Thermal Dynamics CE PAKMaster 75 XL Plus Operating Manual
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Thermal Dynamics CE PAKMaster 75 XL Plus Operating Manual

Thermal Dynamics CE PAKMaster 75 XL Plus Operating Manual

Plasma cutting power supply
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Plasma Cutting
Power Supply
©
TM
CE PAKMaster
75 XL
Plus
A-02464
Operating Manual
July 7, 2003
Manual No. 0-2782

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  • Page 1 Plasma Cutting Power Supply © CE PAKMaster 75 XL Plus A-02464 Operating Manual July 7, 2003 Manual No. 0-2782...
  • Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, oper- ating, 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 ®...

  • 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 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • 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 ....................

  • 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: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection 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.

  • Page 13: Declaration Of Conformity

    1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 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.

  • Page 14: Statement Of Warranty

    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 stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole...

  • Page 15: Introduction

    The system provides a maximum 1 inch (25.4 mm) cut SECTION 2: capacity. Torch heads are available in various configura- INTRODUCTION tions. Torch leads are available in various lengths with fittings for simple installation. Spare Parts Kits are avail- able for the torches which provide an assortment of re- placement torch parts.

  • Page 16: Power Supply Options And Accessories

    8. Pilot Circuitry C. High Pressure Regulators Capacitive Discharge (CD), Pulsed DC High pressure regulators are available for air and ni- trogen. The regulators are used to set the proper pres- 9. Weight sure for the type gas being used. 71 lbs (32 kg) withwork lead, input power cable NOTE 78 lbs (35.4 kg) withwork lead, torch &...

  • Page 17: Installation

    SECTION 3: 3.03 Unpacking INSTALLATION Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping. 3.01 Introduction l. Unpack each item and remove any packing material. NOTE NOTE Depending on how the system was ordered, some The Cutting Spare Parts Kit is shipped in the Torch Power Supply Options may already be installed.

  • Page 18: Input Power Cable Connections

    3.05 Input Power Cable Connections 3.06 Gas Connections The 75XL PLUS Power Supply operates on three phase, A. Gas Requirements 380-415 VAC ± 10% 50/60 Hz input. WARNING CAUTION The primary power source, power cable, and plug This unit not to be used with oxygen (O must all conform to local electric code and the rec- ommended circuit protection and wiring require- Gases: Compressed Air or Nitrogen (N2) Only...
  • Page 19 Single-Stage Air Filter Kit or Two Stage Filter Kit As- sembly Regulator/Filter Assembly 1/4 NPT to #4 (6 mm) Hose A-02607 Fitting Hose Clamp Air Line Filter Assembly #4 (6 mm) Gas 1/4 NPT to #4 (6mm) Supply Hose Hose Fitting Hose Clamp #4 (6mm) Gas A-01149...

  • Page 20: Connecting Torch Leads

    E. Using High Pressure Gas Cylinders A. Hand Systems 1. Refer to the following when using high pressure gas cylinders as the gas supply: WARNING CAUTION Disconnect primary power at the source before as- sembling or disassembling the power supply, torch Pressure should be set at 100 psi (6.9 bar) at the parts, or torch and leads assemblies.
  • Page 21 6. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply. Torch Leads Assembly Strain Relief Adapter Adapter Pilot Lead Stud Connector (Supplied With Power Supply) Control (PIP) Circuit Connectors A-02836 Retaining Nut Negative/Plasma Lead Connection Figure 3-5a Torch Strain Relief Nut (Leads with Pilot Lead Two Control Wires) Negative/Plasma...
  • Page 22 8. Remove the top nut and washer from the Pilot c. Feed the end of the torch lead and the Strain Stud. Relief into the hole in the unit while routing the single black wire into the notch of the Strain 9.
  • Page 23 10. Check the torch for proper parts assembly. 11. Close the access panel and turn the latching screw. Adapter Connector C. Machine Systems (PCM-62 Torch with Negative/Plasma Adapter Lead Connection Shielded Leads) (Supplied With Power Supply) Control (PIP) Circuit WARNING Connectors Shield Connectors Disconnect primary power at the source before as-...
  • Page 24 D. Machine Systems (SL100 Torch) 6. Connect the control circuit connectors on the Torch Leads to the mating connectors on the Remote Torches with O2B connectors connect directly to the Pendant Adapter and Power Supply Adapter (see power supply bulkhead. Mechanized torch leads with Warning).

  • Page 25: Ground Connections For Mechanized Applications

    3.08 Ground Connections For Mechanized Applications Power Supply Adapter Control Circuit A. Electromagnetic Interference (EMI) Connectors Pilot arc initiation generates a certain amount of electro- magnetic interference (EMI), commonly called RF noise. Open This RF noise may interfere with other electronic equip- ment such as CNC controllers, remote controls, height Remote Pendant controllers, etc.
  • Page 26 4. The plasma power supply work cable (see NOTE) is To test for a proper earth ground, refer to the follow- connected to the cutting table at the single point “Star” ing diagram. Ideally, the reading on the multimeter ground. should be as follows: NOTE •...

  • Page 27: Tip Saver/Drag Sensing Circuit

    D. Routing Of Torch Leads 1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive mo- tors, 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.
  • Page 28 INSTALLATION 3-12 Manual 0-2782...

  • Page 29: Operation

    5. Torch Leads and Spare Parts Kit Storage Area SECTION 4: Bracket connected to the side panel of the unit for use OPERATION 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 30 D. Rear Panel Features 5. TEMP Indicator 1. Gas Input Normally OFF. Yellow indicator turns ON when the Input connection for air or nitrogen (N2) input. internal temperature senors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation.

  • Page 31: Sequence Of Operation

    4. Optional Filters Two Stage Air Line Filter Single-Stage Air Filter Assembly This optional filter will also remove moisture and con- taminants from the air stream when using compressed This in-line filter removes moisture and contaminants air. Filters to 5.0 microns. from the air stream when using compressed air.
  • Page 32 4. Place RUN/SET/LATCH switch to SET mode. 12. Release or deactivate the torch switch. a. Gas solenoid opens and gas flows to set pres- a. Main arc stops. sure. b. Pilot arc stops (power supply enable signal re- b. GAS indicator turns ON. moved).

  • Page 33: Preparations For Operating

    E. Torch Connection 4.04 Preparations for Operating Check that the torch is properly connected. Follow this set-up procedure each time the system is op- erated: F. Power Supply On Move the ON/OFF switch to ON position. WARNING G. Select Output Current Select the desired current output level for the operation: Disconnect primary power at the source before dis- assembling the power supply, torch, or torch leads.

  • Page 34: Cut Quality

    4.05 Cut Quality Kerf Width Cut quality requirements differ depending on applica- Cut Surface tion. For instance, nitride build-up and bevel angle may Bevel Angle be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut Spatter quality is desired to avoid a secondary cleaning opera- tion.

  • Page 35: Service

    SECTION 5: SERVICE Regulator/Filter Assembly 5.01 Introduction This section describes basic maintenance procedures per- formable by operating personnel. No other adjustments or repairs are to be attempted by other than properly Baffle trained personnel. Ring For major troubleshooting and parts replacement pro- Filter cedures refer to PAK Master 75XL Plus Power Supply Element...
  • Page 36 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. Housing 1. Remove power from power supply. 2. Shut off air supply and bleed down system before changing Filter Elements.

  • Page 37: Common Operating Problems

    5.03 Common Operating Problems Left Side Cut Angle Right Side Cut Angle WARNINGS Disconnect primary power at the source before dis- assembling the power supply, torch, or torch leads. Frequently review the Important Safety Precau- tions (Section 1). Be sure the operator is equipped A-00512 with proper gloves, clothing, eye and ear protec- tion.

  • Page 38: Troubleshooting Guide

    3. Excessive Dross Formation C. How to use this Guide a. Cutting speed too slow The following information is a guide to help the Cus- tomer/Operator determine the most likely causes for b. Torch standoff too high from workpiece various symptoms. c.
  • Page 39 3. Unit is overheated G. Erratic or improper cutting output a. Allow unit to cool down. Make sure the unit 1. Poor input or output connections has not been operated beyond duty cycle limit. a. Check all input and output connections. 4.

  • Page 40: Power Supply Parts Replacement

    B. Fuse Replacement 5.05 Power Supply Parts Replacement 1. Remove the left side panel per paragraph "A" above. 2. Locate the internal fuse above the input power con- WARNING tactor on the left side of the unit. 3. Replace the fuse. See Section 6, Parts Lists, for re- Disconnect primary power to the system before dis- placement fuse catalog number.

  • Page 41: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction 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 42: Complete Power Supply Replacement

    6.03 Complete Power Supply Replacement Power supply includes: Work cable and clamp, pressure regulator/air filter, input power cable, and operating manual. Description Catalog # PAK MASTER 75XL PLUS Power Supply (CE), 380/415VAC, 3-7856 Three-Phase With EMC Input Cable (no plug) 6.04 Replacement Parts Description Catalog #...

  • Page 43: Appendix 1: Input Wiring Requirements

    APPENDIX 1: INPUT WIRING REQUIREMENTS Input Power Input Current Input Suggested Sizes Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (mm (Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 50/60 12.4 18.9 50/60 12.6 17.5 Line Voltages with Recommended Circuit Protection and Wire Sizes 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.

  • Page 44: 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 45: 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 46: 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 47 This page left blank. Manual 0-2782 APPENDIX...

  • Page 48: Appendix 5: System Schematic

    APPENDIX 5: SYSTEM SCHEMATIC A-02638 APPENDIX Manual 0-2782...
  • Page 49 A-02638 Manual 0-2782 APPENDIX...

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