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GENERAL INFORMATION

1-2

May 14, 2002

• Wear dry gloves and clothing.  Insulate yourself

from the work piece or other parts of the welding
circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, 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, or
the plasma arc.

• Be sure there is no combustible or flammable mate-

rial in the workplace.  Any material that cannot be
removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have held

combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum 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 or
dissipated.  Trapped hydrogen gas that is ignited
will cause an explosion.

NOISE

Noise can cause permanent hearing loss.  Plasma arc pro-
cesses can cause noise levels to exceed safe limits.  You
must 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 others
in 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 1

in 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 violet
and infra red light.  These arc rays will damage your eyes
and 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 with
side 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 following

per ANSI/ASC Z49.1:

Minimum Protective

Suggested

Arc 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 clearly
seen.  Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions
for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL  33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing 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 MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway, New
York, NY  10018

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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