Вы находитесь на странице: 1из 48

July 8, 2003 Manual No.

0-2746
Operating Manual
Plasma Cutting
Power Supply
PakMaster

75XL
TM
Plus
A-02464
Plasma Cutting Power Supply PAKMaster

75 XL
TM
Plus
Operating Manual Number 0-2746
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2000 by
Thermal 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 to
any party for any loss or damage caused by any error or omission 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 Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
WARNI NGS
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, the
Manufacturer assumes no liability for its use.
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and Warnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.07 Declaration of Conformity ............................................................................. 1-4
1.08 Statement of Warranty.................................................................................. 1-5
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual ......................................................................................... 2-1
2.02 General Description of System.................................................................... 2-1
2.03 Specifications / Design Features ................................................................. 2-1
2.04 Power Supply Options 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 ................................................................................. 3-2
3.07 Primary Input Power Cable Connections ...................................................... 3-3
3.08 Gas Connections ......................................................................................... 3-4
3.09 Connecting Torch Leads ............................................................................... 3-6
3.10 Ground Connections for Mechanized Applications ..................................... 3-10
3.11 Tip Saver / Drag Cut Sensing Circuit .......................................................... 3-11
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction .................................................................................................. 4-1
4.02 Operating Controls ....................................................................................... 4-1
4.03 Sequence of Operation ................................................................................ 4-4
4.04 Preparations for Operating ........................................................................... 4-5
4.05 Cut Quality ................................................................................................... 4-6
TABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Maintenance ................................................................................... 5-1
5.03 Common Operating Problems ...................................................................... 5-3
5.04 Troubleshooting Guide ................................................................................. 5-4
5.05 Power Supply Parts Replacement ................................................................ 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
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 Warnings
Throughout this manual, notes, cautions, and warnings
are 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.
CAUTI ON
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNI NG
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
WARNI NGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.
To prevent possible injury, read, understand and
follow 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 cutting
process 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 not
adequate to remove all fumes and gases.
The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the in-
formation regarding the kind and amount of fumes
and gases that may be dangerous to your health.
For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
Use special equipment, such as water or down draft
cutting 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 vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
This product, when used for welding or cutting, pro-
duces fumes or gases which contain chemicals
known 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 process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
Never touch any parts that are electrically live or
hot.
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 MENS
SAFETY-TOE FOOTWEAR, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway, New
York, NY 10018
May 14, 2002 1-3 GENERAL INFORMATION
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able from American National Standards Institute, 1430
Broadway, 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 SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, 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 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
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-
ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable 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 HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
GENERAL INFORMATION 1-4 May 14, 2002
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
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 for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and 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 related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the 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 our
area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
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 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 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 customers risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001
GENERAL INFORMATION 1-6 May 14, 2002
Manual 0-2746 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
75XL Plus Air Plasma Cutting Power Supply. Service of
this equipment is restricted to properly trained person-
nel; unqualified personnel are strictly cautioned against
attempting repairs or adjustments not covered in this
manual, 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 it
was designed.
2.02 General Description of System
The 75XL PLUS System includes a power supply, torch &
leads and work cable & clamp.
The Power Supply provides 60 amp maximum output
and includes all control circuitry, electrical and gas in-
puts and outputs, pilot circuitry, torch leads receptacle
and 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-02462
Torch 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 cut
capacity. Hand torches are available in various torch head
configurations, a machine torch is available in a 180 torch
head configuration. Torch leads are available in various
lengths with fittings for simple installation. Spare Parts
Kits are available for the torches which provide an as-
sortment of replacement torch parts.
2.03 Specifications / Design
Features
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON / OFF Switch, RUN / SET / LATCH Switch and
Output 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 or
Three - 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 higher
than shown in the chart.
Ambient
Temperature
104F
(40C)
104F
(40C)
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 Wrap
Bracket, and Gas Regulator / Filter Assembly in-
stalled.
B. Gas Regulator / Filter Assembly
Specifications
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 and
Accessories
The following accessories are available for this power
supply. Refer to Section 6, Parts Lists, for catalog num-
bers and ordering information.
A. Single - Stage Air Line Filter
A 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 Filter
A Two Stage In - Line Air Filter for use on compressed
air shop systems. Filters moisture and particulate
matter from the air stream to at least 5.0 microns.
C. High Pressure Regulators
High 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 A
or B above.
D. Multi-Purpose Cart
Rugged steel cart on easy-rolling rear wheels and
front-mounted swivel casters. Provides maximum
mobility for the power supply and can also serve as
a display cart. Top shelf is 12 " / 305 mm x 20 / 508
mm. 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 input
power.
F. Computer Control Cable (CNC)
NOTE
This accessory can be used only with the PCM - 60
Torches.
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 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply Options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all subsections be read for general informa-
tion.
This section describes installation of the Power Supply
and 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 those
units.
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 Selection
Select 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 safety
requirements.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be ob-
structed. Provide at least 2 feet / 0.61 m in the rear and
at least 6 inches / 150 mm 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
150 mm.
CAUTI ON
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
l. Unpack each item and remove any packing material.
NOTE
The Cutting Spare Parts Kit is shipped in the Torch
Leads Storage Area on the side of the Power Sup-
ply.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and / or
shipping company before proceeding with system in-
stallation.
3.04 Lifting Options
WARNI NGS
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.
FALLI NG EQUI PMENT can cause serious per-
sonal injury and equipment damage.
This unit is equipped with one handle mounted onto the
top of the enclosure for hand carrying purposes.
Lift unit with the handle on top of the enclosure.
Only persons of adequate physical strength should
lift the unit.
Use hand cart, optional Cart, or similar device of
adequate capacity.
If using a fork lift vehicle, place and secure unit on
a 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 and
transported safely and securely.
INSTALLATION 3-2 Manual 0-2746
3.05 Input Power Connections
The Power Supply accepts input voltages from 208V to
460V. 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 must
be changed using the procedure in Sections 3.06.
A. Electrical Connections
The power source must conform to local and national elec-
tric codes. Recommended circuit protection and wiring
requirements are shown in Appendix 1.
B. Opening Power Supply Enclosure
The left side panel of the Power Supply must be removed
to gain access to the input power connections and the
input voltage selection.
WARNI NG
Disconnect primary power at the source before as-
sembling or disassembling the Power Supply, torch
parts, 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 Side
Panel on the inside of the unit.
Ground
Wire
Screws
(5 places)
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
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 must
be installed.
The Power Supply has three voltage settings; 208 / 230 /
240VAC, 380 / 415VAC, or 460VAC. Power Supplies are
factory - 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 must
be properly installed depending on the input used.
WARNI NG
Disconnect primary power at the source before as-
sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Move the power selection plug to the desired input
connection for 208 / 230 / 240V, 380 / 415V, or 460V
operation 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 be
left in this storage connection.
Voltage Selection
Connector
380/415 Volts
460 Volts
208/230/240 Volts
A-00911
Voltage Selection
Label
Figure 3-2 Input Voltage Selection
Manual 0-2746 3-3 INSTALLATION
For single - phase operation the jumper wire must be
installed on the contactor as described in Section 3.07
for single - phase input voltage.
3.07 Primary Input Power Cable
Connections
Units ordered as 230V, single - phase, will have a six foot
power input cable and plug factory installed. For all other
units, 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 and
tighten strain relief screws.
AC Input Power
Cable Strain Relief
AC Input
Power Cable
A-00912
Figure 3-3 AC Input Power Cable Strain Relief
2. Connect the input cable inside the Power Supply for
the type of 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 on the ground wire.
c. Place the ground wire onto the ground stud
and secure with the nut and washer.
d. Insert the other three wires into the L1, L2, and
L3 terminals on the contactor.
e. Tighten all set screws.
NOTE
The jumper wire from L1 to L4 must not be re-
moved.
L1
L2
L3
Input
Contactor
AC Input
Power Cable
GND
Unused Jumper
L3 to L3 (storage)
A-02670
Figure 3-4 Primary Power Cable Connections -
Three - Phase Operation
B. Single - Phase Operation
Single - phase operation requires a 2 - conductor cable
with ground.
a. Locate the single - phase jumper wire con-
nected between the two L3 terminal lugs on
the 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.
INSTALLATION 3-4 Manual 0-2746
Single Phase
Jumper Wire
(L2 to L3)
Input Contactor
A-00914
L3
L2
Figure 3-5 Single Phase Jumper Wire Installation
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 terminal onto the ground
stud and secure with the nut and washer.
f. Insert the other two wires into the L1 and L2
terminals on the contactor.
g. Tighten all set screws.
AC Input
Power Cable
L1
L2
GND
Input Contactor
A-00915
Figure 3-6 Primary Power Cable Connections -
Single - Phase Operation
3.08 Gas Connections
A. Gas Requirements
WARNI NG
This unit not to be used with oxygen (O
2
).
Gases: Compressed Air or Nitrogen (N2) Only
Pressure: Unshielded Leads: 70 psi / 4.8 bar
Shielded Leads: 60 psi / 4.1 bar
CAUTI ON
Maximum input gas pressure must not exceed 125
psi / 8.6 bar
Flow: Cutting - 300 scfh (standard cubic feet / hr ) / 142 lpm
Gouging - 300 scfh / 142 lpm
B. Checking Air Quality
To test the quality of air, place the RUN / SET / LATCH
switch to SET position, place a welding filter lens in front
of the torch and turn on the gas. Any oil or moisture in
the air will be visible on the lens. Do not initiate an arc!
CAUTI ON
The air supply must be free of oil, moisture, and
other contaminants. Excessive oil and moisture
may cause double - arcing, rapid tip wear, or even
complete torch failure. Contaminants may cause
poor cutting performance and rapid electrode wear.
Manual 0-2746 3-5 INSTALLATION
C. Gas Connections
The 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 pressure
gas cylinders.
Connect the gas supply as follows:
1. Use customer-supplied fittings to connect the gas line
to the power supply Regulator/Filter Assembly. Typi-
cal fittings are shown as an example. Other fittings
may be used.
2. If an optional air line filter is to be installed, refer to
subsection 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 as
small particles of the tape may break off and block
the small gas passages in the torch. 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 Air Line Filter Installation
Filtering is required when using air from a compressor to
insure that moisture and debris from the supply hose does
not enter the torch. Although the Regulator does have its
own filter, it is recommended the optional Single - Stage
Air Filter or optional Two Stage Air Line Filter be installed
for 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 Filter
Assembly
#4 (6mm)
Gas Supply
Hose
Hose Clamp
Figure 3-8 Gas Connection to Optional Single -
Stage Air Filter Assembly
Two Stage Filter
Assembly
1/4 NPT to
#4 (6mm) Hose
Fitting
#4 (6mm) Gas
Supply Hose
Hose Clamp
A-00917
Figure 3-9 Gas Connection To Optional Two Stage
Filter Assembly
INSTALLATION 3-6 Manual 0-2746
E. Using High Pressure Gas Cylinders
1. Refer to the following when using high pressure gas
cylinders as the gas supply:
CAUTI ON
Pressure should be set at 100 psi / 6.9 bar at the
high pressure gas cylinder regulator.
a. Refer to the manufacturers specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
b. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-
rial. Momentarily open each cylinder valve to blow
out any dust which may be present.
c. The cylinder must be equipped with an adjustable
high - pressure regulator capable of outlet pres-
sures up to 100 psi / 6.9 bar maximum and flows
of up to 300 scfh / 141.5 lpm.
2. Use customer-supplied fittings to connect the gas line
to 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 as
small particles of the tape may break off and block
the small gas passages in the torch. Connect the
gas supply as follows:
NOTE
Supply hose must be at least #4 hose / 1/4 in or 6
mm I.D.).
3.09 Connecting Torch Leads
CAUTI ON
This system is designed for use with the PCH / M
- 102 torch only. Do not connect any other torch to
this power supply.
The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub - section covers connecting the Torch for
the following applications:
A. Hand Systems
B. Machine Systems (Unshielded Leads)
C. Machine Systems (Shielded Leads)
The Torch Leads must be properly installed to the Power
Supply for proper operation. If the torch leads were not
factory - installed, make all torch connections to the Torch
Bulkhead Panel for the desired application.
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
Manual 0-2746 3-7 INSTALLATION
A. Hand Systems
WARNI NG
Disconnect primary power at the source before as-
sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Turn the screw latch securing the front access panel
to the power supply front panel.
Access
Panel
Screw
Latch
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 Relief
Nut
Strain Relief
Torch 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 into
the hole 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
Torch Leads
Assembly
Negative/Plasma
Lead
Adapter
Connector
Pilot Lead Stud
Negative/Plasma Lead
Connection
A-03613
Control Circuit
Connectors
Note: Actual Bulkhead
configuration may
differ from that shown.
Figure 3-12 Torch Lead Connections
7. Connect the Cables to the mating connectors on
the Adapter supplied on the Power Supply.
8. Remove the top nut and washer from the Pilot
Stud.
9. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in 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.
INSTALLATION 3-8 Manual 0-2746
B. Machine Systems (Unshielded Leads)
WARNI NG
Disconnect primary power at the source before as-
sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Turn the screw latch securing the front access panel
to the power supply front panel.
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 covered
with an insulator and joined with mating connec-
tors. Remove the tie wrap, remove the insulator,
and disconnect the wires.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-03609
Remove Tie Wrap,
Remove Insulator,
Disconnect Wires
Figure 3-13 Strain Relief Nut Removal
5. The Power Supply Adapter must be installed as
follows:
a. Inside the Power Supply Bulkhead area, route
the wires on the Adapter 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 hole in the unit while routing
the wire into the notch of the Strain Relief.
d. Tighten the Strain Relief Nut to secure the
Strain Relief to the Power Supply.
Power Supply Adapter
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Adapter Connector
Negative/Plasma
Lead Connection
A-03612
Control Circuit
Connectors
Remote
Pendant Adapter
Open
Open
Figure 3-14A Torch Lead Connections
A-03611
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Control Circuit
Connectors
Open
Open
Power Supply Adapter
Figure 3-14B Torch Lead Connection Detail
6. Connect the torch Negative / Plasma Lead to the
bulkhead connection inside the Power Supply.
7. Connect the Control Circuit Connectors to the mat-
ing connectors on the Power Supply Adapter. Two
wires from the torch leads will remain open.
8. Remove the top nut and washer from the Pilot
Stud.
Manual 0-2746 3-9 INSTALLATION
9. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
10. Tighten the Strain Relief onto the Torch Leads.
11. Check the torch for proper parts assembly. Refer
to the Torch manual for parts selection.
12. Close the access panel and turn the latching screw.
C. Machine Systems (Shielded Leads)
WARNI NG
Disconnect primary power at the source before as-
sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Turn the screw latch securing the front access panel
to the power supply front panel.
2. Lift up on the access panel to gain access to the
torch bulkhead panel.
3. Remove the retaining nut from the Strain Relief.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-02826
Figure 3-15 Strain Relief Nut Removal
4. The Adapter supplied with the Power Supply must
be installed per the following:
a. Inside the Power Supply Bulkhead area, route
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 Strain
Relief into the hole in the unit while routing
the single black wire into the notch of the Strain
Relief.
d. Tighten the Strain Relief Nut to secure the
Strain Relief to the Power Supply.
Adapter
(Supplied With
Power Supply)
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Adapter Connector
Pilot Lead
Stud
Negative/Plasma
Lead Connection
A-02829
Control (PIP) Circuit
Connectors
Shield Connectors
Figure 3-16 Torch Lead Connections
5. Connect the torch Negative / Plasma Lead to the
bulkhead connection inside the Power Supply.
6. Connect the PIP and Shield Cables to the mating
connectors on the Adapter supplied on the Power
Supply.
7. Remove the top nut and washer from the Pilot
Stud.
8. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.
9. Tighten the Strain Relief Nut onto the Torch Leads.
10. Check the torch for proper parts assembly.
11. Close the access panel and turn the latching screw.
INSTALLATION 3-10 Manual 0-2746
3.10 Ground Connections for
Mechanized 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, height
controllers, etc. To minimize RF interference, follow these
grounding procedures when installing mechanized sys-
tems:
B. Grounding
1. The preferred grounding arrangement is a single point
or Star ground. The single point, usually on the
cutting table, is connected with 1/0 AWG (European
50 mm
2
) or larger wire to a good earth ground (refer
to paragraph C, Creating An Earth Ground). The
ground rod must be placed as close as possible to the
cutting table, ideally less than 10 ft (3.0 m), but no
more than 20 ft (6.1 m).
NOTE
All ground wires should be as short as possible.
Long wires will have increased resistance to RF
frequencies. Smaller diameter wire has increased
resistance to RF frequencies, so using a larger di-
ameter wire is better.
2. Grounding for components mounted on the cutting
table (CNC controllers, height controllers, plasma re-
mote controls, etc.) should follow the manufacturers
recommendations for wire size, type, and connection
point locations.
For Thermal Dynamics components it is recom-
mended to use a minimum of 10 AWG (European 6
mm
2
) wire or flat copper braid with cross section equal
to or greater than 10 AWG connected to the cutting
table frame. The connection point must be clean bare
metal; rust and paint make poor connections. For all
components, wires larger than the recommended
minimum can be used and may improve noise pro-
tection.
3. The cutting machine frame is then connected to the
Star point using 1/0 AWG (European 50 mm
2
) or
larger wire.
4. The plasma power supply work cable (see NOTE) is
connected to the cutting table at the single point Star
ground.
NOTE
Do Not connect the work cable directly to the
ground 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, grease, oil
and paint. If necessary grind or sand down to bare
metal. Use lock washers to keep the connections tight.
Using electrical joint compound to prevent corrosion
is also recommended.
6. The plasma power supply chassis is connected to the
power 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 can
set up ground loop currents that cause interference.
When the plasma power supply is far away from the
ground rod and interference is experienced, it may
help to install a second earth ground rod next to the
plasma power supply. The plasma power supply
chassis would then be connected to this ground rod.
NOTE
It is recommended that the Plasma Power Supply
be within 20 - 30 ft (6.1 9.1 m) of the cutting
table, if possible.
7. The plasma control cable should be shielded with the
shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground
loop currents which may cause more interference than
with no shield at all.
C. Creating An Earth Ground
1. To create a solid, low resistance, earth ground, drive a
1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that
the 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 be
welded end to end for greater lengths. Locate the rod
as close as possible to the work table. Install a ground
wire, 1/0 AWG (European 50 mm
2
) or greater, between
the ground rod and the star ground point on the cut-
ting table.
NOTE
Ideally, a properly installed ground rod will have a
resistance of three ohms or less.
To test for a proper earth ground, refer to the follow-
ing diagram. Ideally, the reading on the multimeter
should be as follows:
For 115VAC: 3.0 VAC
For 230VAC: 1.5 VAC
Manual 0-2746 3-11 INSTALLATION
A-02971
+
_
Meter set to
VAC setting
Machine
Earth Ground
Neutral
Line (Hot)
100W
Light Bulb
115 or 230VAC
WARNING
Use extreme caution. This
test uses live voltage.
115VAC: 3.0 VAC
230VAC: 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 which
has more surface area may help. Sometimes keeping
the soil around the ground rod moist by continuously
running a small amount of water into it will work.
Adding salt to the soil by soaking it in salt water may
also reduce its resistance. When these methods are
used, periodic checking of the ground resistance is re-
quired to make sure the ground is still good.
D. Routing Of Torch Leads
1. 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 cables
have to pass over torch leads, do so at an angle. Do
not run the plasma control or other control cables in
parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed
off energy, which causes difficult starting and in-
creased chance of RF interference.
3.11 Tip Saver / Drag Cut Sensing
Circuit
This power supply is equipped with a Tip Saver / Drag
Cut Sensing Circuit which cuts current back to 35 amps if
the tip touches the workpiece. The purpose of this is to
prolong the life of the tip. Tip life will be considerably
shortened if tip is repeatedly touched to the workpiece
without the Tip Saver / Drag Sensing Circuit feature ac-
tive.
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 white toggle on SW1 - 1 to the right
to close circuit.
A-02569
Gate/Logic PC Board
SW1
1




2
O
N
Figure 3-18 SW1 Switch Location
INSTALLATION 3-12 Manual 0-2746
Manual 0-2746 4-1 OPERATION
SECTION 4:
OPERATION
4.01 Introduction
This Section provides a description of the Power Supply
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operat-
ing procedures.
4.02 Operating Controls
This subsection provides specific functional descriptions
of the Power Supply operating controls and indicators.
A. Front and Side Panel Components
1. 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 containing
the torch connections.
3. Torch Leads Input
Hole in the front panel to feed the torch leads through
to 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 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 bracket. The
torch leads and work cable wrap around the bracket
for 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 between
15 - 60 amps. For drag cutting applications set the
control between 15 - 35 amps. The unit has an auto-
matic fold - back circuit that limits current to 35 amps
during 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 the
internal temperature senors detect temperatures
above normal limits. The unit should be allowed to
cool 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 will
be OFF when the pressure falls below 35 psi / 2.4
bar.
NOTE
Minimum pressure for power supply operation is
lower than minimum pressure for torch operation.
7. DC Indicator
Green indicator turns ON while the torch switch is
pressed.
C. Torch Bulkhead Panel
The torch bulkhead 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 Connector
Used to interface the Adapter (supplied with Power
Supply) to the Torch Leads Control Cable.
3. Negative / Plasma Lead Connection
Connects the torch negative / plasma lead to the unit.
D. Rear Panel
1. Gas Input
Input connection for air or nitrogen (N2) input.
WARNI NG
This unit not to be used with oxygen (O
2
).
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.
Manual 0-2746 4-3 OPERATION
3. Gas Pressure Regulator / Filter Assembly
Pressure regulator to adjust the input gas pressure to
the Power Supply. An air line filter is supplied as
part of the pressure regulator.
4. Optional Filters
a. Single - Stage Air Filter Assembly
An In - Line Air 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 -
Stage Air Filter
b. Two - Stage Air Line Filter
A Two Stage In - Line Air Filter for use on compressed
air shop systems. Filters moisture and particulate
matter 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
OPERATION 4-4 Manual 0-2746
4.03 Sequence of Operation
The following is a typical sequence of operation for this
cutting 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 front
panel of the Power Supply to ON.
a. AC Power indicator blinks ON and OFF for
eight 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 is
lower 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 LATCH
mode.
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc trans-
fer.
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.
11. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece, with torch
switch activated, the main arc will stop and the
pilot 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 arc
will immediately restart.
If torch is within 3/8 in / 9.5mm transfer distance
of 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 front
panel 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.
Manual 0-2746 4-5 OPERATION
4.04 Preparations for Operating
Follow this set - up procedure each time the system is
operated:
WARNI NG
Disconnect primary power at the source before dis-
assembling the power supply, torch, or torch leads.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate front
end 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 power
requirements 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 Selection
Select desired gas (air or nitrogen). Make sure gas source
meets pressure and flow requirements (refer to Section
3.08, Gas Connections). Check 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
connection to the work-
piece or cutting table
A-00925
Figure 4-7 Work Cable Connection To Workpiece
E. Torch Connection
Check that the torch is properly connected.
F. Power Supply On
Move the ON / OFF switch to ON position.
G. Select Output Current
Select 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 Pressure
Move the RUN / SET / LATCH switch to SET position.
Adjust the gas pressure to 60 -75 psi / 4.1 - 5.2 bar. Refer
to the Torch manual for specific pressure settings.
I. RUN / SET Switch
Set the RUN / SET / LATCH switch to RUN position.
The system is now ready for operation.
NOTE
For general cutting, use the RUN position which
provides normal touch operation where the torch
switch must be held throughout the main arc trans-
fer.
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.
OPERATION 4-6 Manual 0-2746
4.05 Cut Quality
Cut quality requirements differ depending on applica-
tion. For instance, nitride build - up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross - free cutting is important when finish cut
quality is desired to avoid a secondary cleaning opera-
tion.
The following cut quality characteristics are illustrated
in 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 plane
perpendicular 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 from
the 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 the
cut area and re - solidifies on the plate. Top spatter is
dross which accumulates on the top surface of the work-
piece. Excessive dross may require secondary clean - up
operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Build - 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 process.
Kerf Width
Cut Surface
Bevel Angle
Top Edge
Rounding
Cut Surface
Drag Lines
Dross
Build-Up
Top
Spatter
A-00007
Figure 4-8 Cut Quality Characteristics
Cut quality will vary on different types of material and
thicknesses.
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:
Type of M ater ial
Gas
Car bon
St eel
St ainless
St eel
Aluminum
Ai r
Good -
Ex c el l ent
Good -
Ex c el l ent
Good -
Ex c el l ent
Ni trogen Good Good Good
Description of Cut Characteristics
Excellent - Minimum bevel (0 - 4), minimum kerf (2 x
tip orifice diameter), little or no dross, smooth
cut surface.
Good - Slight bevel (0 - 10), slightly wider kerf (2-1/2 x
tip orifice diameter), some dross (easily re-
moved), medium - smooth cut surface, slight top
edge rounding.
Fair - Excessive bevel (over 10), wide kerf (over 2-1/2 x
tip orifice diameter), medium to heavy dross, rough
cut surface, top edge rounding.
NOTES
Cut quality depends heavily on set - up and pa-
rameters such as torch standoff, alignment with
the workpiece, cutting speed, gas pressures, and
operator ability.
Manual 0-2746 5-1 SERVICE
SECTION 5:
SERVICE
5.01 Introduction
This section describes basic maintenance procedures per-
formable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly
trained 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
WARNI NG
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
A. General Maintenance
To 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 should
also be wiped clean. If necessary, solvents recommended
for cleaning electrical apparatus may be used.
Refer to Appendix 3, Maintenance Schedule, for specific
procedures.
B. Filter / Regulator Element Replacement
The Filter / Regulator Assembly is on the rear panel. For
better system performance, the Filter / Regulator Assem-
bly filter element should be checked per the Maintenance
Schedule, and either cleaned or replaced.
1. Remove power from the power supply; 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 Regulator.
3. Grasp the filter element and unscrew it from the
Filter / Regulator body. The filter element will
come off with a spool and some additional pieces.
4. Note the correct assembly of the filter / spool then
remove the filter from the spool and either clean
it or replace it. See Section 6 for catalog number.
5. The filter element and spool, with the baffle ring
in place (teeth facing downward) can be screwed
back into the Regulator body by compressing the
spring on the spool. Tighten firmly by hand.
Regulator/Filter
Assembly
Spool
Bowl
Spring
Filter
Element
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 Element
Replacement
NOTE
The XL PLUS Power Supply shuts down automati-
cally when the Filter Element becomes completely
saturated. The Filter Element can be removed from
its housing, dried out, and reused. Allow 24 hours
for 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. See
Section 6 for replacement element catalog num-
ber.
SERVICE 5-2 Manual 0-2746
A-02476
Filter
Element
(Cat. No. 9-7741)
Housing
Cover
Barbed
Fitting
Spring
Assembled Filter
O-ring
Figure 5-2 Optional Single - Stage Air Filter
Replacement
3. Disconnect gas supply hose.
4. Turn the Cover counterclockwise and remove it
from the Filter Housing. The Filter Element is lo-
cated inside the housing.
5. Remove the Filter Element from the Housing and
set Element aside to dry.
6. Wipe inside of housing clean, then insert the re-
placement Filter Element cup side first, as shown
below.
7. Replace Housing on Cover.
8. Reattach gas supply hose.
NOTE
If unit leaks between housing and cover, inspect
the "O" Ring for cuts or other damage.
D. Optional Two - Stage Filter
Element Replacement
NOTES
These instructions apply to any power supply with
the optional Two - Stage Filter installed.
The Two - Stage Air 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 supply and bleed down system be-
fore changing Filter Elements.
WARNI NG
Always turn off the air supply and bleed the sys-
tem before disassembling the Filter Assembly as
injury could result.
3. Loosen the two bolts on the top of the Filter As-
sembly enough to allow the Filter Elements to
move freely.
First & Second
Stage
Cartridges
(as marked)
A-02942
Figure 5-3 Optional Two - Stage Filter Replacement
4. Note the location and orientation of the old Filter
Elements.
5. Slide out the old Filter Elements. See Section 6 for
replacement element catalog numbers.
6. Slide the replacement Filter Elements into the Fil-
ter Assembly, with the same orientation as noted
in Step 4 above.
7. Hand tighten the two bolts evenly, then torque
each bolt to 20 - 30 in-lbs / 2.3 - 3.4 Nm.
8. Slowly apply air pressure to the assembly, check-
ing for leaks.
Manual 0-2746 5-3 SERVICE
5.03 Common Operating Problems
WARNI NGS
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 equipped
with proper gloves, clothing, eye and ear protec-
tion. Make sure no part of the operators body comes
into contact with the workpiece while the torch is
activated.
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
Handle torch leads carefully 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. Whenever possible, avoid excessive
pilot arc time to improve parts life.
B. Torch Standoff
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield
cup life. Standoff may also significantly affect the bevel
angle. Reducing standoff will generally result in a more
square cut.
C. Edge Starting
For 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 starting
at the edge of the plate, do not pause at the edge and
force the arc to "reach" for the edge of the metal. Estab-
lish the cutting arc as quickly as possible.
D. Direction of Cut
In the torches, the 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, the right
side of the cut is more square than the left (Refer to Fig-
ure 5-2). To make a square - edged cut along an inside
diameter of a circle, the torch should move counterclock-
wise around the circle. To keep the square edge along an
outside diameter cut, the torch should travel in a clock-
wise direction.
Right Side
Cut Angle
Left Side
Cut Angle
A-00512
Figure 5-4 Side Characteristics Of Cut
E. Dross
Generally 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 along
the bottom of the cut edge and is very difficult to remove.
"Slow speed dross" will be in larger quantities but does
not adhere tightly to the cut edge and can be easily re-
moved.
When cutting a troublesome steel, it is suggested that the
torch travel speed be reduced to produce "slow speed
dross". Any required cleanup can then be done by scrap-
ping, not grinding.
Dross present on top of the plate (top spatter), is normally
caused by a slow torch travel speed or too high of a torch
standoff distance.
F. Common Cutting Faults
1. 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
f. Non - Genuine Thermal Dynamics parts used
SERVICE 5-4 Manual 0-2746
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
f. Non - Genuine Thermal Dynamics parts used
5.04 Troubleshooting Guide
A. General
Troubleshooting and repairing this unit should be under-
taken only by those familiar with high voltage high power
electronic equipment.
WARNI NG
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
B. Basic Troubleshooting
This manual covers a basic level of troubleshooting that
requires limited disassembly and measurements. It is
helpful for solving many of the common problems that
can arise with this system.
If major complex subassemblies are faulty, the unit must
be 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 Guide
The following information is a guide to help the Customer
/ Operator determine the most likely causes for various
symptoms.
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 that
unit 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 main
power panel
a. Check that input power is present and unit is
properly 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 replace
as required.
4. Actual input voltage does not correspond to voltage
selection 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 against
voltage selection (inside of unit) and replace
fuse 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 for
repair or have qualified technician repair per
Service Manual.
B. AC Power indicator ON; TEMP indicator ON
1. Airflow obstructed
a. Check for obstructed air flow and correct con-
dition.
Manual 0-2746 5-5 SERVICE
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.
5. Faulty components in unit
a. Return for repair or have qualified technician
repair 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.
4. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
D. No cutting output; AC Power indicator ON; Fans
operating
1. Torch not properly connected to power supply
a. Check that torch leads are properly attached
to power supply.
2. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against
torch head (do not overtighten if screwed on).
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
4. Faulty Torch
a. Return 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. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
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.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
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.
2. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
I. No gas flow; AC POWER indicator ON; Fans
operate
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.
3. Faulty components in unit
a. Return for repair or have qualified technician
repair per Service Manual.
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.
SERVICE 5-6 Manual 0-2746
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 torch
a. Hold torch 1/8 inch / 3 mm from clean sur-
face while purging and observe oil or moisture
buildup (do not activate torch).
5.05 Power Supply Parts
Replacement
WARNI NG
Disconnect primary power to the system before dis-
assembling the torch, leads, or power supply.
A. Left Side Panel Removal
1. Remove the screws which secure the left side
panel (viewed from front of unit) to the frame as-
sembly.
Ground
Wire
Screws
(5 places)
Left Side
Panel
A-02468
Figure 5-5 Left 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 away
from the unit to gain access to the inside of the
unit.
3. Reinstall the left side panel as follows:
a. Place the left side panel onto the frame and
slide the top edge under the lip on the top of
the right side panel.
b. Reinstall all the screws to secure the left side
panel.
B. Fuse Replacement
1. Remove the left side panel per paragraph "A"
above.
2. Locate the internal fuse above the input power
contactor 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-00919 Internal Fuse
0.8 Amps, 600V
Figure 5-6 Internal Fuse Location
Manual 0-2746 6-1 PARTS LISTS
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The 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. Returns
If a product must be returned for service, contact your
distributor. Materials returned without proper authori-
zation will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your autho-
rized distributor.
PARTS LISTS 6-2 Manual 0-2746
6.03 Complete Power Supply Replacement
Power supply includes: Work cable and clamp, pressure regulator / air filter, and operating manual.
Qty Description Catalog #
PAK MASTER 75XL PLUS Power Supply
1 208 / 230VAC, Single - Phase, With 50 Amp Input Plug and Cable 3-7556-1
1 460VAC, Three - Phase, Without Input Plug and Cable 3-7556-2
6.04 Replacement Parts
Qty Description Catalog #
1 Fuse (0.8 amp, 600V) 9-7526
1 220V Single - Phase Input Power Cable 9-7512
1 Filter / Regulator Assembly Replacement Element 9-4414
6.05 Options and Accessories
Qty 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 9-7741
1 Replacement Filter Hose (not shown) 9-7742
1 Two - Stage Air Line Filter Kit 7-7500
1 Dual Stage Air Filter Assembly 9-7527
1 Replacement First Stage Filter 9-1021
1 Replacement Second Stage Filter 9-1022
1 Bracket, Filter Mounting (not shown) 9-7535
Computer Control Cable (CNC)
1 25 Foot / 7.6 m 8-5557
1 50 Foot / 15.2 m 8-5558
Optional Single - Stage Air Line Filter Kit
A-02476
Filter
Element
(Cat. No. 9-7741)
Housing
Cover
Barbed
Fitting
Spring
Assembled Filter
O-ring
First & Second
Stage
Cartridges
(as marked)
A-02942
Optional Two - Stage Air Line Filter
Kit
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 8
230 50/60 12.5 11.3 54.1 28.3 70 35 4 8 4 8
240 50/60 12.6 11.4 52.3 27.5 60 35 6 8 6 8
380 50/60 13.9 12.4 36.5 18.9 45 25 8 10 8 10
415 50/60 13.9 12.6 33.4 17.5 40 25 8 12 8 12
460 50/60 13.9 12.7 30.1 16 35 25 8 12 8 12
575 Requi res Transformer Modul e
Li ne Voltages wi th Recommended Ci rcuit Protecti on and Wi re Si zes
(Based on Tabl e 310-16, 1987 National Electric Code) and Table 4, Canadian El ectrical 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 be
used 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 switch
to OFF
RESULT
All indicators off.
Power supply fans off.
ACTION
RUN/SET/LATCH
switch 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 external
disconnect 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 switch
to ON.
RESULT
AC indicator blinks for 8
seconds 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
ACTION
Torch Switch
can be released.
RESULT
Transfer will continue
until torch is removed
from workpiece.
APPENDIX 2: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
Manual 0-2746 A-3 APPENDIX
APPENDIX 3: MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts 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.
CAUTI ON
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere 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 f
f
1
2
West Lebanon, NH USA 03784
Made in USA
Model:
U1 1 1
1max 1eff I
I
U
2
3 3 1 1
S/N
U0
=
X
Standard Symbols

AC
DC
Phase
NOTES:
1. Symbol shown indicates single- or three-phase AC input,
static frequency converter-transformer-rectifier, DC output.
2. Indicates input voltages for this power supply. Most power
supplies carry a label at the input power cord showing input
voltage requirements for the power supply as built.
3. Top row: Duty cycle 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 Voltage
Plasma Cutting
Symbol
Manufacturer's Name and/or
Logo, Location, Model and
Revision Level, Serial Number
and Production Code
Conventional
Load Voltage
Regulatory Standard Covering
This Type of Power Supply
Duty Cycle Data (Note 3)
Duty Cycle Factor
Input Power
Specifications
(Phase, AC or DC
Hertz Rating)
Input Power
Symbol
Rated Supply
Voltage (Note 2)
Rated Maximum
Supply Current
Maximum Effective
Supply Current
Degree of Protection
Manufacturer's Electrical
Schematic File Number
and Revision Level
Manual 0-2746 A-5 APPENDIX
This page left blank.
APPENDIX A-6 Manual 0-2746
A-02503
APPENDIX 5: SYSTEM SCHEMATIC
Manual 0-2746 A-7 APPENDIX
A-02503