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May 14, 2002

1-5

GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY:

  Thermal Dynamics

®

 Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in

workmanship or material.  Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, 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 A
PARTICULAR PURPOSE.

LIMITATION OF LIABILITY:

  Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption.  The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, 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 any
warranty, 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 THE
SAFETY 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 , 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 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 date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with 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 an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts

XL Plus &

Parts

Parts

PAK 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 Year

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat

1 Year

1 Year

1 Year

Exchanges, 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® repair
facility within thirty (30) days of the repair.  No transportation costs of any kind will be paid under this warranty.  Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.  All returned goods shall
be at the customer’s risk and expense.  This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001

Содержание PakMaster 75XL Plus

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

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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