procedures per- Regulator/Filter formable by operating personnel. - Page 34 1. Remove power from power supply. 2. Shut off air supply and bleed down system be- fore changing Filter Elements. Housing WARNING Filter Always turn off the air supply and bleed the sys- Element (Cat. No. 9-7741) tem before disassembling the Filter Assembly as injury could result.
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Page 35: Common Operating Problems
"reach" for the edge of the metal. Estab- e. Cutting current too low lish the cutting arc as quickly as possible. f. Non - Genuine Thermal Dynamics parts used D. Direction of Cut 2. Main Arc Extinguishes In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. -
Page 36: Troubleshooting Guide
Worn torch parts This guide is set up in the following manner: d. Improper cutting current X. Symptom (Bold Type) e. Non - Genuine Thermal Dynamics parts used Any Special Instructions (Text Type) 4. Short Torch Parts Life 1. Cause (Italic Type) a. - Page 37 2. Fan blocked 2. Faulty components in unit a. Check and correct condition. a. Return for repair or have qualified technician repair per Service Manual. 3. Unit is overheated F. Limited output with no control a. Allow unit to cool down for about 5 minutes. Make sure the unit has not been operated be- 1.
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Page 38: Power Supply Parts Replacement
3. Torch is being moved too fast across workpiece 3. Reinstall the left side panel as follows: a. Reduce cutting speed (refer to Instruction a. Place the left side panel onto the frame and Manual supplied with torch). slide the top edge under the lip on the top of the right side panel. -
Page 39: Parts Lists
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable com- ponents. 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. -
Page 40: Complete Power Supply Replacement
6.03 Complete Power Supply Replacement Power supply includes: Work cable and clamp, pressure regulator / air filter, and operating manual. Description Catalog # PAK MASTER 75XL PLUS Power Supply 208 / 230VAC, Single - Phase, With 50 Amp Input Plug and Cable 3-7556-1 460VAC, Three - Phase, Without Input Plug and Cable 3-7556-2... -
Page 41: Appendix 1: Input Wiring Requirements
APPENDIX 1: INPUT WIRING REQUIREMENTS Input P ower Input Current Input Recommended S izes (See Notes) V oltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) W ire (AW G) W ire (Canada) (V olts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph... -
Page 42: Appendix 2: Sequence Of Operation (Block Diagram
APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) LATCH ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET/LATCH RUN/SET/LATCH switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops. -
Page 43: Appendix 3: Maintenance Schedule
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: Check torch consumable parts, replace if damaged or worn. -
Page 44: Appendix 4: Data Tag Information
APPENDIX 4: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor Output Range (Amperage/... - Page 45 This page left blank. Manual 0-2746 APPENDIX...
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Page 46: Appendix 5: System Schematic
APPENDIX 5: SYSTEM SCHEMATIC A-02503 APPENDIX Manual 0-2746... - Page 47 A-02503 Manual 0-2746 APPENDIX...
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