Tweco 75XL Plus PAK Master Manuel d'utilisateur

June 26, 2003 Manual No. 0-2807Operating ManualA-02751Automated PlasmaCutting Power SupplyPak Master 75XL Plus

GENERAL INFORMATION 1-4 Date: November 15, 2001• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fu

Date: November 15, 2001 1-5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous

GENERAL INFORMATION 1-6 Date: November 15, 20019. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection A

Date: November 15, 2001 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest

GENERAL INFORMATION 1-8 Date: November 15, 20011.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) war

Manual 0-2807 2-1 INTRODUCTIONSECTION 2:INTRODUCTION2.01 Scope of ManualThis manual contains descriptions, operating instructionsand basic maintenance

INTRODUCTION 2-2 Manual 0-28076. Duty Cycle (Refer to NOTE)NOTEThe duty cycle will be reduced if the primary in-put voltage (AC) is low or the DC volt

Manual 0-2807 2-3 INTRODUCTION2.04 Power Supply Options andAccessoriesNOTERefer to Section 6, Parts Lists, for part numbersand ordering information.Th

INTRODUCTION 2-4 Manual 0-2807

Manual 0-2807 3-1 INSTALLATIONSECTION 3:INSTALLATION3.01 IntroductionNOTEDepending on how the system was ordered, somePower Supply Options may alread

INSTALLATION 3-2 Manual 0-28073.04 Lifting OptionsWARNINGSDo not touch live electrical parts.Disconnect input power conductors from de-ener-gized supp

Manual 0-2807 3-3 INSTALLATION3.06 Input Voltage SelectionNOTEFor power supplies to use 575 VAC input power,the unit must be setup for 460V three-phas

INSTALLATION 3-4 Manual 0-2807NOTEThe jumper wire from L1 to L4 must not be re-moved.L1L2L3Conjoncteur de Puissance d'entréeCâble De Puissance D&

Manual 0-2807 3-5 INSTALLATIONB. Checking Air QualityTo test the quality of air, place the RUN/SET/LATCHswitch to SET position, place a welding filter

INSTALLATION 3-6 Manual 0-2807CAUTIONPressure should be set at 100 psi (6.9 bar) at thehigh pressure gas cylinder regulator.• Refer to the manufacture

Manual 0-2807 3-7 INSTALLATIONA. PCM-102 Torch Installation1. Remove the retaining nut from the Strain Relief.Strain ReliefNutStrain ReliefTorch Leads

INSTALLATION 3-8 Manual 0-28075. Remove the top nut and washer from the PilotStud.6. Connect the pilot lead terminal to the stud andsecure with the nu

Manual 0-2807 3-9 INSTALLATION5. Make sure work cable and ground cables are prop-erly connected. The work cable must have a solidconnection to the cu

INSTALLATION 3-10 Manual 0-28073.11 Tip Saver/Drag Cut SensingCircuitThis power supply is equipped with a Tip Saver/DragCut Sensing Circuit which cuts

Manual 0-2807 3-11 INSTALLATIONCNC KnockoutA-02756Rear Panel1/2" (12.7 mm)Strain Relief(Customer Supplied)Figure 3-13 Rear Panel Knockout Locati

WARNINGSRead and understand this entire Manual and your employer’s safety prac-tices before installing, operating, or servicing the equipment.While th

INSTALLATION 3-12 Manual 0-2807ARC V. START OK TOMOVE+123456-+-A-02754Figure 3-16 Terminal Block PositionsNOTESARC V+ Power supply positive output vo

Manual 0-2807 4-1 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis Section provides a description of the Power Supplyoperating controls and procedure

OPERATION 4-2 Manual 0-28073. RUN /SET /LATCH Switch (See Note)RUN position is used for torch operation. SET posi-tion used for setting gas

Manual 0-2807 4-3 OPERATIOND. Rear Panel1. Gas InputInput connection for air or nitrogen (N2) input.WARNINGThis unit not to be used with oxygen (O2).A

OPERATION 4-4 Manual 0-28074.03 Sequence of OperationThe following is a typical sequence of operation for thiscutting system. Refer to Appendix II fo

Manual 0-2807 4-5 OPERATION4.04 Preparations for OperatingFollow this set-up procedure each time the system is op-erated:WARNINGDisconnect primary pow

OPERATION 4-6 Manual 0-2807Nitride Build-upNitride deposits which may remain on the surface of thecut when nitrogen is present in the plasma gas strea

Manual 0-2807 5-1 SERVICESECTION 5:SERVICE5.01 IntroductionThis section describes basic maintenance procedures per-formable by operating personnel. N

SERVICE 5-2 Manual 0-2807C. Optional Single-stage Filter ElementReplacementNOTEThe Power Supply shuts down automatically whenthe Filter Element become

Manual 0-2807 5-3 SERVICEure 5-2). To make a square-edged cut along an inside di-ameter of a circle, the torch should move counterclock-wise around th

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.01

SERVICE 5-4 Manual 0-28075.04 Troubleshooting GuideA. GeneralTroubleshooting and repairing this unit is a process whichshould be undertaken only by th

Manual 0-2807 5-5 SERVICEC. Torch will not pilot when torch is activated (handpendant or CNC start signal)1. RUN/SET/LATCH switch in SET positiona. Mo

SERVICE 5-6 Manual 0-28075.05 Power Supply PartsReplacementWARNINGDisconnect primary power to the system before dis-assembling the torch, leads, or po

Manual 0-2807 6-1 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provide a breakdown of all replaceable com-

PARTS LISTS 6-2 Manual 0-28076.03 Complete Power Supply ReplacementPower supply includes: Work cable and ring terminal, pressure regulator/air filte

Manual 0-2807 A-1 APPENDIXAPPENDIX I: INPUT WIRING REQUIREMENTSNOTESThe table above is based on the following output current and voltage: 130VDC @ 6

APPENDIX A-2 Manual 0-2807APPENDIX II: SEQUENCE OF OPERATION(BLOCK DIAGRAM)ACTIONON/OFF switchto OFFRESULTAll indicators off.Power supply fans off.A

Manual 0-2807 A-3 APPENDIXAPPENDIX III: POWER SUPPLY CNC INTERFACEDIAGRAMNOTECable connections from Cutting Machine Controller (CNC) to Plasma Power

APPENDIX A-4 Manual 0-2807APPENDIX IV: DATA TAG INFORMATION1/3ff12West Lebanon, NH USA 03784Made in USAModel:U1111max 1effIIU23Ø3Ø1Ø1ØS/NU0=XStanda

Manual 0-2807 A-5 APPENDIXThis page left blank.

TABLE OF CONTENTS (continued)SECTION 5:SERVICE ...

APPENDIX A-6 Manual 0-2807APPENDIX V: SYSTEM SCHEMATICA-02755

Manual 0-2807 A-7 APPENDIXA-02755

Date: November 15, 2001 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions,

GENERAL INFORMATION 1-2 Date: November 15, 2001• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcir

Date: November 15, 2001 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from A