Tweco CE PAK Master 150XL Without Latch Circuit Manuel d'utilisateur

December 21, 2004 Manual No. 0-2696Operating ManualPLASMA CUTTINGPOWER SUPPLYPAK Master® 150XL™Without Latch CircuitTMTMA-02072

GENERAL INFORMATION 1-4 Date: January 27, 2004• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fum

Date: January 27, 2004 1-5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous p

GENERAL INFORMATION 1-6 Date: January 27, 20049. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection As

Date: January 27, 2004 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest

GENERAL INFORMATION 1-8 Date: January 27, 20041.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warr

Manual 0-2696 2-1 INTRODUCTIONSECTION 2:INTRODUCTION2.01 Scope of ManualThis manual contains descriptions, operating instructionsand basic maintenanc

INTRODUCTION 2-2 Manual 0-26962.03 Specifications/DesignFeaturesA. Power Supply SpecificationsThe following specifications apply to the Power Supplyon

Manual 0-2696 2-3 INTRODUCTIONB. Gas Regulator/Filter AssemblySpecificationsThe following specifications apply to the Gas Regulator/Filter Assembly on

INTRODUCTION 2-4 Manual 0-2696G. Remote Pendant ControlNOTEAccessory is for use with Unshielded PCM Torch& Leads.Control used to manually start an

Manual 0-2696 3-1 INSTALLATIONSECTION 3:INSTALLATION3.01 IntroductionNOTEDepending on how the system was ordered, somePower Supply options may already

INSTALLATION 3-2 Manual 0-26963.05 Input Power ConnectionsThe Power Supply accepts input voltages in ranges from 208/230/460 VAC or 220/380-415 VAC, 5

Manual 0-2696 3-3 INSTALLATIONPower supplies are factory-wired for HIGH VOLTAGE, either460VAC or 380-415VAC, as ordered. Voltage can be changedfrom H

INSTALLATION 3-4 Manual 0-26963.07 Input Power CableConnectionsWARNINGDisconnect primary power at the source before con-necting the primary power cabl

Manual 0-2696 3-5 INSTALLATION3.08 Gas ConnectionsThe Power Supply provides the liquid cooling and gasesto support operation of the Torch.NOTERefer to

INSTALLATION 3-6 Manual 0-2696B. Using Shop Air Only with Optional TwoStage Filter AssemblyNOTEFor units where the Optional Two Stage Air LineFilter h

Manual 0-2696 3-7 INSTALLATIONA-02948T-FittingGas RegulatorSupply Hose1/4 NPT - Inert B, R.HFittingFigure 3-8 Connection Using Single Gas Cylinder• U

INSTALLATION 3-8 Manual 0-26963. Connect the SECONDARY gas supply to the rear of thePower Supply as follows:a. Remove the factory installed plug fitti

Manual 0-2696 3-9 INSTALLATION2. Connect the SECONDARY gas supply to the rear of thePower Supply as follows:a. Remove the Secondary Hose from the Iner

INSTALLATION 3-10 Manual 0-2696A. Hand SystemsConnect the Hand Torch to the Power Supply as follows:1. Open the Access Panel to gain access to the Tor

Manual 0-2696 3-11 INSTALLATIONA-02950SecondaryGasPlasma (+)GasRemote HandPendant ControlCableCoolantReturnCoolantSupply (-)Control CableConnectorFigu

Record the following information for Warranty purposes:Where Purchased: _______________________________________Purchase Date: ________________________

INSTALLATION 3-12 Manual 0-26967. Connect torch coolant and gas leads to connectors onthe Torch Bulkhead Panel.8. Close the Access Panel and turn the

Manual 0-2696 3-13 INSTALLATIONC. Creating An Earth Ground1. To create a solid, low resistance, earth ground, drive a1/2 in (12 mm) or greater diamete

INSTALLATION 3-14 Manual 0-2696D. Routing Of Torch Leads1. To minimize RF interference, position torch leads as far aspossible from any CNC components

Manual 0-2696 4-1 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis section provides a description of the Power Supplyoperating controls and procedure

OPERATION 4-2 Manual 0-26963. RUN/SET SwitchRUN position is used for torch operation. SET po-sition used for setting gas pressure and purginglines.4.

Manual 0-2696 4-3 OPERATIONA-0211035142Figure 4-4 Rear Panel3. Secondary Gas Pressure Regulator/Filter Assem-blyPressure Regulator to adjust the seco

OPERATION 4-4 Manual 0-26964.03 Sequence of OperationThe following is a typical sequence of operation for thiscutting system. Refer to Appendix 2 for

Manual 0-2696 4-5 OPERATIONB. Deionizer Bag InspectionCheck the condition of the deionizer bag in the reservoirbasket. If the bag is a yellowish brow

OPERATION 4-6 Manual 0-2696Rounding on the top edge of a cut due to wearing from theinitial contact of the plasma arc on the workpiece.Dross Build-up

Manual 0-2696 4-7 OPERATION4.06 System OperationNOTEFrequently review the safety precautions at the frontof this manual.This section contains operatin

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.

OPERATION 4-8 Manual 0-2696Select the desired function as shown in the following chart:High/Low Speed Auto-Restart FunctionSpeed SW5-1 SW5-2High 0 (OF

Manual 0-2696 5-1 SERVICESECTION 5:SERVICE5.01 IntroductionThis section describes maintenance procedures, basic trouble-shooting and service performa

SERVICE 5-2 Manual 0-2696D. In-Line Coolant Filter Assembly CleaningThe In-line Coolant Filter Screen should be cleaned periodi-cally. To gain acces

Manual 0-2696 5-3 SERVICE5.03 Common Operating FaultsListed below are common cutting problems followed by prob-able causes of each. If the problems a

SERVICE 5-4 Manual 0-2696C. Edge StartingFor edge starts, hold the torch perpendicular to the workpiecewith the front of the tip at the edge of the w

Manual 0-2696 5-5 SERVICE3. Actual input voltage does not correspond to voltageselection inside unita. Check actual line voltage vs. voltage selectio

SERVICE 5-6 Manual 0-2696H. AC POWER Indicator ON; Fans operate; No gas flow1. Gas not connected or pressure too lowa. Check source for at least 100

Manual 0-2696 5-7 SERVICE5.06 Power Supply PartsReplacementWARNINGDisconnect primary power to the system before dis-assembling the torch, leads, or p

SERVICE 5-8 Manual 0-2696C. Coolant Filter Assembly ReplacementThe Coolant Filter Assembly is located inside the Power Sup-ply behind the Right Side

Manual 0-2696 6-1 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provide a breakdown of all replaceable com-po

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

PARTS LISTS 6-2 Manual 0-26966.03 System ReplacementIncludes the following components: Power Supply with Work Cable and Clamp, Torch and Leads (as or

Manual 0-2696 6-3 PARTS LISTS6.05 Basic Replacement PartsQty Description Catalog #1 Fuse, 5 Amp, 600V, Delay 10-22741 In-Line Coolant Filter 8-34601 C

PARTS LISTS 6-4 Manual 0-2696

Manual 0-2696 A-1 APPENDIXAPPENDIX 1: INPUT WIRING REQUIREMENTSNOTESRefer to Local and National Codes or local authority having jurisdiction for prop

APPENDIX A-2 Manual 0-2696APPENDIX 2: SEQUENCE OF OPERATION BLOCKDIAGRAMACTIONON/OFF switchto OFFRESULTAll indicators off.Power supply fans off.ACTI

Manual 0-2696 A-3 APPENDIXAPPENDIX 3: GROUNDING DIAGRAMEarthGroundPowerSupplyWork CableWorkpiece3-PhaseInputA-02183EarthGroundNOTEWork Cable must con

APPENDIX A-4 Manual 0-2696APPENDIX 4: ROUTINE MAINTENANCE SCHEDULEThis schedule applies to all types of liquid cooled plasma cutting systems. Some s

Manual 0-2696 A-5 APPENDIXAPPENDIX 5: POWER SUPPLY CNC INTERFACE DIAGRAMA-02259Start Motion(OK-To-Move)J223410111214RedBlackBlueOrangeWhiteGreenSourc

APPENDIX A-6 Manual 0-2696APPENDIX 6: SCHEMATIC DIAGRAMArt # A-04328

Manual 0-2696 A-7 APPENDIXArt # A-04328

Date: January 27, 2004 1-1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions,

GENERAL INFORMATION 1-2 Date: January 27, 2004• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcirc

Date: January 27, 2004 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from Am