Thermal Dynamics PakMaster 75XL Plus Operating Manual Download | Manualshive

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Summary of Contents for PakMaster 75XL Plus

Page 1: ...July 8 2003 Manual No 0 2746 Operating Manual Plasma Cutting Power Supply PakMaster 75XLTM Plus A 02464...

Page 2: ......

Page 3: ...mission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date July 8 2003 Record the following information for...

Page 4: ...and Accessories 2 2 SECTION 3 INSTALLATION 3 1 3 01 Introduction 3 1 3 02 Site Selection 3 1 3 03 Unpacking 3 1 3 04 Lifting Options 3 1 3 05 Input Power Connections 3 2 3 06 Input Voltage Selection...

Page 5: ...eplacement 5 6 SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Ordering Information 6 1 6 03 Complete Power Supply Replacement 6 2 6 04 Replacement Parts 6 2 6 05 Options and Accessories 6 2 APPE...

Page 6: ......

Page 7: ...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 kind of me...

Page 8: ...this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes an...

Page 9: ...e Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highw...

Page 10: ...tandard 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 EN5007...

Page 11: ...follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of s...

Page 12: ...GENERAL INFORMATION 1 6 May 14 2002...

Page 13: ...PLUS Power Supply Figure 2 1 Pak Master 75XL Plus System The torch provides a maximum 1 inch 25 4 mm cut capacity Hand torches are available in various torch head configurations a machine torch is ava...

Page 14: ...ers moisture and par ticulate matter from the air stream to at least 0 85 mi crons B Two Stage Air Line Filter ATwo Stage In LineAir Filter for use on compressed air shop systems Filters moisture and...

Page 15: ...cess to the front panel controls minimum 6 inches or 150 mm CAUTION Operation without proper air flow will inhibit proper cooling and reduce duty cycle 3 03 Unpacking Each component of the system is p...

Page 16: ...Left Side Panel A 02468 Figure 3 1 Removing Left Side Panel 2 Carefully pull the Left Side Panel up and away from the unit to gain access to the inside of the unit 3 06 Input Voltage Selection NOTE F...

Page 17: ...operation per the following A Three Phase Operation Three phase operation requires a 3 conductor cable with ground a Locate the ground stud and remove the top nut and washer b Install a lug terminal o...

Page 18: ...ARNING 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 n...

Page 19: ...rch Connect the gas supply as follows Regulator Filter Assembly 1 4 NPT to 4 6mm Hose Fitting 4 6mm Gas Supply Hose Hose Clamp A 00916 Figure 3 7 Gas Connection To Regulator Filter Assembly D Optional...

Page 20: ...al apply thread sealant to the fit ting threads according to manufacturer s instruc tions Do Not use Teflon tape as a thread sealer as small particles of the tape may break off and block the small gas...

Page 21: ...e in the unit 5 Secure the Strain Relief with the retaining nut re moved earlier 6 Connect the torch Negative Plasma Lead to the bulkhead connection inside the Power Supply Adapter Plug Pilot Lead Tor...

Page 22: ...the wires on theAdapter through the Strain Re lief Nut b Continue routing the wires out the hole in the front panel of the Power Supply c Feed the end of the torch lead and the Strain Relief into the...

Page 23: ...e the connector on the free end of the Adapter through the Strain Relief Nut b Continue routing the connector out the hole in the front of the Power Supply c Feed the end of the torch lead and the Str...

Page 24: ...rod 5 Make sure work cable and ground cables are prop erly connected The work cable must have a solid connection to the cutting table The work and ground connections must be free from rust dirt greas...

Page 25: ...e from any CNC components drive mo tors control cables or primary power lines If cables have to pass over torch leads do so at an angle Do not run the plasma control or other control cables in paralle...

Page 26: ...INSTALLATION 3 12 Manual 0 2746...

Page 27: ...a Bracket connected to the side panel of the unit for use in storing the torch torch leads work cable and spare parts kit when not in use The spare parts kit fits into the opening on the top of the br...

Page 28: ...panel is located under the access panel 1 Pilot Lead Stud Stud used to connect the Torch Leads Pilot Lead to the Power Supply 2 1 3 A 00923 Figure 4 3 Torch Panel Connections 2 Control Cable Connecto...

Page 29: ...ir Filter for use with compressed air shop systems Filters moisture and particulate mat ter from the air stream to at least 0 85 microns 1 2 3 4 A 02460 Figure 4 5 Rear Panel Showing Optional Single S...

Page 30: ...ay 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 LATCH mode NOTE For general cutting use t...

Page 31: ...heck connection and 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 conn...

Page 32: ...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 cutting pr...

Page 33: ...pply turn off the gas supply and bleed the system 2 Unscrew the bowl on the bottom of the Filter Regulator Assembly The filter element will be visible and still attached to the main body of the Filter...

Page 34: ...r Filter has two Filter Elements When the Filter Elements become dirty the Power Supply will continue to operate but cut quality may become unacceptable 1 Remove power from power supply 2 Shut off air...

Page 35: ...plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel...

Page 36: ...o PAK Master 75XLPLUS Power Supply Ser vice Manual 0 2747 C How to use this Guide The following information is a guide to help the Customer Operator determine the most likely causes for various sympto...

Page 37: ...eturn for repair or have qualified technician repair 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 2 F...

Page 38: ...ft Side Panel Removal NOTE There is a ground wire connection to the Left Side Panel on the inside of the unit There is no need to disconnect the ground wire 2 Carefully pull the Left Side Panel up and...

Page 39: ...TE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your distributor Materials returned withou...

Page 40: ...y Description Catalog 1 Multi Purpose Cart 7 8888 1 575V Transformer 9 7500 1 Single Stage Air Filter Kit Includes Filter And Hose 7 7507 1 Replacement Filter Body 9 7740 2 Replacement Filter Element...

Page 41: ...0 50 60 13 9 12 7 30 1 16 35 25 8 12 8 12 575 Requires Transformer Module Line Voltages with Recommended Circuit Protection and Wire Sizes Based on Table 310 16 1987 National Electric Code and Table 4...

Page 42: ...id closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to system ACTION Close external disconnect switch RESULT Power to system ACTION RUN SET LATCH switch to SET R...

Page 43: ...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 f...

Page 44: ...e values Second row Rated cutting current values Third row Conventional load voltage values I A 03288 Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltag...

Page 45: ...Manual 0 2746 A 5 APPENDIX This page left blank...

Page 46: ...APPENDIX A 6 Manual 0 2746 A 02503 APPENDIX 5 SYSTEM SCHEMATIC...

Page 47: ...Manual 0 2746 A 7 APPENDIX A 02503...

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