Thermal Dynamics CE PAK Master 75XL Operating Manual Download

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Manual No. 0-2746

August 23, 1999

Operating Manual

A-02464

Air Plasma Cutting

Power Supply

Summary of Contents for CE PAK Master 75XL

Page 1: ...Manual No 0 2746 August 23 1999 Operating Manual A 02464 Air Plasma Cutting Power Supply...

Page 2: ...Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1999 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whol...

Page 3: ...Purchase Date Power Supply Torch Record Serial Numbers For Warranty Purposes...

Page 4: ......

Page 5: ...S 11 3 01 Introduction 11 3 02 Site Selection 11 3 03 Unpacking 11 3 04 Lifting Options 11 3 05 Input Power Connections 12 3 06 Input Voltage Selection 12 3 07 Primary Input Power Cable Connections 13...

Page 6: ...duction 31 6 02 Ordering Information 31 6 03 Complete Power Supply Replacement 32 6 04 Replacement Parts 32 6 05 Options and Accessories 32 APPENDIX I INPUT WIRING REQUIREMENTS 33 APPENDIX II SEQUENCE...

Page 7: ...ep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the ki...

Page 8: ...yes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect your skin from...

Page 9: ...uit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION Toute proc dure pouvant r sul...

Page 10: ...9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes INCENDIE ET EXPLOSION Les incendies et les explos...

Page 11: ...ashington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l InstitutAm ricain des Normes Nationales Ameri can National...

Page 12: ...LAPR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2...

Page 13: ...andardsAssociation standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 9...

Page 14: ...roducts shall be as follows with the exception of XL Plus Series CutMaster 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 yea...

Page 15: ...imum 1 inch 25 4 mm cut capacity Hand torches are available in a 70 and 90 torch head configuration a machine torch is avail able in a 180 torch head configuration Torch leads are available in 25 ft 7...

Page 16: ...he Dry Air filter this optional two stage air line filter is for use on compressed air shop systems Filters moisture and contaminants to 5 mi crons This filter assembly is pre assembled at the fac tor...

Page 17: ...least 2 feet 0 61 m in the rear and at least 6 inches 0 2 m on each side for clearance Provide sufficient clearance in front of the unit to allow access to the front panel controls minimum 6 inches or...

Page 18: ...torch parts or torch and leads assemblies 1 Using a phillips head screw driver remove the five screws which secure the left side panel viewed from front of unit to the frame assembly Screws 5 Places L...

Page 19: ...rimary power cable through the strain re lief fitting in the rear panel of the Power Supply and tighten strain relief screws AC Input Power Cable Strain Relief AC Input Power Cable A 00912 Figure 3 3...

Page 20: ...ation c Locate the ground stud and remove the top nut and washer d Install a lug terminal on the ground wire e Place the ground wire onto the ground stud and secure with the nut and washer f Insert th...

Page 21: ...s to be installed refer to subsection D 3 Install the barbed fitting as shown below 4 Tighten the barbed fitting 5 Place an adjustable hose clamp customer supplied 1 4 6 5mm to 5 8 15 9mm over the gas...

Page 22: ...adjust able hose clamp NOTE Supply hose must be at least 4 hose 1 4 in or 6 mm I D 3 09 Connecting Torch Leads WARNING Disconnect primary power at the source before as sembling or disassembling the po...

Page 23: ...hen install ing mechanized systems B Creating an Earth Ground 1 Install a ground wire not included between the sys tem and a solid earth ground also called star ground To create a solid earth ground d...

Page 24: ...ife of the tip If the user does not want the current to be decreasedwhen the tip touches the workpiece the sensing circuit can be defeated by closing switch SW1 1 on the Gate Logic PC Board Slide top...

Page 25: ...e 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 for use in...

Page 26: ...torch switch is pressed C Torch Panel Bulkhead The torch panel bulkhead is located under the access panel 1 Pilot Lead Stud Connects the pilot control wire on the torch to the unit 2 1 3 A 00923 Figur...

Page 27: ...lter this optional filter will also remove moisture and contaminants from the air stream when using compressed air Filters to 5 microns A 00924 1 2 3 4 Figure 4 6 Rear Panel Showing Optional Two Stage...

Page 28: ...ing operation NOTE If the torch is lifted from the workpiece while still having torch swicth activated the main arc will stop and the pilot arc will automatically restart 12 Release or deactivate the...

Page 29: ...turn gas supply on D Work Cable Connection Check for a solid and clean work cable connection to the workpiece The area must be free from paint and rust Make a solid work cable connection to the work...

Page 30: ...ild up Nitride deposits which may remain on the surface of the cut when nitrogen is present in the plasma gas stream Nitride buildups may create difficulties if the material is welded after the cuttin...

Page 31: ...al 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 re place if necessary 3 Check plasma and secondary supply...

Page 32: ...ith care and protect them from damage A Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Wheneve...

Page 33: ...ts d Improper cutting current 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...

Page 34: ...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 5 Faulty components in unit a Return fo...

Page 35: ...2 Current set too low a Increase current setting 3 Torch is being moved too fast across workpiece a Reduce cutting speed refer to Instruction Manual supplied with torch 4 Excessive oil or moisture in...

Page 36: ...e panel per paragraph A above 2 Locate the internal fuse above the input power con tactor on the left side of the unit 3 Replace the fuse 0 8 amp 600V 4 Reinstall the left side panel per paragraph A a...

Page 37: ...bers 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 Dynamics distributor Mate rials returned to...

Page 38: ...5 Options and Accessories Qty Description Catalog 1 Smart Cart 7 7777 1 575V Transformer 9 7500 1 Filter Kit Dry Air Includes Filter And Hose Optional 7 7507 1 Replacement Filter Body Dry Air 9 7740 2...

Page 39: ...ter of 0 69 inches 17 5 mm or greater 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...

Page 40: ...in 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 external disconnect switch RESULT Power...

Page 41: ...Manual 0 2746 35 APPENDIX This Page Left Blank...

Page 42: ...APPENDIX 36 Manual 0 2746 APPENDIX III SYSTEM SCHEMATIC A 02503 9 13 16 J21 J20 J19 GAS SOL GAS INRUSH INRUSH...

Page 43: ...Manual 0 2746 37 APPENDIX A 02503 OK OK TO MOVE 8 11 99...

Page 44: ...APPENDIX 38 Manual 0 2746...

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