2746 PakMaster 75XL Plus (O)

July 8, 2003 Manual No. 0-2746

Operating Manual

Plasma CuttingPower Supply

PakMaster 75XLTM Plus

A-02464

Plasma Cutting Power Supply PAKMaster 75 XLTM PlusOperating Manual Number 0-2746

Published by:Thermal Dynamics Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

Copyright 2000 byThermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written per-mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability toany party for any loss or damage caused by any error or omission inthis Manual, whether such error results from negligence, accident, orany other cause.

Printed in the United States of America

Publication Date: July 8, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

WARNINGS

Read and understand this entire Manual and your employers safety practices before installing, oper-ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, theManufacturer assumes no liability for its use.

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-11.02 Important Safety Precautions ....................................................................... 1-11.03 Publications .................................................................................................. 1-21.07 Declaration of Conformity ............................................................................. 1-41.08 Statement of Warranty .................................................................................. 1-5

SECTION 2:INTRODUCTION .............................................................................................................. 2-1

2.01 Scope of Manual ......................................................................................... 2-12.02 General Description of System .................................................................... 2-12.03 Specifications / Design Features ................................................................. 2-12.04 Power Supply Options and Accessories ...................................................... 2-2

SECTION 3:INSTALLATION ................................................................................................................. 3-1

3.01 Introduction .................................................................................................. 3-13.02 Site Selection ............................................................................................... 3-13.03 Unpacking .................................................................................................... 3-13.04 Lifting Options .............................................................................................. 3-13.05 Input Power Connections ............................................................................. 3-23.06 Input Voltage Selection ................................................................................. 3-23.07 Primary Input Power Cable Connections ...................................................... 3-33.08 Gas Connections ......................................................................................... 3-43.09 Connecting Torch Leads ............................................................................... 3-63.10 Ground Connections for Mechanized Applications ..................................... 3-103.11 Tip Saver / Drag Cut Sensing Circuit .......................................................... 3-11

SECTION 4:OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-14.02 Operating Controls ....................................................................................... 4-14.03 Sequence of Operation ................................................................................ 4-44.04 Preparations for Operating ........................................................................... 4-54.05 Cut Quality ................................................................................................... 4-6

TABLE OF CONTENTS (continued)

SECTION 5:SERVICE .......................................................................................................................... 5-1

5.01 Introduction .................................................................................................. 5-15.02 General Maintenance ................................................................................... 5-15.03 Common Operating Problems ...................................................................... 5-35.04 Troubleshooting Guide ................................................................................. 5-45.05 Power Supply Parts Replacement ................................................................ 5-6

SECTION 6:PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction ................................................................................................. 6-16.02 Ordering Information ................................................................................... 6-16.03 Complete Power Supply Replacement ........................................................ 6-26.04 Replacement Parts ...................................................................................... 6-26.05 Options and Accessories ............................................................................. 6-2

APPENDIX 1: INPUT WIRING REQUIREMENTS .................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ......................................... A-2

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................ A-3

APPENDIX 4: DATA TAG INFORMATION ................................................................................. A-4

APPENDIX 5: SYSTEM SCHEMATIC....................................................................................... A-6

May 14, 2002 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and warningsare used to highlight important information. These high-lights are categorized as follows:

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, maycause damage to the equipment.

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in the oper-ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO YOURHEALTH.

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with theproper function of cardiac pacemakers, hearing aids,or other electronic health equipment. Persons whowork near plasma arc cutting applications shouldconsult their medical health professional and themanufacturer of the health equipment to determinewhether a hazard exists.

To prevent possible injury, read, understand andfollow all warnings, safety precautions and instruc-tions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any ques-tions.

GASES AND FUMES

Gases and fumes produced during the plasma cuttingprocess 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 notadequate to remove all fumes and gases.

The kinds of fumes and gases from the plasma arcdepend on the kind of metal being used, coatingson the metal, and the different processes. You mustbe very careful when cutting or welding any met-als which may contain one or more of the follow-ing:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

For information on how to test for fumes and gasesin your workplace, refer to item 1 in Subsection 1.03,Publications in this manual.

Use special equipment, such as water or down draftcutting tables, to capture fumes and gases.

Do not use the plasma torch in an area where com-bustible or explosive gases or materials are located.

Phosgene, a toxic gas, is generated from the vaporsof chlorinated solvents and cleansers. Remove allsources of these vapors.

This product, when used for welding or cutting, pro-duces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects 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 processuses and produces high voltage electrical energy. Thiselectric energy can cause severe or fatal shock to the op-erator or others in the workplace.

Never touch any parts that are electrically live orhot.

GENERAL INFORMATION 1-2 May 14, 2002

Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.

Repair or replace all worn or damaged parts.

Extra care must be taken when the workplace ismoist or damp.

Install and maintain equipment according to NECcode, refer to item 9 in Subsection 1.03, Publications.

Disconnect power source before performing any ser-vice or repairs.

Read and follow all the instructions in the Operat-ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, orthe plasma arc.

Be sure there is no combustible or flammable mate-rial in the workplace. Any material that cannot beremoved must be protected.

Ventilate all flammable or explosive vapors fromthe workplace.

Do not cut or weld on containers that may have heldcombustibles.

Provide a fire watch when working in an area wherefire hazards may exist.

Hydrogen gas may be formed and trapped underaluminum workpieces when they are cut underwa-ter or while using a water table. DO NOT cut alu-minum alloys underwater or on a water table un-less the hydrogen gas can be eliminated ordissipated. Trapped hydrogen gas that is ignitedwill cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-cesses can cause noise levels to exceed safe limits. Youmust protect your ears from loud noise to prevent per-manent loss of hearing.

To protect your hearing from loud noise, wear pro-tective ear plugs and/or ear muffs. Protect othersin the workplace.

Noise levels should be measured to be sure the deci-bels (sound) do not exceed safe levels.

For information on how to test for noise, see item 1in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.The plasma arc process produces very bright ultra violetand infra red light. These arc rays will damage your eyesand burn your skin if you are not properly protected.

To protect your eyes, always wear a welding hel-met or shield. Also always wear safety glasses withside shields, goggles or other protective eye wear.

Wear welding gloves and suitable clothing to pro-tect 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 followingper ANSI/ASC Z49.1:

Minimum Protective SuggestedArc 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 clearlyseen. Experience has shown that lighter filters maybe used when the arc is hidden by the workpiece.

1.03 PublicationsRefer to the following standards or their latest revisionsfor more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR1910, obtainable from the Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable from the American Welding So-ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDINGAND GAS WELDING AND CUTTING, obtainable fromthe Superintendent of Documents, U.S. GovernmentPrinting Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-PATION AND EDUCATIONAL EYE AND FACE PRO-TECTION, obtainable from American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MENSSAFETY-TOE FOOTWEAR, obtainable from the Ameri-can National Standards Institute, 1430 Broadway, NewYork, NY 10018


6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from American National Standards Institute, 1430Broadway, 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.LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,obtainable from the National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN CYLINDERS, obtainable from theCompressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-ING AND CUTTING, obtainable from the CanadianStandards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHYobtainable from the National Welding Supply Associa-tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARA-TION FOR WELDING AND CUTTING OF CONTAIN-ERS AND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018


1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

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 forthe enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unitand date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-ated accessories.

* 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 relatedindustry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensurethe 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 ourarea of manufacture.

Manufacturers responsible representative: Giorgio BassiManaging DirectorThermal Dynamics EuropeVia rio Fabbiani 8A40067 Rastignano (BO)Italy


1.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal) warrants that its products will be free of defects inworkmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermalproducts as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,and maintained in accordance with Thermals 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 Thermals soleoption, 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 APARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, butnot limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) forservice interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to anycontract, 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 anywarranty, 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 THESAFETY 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 , Cougarand DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years fromdate 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 dateof sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, andwith 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 anauthorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the furtherlimitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts PartsPAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 YearBut Not Limited To, Starting Circuit,Contactors, Relays, Solenoids, Pumps,Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 YearExchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repairfacility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportationcharges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shallbe at the customers risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001

Manual 0-2746 2-1 INTRODUCTION

SECTION 2:INTRODUCTION

2.01 Scope of ManualThis manual contains descriptions, operating instructionsand basic maintenance procedures for the PAK Master75XL Plus Air Plasma Cutting Power Supply. Service ofthis equipment is restricted to properly trained person-nel; unqualified personnel are strictly cautioned againstattempting repairs or adjustments not covered in thismanual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understand-ing of the characteristics and capabilities of this equip-ment will assure the dependable operation for which itwas designed.

2.02 General Description of SystemThe 75XL PLUS System includes a power supply, torch &leads and work cable & clamp.

The Power Supply provides 60 amp maximum outputand includes all control circuitry, electrical and gas in-puts and outputs, pilot circuitry, torch leads receptacleand a work cable with clamp.

The power supply can be ordered in various configura-tions with various options factory installed. Refer to Sec-tion 2.04 for list of power supply options and accesso-ries.

A-02462Torch and Leads

Work Cable and Clamp

XL PLUS Power Supply

Figure 2-1 Pak Master 75XL Plus System

The torch provides a maximum 1 inch / 25.4 mm cutcapacity. Hand torches are available in various torch headconfigurations, a machine torch is available in a 180 torchhead configuration. Torch leads are available in various

lengths with fittings for simple installation. Spare PartsKits are available for the torches which provide an as-sortment of replacement torch parts.

2.03 Specifications / DesignFeatures

A. Power Supply Technical SpecificationsThe following specifications apply to the Power Supplyonly:

1. Front Panel Controls

ON / OFF Switch, RUN / SET / LATCH Switch andOutput Current Control (A)

2. Front Panel LED Indicators

AC , TEMP , GAS , DC

3. Rear Panel

Input Power Cable Strain Relief*, Gas Connection,Gas Regulator / Filter Assembly

*208 / 230 / 240 units include input power cable

4. Input Power

Can be configured for the following:

208 / 230 / 240 VAC (10%), 50 / 60 Hz, Single orThree - Phase

380 / 415 VAC (10%), 50 / 60 Hz, Three - Phase

460 VAC (10%), 50 / 60 Hz, Single or Three - Phase

5. Output Power

Continuously variable from 15 to 60 Amps maximum

6. Duty Cycle

NOTE

The duty cycle will be reduced if the primary in-put voltage (AC) is low or the DC voltage is higherthan shown in the chart.

AmbientTemperature

104 F(40 C)

104 F(40 C)

Duty Cycle 65% 100%Current 60 Amps 50 Amps

DC Voltage 104 vdc 104 vdc

Power Supply Duty Cycle

INTRODUCTION 2-2 Manual 0-2746

7. Cut Capacity (Mild Steel)

3/4 inch / 19.1 mm ; 1 inch / 25.4 mm severance

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. Weight

64 pounds / 29 kg with work lead

71 pounds / 32 kg with work lead and 25' Torch &Lead

10. Overall Dimensions

19" / 482 mm High x 13" / 330 mm Wide x 24.8" /630 mm Long

Overall dimensions are with Handle, Lead WrapBracket, and Gas Regulator / Filter Assembly in-stalled.

B. Gas Regulator / Filter AssemblySpecifications

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 andAccessories

The following accessories are available for this powersupply. Refer to Section 6, Parts Lists, for catalog num-bers and ordering information.

A. Single - Stage Air Line FilterA Single Stage In - Line Air Filter for use with com-pressed air shop systems. Filters moisture and par-ticulate matter from the air stream to at least 0.85 mi-crons.

B. Two Stage Air Line FilterA Two Stage In - Line Air Filter for use on compressedair shop systems. Filters moisture and particulatematter from the air stream to at least 5.0 microns.

C. High Pressure RegulatorsHigh pressure regulators are available for air and ni-trogen. The regulators are used to set the proper pres-sure for the type gas being used.

NOTE

Regulators should not be installed with options Aor B above.

D. Multi-Purpose CartRugged steel cart on easy-rolling rear wheels andfront-mounted swivel casters. Provides maximummobility for the power supply and can also serve asa display cart. Top shelf is 12 " / 305 mm x 20 / 508mm. Steel handle is 30" / 762 mm high.

E. 575V Transformer

This step - down transformer allows the power sup-ply to operate with 575 VAC three - phase inputpower.

F. Computer Control Cable (CNC)NOTE

This accessory can be used only with the PCM - 60Torches.

The interface cable is available in two lengths, 25 ft /7.6 m and 50 ft / 15.2 m . The cable is used to inter-face the power supply with an auxiliary control de-vice to provide OK - To - Move and ON / OFF sig-nals.

Manual 0-2746 3-1 INSTALLATION

SECTION 3:INSTALLATION

3.01 IntroductionNOTE

Depending on how the system was ordered, somePower Supply Options may already be installed.

If option(s) have been factory installed some of theinstructions may not apply. It is recommendedthat all subsections be read for general informa-tion.

This section describes installation of the Power Supplyand connecting the Torch.

These instructions apply to the Power Supply only; in-stallation procedures for the Torch, Options, and Acces-sories are given in Manuals specifically provided for thoseunits.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input power

b. Gas

c. Work cable

d. Torch Leads

4. Grounding

5. Operator training

3.02 Site SelectionSelect a clean, dry location with good ventilation and ad-equate working space around all components.

NOTE

Review Important Safety Precautions (Section 1)to be sure that the selected location meets all safetyrequirements.

The power supply is fan cooled by air flow through thefront panel to the rear panel. Air flow must not be ob-structed. Provide at least 2 feet / 0.61 m in the rear andat least 6 inches / 150 mm on each side for clearance.Provide sufficient clearance in front of the unit to allowaccess to the front panel controls / minimum 6 inches or150 mm.

CAUTION

Operation without proper air flow will inhibitproper cooling and reduce duty cycle.

3.03 UnpackingEach component of the system is packaged and protectedwith a carton and packing material to prevent damageduring shipping.

l. Unpack each item and remove any packing material.

NOTE

The Cutting Spare Parts Kit is shipped in the TorchLeads Storage Area on the side of the Power Sup-ply.

2. Locate the packing list(s) and use the list to identifyand account for each item.

3. Inspect each item for possible shipping damage. Ifdamage is evident, contact your distributor and / orshipping company before proceeding with system in-stallation.

3.04 Lifting Options

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de - en-ergized supply line before moving unit.

HANDLE is not for mechanical lifting.

FALLING EQUIPMENT can cause serious per-sonal injury and equipment damage.

This unit is equipped with one handle mounted onto thetop of the enclosure for hand carrying purposes.

Lift unit with the handle on top of the enclosure.

Only persons of adequate physical strength shouldlift the unit.

Use hand cart, optional Cart, or similar device ofadequate capacity.

If using a fork lift vehicle, place and secure unit ona proper skid before transporting.

This unit has a handle mounted on top of the enclo-sure for hand lifting only. Be sure unit is lifted andtransported safely and securely.

INSTALLATION 3-2 Manual 0-2746

3.05 Input Power ConnectionsThe Power Supply accepts input voltages from 208V to460V. Input can be 50 or 60 Hz, single - phase or three -phase.

The Power Supply is factory - wired for 230V single -phase or 460V three - phase input depending on the or-der. For any other input voltage, the Power Supply mustbe changed using the procedure in Sections 3.06.

A. Electrical ConnectionsThe power source must conform to local and national elec-tric codes. Recommended circuit protection and wiringrequirements are shown in Appendix 1.

B. Opening Power Supply EnclosureThe left side panel of the Power Supply must be removedto gain access to the input power connections and theinput voltage selection.

WARNING

Disconnect primary power at the source before as-sembling or disassembling the Power Supply, torchparts, or torch and leads assemblies.

1. Remove the screws which secure the left side panel(viewed from front of unit) to the frame assembly.

NOTE

There is a ground wire connection to the Left SidePanel on the inside of the unit.

GroundWire

Screws(5 places)

Left SidePanel

A-02468

Figure 3-1 Removing Left Side Panel

2. Carefully pull the Left Side Panel up and away fromthe unit to gain access to the inside of the unit.

3.06 Input Voltage SelectionNOTE

For power supplies to use 575 VAC input power,the unit must be setup for 460V three - phase op-eration and the 575V Transformer Accessory mustbe installed.

The Power Supply has three voltage settings; 208 / 230 /240VAC, 380 / 415VAC, or 460VAC. Power Supplies arefactory - wired for 230V single - phase or 460VAC three -phase input depending on the order. Input voltage se-lection is accomplished by switching a wire harness con-nector inside the Power Supply. Also, a jumper wire mustbe properly installed depending on the input used.

WARNING

Disconnect primary power at the source before as-sembling or disassembling the power supply, torchparts, or torch and leads assemblies.

1. Move the power selection plug to the desired inputconnection for 208 / 230 / 240V, 380 / 415V, or 460Voperation per the label attached to the panel.

2. For three - phase 460VAC input, the jumper wire be-tween L3 and L3 (storage) on the contactor must beleft in this storage connection.

Voltage SelectionConnector

380/415 Volts460 Volts

208/230/240 Volts

A-00911

Voltage SelectionLabel

Figure 3-2 Input Voltage Selection


For single - phase operation the jumper wire must beinstalled on the contactor as described in Section 3.07for single - phase input voltage.

3.07 Primary Input Power CableConnections

Units ordered as 230V, single - phase, will have a six footpower input cable and plug factory installed. For all otherunits, a cable must be provided by the end user. Recom-mended cable sizes are specified in Appendix 1.

1. Route the primary power cable through the strain re-lief fitting in the rear panel of the Power Supply andtighten strain relief screws.

AC Input PowerCable Strain Relief

AC InputPower CableA-00912

Figure 3-3 AC Input Power Cable Strain Relief

2. Connect the input cable inside the Power Supply forthe type of operation per the following:

A. Three - Phase OperationThree - phase operation requires a 3 - conductor cablewith ground.

a. Locate the ground stud and remove the top nutand washer.

b. Install a lug terminal on the ground wire.

c. Place the ground wire onto the ground studand secure with the nut and washer.

d. Insert the other three wires into the L1, L2, andL3 terminals on the contactor.

e. Tighten all set screws.

NOTE

The jumper wire from L1 to L4 must not be re-moved.

L1

L2L3Input

Contactor

AC InputPower Cable

GND

Unused JumperL3 to L3 (storage)

A-02670

Figure 3-4 Primary Power Cable Connections -Three - Phase Operation

B. Single - Phase OperationSingle - phase operation requires a 2 - conductor cablewith ground.

a. Locate the single - phase jumper wire con-nected between the two L3 terminal lugs onthe input contactor.

b. Move one end of the jumper wire from termi-nal lug L3 to L2 at the contactor.

NOTE

The jumper wire from L1 to L4 must not be re-moved.


Single PhaseJumper Wire

(L2 to L3)

Input Contactor

A-00914

L3L2

Figure 3-5 Single Phase Jumper Wire Installation

c. Locate the ground stud and remove the top nutand washer.

d. Install a lug terminal on the ground wire.

e. Place the ground wire terminal onto the groundstud and secure with the nut and washer.

f. Insert the other two wires into the L1 and L2terminals on the contactor.

g. Tighten all set screws.

AC InputPower Cable

L1L2

GND

Input Contactor

A-00915

Figure 3-6 Primary Power Cable Connections -Single - Phase Operation

3.08 Gas ConnectionsA. Gas Requirements

WARNING

This unit not to be used with oxygen (O2).

Gases: Compressed Air or Nitrogen (N2) Only

Pressure: Unshielded Leads: 70 psi / 4.8 bar

Shielded Leads: 60 psi / 4.1 bar

CAUTION

Maximum input gas pressure must not exceed 125psi / 8.6 bar

Flow: Cutting - 300 scfh (standard cubic feet / hr ) / 142 lpm

Gouging - 300 scfh / 142 lpm

B. Checking Air QualityTo test the quality of air, place the RUN / SET / LATCHswitch to SET position, place a welding filter lens in frontof the torch and turn on the gas. Any oil or moisture inthe air will be visible on the lens. Do not initiate an arc!

CAUTION

The air supply must be free of oil, moisture, andother contaminants. Excessive oil and moisturemay cause double - arcing, rapid tip wear, or evencomplete torch failure. Contaminants may causepoor cutting performance and rapid electrode wear.


C. Gas ConnectionsThe gas supply is connected to the Pressure Regulator /Filter Assembly installed on the rear of the unit. The con-nection is the same for compressed air or high pressuregas cylinders.

Connect the gas supply as follows:

1. Use customer-supplied fittings to connect the gas lineto the power supply Regulator/Filter Assembly. Typi-cal fittings are shown as an example. Other fittingsmay be used.

2. If an optional air line filter is to be installed, refer tosubsection D.

NOTE

For a secure seal, apply thread sealant to the fit-ting threads, according to manufacturer's instruc-tions. Do Not use Teflon tape as a thread sealer assmall particles of the tape may break off and blockthe small gas passages in the torch. Connect thegas supply as follows:

Regulator/FilterAssembly

1/4 NPT to #4 (6mm)Hose Fitting

#4 (6mm) GasSupply Hose

Hose Clamp

A-00916

Figure 3-7 Gas Connection To Regulator / FilterAssembly

D. Optional Air Line Filter InstallationFiltering is required when using air from a compressor toinsure that moisture and debris from the supply hose doesnot enter the torch. Although the Regulator does have itsown filter, it is recommended the optional Single - StageAir Filter or optional Two Stage Air Line Filter be installedfor improved filtering. Gas connections to optional fil-ters are shown in Figures 3-8 and 3-9.

A-02469

1/4 NPT to#4 (6mm)Hose Fitting

Single-Stage Air FilterAssembly

#4 (6mm)Gas SupplyHose

Hose Clamp

Figure 3-8 Gas Connection to Optional Single -Stage Air Filter Assembly

Two Stage FilterAssembly

1/4 NPT to#4 (6mm) Hose

Fitting

#4 (6mm) GasSupply Hose

Hose Clamp

A-00917

Figure 3-9 Gas Connection To Optional Two StageFilter Assembly


E. Using High Pressure Gas Cylinders1. Refer to the following when using high pressure gas

cylinders as the gas supply:

CAUTION

Pressure should be set at 100 psi / 6.9 bar at thehigh pressure gas cylinder regulator.

a. Refer to the manufacturers specifications for in-stallation and maintenance procedures for highpressure gas regulators.

b. Examine the cylinder valves to be sure they areclean and free of oil, grease or any foreign mate-rial. Momentarily open each cylinder valve to blowout any dust which may be present.

c. The cylinder must be equipped with an adjustablehigh - pressure regulator capable of outlet pres-sures up to 100 psi / 6.9 bar maximum and flowsof up to 300 scfh / 141.5 lpm.

2. Use customer-supplied fittings to connect the gas lineto the power supply Regulator/Filter Assembly.

NOTE

For a secure seal, apply thread sealant to the fit-ting threads, according to manufacturer's instruc-tions. Do Not use Teflon tape as a thread sealer assmall particles of the tape may break off and blockthe small gas passages in the torch. Connect thegas supply as follows:

NOTE

Supply hose must be at least #4 hose / 1/4 in or 6mm I.D.).

3.09 Connecting Torch Leads

CAUTION

This system is designed for use with the PCH / M- 102 torch only. Do not connect any other torch tothis power supply.

The instructions for connecting the Torch Leads to thePower Supply are different depending on the type ofleads. This sub - section covers connecting the Torch forthe following applications:

A. Hand Systems

B. Machine Systems (Unshielded Leads)

C. Machine Systems (Shielded Leads)

The Torch Leads must be properly installed to the PowerSupply for proper operation. If the torch leads were notfactory - installed, make all torch connections to the TorchBulkhead Panel for the desired application.

NOTE

Equipment ordered as a system will have the Torchfactory connected to the Power Supply.


A. Hand Systems

WARNING


1. Turn the screw latch securing the front access panelto the power supply front panel.

AccessPanel

ScrewLatch

A-02467

Figure 3-10 Front Access Panel

2. Lift the access panel for access to the torch bulk-head panel.

3. Remove the retaining nut from the strain relief.

Strain ReliefNut

Strain ReliefTorch Leads

Assembly

A-03607

Negative / Plasma Lead

Pilot Lead

Figure 3-11 Torch Leads Strain Relief Nut

4. Feed the torch lead ends and the Strain Relief intothe hole in the unit.

5. Secure the Strain Relief with the retaining nut re-moved earlier.

6. Connect the torch Negative / Plasma Lead to thebulkhead connection inside the Power Supply.

AdapterPlug

Pilot LeadTorch LeadsAssembly

Negative/PlasmaLead

AdapterConnector

Pilot Lead Stud

Negative/Plasma LeadConnection

A-03613

Control CircuitConnectors

Note: Actual Bulkhead configuration maydiffer from that shown.

Figure 3-12 Torch Lead Connections

7. Connect the Cables to the mating connectors onthe Adapter supplied on the Power Supply.

8. Remove the top nut and washer from the PilotStud.

9. Place the lug on the Pilot Control Wire onto thestud and secure with the nut and washer removedin the above Step.

10. Tighten the Strain Relief nut onto the Torch Leads.

11. Check the torch for proper parts assembly.

12. Close the access panel and turn the latching screw.


B. Machine Systems (Unshielded Leads)

WARNING



2. Lift the access panel for access to the torch bulk-head panel.

3. Remove the retaining nut from the Strain Relief.

4. The torch leads includes a pair of wires coveredwith an insulator and joined with mating connec-tors. Remove the tie wrap, remove the insulator,and disconnect the wires.

Strain ReliefNut

Strain Relief

Torch LeadsAssembly

A-03609

Remove Tie Wrap,Remove Insulator,Disconnect Wires

Figure 3-13 Strain Relief Nut Removal

5. The Power Supply Adapter must be installed asfollows:

a. Inside the Power Supply Bulkhead area, routethe wires on the Adapter through the Strain Re-lief Nut.

b. Continue routing the wires out the hole in thefront panel of the Power Supply.

c. Feed the end of the torch lead and the StrainRelief into the hole in the unit while routingthe wire into the notch of the Strain Relief.

d. Tighten the Strain Relief Nut to secure theStrain Relief to the Power Supply.

Power Supply Adapter

Pilot Lead

Torch LeadAssembly

Negative/PlasmaLead

Adapter Connector Negative/PlasmaLead Connection

A-03612


RemotePendant Adapter

Open

Open

Figure 3-14A Torch Lead Connections

A-03611

Pilot Lead

Torch LeadAssembly

Negative/PlasmaLead


Open

Open

Power Supply Adapter

Figure 3-14B Torch Lead Connection Detail


7. Connect the Control Circuit Connectors to the mat-ing connectors on the Power Supply Adapter. Twowires from the torch leads will remain open.




10. Tighten the Strain Relief onto the Torch Leads.

11. Check the torch for proper parts assembly. Referto the Torch manual for parts selection.


C. Machine Systems (Shielded Leads)

WARNING



2. Lift up on the access panel to gain access to thetorch bulkhead panel.

3. Remove the retaining nut from the Strain Relief.

Strain ReliefNut

Strain ReliefTorch LeadsAssembly

A-02826

Figure 3-15 Strain Relief Nut Removal

4. The Adapter supplied with the Power Supply mustbe installed per the following:

a. Inside the Power Supply Bulkhead area, routethe connector on the free end of the Adapterthrough the Strain Relief Nut.

b. Continue routing the connector out the hole inthe front of the Power Supply.

c. Feed the end of the torch lead and the StrainRelief into the hole in the unit while routingthe single black wire into the notch of the StrainRelief.

d. Tighten the Strain Relief Nut to secure theStrain Relief to the Power Supply.

Adapter(Supplied WithPower Supply)

Pilot Lead

Torch LeadAssembly

Negative/PlasmaLead

Adapter Connector

Pilot LeadStud

Negative/PlasmaLead Connection

A-02829

Control (PIP) CircuitConnectors

Shield Connectors

Figure 3-16 Torch Lead Connections


6. Connect the PIP and Shield Cables to the matingconnectors on the Adapter supplied on the PowerSupply.



9. Tighten the Strain Relief Nut onto the Torch Leads.

10. Check the torch for proper parts assembly.



3.10 Ground Connections forMechanized Applications

A. Electromagnetic Interference (EMI)Pilot arc initiation generates a certain amount of electro-magnetic interference (EMI), commonly called RF noise.This RF noise may interfere with other electronic equip-ment such as CNC controllers, remote controls, heightcontrollers, etc. To minimize RF interference, follow thesegrounding procedures when installing mechanized sys-tems:

B. Grounding1. The preferred grounding arrangement is a single point

or Star ground. The single point, usually on thecutting table, is connected with 1/0 AWG (European50 mm2) or larger wire to a good earth ground (referto paragraph C, Creating An Earth Ground). Theground rod must be placed as close as possible to thecutting table, ideally less than 10 ft (3.0 m), but nomore than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible.Long wires will have increased resistance to RFfrequencies. Smaller diameter wire has increasedresistance to RF frequencies, so using a larger di-ameter wire is better.

2. Grounding for components mounted on the cuttingtable (CNC controllers, height controllers, plasma re-mote controls, etc.) should follow the manufacturersrecommendations for wire size, type, and connectionpoint locations.

For Thermal Dynamics components it is recom-mended to use a minimum of 10 AWG (European 6mm2) wire or flat copper braid with cross section equalto or greater than 10 AWG connected to the cuttingtable frame. The connection point must be clean baremetal; rust and paint make poor connections. For allcomponents, wires larger than the recommendedminimum can be used and may improve noise pro-tection.

3. The cutting machine frame is then connected to theStar point using 1/0 AWG (European 50 mm2) orlarger wire.

4. The plasma power supply work cable (see NOTE) isconnected to the cutting table at the single point Starground.

NOTE

Do Not connect the work cable directly to theground rod.

5. Make sure work cable and ground cables are prop-erly connected. The work cable must have a solidconnection to the cutting table. The work and groundconnections must be free from rust, dirt, grease, oiland paint. If necessary grind or sand down to baremetal. Use lock washers to keep the connections tight.Using electrical joint compound to prevent corrosionis also recommended.

6. The plasma power supply chassis is connected to thepower distribution system ground as required by elec-trical codes. If the plasma supply is close to the cut-ting table (see NOTE) a second ground rod is not usu-ally needed, in fact it could be detrimental as it canset up ground loop currents that cause interference.

When the plasma power supply is far away from theground rod and interference is experienced, it mayhelp to install a second earth ground rod next to theplasma power supply. The plasma power supplychassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supplybe within 20 - 30 ft (6.1 9.1 m) of the cuttingtable, if possible.

7. The plasma control cable should be shielded with theshield connected only at the cutting machine end.Connecting the shield at both ends will allow groundloop currents which may cause more interference thanwith no shield at all.

C. Creating An Earth Ground1. To create a solid, low resistance, earth ground, drive a

1/2 in (12 mm) or greater diameter copper clad groundrod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so thatthe rod contacts moist soil over most of its length.Depending on location, a greater depth may be re-quired to obtain a low resistance ground (see NOTE).Ground rods, typically 10 ft (3.0 m) long, may bewelded end to end for greater lengths. Locate the rodas close as possible to the work table. Install a groundwire, 1/0 AWG (European 50 mm2) or greater, betweenthe ground rod and the star ground point on the cut-ting table.

NOTE

Ideally, a properly installed ground rod will have aresistance of three ohms or less.

To test for a proper earth ground, refer to the follow-ing diagram. Ideally, the reading on the multimetershould be as follows:

For 115VAC: 3.0 VAC

For 230VAC: 1.5 VAC


A-02971

+ _

Meter set toVAC setting

MachineEarth Ground

Neutral

Line (Hot)

100WLight Bulb115 or 230VAC

WARNINGUse extreme caution. This

test uses live voltage.

115VAC: 3.0 VAC230VAC: 1.5 VAC

V~V~

VR COM A

Figure 3-17 Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft(6.1 9.1 m) does not generally increase the effective-ness of the ground rod. A larger diameter rod whichhas more surface area may help. Sometimes keepingthe soil around the ground rod moist by continuouslyrunning a small amount of water into it will work.Adding salt to the soil by soaking it in salt water mayalso reduce its resistance. When these methods areused, periodic checking of the ground resistance is re-quired to make sure the ground is still good.

D. Routing Of Torch Leads1. 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 cableshave to pass over torch leads, do so at an angle. Donot run the plasma control or other control cables inparallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleedoff energy, which causes difficult starting and in-creased chance of RF interference.

3.11 Tip Saver / Drag Cut SensingCircuit

This power supply is equipped with a Tip Saver / DragCut Sensing Circuit which cuts current back to 35 amps ifthe tip touches the workpiece. The purpose of this is toprolong the life of the tip. Tip life will be considerablyshortened if tip is repeatedly touched to the workpiecewithout the Tip Saver / Drag Sensing Circuit feature ac-tive.

If the user does not want the current to be decreasedwhenthe tip touches the workpiece, the sensing circuit can bedefeated by closing switch SW1 - 1 on the Gate / LogicPC Board. Slide top white toggle on SW1 - 1 to the rightto close circuit.

A-02569

Gate/Logic PC Board

SW1

1 2

ON

Figure 3-18 SW1 Switch Location

Manual 0-2746 4-1 OPERATION

SECTION 4:OPERATION

4.01 IntroductionThis Section provides a description of the Power Supplyoperating controls and procedures. Identification of theFront and Rear Panel components is followed by operat-ing procedures.

4.02 Operating ControlsThis subsection provides specific functional descriptionsof the Power Supply operating controls and indicators.

A. Front and Side Panel Components1. Control Panel

All operator controls, except gas pressure adjustment,are located on this panel. Power ON / OFF and RUN/ SET / LATCH switches; CURRENT control; indi-cators for AC Power, TEMP, GAS, and DC.

A-02458

1

2

3

4

5

Figure 4-1 Front and Side Panel Connections

2. Access Panel

A panel for access to the bulkhead area containingthe torch connections.

3. Torch Leads Input

Hole in the front panel to feed the torch leads throughto the internal bulkhead connections.

4. Work Cable and Clamp

Work cable with clamp (factory installed).

5. Torch Leads and Spare Parts Kit Storage Area

Bracket connected to the side panel of the unit foruse in storing the torch, torch leads, work cable, andspare parts kit when not in use. The spare parts kitfits into the opening on the top of the bracket. Thetorch leads and work cable wrap around the bracketfor easy storage.

B. Control Panel Components

A

A-03625

15

40

60

1

2 3

4

5

6 7

Figure 4-2 Operating Controls

1. Current Control (A)

Adjustment to set the desired output current between15 - 60 amps. For drag cutting applications set thecontrol between 15 - 35 amps. The unit has an auto-matic fold - back circuit that limits current to 35 ampsduring drag cutting.

2. ON / OFF Power Switch

ON position supplies AC power to activate all sys-tem control circuits. OFF position deactivates con-trol circuits.

3. RUN / SET / LATCH

Switch

RUN position is used for torch operation. SET posi-tion used for setting gas pressure and purging lines.LATCH 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 approxi-mately eight seconds and then stay ON after the ON/ OFF power switch is set to ON. Indicates operat-ing power is present in the unit.

OPERATION 4-2 Manual 0-2746

5. TEMP Indicator

Normally OFF. Yellow indicator turns ON when theinternal temperature senors detect temperaturesabove normal limits. The unit should be allowed tocool before continuing operation.

6. GAS Indicator

Green indicator turns ON when the input gas pres-sure is set to 35 psi / 2.4 bar or higher. Indicator willbe OFF when the pressure falls below 35 psi / 2.4bar.

NOTE

Minimum pressure for power supply operation islower than minimum pressure for torch operation.

7. DC Indicator

Green indicator turns ON while the torch switch ispressed.

C. Torch Bulkhead PanelThe torch bulkhead panel is located under the accesspanel.

1. Pilot Lead Stud

Stud used to connect the Torch Leads Pilot Lead tothe Power Supply.

2

1

3

A-00923

Figure 4-3 Torch Panel Connections

2. Control Cable Connector

Used to interface the Adapter (supplied with PowerSupply) to the Torch Leads Control Cable.

3. Negative / Plasma Lead Connection

Connects the torch negative / plasma lead to the unit.

D. Rear Panel1. Gas Input

Input connection for air or nitrogen (N2) input.

WARNING

This unit not to be used with oxygen (O2).

1

2

3

A-00928

Figure 4-4 Rear Panel

2. Primary Input Power Cable Strain Relief

NOTE

Input power cable is supplied on units when or-dered for 230V single - phase operation.

Primary input power cable strain relief for the pri-mary power cable (see Note above) capable of han-dling the input voltage designed for this unit.


3. Gas Pressure Regulator / Filter Assembly

Pressure regulator to adjust the input gas pressure tothe Power Supply. An air line filter is supplied aspart of the pressure regulator.

4. Optional Filters

a. Single - Stage Air Filter Assembly

An In - Line Air Filter for use with compressed airshop systems. Filters moisture and particulate mat-ter from the air stream to at least 0.85 microns.

12

34

A-02460

Figure 4-5 Rear Panel Showing Optional Single -Stage Air Filter

b. Two - Stage Air Line Filter

A Two Stage In - Line Air Filter for use on compressedair shop systems. Filters moisture and particulatematter from the air stream to at least 5.0 microns.

A-00924

1

2

3

4

Figure 4-6 Rear Panel Showing Optional Two -Stage Air Filter


4.03 Sequence of OperationThe following is a typical sequence of operation for thiscutting 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 frontpanel of the Power Supply to ON.

a. AC Power indicator blinks ON and OFF foreight seconds then stays ON.

b. Fans turn on.

4. Place RUN / SET / LATCH 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 35 psi / 2.4 bar at the Regulator/ Filter Assembly.

NOTE

Minimum pressure for power supply operation islower than minimum pressure for torch operation.

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. 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 LATCHmode.

NOTE

For general cutting, use the RUN position whichprovides normal touch operation where the torchswitch must be held throughout the main arc trans-fer.

For specific applications, use the LATCH positionwhere the torch switch can be released after the mainarc transfer. The torch remains activated until themain arc breaks from the workpiece.

11. Complete cutting operation.

NOTE

If the torch is lifted from the workpiece, with torchswitch activated, the main arc will stop and thepilot arc will automatically restart.

12. Release or deactivate the torch switch.

a. Main arc stops.

b. Pilot arc stops (power supply enable signal re-moved).

NOTE

If torch is activated during post - flow, pilot arcwill immediately restart.

If torch is within 3/8 in / 9.5mm transfer distanceof 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 frontpanel of the unit to OFF

a. AC Power indicator turns OFF.

b. Fans turn OFF.

15. Place the main power disconnect to open.

a. Main AC power is removed from the system.


4.04 Preparations for OperatingFollow this set - up procedure each time the system isoperated:

WARNING

Disconnect primary power at the source before dis-assembling the power supply, torch, or torch leads.

A. Torch Parts SelectionCheck the torch for proper assembly and appropriate frontend torch parts. The torch parts (shield cup, tip and elec-trode) must correspond with the type of operation (cut-ting or gouging). Refer to the Instruction Manual sup-plied with the Torch 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 powerrequirements for the unit per Section 2.03-A-4, Speci-fications / Design Features.

2. Connect the input power cable (or close the main dis-connect switch) to supply power to the system.

C. Gas SelectionSelect desired gas (air or nitrogen). Make sure gas sourcemeets pressure and flow requirements (refer to Section3.08, Gas Connections). Check connection and turn gassupply on.

D. Work Cable ConnectionCheck for a solid and clean work cable connection to theworkpiece. The area must be free from paint and rust.

Make a solid work cableconnection to the work-piece or cutting table

A-00925

Figure 4-7 Work Cable Connection To Workpiece

E. Torch ConnectionCheck that the torch is properly connected.

F. Power Supply OnMove the ON / OFF switch to ON position.

G. Select Output CurrentSelect the desired current output level for the operation:

15 to 60 amps for standoff cutting and gouging

15 to 35 amps for drag cutting

H. Set Operating PressureMove the RUN / SET / LATCH switch to SET position.Adjust the gas pressure to 60 -75 psi / 4.1 - 5.2 bar. Referto the Torch manual for specific pressure settings.

I. RUN / SET SwitchSet the RUN / SET / LATCH switch to RUN position.

The system is now ready for operation.

NOTE

For general cutting, use the RUN position whichprovides normal touch operation where the torchswitch must be held throughout the main arc trans-fer.

For specific applications, use the LATCH positionwhere the torch switch can be released after the mainarc transfer. The torch remains activated until themain arc breaks from the workpiece.


4.05 Cut QualityCut quality requirements differ depending on applica-tion. For instance, nitride build - up and bevel angle maybe major factors when the surface will be welded aftercutting. Dross - free cutting is important when finish cutquality is desired to avoid a secondary cleaning opera-tion.

The following cut quality characteristics are illustratedin Figure 4-8 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 planeperpendicular to the surface of the plate. A perfectly per-pendicular cut would result in a 0 bevel angle.

Top - Edge Rounding

Rounding on the top edge of a cut due to wearing fromthe 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 thecut area and re - solidifies on the plate. Top spatter isdross which accumulates on the top surface of the work-piece. Excessive dross may require secondary clean - upoperations after cutting.

Kerf Width

The width of material removed during the cut.

Nitride Build - up

Nitride deposits which may remain on the surface of thecut when nitrogen is present in the plasma gas stream.Nitride buildups may create difficulties if the material iswelded after the cutting process.

Kerf WidthCut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Figure 4-8 Cut Quality Characteristics

Cut quality will vary on different types of material andthicknesses.

The following table shows the cut quality that can be ex-pected from this equipment for materials with a thick-ness from gauge to 3/4 inch / 19.1mm:

T yp e o f M ater ial

G as C ar b o nS teelS tain less

S teel A lu m in u m

A ir G ood -E x c el lent

G ood -E x c el lent

G ood -E x c el lent

N i trogen G ood G ood G ood

Description of Cut Characteristics

Excellent - Minimum bevel (0 - 4), minimum kerf (2 xtip orifice diameter), little or no dross, smoothcut surface.

Good - Slight bevel (0 - 10), slightly wider kerf (2-1/2 xtip orifice diameter), some dross (easily re-moved), medium - smooth cut surface, slight topedge rounding.

Fair - Excessive bevel (over 10), wide kerf (over 2-1/2 xtip orifice diameter), medium to heavy dross, roughcut surface, top edge rounding.

NOTES

Cut quality depends heavily on set - up and pa-rameters such as torch standoff, alignment withthe workpiece, cutting speed, gas pressures, andoperator ability.

Manual 0-2746 5-1 SERVICE

SECTION 5:SERVICE

5.01 IntroductionThis section describes basic maintenance procedures per-formable by operating personnel. No other adjustmentsor repairs are to be attempted by other than properlytrained personnel.

For major troubleshooting and parts replacement proce-dures refer to PAK Master 75XL Plus Power Supply Ser-vice Manual 0-2747.

5.02 General Maintenance

WARNING

Disconnect primary power to the system before dis-assembling the torch, leads, or power supply.

A. General MaintenanceTo clean the unit, open the enclosure (refer to Section 5.05-A, Opening Enclosure) and use a vacuum cleaner to re-move any accumulated dirt and dust. The unit shouldalso be wiped clean. If necessary, solvents recommendedfor cleaning electrical apparatus may be used.

Refer to Appendix 3, Maintenance Schedule, for specificprocedures.

B. Filter / Regulator Element ReplacementThe Filter / Regulator Assembly is on the rear panel. Forbetter system performance, the Filter / Regulator Assem-bly filter element should be checked per the MaintenanceSchedule, and either cleaned or replaced.

1. Remove power from the power supply; turn offthe gas supply and bleed the system.

2. Unscrew the bowl on the bottom of the Filter /Regulator Assembly. The filter element will bevisible and still attached to the main body of theFilter Regulator.

3. Grasp the filter element and unscrew it from theFilter / Regulator body. The filter element willcome off with a spool and some additional pieces.

4. Note the correct assembly of the filter / spool thenremove the filter from the spool and either cleanit or replace it. See Section 6 for catalog number.

5. The filter element and spool, with the baffle ringin place (teeth facing downward) can be screwedback into the Regulator body by compressing thespring on the spool. Tighten firmly by hand.

Regulator/FilterAssembly

SpoolBowl

Spring

FilterElement

Baffle Ring

A-02988

Figure 5-1 Filter / Regulator Element Replacement

6. Reinstall the bowl.

7. Turn on the air supply.

C. Optional Single - Stage Air Filter ElementReplacement

NOTE

The XL PLUS Power Supply shuts down automati-cally when the Filter Element becomes completelysaturated. The Filter Element can be removed fromits housing, dried out, and reused. Allow 24 hoursfor Element to dry.

1. Remove power from power supply.

2. Shut off air supply and bleed down system be-fore disassembly to change Filter Element. SeeSection 6 for replacement element catalog num-ber.

SERVICE 5-2 Manual 0-2746

A-02476

FilterElement

(Cat. No. 9-7741)

Housing

Cover

BarbedFitting

Spring

Assembled FilterO-ring

Figure 5-2 Optional Single - Stage Air FilterReplacement

3. Disconnect gas supply hose.

4. Turn the Cover counterclockwise and remove itfrom the Filter Housing. The Filter Element is lo-cated inside the housing.

5. Remove the Filter Element from the Housing andset Element aside to dry.

6. Wipe inside of housing clean, then insert the re-placement Filter Element cup side first, as shownbelow.

7. Replace Housing on Cover.

8. Reattach gas supply hose.

NOTE

If unit leaks between housing and cover, inspectthe "O" Ring for cuts or other damage.

D. Optional Two - Stage FilterElement Replacement

NOTES

These instructions apply to any power supply withthe optional Two - Stage Filter installed.

The Two - Stage Air Filter has two Filter Elements.When the Filter Elements become dirty the PowerSupply will continue to operate but cut quality maybecome unacceptable.

1. Remove power from power supply.

2. Shut off air supply and bleed down system be-fore changing Filter Elements.

WARNING

Always turn off the air supply and bleed the sys-tem before disassembling the Filter Assembly asinjury could result.

3. Loosen the two bolts on the top of the Filter As-sembly enough to allow the Filter Elements tomove freely.

First & Second StageCartridges (as marked)

A-02942

Figure 5-3 Optional Two - Stage Filter Replacement

4. Note the location and orientation of the old FilterElements.

5. Slide out the old Filter Elements. See Section 6 forreplacement element catalog numbers.

6. Slide the replacement Filter Elements into the Fil-ter Assembly, with the same orientation as notedin Step 4 above.

7. Hand tighten the two bolts evenly, then torqueeach bolt to 20 - 30 in-lbs / 2.3 - 3.4 Nm.

8. Slowly apply air pressure to the assembly, check-ing for leaks.


5.03 Common Operating Problems

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 equippedwith proper gloves, clothing, eye and ear protec-tion. Make sure no part of the operators body comesinto contact with the workpiece while the torch isactivated.

Sparks from the cutting process can cause damageto coated, painted, and other surfaces such as glass,plastic and metal.

Handle torch leads carefully and protect them fromdamage.

A. PilotingPiloting is harder on parts life than actual cutting becausethe pilot arc is directed from the electrode to the tip ratherthan to a workpiece. Whenever possible, avoid excessivepilot arc time to improve parts life.

B. Torch StandoffImproper standoff (the distance between the torch tip andworkpiece) can adversely affect tip life as well as shieldcup life. Standoff may also significantly affect the bevelangle. Reducing standoff will generally result in a moresquare cut.

C. Edge StartingFor edge starts, hold the torch perpendicular to the work-piece with the front of the tip at the edge of the work-piece at the point where the cut is to start. When startingat the edge of the plate, do not pause at the edge andforce the arc to "reach" for the edge of the metal. Estab-lish the cutting arc as quickly as possible.

D. Direction of CutIn the torches, the plasma gas stream swirls as it leavesthe torch to maintain a smooth column of gas. This swirleffect results in one side of a cut being more square thanthe other. Viewed along the direction of travel, the rightside of the cut is more square than the left (Refer to Fig-ure 5-2). To make a square - edged cut along an insidediameter of a circle, the torch should move counterclock-wise around the circle. To keep the square edge along anoutside diameter cut, the torch should travel in a clock-wise direction.

Right SideCut Angle

Left SideCut Angle

A-00512

Figure 5-4 Side Characteristics Of Cut

E. DrossGenerally when dross is present on carbon steel, it is re-ferred to as either "high speed or slow speed dross".

"High speed dross" usually forms a narrow bead alongthe bottom of the cut edge and is very difficult to remove."Slow speed dross" will be in larger quantities but doesnot adhere tightly to the cut edge and can be easily re-moved.

When cutting a troublesome steel, it is suggested that thetorch travel speed be reduced to produce "slow speeddross". Any required cleanup can then be done by scrap-ping, not grinding.

Dross present on top of the plate (top spatter), is normallycaused by a slow torch travel speed or too high of a torchstandoff distance.

F. Common Cutting Faults1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current 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. Worn torch parts



3. Excessive Dross Formation

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. Improperly assembled torch


5.04 Troubleshooting GuideA. GeneralTroubleshooting and repairing this unit should be under-taken only by those familiar with high voltage high powerelectronic equipment.

WARNING

There are extremely dangerous voltage and powerlevels present inside this unit. Do not attempt todiagnose or repair unless you have had training inpower electronics measurement and troubleshoot-ing techniques.

B. Basic TroubleshootingThis manual covers a basic level of troubleshooting thatrequires limited disassembly and measurements. It ishelpful for solving many of the common problems thatcan arise with this system.

If major complex subassemblies are faulty, the unit mustbe returned to an authorized service center for repair.

Follow all instructions as listed and complete each sec-tion in the order presented.

For major troubleshooting and parts replacement proce-dures refer to PAK Master 75XL PLUS Power Supply Ser-vice Manual 0-2747.

C. How to use this GuideThe following information is a guide to help the Customer/ Operator determine the most likely causes for varioussymptoms.

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 thatunit is fully operational after any repairs.

A. AC Power indicator OFF

1. Switch at customer's main power panel in OFF posi-tion.

a. Close main power panel switch.

2. Input power not properly connected to customer's mainpower panel

a. Check that input power is present and unit isproperly connected (refer to Section 3.05, In-put Power Connections.)

3. Customer's main power line fuse(s) blown

a. Check main power panel fuse(s) and replaceas required.

4. Actual input voltage does not correspond to voltageselection inside unit

a. Check actual line voltage against voltage se-lection (inside of unit).

5. Unit internal fuse blown or loose

a. If blown, double check input voltage againstvoltage selection (inside of unit) and replacefuse per Section 5.05-B. If fuse blows again,components inside the unit may be faulty.

6. Faulty components in unit

a Return unit to an authorized service center forrepair or have qualified technician repair perService Manual.

B. 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.

3. Unit is overheated

a. Allow unit to cool down for about 5 minutes.Make sure the unit has not been operated be-yond duty cycle limit.

4. Input line voltage is below 75% of rated level

a. Check and connect to proper input power line.


a. Return for repair or have qualified technicianrepair per Service Manual.

C. 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 - 75 psi / 4.1 - 5.2 bar.



D. No cutting output; AC Power indicator ON; Fansoperating

1. Torch not properly connected to power supply

a. Check that torch leads are properly attachedto power supply.

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated againsttorch head (do not overtighten if screwed on).



4. Faulty Torch

a. Return for repair or have qualified technicianrepair per Torch Instruction Manual.

E. Low cutting output with no control

1. Incorrect setting of CURRENT (A) control

a. Check and adjust to proper setting.



F. Limited output with no control

1. Poor input or output connections

a. Check all input and output connections.

2 Incorrect setting of CURRENT control

a. Check and adjust to proper setting.



G. Erratic or improper cutting output

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. Fans not operating; AC Power indicator ON;Cutting output available

1. Fan blades blocked

a. Check and clear blades.



I. No gas flow; AC POWER indicator ON; Fansoperate

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. Set to maximum of 125 psi inlet pressure.



J. Torch cuts but not adequately

1. Drag circuit active

a. Lift tip from work piece.

2. Current (A) set too low

a. Increase current setting.


3. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to InstructionManual supplied with torch).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch / 3 mm from clean sur-face while purging and observe oil or moisturebuildup (do not activate torch).

5.05 Power Supply PartsReplacement

WARNING

Disconnect primary power to the system before dis-assembling the torch, leads, or power supply.

A. Left Side Panel Removal1. Remove the screws which secure the left side

panel (viewed from front of unit) to the frame as-sembly.

GroundWire

Screws(5 places)

Left SidePanel

A-02468

Figure 5-5 Left Side Panel Removal

NOTE

There is a ground wire connection to the Left SidePanel on the inside of the unit. There is no need todisconnect the ground wire.

2. Carefully pull the Left Side Panel up and awayfrom the unit to gain access to the inside of theunit.

3. Reinstall the left side panel as follows:

a. Place the left side panel onto the frame andslide the top edge under the lip on the top ofthe right side panel.

b. Reinstall all the screws to secure the left sidepanel.

B. Fuse Replacement1. Remove the left side panel per paragraph "A"

above.

2. Locate the internal fuse above the input powercontactor on the left side of the unit.

3. Replace the fuse. Refer to Section 6 for replace-ment fuse catalog number.

4. Reinstall the left side panel per paragraph "A"above.

A-00919Internal Fuse0.8 Amps, 600V

Figure 5-6 Internal Fuse Location

Manual 0-2746 6-1 PARTS LISTS

SECTION 6:PARTS LISTS

6.01 IntroductionA. Parts List BreakdownThe 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.

B. ReturnsIf a product must be returned for service, contact yourdistributor. Materials returned without proper authori-zation will not be accepted.

6.02 Ordering InformationOrder replacement parts by catalog number and completedescription of the part or assembly, as listed in the partslist for each type item. Also include the model and serialnumber of the torch. Address all inquiries to your autho-rized distributor.

PARTS LISTS 6-2 Manual 0-2746

6.03 Complete Power Supply ReplacementPower supply includes: Work cable and clamp, pressure regulator / air filter, and operating manual.

Qty Description Catalog #

PAK MASTER 75XL PLUS Power Supply1 208 / 230VAC, Single - Phase, With 50 Amp Input Plug and Cable 3-7556-11 460VAC, Three - Phase, Without Input Plug and Cable 3-7556-2

6.04 Replacement PartsQty Description Catalog #

1 Fuse (0.8 amp, 600V) 9-75261 220V Single - Phase Input Power Cable 9-75121 Filter / Regulator Assembly Replacement Element 9-4414

6.05 Options and AccessoriesQty Description Catalog #

1 Multi - Purpose Cart 7-88881 575V Transformer 9-75001 Single - Stage Air Filter Kit Includes Filter And Hose 7-75071 Replacement Filter Body 9-77402 Replacement Filter Element 9-77411 Replacement Filter Hose (not shown) 9-77421 Two - Stage Air Line Filter Kit 7-75001 Dual Stage Air Filter Assembly 9-75271 Replacement First Stage Filter 9-10211 Replacement Second Stage Filter 9-10221 Bracket, Filter Mounting (not shown) 9-7535

Computer Control Cable (CNC)1 25 Foot / 7.6 m 8-55571 50 Foot / 15.2 m 8-5558

Optional Single - Stage Air Line Filter Kit

A-02476

FilterElement

(Cat. No. 9-7741)

Housing

Cover

BarbedFitting

Spring

Assembled FilterO-ring First & Second

StageCartridges (as marked)

A-02942

Optional Two - Stage Air Line FilterKit

Manual 0-2746 A-1 APPENDIX

APPENDIX 1: INPUT WIRING REQUIREMENTS

Input Power Input Current Input Recommended Sizes (See Notes)Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)(Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph

208 50/60 12.5 11.2 60 31.1 70 40 4 8 4 8230 50/60 12.5 11.3 54.1 28.3 70 35 4 8 4 8240 50/60 12.6 11.4 52.3 27.5 60 35 6 8 6 8380 50/60 13.9 12.4 36.5 18.9 45 25 8 10 8 10415 50/60 13.9 12.6 33.4 17.5 40 25 8 12 8 12460 50/60 13.9 12.7 30.1 16 35 25 8 12 8 12

575 Requires Transformer Module

Line Voltages with Recomm ended Circuit Protection and Wire Sizes(Based on Table 310-16, 1987 National Electric Code) and Table 4, Canadian Electrical Code.

NOTES

The table above is based on the following output current and voltage: 130vdc @ 60A

An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should beused 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.

Primary input power cable must have an outside diameter of 0.69 inches / 17.5 mm or greater.

APPENDIX A-2 Manual 0-2746

ACTION

ON/OFF switchto OFF

RESULT

All indicators off.Power supply fans off.

ACTION

RUN/SET/LATCHswitch to RUN.

RESULT

Gas flow stops. GAS indicator off.

ACTION

Torch moved within transfer distance of workpiece.

RESULT

Main arc transfer.Pilot arc off.

ACTION

Torch deactivated (by torch switch release or by remote device).

RESULT

Main arc stops.(Power supply enable signal removed.)

Gas flows (15 seconds)NOTE - If torch is activated during

post-flow, pilot arc will immediately restart. If torch is within transfer distance (3/8 in) of

workpiece, main arc will transfer.

After post-flow:

Gas solenoid closes, gas flow stops. GAS indicator off.

ACTION

Open external disconnect.

RESULT

No power to system.

ACTION

Close externaldisconnect switch.

RESULT

Power to system.

ACTION

RUN/SET/LATCH switch to SET.

RESULT

Gas solenoid open, gas flows to set pressure.

GAS indicator on.

ACTION

Torch moved away from work (while

still activated).RESULT

Main arc stops.Pilot arc automatically

restarts.PILOT ARC

ACTION

ON/OFF switchto ON.

RESULT

AC indicator blinks for 8seconds then steady on.

Fans on. Power circuit ready.

ACTION

Protect eyes and activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on. Pilot relay closes.

Pilot arc established

A-02461

LATCH

ACTIONTorch Switch

can be released.

RESULTTransfer will continue until torch is removed

from workpiece.

APPENDIX 2: SEQUENCE OF OPERATION(BLOCK DIAGRAM)

Manual 0-2746 A-3 APPENDIX

APPENDIX 3: MAINTENANCE SCHEDULEThis schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all theparts 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 tointerfere 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.

APPENDIX A-4 Manual 0-2746

APPENDIX 4: DATA TAG INFORMATION

1/3 ff12

West Lebanon, NH USA 03784

Made in USA

Model:

U1 1 11max 1effI I

U2

3 311

S/N

U0 =X

Standard Symbols

2746 PakMaster 75XL Plus (O)

Documents

entire manual

scope of manual

power supply options

power supply serial

general information

power supply pakmaster

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