ESAB Plasma Cutting Power Supply CE PAKMaster© 75 XLTM Plus User manual

Brand: ESAB

Model: Plasma Cutting Power Supply CE PAKMaster© 75 XLTM Plus

Category: Welding System

Type: User manual

July 7, 2003 Manual No. 0-2782

Operating Manual

Plasma Cutting

Power Supply

CE PAKMaster

75 XL

Plus

A-02464

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Plasma Cutting Power Supply

CE Pak Master

75XL

Plus

Service Manual Number 0-2782

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

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 7, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:____________________________________

WARNINGS

Read and understand this entire Manual and your employer’s 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

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference ............................................................................ 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty.................................................................................. 1-8

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 Cable Connections ................................................................... 3-2

3.06 Gas Connections ......................................................................................... 3-2

3.07 Connecting Torch Leads............................................................................... 3-4

3.08 Ground Connections For Mechanized Applications ...................................... 3-9

3.09 Tip Saver/Drag 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 ................................................................................ 4-3

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 w(BLOCK DIAGRAM).......................................A-2

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................A-3

APPENDIX 4: DATA TAG INFORMATION .................................................................................A-4

APPENDIX 5: SYSTEM SCHEMATIC.......................................................................................A-6

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Date: November 15, 2001 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.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

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

WARNINGS

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. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional 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 in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

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,

produces 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 Date: November 15, 2001

• 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, Publica-

tions.

• Disconnect power source before performing any

service 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 ma-

terial 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 under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. 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 work-

piece.

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 Docu-

ments, 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. Govern-

ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 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

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

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GENERAL INFORMATION 1-6 Date: November 15, 2001

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA

SÉCURITÉ DU SOUDAGE, disponible auprès de

l’Association Nationale de Fournitures de Soudage

(National Welding Supply Association), 1900 Arch

Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 1-7 GENERAL INFORMATION

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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-

pean Council Directive 89/336/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.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the

mark conform to EN50192

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* 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

GENERAL INFORMATION 1-8 Date: November 15, 2001

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics

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

workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

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

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges

to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the

customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

Manual 0-2782 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 (CE). Ser-

vice of this equipment is restricted to properly trained

personnel; 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 (CE) System includes a power supply,

torch & leads and work cable & clamp, and input power

cable.

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,

work cable with clamp, and input power cable.

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

Pak Master 75XL PLUS (CE) System

The system provides a maximum 1 inch (25.4 mm) cut

capacity. Torch heads are available in various configura-

tions. Torch leads are available in various lengths with

fittings for simple installation. Spare Parts Kits are avail-

able for the torches which provide an assortment of re-

placement 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

2. Front Panel Indicators

AC , TEMP , GAS , DC

3. Rear Panel

Input Power Cable, Gas Connection, Gas Regulator/

Filter Assembly

4. Input Power

380/415 VAC (±10%), 50/60 Hz, Three-Phase

Supplied with a 10 ft. (3.1 m) 4-Conductor Input

Power Cable with filtering beads.

5. Output Power

Continuously variable from 15 to 60 Amps maximum

6. Duty Cycle (see NOTE)

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

Tem

erature

104° F

(40° C)

104° F

(40° C)

Duty Cycle

65% 100%

Current

60 Amps 50 Amps

DC Voltage

104 vdc 104 vdc

Power Supply Duty Cycle

7. Cut Capacity (Mild Steel)

3/4 inch (19.1 mm); 1 inch (25.4 mm) severance

INTRODUCTION 2-2 Manual 0-2782

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. Weight

71 lbs (32 kg) withwork lead, input power cable

78 lbs (35.4 kg) withwork lead, torch & lead, input power

cable

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 installed.

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 part numbers

and ordering information

A. Single Stage Air Line Filter Kit

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 mat-

ter 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. 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 signals.

F. Remote Hand Pendant Control

The remote hand pendant control is available with a

20 ft. (6.1 m) cable. An extension cable of 25 ft. (7.6 m)

can be added to the standard hand pendant control to

produce a total length of 50 ft. (15.2 m).

G. Cutting Guide Kit

Easy add-on attachments to allow for straight line,

circle, or bevel cutting.

H. Standoff Cutting Guide

Simple, push-on guide attachment to allow for torch

dragging without risk of touching tip.

Manual 0-2782 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 information.

This section describes installation of the Power Supply

and connecting the Torch.

These instructions apply to the Power Supply only; instal-

lation procedures for the Torch, Options, and Accessories

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 . Pro-

vide sufficient clearance in front of the unit to allow ac-

cess to the front panel controls (minimum 6 inches or 150

mm).

CAUTION

Operation without proper air flow will inhibit

proper cooling and reduce duty cycle.

3.03 Unpacking

Each component of the system is 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

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-ener-

gized supply line before moving unit.

FALLING EQUIPMENT 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.

WARNING

HANDLE is not for mechanical lifting.

INSTALLATION 3-2 Manual 0-2782

3.05 Input Power Cable Connections

The 75XL PLUS Power Supply operates on three phase,

380-415 VAC ± 10% 50/60 Hz input.

CAUTION

The primary power source, power cable, and plug

must all conform to local electric code and the rec-

ommended circuit protection and wiring require-

ments (refer to Appendix 1).

The Power Supply is supplied with a three-phase, four

conductor, input EMC power Cable attached. Connect

the supplied input EMC power cable to the customer's

power source per the following procedure:

NOTE

The input power cable must not be modified in any

way as filtering beads are installed onthe cable.

1. Strip back the outer covering approximately 3

inches (76 mm) to expose the individual wires at

the free end of the cable.

2. Cut back the insulation on the individual wires

approximately 1/8 - 3/16 inch (3-5 mm).

3. Connect the ends of the individual wires a cus-

tomer supplied plug or main disconnect per the

following:

NOTE

All the input cable wires must be connected for

three-phase operation.

• Blue wire to Line 2 (Live)

• Black wire to Line 3 (Live), refer to Note above

• Brown wire to Line 1 (Live)

• Green/Yellow wire to Ground (Earth)

3.06 Gas Connections

A. Gas Requirements

WARNING

This unit not to be used with oxygen (O

Gases: Compressed Air or Nitrogen (N2) Only

Pressure: 60 - 75 psi (4.1 - 5.2 bar)

CAUTION

Maximum input gas pressure must not exceed 125

psi (8.6 bar)

Flow: Cutting - 300 scfh standard cubic feet/hour(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!

CAUTION

The air supply must be free of moisture, and other

contaminants. Excessive moisture may cause

double-arcing, rapid tip wear, or even complete

torch failure. Contaminants may cause poor cut-

ting performance and rapid electrode wear.

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 illustrated. Typical fittings are

shown as examples. Other fittings may be used.

1. If an optional air line filter is to be installed, refer to

subsection D.

NOTE

Filtering is required when using air from a com-

pressor to ensure that moisture and debris from the

supply hose does not enter the torch. It is recom-

mended to order the optional

Manual 0-2782 3-3 INSTALLATION

Regulator/Filter

Assembly

1/4 NPT to #4 (6 mm) Hose

Fitting

#4 (6 mm) Gas

Supply Hose

Hose Clamp

A-01149

Figure 3-1 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

Filter or optional Two Stage Air Line Filter be installed

for improved filtering. Gas connections to optional fil-

ters are shown in Figures 3-2 and 3-3.

Single-Stage Air Filter Kit or Two Stage Filter Kit As-

sembly

A-02607

1/4 NPT to #4 (6mm)

Hose Fitting

Air Line Filter

Assembly

#4 (6mm) Gas

Supply Hose

Hose Clamp

Figure 3-2 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-01150

Figure 3-3 Gas Connection To Optional Two Stage

Filter Assembly

INSTALLATION 3-4 Manual 0-2782

E. Using High Pressure Gas Cylinders

1. Refer to the following when using high pressure gas

cylinders as the gas supply:

CAUTION

Pressure should be set at 100 psi (6.9 bar) at the

high pressure gas cylinder regulator.

a. Refer to the manufacturer’s 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 pressures

up to 100 psi (6.9 bar) maximum and flows of up

to 300 scfh (141.5 lpm).

NOTE

Supply hose must be at least #4 hose (1/4 in or 6

mm I.D.).

3.07 Connecting Torch Leads

CAUTION

This system is designed for use with the PCH/M-

102, SL60, or SL100 torches 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.

A. Hand Systems

WARNING

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 3-4 Front Access Panel

2. Lift the access panel to gain access to the torch

bulkhead panel.

3. Remove the securing nut from the strain relief sup-

plied on the end of the Torch Leads.

NOTE

The leads may include a pair of wires connected

together and covered with an insulating sleeve.

These wires must remain connected and insulated.

Manual 0-2782 3-5 INSTALLATION

Retaining Nut

Strain Relief

Torch Leads

Assembly

A-02836

Figure 3-5a Torch Strain Relief Nut (Leads with

Two Control Wires)

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-03607

Negative /

Plasma Lead

Pilot Lead

Figure 3-5b Torch Strain Relief Nut (Leads with

Four Control Wires)

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

(Supplied With

Power Supply)

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma Lead

Connection

A-02825

Control (PIP) Circuit

Connectors

Figure 3-6a Torch Lead Connections (Leads with

Two Control Wires)

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma

Lead Connection

A-03608

Note: Actual Bulkhead

configuration may

differ from that shown.

Adapter

Control Circuit

Connectors

Figure 3-6b Torch Lead Connections (Leads with

Four Control Wires)

7. Connect the Control Cables to the mating connec-

tors on the Adapter supplied on the Power Sup-

ply.

INSTALLATION 3-6 Manual 0-2782

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 onto the Torch Leads.

11. Check the torch for proper parts assembly.

12. Close the access panel and turn the latching screw.

B. Machine Systems (PCM-62 Torch with

Unshielded Leads)

WARNING

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 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-02827

Figure 3-7 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 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 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-02828

Control (PIP) Circuit

Connectors

Shield Connectors

(Not Used)

Remote

Cable

Connector

Figure 3-8 Torch Lead Connections

5. Connect the torch Negative/Plasma Lead to the

bulkhead connection inside the Power Supply.

6. Connect the Control (PIP) Circuit Connectors to

the mating connectors on the Adapter supplied on

the Power Supply (see Warning).

WARNING

The Adapter supplied with the Power Supply has

two additional Shield Connectors that are used for

Shielded Systems only. These two connectors are

not used and need to be taped out of the way to

prevent contacting the Negative/Plasma or Pilot

Leads.

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 onto the Torch Leads.

Manual 0-2782 3-7 INSTALLATION

10. Check the torch for proper parts assembly.

11. Close the access panel and turn the latching screw.

C. Machine Systems (PCM-62 Torch with

Shielded Leads)

WARNING

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 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 3-9 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 3-10 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 onto the Torch Leads.

10. Check the torch for proper parts assembly.

11. Close the access panel and turn the latching screw.

INSTALLATION 3-8 Manual 0-2782

D. Machine Systems (SL100 Torch)

Torches with O2B connectors connect directly to the

power supply bulkhead. Mechanized torch leads with

O2B connectors require a remote pendant adapter to ac-

cept a remote pendant.

WARNING

Disconnect primary power at the source before dis-

assembling the torch or torch leads.

1. Remove the Strain Relief Nut from the Strain Re-

lief.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly or ATC Adapter

A-03530

Remove Tie Wrap,

Remove Insulator,

Disconnect Wires

Strain Relief Nut Removal

2. The leads Assembly includes two wires joined with

mating connectors and covered with an insulat-

ing sleeve. Remove the tie wrap and insulating

sleeve. Disconnect the two joined wires.

3. Feed the end of the torch leads and the Strain Re-

lief into the hole in the unit.

4. Route the wire harness on the Remote Pendant

Adapter through the Strain Relief and Strain Re-

lief Nut. Tighten the Strain Relief Nut to secure

the Strain Relief to the Power Supply.

5. Connect the Negative / Plasma lead to the bulk-

head connection inside the power supply.

6. Connect the control circuit connectors on the Torch

Leads to the mating connectors on the Remote

Pendant Adapter and Power Supply Adapter (see

Warning).

WARNING

There are two additional connectors that are not

used and must be taped out of the way to prevent

contacting the Negative / Plasma or Pilot Leads.

7. Remove the top nut and washer from the Pilot Stud

on the power supply bulkhead.

8. Place the Torch Leads Pilot lead terminal on onto

the stud and secure with the nut and washer re-

moved in the above Step.

A-03675

Torch Lead

Assembly

Control Circuit

Connectors

Open

Power Supply

Adapter

Pilot Lead

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma

Lead Connection

Note: Actual Bulkhead

configuration may

differ from that shown.

Remote Pendant

Adapter Wire Harness

Bulkhead Connection - Unshielded Machine Torch

with O2B Fittings and Remote Pendant Adapter

9. Connect the Torch Leads connectors and the re-

mote pendant adapter connector to the power sup-

ply adapter as shown.

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Brand: ESAB

Category: Welding System

Type: User manual

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ESAB Plasma Cutting Power Supply CE PAKMaster© 75 XLTM Plus User manual

ESAB Plasma Cutting Power Supply CE PAKMaster© 75 XLTM Plus User manual

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