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Summary of Contents for Thermal Dynamics CE PAK Master 75XL
- Page 1 PLASMA CUTTING POWER SUPPLY ® CE PAK Master 75XL A-00909 Operating Manual September 25, 2001 Manual No. 0-2607...
- Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply ® CE PAK Master 75XL Operating Manual Number 0-2607 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 Copyright 1997 by Thermal Dynamics Corporation All rights reserved.
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Page 4: Table Of Contents
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1 1.01 Notes, Cautions and Warnings ................ 1 1.02 Important Safety Precautions ................1 1.03 Publications ..................... 2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes .............. 3 1.06 Documents De Reference ................ - Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................29 6.01 Introduction ....................29 6.02 Ordering Information ..................29 6.03 Complete Power Supply Replacement ............30 6.04 Options and Accessories ................30 APPENDIX I: INPUT WIRING REQUIREMENTS ..............31 APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........... 32 APPENDIX III: SYSTEM SCHEMATIC ..................
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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: 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.
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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.
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Page 13: 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 14: 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 15: Introduction
NOTE 75XL Air Plasma Cutting Power Supply (EMC). Service Refer to Section 2.04 for list of power supply op- of this equipment is restricted to Thermal Dynamics tions and accessories. trained personnel; unqualified personnel are strictly cau- tioned against attempting repairs or adjustments not cov- 2.03 Specifications/Design Features... -
Page 16: Power Supply Options And Accessories
9. Weight D. Interface Cable 72 lbs (32.7 kg) NOTE This accessory can be used only with the PCM-75 10. Overall Dimensions Torches. 18.9" (480 mm) High x 13" (330 mm) Wide x 23.5" (597 mm) Long The interface cable is available in two lengths, 25 ft (7.6 m) and 50 ft (15.2 m). -
Page 17: Installation Procedures
Provide sufficient clearance in front of the unit to allow SECTION 3: access to the front panel controls (minimum 6 inches or 0.15 m). INSTALLATION PROCEDURES CAUTION Operation without proper air flow will inhibit 3.01 Introduction proper cooling and reduce duty cycle. NOTE 3.03 Unpacking Depending on how the system was ordered, some... -
Page 18: Lifting Options
B. Electrical Connections 3.04 Lifting Options The power source must conform to local and national electric codes. Recommended circuit protection and wir- WARNINGS ing requirements are shown in Appendix I. C. Opening Power Supply Enclosure Do not touch live electrical parts. The left side panel of the Power Supply must be removed to gain access to the input power connections and the Disconnect input power conductors from de-en-... -
Page 19: Input Power Cable Connections
3. Connect the ends of the individual wires a cus- tomer supplied plug or main disconnect per the WARNING following: NOTE Disconnect primary power at the source before as- All the input cable wires must be connected for sembling or disassembling the power supply, torch three-phase operation. - Page 20 B. Checking Air Quality Regulator/Filter Assembly To test the quality of air, place the RUN/SET switch to SET position, place a welding filter lens in front of the 1/4 NPT to #4 (6 mm) Hose torch and turn on the gas. Any oil or moisture in the air Fitting will be visible on the lens.
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Page 21: Connecting Torch Leads
Access Panel CAUTION Pressure should be set at 100 psi (6.9 BAR or 690 kPa) 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 Screw Latch clean and free of oil, grease or any foreign mate- rial. -
Page 22: Work Cable And Ground Connections
6. Connect the torch gas/power lead fitting onto the possible to the power supply. The work table should Gas/Power Lead Connection. be connected to the same earth ground as the power supply. 2. Connect the control device (CNC) to a separate earth Pilot Lead Stud ground similar to the ground rod described above. -
Page 23: Operation
3. Torch Leads Input SECTION 4: Hole in the front panel to feed the torch leads through OPERATION to the internal bulkhead connections. 4. Work Cable and Clamp 4.01 Introduction Work cable with clamp (factory Installed). This Section provides a description of the Power Supply 5. - Page 24 5. TEMP Indicator D. Rear Panel Normally OFF. Yellow LED indicator will come ON 1. Gas Input when the internal temperature senors detect tempera- Input connection for nitrogen (N2) or air input. tures above normal limits. The unit should be al- lowed to cool before continuing operation.
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Page 25: Sequence Of Operation
4. Place RUN/SET switch to SET mode. a. Gas solenoid opens and gas flows to set pres- sure. b. GAS indicator turns ON. NOTE GAS indicator will not come ON if the gas pres- sure is set below 45 psi (3.1 BAR or 310 kPa) at the Regulator/Filter Assembly. -
Page 26: Preparations For Operating
12. Gas will flow for 15 seconds (post-flow). Make a solid work cable connection to the work- a. Gas solenoid closes piece or cutting table b. Gas flow stops. c. GAS indicator turns OFF. 13. Place the ON/OFF power switch on the front panel of the unit to OFF a. - Page 27 Cut Surface T y p e o f M a t e r ia l The condition (smooth or rough) of the face of the cut. C a r b o n S t a in le s s G a s A lu m in u m S t e e l S t e e l...
- Page 28 OPERATION Manual 0-2607...
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Page 29: Customer/Operator Service
SECTION 5: 5.03 Common Operating Problems CUSTOMER/OPERATOR WARNINGS SERVICE Disconnect primary power at the source before dis- 5.01 Introduction assembling the power supply, torch, or torch leads. This Section describes basic maintenance procedures per- Frequently review the Important Safety Precau- tions (page 1). -
Page 30: Troubleshooting Guide
more square than the other. Viewed along the direction d. Work cable disconnected of travel, the right side of the cut is more square than the e. Worn torch parts left (Refer to Figure 5-1). To make a square-edged cut along an inside diameter of a circle, the torch should 3. - Page 31 C. How to use this Guide 3. Unit is overheated a. Allow unit to cool down for about 5 minutes. The following information is a guide to help the Cus- Make sure the unit has not been operated be- tomer/Operator determine the most likely causes for yond duty cycle limit.
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Page 32: Power Supply Parts Replacement
E. Low cutting output with no control 3. Excessive oil or moisture in torch 1. Incorrect setting of CURRENT control a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture a. Check and adjusted to proper setting. buildup (do not activate torch) 2. - Page 33 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. B.
- Page 34 SERVICE Manual 0-2607...
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Page 35: Parts Lists
Parts listed without item numbers are not shown, but may be ordered by the catalog number shown. B. Returns If a Thermal Dynamics product must be returned for ser- vice, contact your Thermal Arc distributor. Materials re- turned to Thermal Dynamics without proper authoriza- tion will not be accepted. -
Page 36: Complete Power Supply Replacement
6.03 Complete Power Supply Replacement Power supply includes: EMC Input Power Cable, Work cable, pressure regulator/air filter, air hose and 1/4 NPT to barb fittings, and operating manual. Description Catalog # PAK MASTER 75XL Power Supply (EMC) 3-7850 6.04 Options and Accessories Description Catalog # Two Stage Air Filter Kit... -
Page 37: Appendix I: Input Wiring Requirements
APPENDIX I: INPUT WIRING REQUIREMENTS In p u t P o w er In p u t C u r r en t S u g g est ed S iz es (S ee N o te) V o ltag e F r eq . -
Page 38: Appendix Ii: Sequence Of Operation (Block Diagram)
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET RUN/SET 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. Gas solenoid open, seconds then steady on. - Page 39 Manual 0-2607 APPENDIX...
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Page 40: Appendix Iii: System Schematic
APPENDIX III: SYSTEM SCHEMATIC A-01544 APPENDIX Manual 0-2607... - Page 41 A-01544 Manual 0-2607 APPENDIX...
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