PAK MASTER 100XL

Air Plasma Cutting Power Supply (CE)

A-01355

Operating Manual
December 16, 1998 Manual No. 0-2611

WARNING

Read and understand this entire Operating Manual and your employers safety practices before installing, operating, or servicing the equipment.

WARNING

While the information contained in this Operating Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Pak Master 100XL Air Plasma Cutting Power Supply (CE) Operating Manual Number 0-2611 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 Copyright 1997 by Thermal Dynamics Corporation All rights reserved. Reproduction of this work, in whole or in part, without written permission 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 the Pak Master 100XL Air Plasma Cutting Power Supply (CE)Operating Manual, whether such error results from negligence, accident, or any other cause. Printed in the United States of America December 16, 1998

TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION .................................................................................................. 1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... 1 Important Safety Precautions ........................................................................ 1 Publications ................................................................................................... 2 Note, Attention et Avertissement ................................................................... 3 Precautions De Securite Importantes ........................................................... 3 Documents De Reference ............................................................................. 5 Declaration of Conformity .............................................................................. 6 Statement of Warranty .................................................................................. 7

SECTION 2: INTRODUCTION ................................................................................................................. 9 2.01 2.02 2.03 2.04 Scope of Manual ........................................................................................... 9 General Description ...................................................................................... 9 Specifications/Design Features ..................................................................... 9 Power Supply Options and Accessories ...................................................... 10

SECTION 3: INSTALLATION PROCEDURES ........................................................................................ 11 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10 Introduction ................................................................................................. 11 Site Selection .............................................................................................. 11 Unpacking ................................................................................................... 11 Lifting Options ............................................................................................. 12 Input Power Connections ............................................................................ 12 Input Voltage Selection ................................................................................ 13 Input Power Cable Connections .................................................................. 13 Gas Connections ......................................................................................... 14 Connecting Torch Leads .............................................................................. 15 Work Cable And Ground Connections ......................................................... 16

SECTION 4: OPERATION ...................................................................................................................... 19 4.01 4.02 4.03 4.04 4.05 4.06 Introduction ................................................................................................. 19 Functional Overview .................................................................................... 19 Operating Controls ...................................................................................... 19 Sequence Of Operation .............................................................................. 21 Preparations for Operating .......................................................................... 22 Cut Quality .................................................................................................. 22

SECTION 5: CUSTOMER/OPERATOR SERVICE ................................................................................. 25 5.01 5.02 5.03 5.04 5.05 Introduction ................................................................................................. 25 General Maintenance .................................................................................. 25 Common Operating Problems ..................................................................... 25 Troubleshooting Guide ................................................................................. 26 Power Supply Parts Replacement ............................................................... 28

TABLE OF CONTENTS (continued)

SECTION 6: PARTS LISTS .................................................................................................................... 31 6.01 6.02 6.03 6.04 Introduction ................................................................................................. 31 Ordering Information ................................................................................... 31 Complete Power Supply Replacement ........................................................ 32 Options and Accessories ............................................................................ 32

APPENDIX I: INPUT WIRING REQUIREMENTS ..................................................................... 33 APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) .......................................... 34 APPENDIX III: SYSTEM SCHEMATIC ..................................................................................... 36

SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.

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 metals which may contain one or more of the following: Antimony Arsenic Barium Beryllium Cadmium Chromium Cobalt Copper Lead Manganese Mercury Nickel Selenium Silver 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 information 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 combustible 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. ELECTRIC SHOCK

WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

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 operator or others in the workplace. Never touch any parts that are electrically live or hot. 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.

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.

Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. Disconnect power source before performing any service or repairs. Read and follow all the instructions in the Operating Manual.

GENERAL INFORMATION

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 material 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 underwater 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 dissipated. Trapped hydrogen gas that is ignited will cause an explosion. NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace. Noise levels should be measured to be sure the decibels (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 helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. Wear welding gloves and suitable clothing to protect 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 recommended in Subsection 1.03, item 4.

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 Society, 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 OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MENS SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable 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 PROCESSES, 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 Association, Batterymarch Park, Quincy, MA 02269 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

GENERAL INFORMATION

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING 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 Association, 1900 Arch Street, Philadelphia, PA 19103 14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS 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

1.05 Precautions De Securite Importantes

AVERTISSEMENT LOPRATION ET LA MAINTENANCE DU MATRIEL DE SOUDAGE LARC AU JET DE PLASMA PEUVENT PRSENTER DES RISQUES ET DES DANGERS DE SANT. Il faut communiquer aux oprateurs et au personnel TOUS les dangers possibles. Afin dviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les prcautions de scurit et toutes les consignes avant dutiliser le matriel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots note, attention, et avertissement sont utiliss pour mettre en relief des informations caractre important. Ces mises en relief sont classifies comme suit : NOTE Toute opration, procdure ou renseignement gnral sur lequel il importe dinsister davantage ou qui contribue lefficacit de fonctionnement du systme. ATTENTION Toute procdure pouvant rsulter lendommagement du matriel en cas de nonrespect de la procdure en question.

FUME et GAZ La fume et les gaz produits par le procd de jet de plasma peuvent prsenter des risques et des dangers de sant. Eloignez toute fume et gaz de votre zone de respiration. Gardez votre tte hors de la plume de fume provenant du chalumeau. Utilisez un appareil respiratoire alimentation en air si laration fournie ne permet pas dliminer la fume et les gaz. Les sortes de gaz et de fume provenant de larc de plasma dpendent du genre de mtal utilis, des revtements se trouvant sur le mtal et des diffrents procds. Vous devez prendre soin lorsque vous coupez ou soudez tout mtal pouvant contenir un ou plusieurs des lments suivants: antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre slnium bryllium manganse vanadium Lisez toujours les fiches de donnes sur la scurit des matires (sigle amricain MSDS); celles-ci devraient tre fournies avec le matriel que vous utilisez. Les MSDS contiennent des renseignements quant la quantit et la nature de la fume et des gaz pouvant poser des dangers de sant. Pour des informations sur la manire de tester la fume et les gaz de votre lieu de travail, consultez larticle 1 et les documents cits la page 5.

AVERTISSEMENT Toute procdure pouvant provoquer des blessures de loprateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procdure en question.

GENERAL INFORMATION

 Utilisez un quipement spcial tel que des tables de coupe dbit deau ou courant descendant pour capter la fume et les gaz. Nutilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des matires ou des gaz combustibles ou explosifs. Le phosgne, un gaz toxique, est gnr par la fume provenant des solvants et des produits de nettoyage chlors. Eliminez toute source de telle fume. CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou mme tuer. Le procd au jet de plasma requiert et produit de lnergie lectrique haute tension. Cette nergie lectrique peut produire des chocs graves, voire mortels, pour loprateur et les autres personnes sur le lieu de travail. Ne touchez jamais une pice sous tension ou vive; portez des gants et des vtements secs. Isolez-vous de la pice de travail ou des autres parties du circuit de soudage. Rparez ou remplacez toute pice use ou endommage. Prenez des soins particuliers lorsque la zone de travail est humide ou moite. Montez et maintenez le matriel conformment au Code lectrique national des Etats-Unis. (Voir la page 5, article 9.) Dbranchez lalimentation lectrique avant tout travail dentretien ou de rparation. Lisez et respectez toutes les consignes du Manuel de consignes. INCENDIE ET EXPLOSION

Prvoyez une veille dincendie lors de tout travail dans une zone prsentant des dangers dincendie. Le gas hydrogne peut se former ou saccumuler sous les pices de travail en aluminium lorsquelles sont coupes sous leau ou sur une table deau. NE PAS couper les alliages en aluminium sous leau ou sur une table deau moins que le gas hydrogne peut schapper ou se dissiper. Le gas hydrogne accumul explosera si enflamm. RAYONS DARC DE PLASMA Les rayons provenant de larc de plasma peuvent blesser vos yeux et brler votre peau. Le procd larc de plasma produit une lumire infra-rouge et des rayons ultra-violets trs forts. Ces rayons darc nuiront vos yeux et brleront votre peau si vous ne vous protgez pas correctement. Pour protger vos yeux, portez toujours un casque ou un cran de soudeur. Portez toujours des lunettes de scurit munies de parois latrales ou des lunettes de protection ou une autre sorte de protection oculaire. Portez des gants de soudeur et un vtement protecteur appropri pour protger votre peau contre les tincelles et les rayons de larc. Maintenez votre casque et vos lunettes de protection en bon tat. Remplacez toute lentille sale ou comportant fissure ou rognure. Protgez les autres personnes se trouvant sur la zone de travail contre les rayons de larc en fournissant des cabines ou des crans de protection. Respectez le teint de lentille recommand dans le article 4, page 5. BRUIT

Les incendies et les explosions peuvent rsulter des scories chaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, des scories chaudes pouvant mettre le feu aux matires combustibles ou provoquer lexplosion de fumes inflammables. Soyez certain quaucune matire combustible ou inflammable ne se trouve sur le lieu de travail. Protgez toute telle matire quil est impossible de retirer de la zone de travail. Procurez une bonne aration de toutes les fumes inflammables ou explosives. Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matires combustibles.

Le bruit peut provoquer une perte permanente de loue. Les procds de soudage larc de plasma peuvent provoquer des niveaux sonores suprieurs aux limites normalement acceptables. Vous d4ez vous protger les oreilles contre les bruits forts afin dviter une perte permanente de loue. Pour protger votre oue contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protgez galement les autres personnes se trouvant sur le lieu de travail. Il faut mesurer les niveaux sonores afin dassurer que les dcibels (le bruit) ne dpassent pas les niveaux srs.

GENERAL INFORMATION

 Pour des renseignements sur la manire de tester le bruit, consultez larticle 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les plus rcentes ayant t faites celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DE PROTECTION DE LA SANT, 29CFR 1910, disponible auprs du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. Norme ANSI Z49.1, LA SCURIT DES OPRATIONS DE COUPE ET DE SOUDAGE, disponible auprs de la Socit Amricaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126 3. NIOSH, LA SCURIT ET LA SANT LORS DES OPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de lInstitut Amricain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018 5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018 Norme ANSI Z49.2, PRVENTION DES INCENDIES LORS DE LEMPLOI DE PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMS EN CYLINDRES, disponible auprs de lAssociation des Gaz Comprims (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. Norme CSA W117.2, CODE DE SCURIT POUR LE SOUDAGE ET LA COUPE, disponible auprs de lAssociation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3 13. ivret NWSA, BIBLIOGRAPHIE SUR LA SCURIT DU SOUDAGE, disponible auprs de lAssociation Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103 14. Norme AWSF4.1 de lAssociation Amricaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRPARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX , disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018

6.

7. Norme A6.0 de lAssociation Amricaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES, disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 8. Norme 51 de lAssociation Amricaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCDS ASSOCIS, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 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" (European 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) applicable to welding equipment and associated accessories. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing 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: David Ashworth Vice President & Managing Director Thermadyne Europe Chorley England.

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 CutMaster 80XL , 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 CutMaster 80XL 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). PAK UNITS, POWER SUPPLIES Main Power Magnetics Original Main Power Rectifier Control PC Board All Other Circuits And Components Including, But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors CONSOLES, CONTROL EQUIPMENT, HEAT EXCHANGES, AND ACCESSORY EQUIPMENT TORCH AND LEADS Maximizer 300 Torch All Other Torches REPAIR/REPLACEMENT PARTS N/A 180 Days 90 Days 180 Days 90 Days 1 Year 180 Days 90 Days 1 Year 180 Days None PARTS CutMaster 80XL 3 Years 3 Years 3 Years 1 Year PARTS Cougar/Drag-Gun 1 Year 1 Year 1 Year 1 Year PARTS All OTHERS 2 Years 2 Years 2 Years 1 Year LABOR 1 Year 1 Year 1 Year 1 Year

1 Year

1 Year

1 Year

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 October 9, 1998

GENERAL INFORMATION

GENERAL INFORMATION

SECTION 2: INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions and basic maintenance procedures for the PAK Master 100XL Air Plasma Cutting Power Supply (CE). Service of this equipment is restricted to Thermal Dynamics 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 understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

Torches will provide a maximum 1 inch (25.4 mm) cut capacity. Hand torches are available in 70 and 90 configurations. Machine torches are available only in Model PCM-100XL and include a rack and pinion mounting assembly. Torch leads are available in 25 ft (7.6 m), or 50 ft (15.2 m) lengths with fittings for simple installation. The torch includes a spare parts kit which provides an assortment of replacement torch parts. NOTE Refer to Section 2.04 for list of power supply options and accessories.

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 Switch and Output Current Control 2. Front Panel LED Indicators AC, TEMP, GAS, DC 3. Rear Panel Input power cable strain relief, gas connection, Gas Regulator/Filter Assembly 4. Input Power

2.02 General Description

The power supply provides 70 amp maximum output and includes all control circuitry, electrical and gas inputs and outputs, pilot circuitry, torch leads receptacle and a work cable with clamp. Machine torch systems also include a remote hand ON/OFF pendant. NOTE The power supply can be ordered in various configurations with various options factory installed.

Pak Master 100XL Power Supply

Available for the following input power: 208/230/240 VAC (8%), 50/60 Hz, Three-Phase 380/415 VAC (10%), 50/60 Hz, Three-Phase 460 VAC (10%), 50/60 Hz, Three-Phase Supplied with 10 ft (3.05 m) 4-Conductor Input Power Cable with filtering beads. 5. Output Power Continuously variable from 15 to 70 Amps maximum

Work Cable With Clamp PCH/M-100XL Torch and Leads

6. Duty Cycle 40% Duty Cycle @ 125V output with 60 Hz input 40% Duty Cycle @ 125V output with 50 Hz input
A-01345

7. Cut Capacity 1 inch (25.4 mm); 1-1/4 inch (31.8 mm) severance 8. Pilot Circuitry

Figure 2-1 Pak Master 100XL Power Supply

The power supply is designed to work with the Model PCH/M-100XL Plasma Torches. Manual 0-2611 9

High Frequency (HF), Pulsed DC

INTRODUCTION

9. Weight 79 lbs (35.8 kg) 10. Overall Dimensions 18.9" (480 mm) High x 13" (330 mm) Wide x 25.5" (648 mm) Long Overall dimensions are with handle, lead wrap bracket, and Gas Regulator/Filter Assembly installed.

D. Interface Cable
NOTE This accessory can be used only with the PCM-100XL 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 interface the power supply with an auxiliary control device to provide OK-To-Move and ON/OFF signals.

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 or 11.03 kPa) 2. Maximum input gas pressure 125 psi (8.6 BAR or 861 kPa) 3. Filter Coalescent type filter

2.04 Power Supply Options and Accessories

NOTE Refer to Section 6, Parts Lists, for part numbers and ordering information. The following are accessories that are available for this power supply:

A. Two Stage Air Line Filter

An optional two stage air line filter is available. The filter will remove moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least 5 microns. The filter assembly is pre-assembled at the factory and need only be attached to the power supply.

B. High Pressure Regulators

High pressure regulators are available for air and nitrogen. The regulators are used to set the proper pressure for the type gas being used.

C. Smart Cart
Steel cart on easy rolling 10" pneumatic tires to provide maximum mobility for the power supply. Handle is 3/4" tubing with hooks for storage of torch leads. A tie down strap is also included.

INTRODUCTION

10

Manual 0-2611

SECTION 3: INSTALLATION PROCEDURES

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 sub-sections 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; installation 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

Provide sufficient clearance in front of the unit to allow access to the front panel controls (minimum 6 inches or 0.15 m). CAUTION Operation without proper air flow will inhibit proper cooling and reduce duty cycle.

3.03 Unpacking
NOTE Equipment that was ordered as a system is packaged in one shipping carton. All options and the Torch are factory installed. Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping.

A. Power Supply
Included with each power supply is Input Power Cable, Work Cable and Clamp; Pressure Regulator/Filter Assembly and connection hardware; Operating Manual.

B. Torch and Leads

Included with each Torch is Torch and Leads with Torch Handle Assembly, Shield Cup, Tip, Electrode, Gas Distributor and all connectors installed; Torch Spare Parts Kit; Operating Manual. Machine Torches also include Metal Rack and Pinion Mounting Assembly, and Remote Control Hand Pendant.

C. Options and Accessories

Options and Accessories are packaged separately if not installed at the factory.

D. Unpacking Procedure
1. Unpack each item and remove all packing material. NOTE The Spare Parts Kit is shipped in the Torch Leads Storage Area on the side of the Power Supply. 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 installation.

3.02 Site Selection

Select a clean, dry location with good ventilation and adequate working space around all components. NOTE Review Important Safety Precautions (page 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 obstructed. Provide at least 2 feet (0.61 m) in the rear and at least 6 inches (0.15 m) on each side for clearance .

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3.04 Lifting Options

WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. This unit is equipped with one handle mounted onto the top of the enclosure for hand carrying purposes.

A. Input Voltage Selection

The Power Supply is factory-wired for 380/415V threephase input. For any other input voltage, the Power Supply must be changed using the procedure in Sections 3.06.

B. Electrical Connections
The power source must conform to local and national electric codes. Recommended circuit protection and wiring requirements are shown in Appendix I.

C. 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.

WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage. Lift unit with the handle on top of the enclosure. Persons only of adequate physical strength should lift the unit. Use hand 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 enclosure for hand lifting only. Be sure unit is lifted and transported safely and securely. WARNING HANDLE is not for mechanical lifting.

WARNING Disconnect primary power at the source before assembling or disassembling the Power Supply, torch parts, or torch and leads assemblies. 1. Using a phillips head screw driver remove the five screws which secure the left side panel (viewed from front of unit) to the frame assembly.

Left Side Panel

3.05 Input Power Connections

The Power Supply accepts input voltages from 208V to 460V. Input can be 50 or 60 Hz, three-phase. The Power Supply is factory wired for 380/415V three-phase input. For any other input voltage, the Power Supply must be internally reset. NOTE Refer to Section 3.06, Input Voltage Selection for procedure.
Screws (5 Places) Ground Wire

A-01560

Figure 3-1 Removing Left Side Panel

NOTE There is a ground wire connection to the Left Side Panel on the inside of the unit. 2. Carefully pull the Left Side Panel up and away from the unit to gain access to the inside of the unit.

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3.06 Input Voltage Selection

The Power Supply has three voltage settings; 208/230/ 240VAC, 380/415VAC, or 460VAC. Power Supplies are factory-wired for 380/415VAC three-phase input. Input voltage selection is accomplished by switching an internal buss bar and connector inside the Power Supply.
Voltage Selection Block
A-01347

460V

220V

220V

WARNING
208/230/240VAC 380-415V/460VAC

Disconnect primary power at the source before assembling or disassembling the power supply, torch parts, or torch and leads assemblies. To change the voltage selection use the following procedure as required: 1. Pull the single wire voltage selection plug from the connector mounted on the internal center chassis.
Voltage Selection Plug (220V) Voltage Selection Plug (460V)

Figure 3-3 Voltage Selection Block Installation

6. Move the voltage selection plug to the desired input connector for 220V (208/230/240V), 380/415V, or 460V input power operation.

3.07 Input Power Cable Connections

CAUTION The primary power source, power cable, and plug all must conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix I). 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 on the 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 customer 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)

460V

220V 380-415V/460V
380415V

220V

220V

A-01361

Voltage Selection Plug (380-415V)

Figure 3-2 Voltage Selection Plug

2. Loosen the screws securing the voltage selection block to the terminal block. 3. Pull the voltage selection block up and out from the terminal block. 4. Turn the voltage selection block to the desired voltage to be used. Use 220V for units using 208/230/ 240V input and 380-415V/460V for 380/415V or 460V input power. 5. Slide the voltage selection block onto the terminal block and tighten all the screws. NOTE All screws must be tightened even if not used on the terminal block.

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INSTALLATION PROCEDURES

220V

380-415V/460V
460V

380415V

220V 380-415V/460V
380415V

220V

380-415V/460V
460V

380415V

CAUTION The primary power source, power cable, and plug all must conform to local electric code and the recommended circuit protection and wiring requirements (refer to Appendix I).

CAUTION 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. An air line filter is supplied as part of the Pressure Regulator/Filter Assembly installed on the rear of the unit. NOTE

3.08 Gas Connections

A. Gas Requirements
WARNING This unit not to be used with oxygen (O2). Gases: Compressed Air or Nitrogen (N2) Only Pressure: 70 psi (4.8 BAR or 482 kPa) CAUTION Maximum input gas pressure must not exceed 125 psi (8.6 BAR or 861 kPa) Flow: Cutting - 400 scfh (188.7 lpm) Gouging - 400 scfh (188.7 lpm) CAUTION 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.

Filtering is required when using air from a compressor to insure that moisture and debris from the supply hose does not enter the torch. It is recommended to order the Optional Two Stage Air Line Filter for improved air filtering. 1. Locate the 1/4 NPT to #4 (6mm) hose barb fitting shipped inside the Torch Spare Parts Kit. NOTE A barb fitting is provided for connection of the gas supply hose to the rear of the Power Supply. The fitting is placed in the Spare Parts Kit for shipment. 2. Depending on the options installed at the factory, install the supplied barb fitting into the input of the Regulator/Filter Assembly or the Optional Two Stage Air Filter Assembly. 3. Tighten the barb fitting. 4. Place an adjustable hose clamp, 1/4" (6.35mm) to 5/ 8" (15.88mm)) over the gas supply hose.

B. Checking Air Quality

To test the quality of air, place the RUN/SET 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!

C. Gas Connection
The gas supply is connected to the rear of the Power Supply. The connection is the same for compressed air or high pressure gas cylinders.

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Regulator/Filter Assembly

5. Refer to the following when using high pressure gas cylinders as the gas supply: CAUTION

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

Pressure should be set at 100 psi (6.9 BAR or 690 kPa) at the high pressure gas cylinder regulator. a. Refer to the manufacturers specifications for installation 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 material. 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 or 690 kPa) maximum and flows of up to 400 scfh (188.7 lpm). 6. Slide the gas supply hose over the barb fitting installed in Step 2. 7. Secure the gas supply hose to the Barb fitting with the adjustable hose clamp. NOTE Supply hose must be at least #4 hose (1/4 in or 6 mm I.D.).

Hose Clamp

#4 (6 mm) Gas Supply Hose

A-01149

Figure 3-4 Gas Connection To Regulator/Filter Assembly

3.09 Connecting Torch Leads

WARNING Disconnect primary power at the source before assembling or disassembling the power supply, torch parts, or torch and leads assemblies. The Torch Leads must be properly installed to the Power Supply for proper operation. Make all torch connections to the Torch Bulkhead Panel per the following: NOTE
#4 (6mm) Gas Supply Hose

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

Equipment ordered as a system will have the Torch factory connected to the Power Supply. 1. Turn the screw latch securing the front access panel to the power supply front panel.
A-01150

Two Stage Filter Assembly

Figure 3-5 Gas Connection To Optional Two Stage Filter Assembly

Manual 0-2611 15 INSTALLATION PROCEDURES

Access Panel

4. Feed the end of the torch leads through the hole in the front panel in the following order: Control Cable Gas lead Pilot Lead 5. Place the strain relief into the hole and secure with the nut removed in Step 3 above. 6. Connect the torch gas/power lead fitting onto the Gas/Power Lead Connection.

Screw Latch

Pilot Lead Stud Control Cable Connector

A-01348

Control Cable

Figure 3-6 Front Access Panel

Pilot Lead

2. Lift up on the access panel to gain access to the torch bulkhead panel. CAUTION This system is designed for use with the PCH/M100XL torch only. Do not connect any other torch to this power supply. 3. Remove the securing nut from the strain relief supplied on the end of the Torch Leads.
Strain Relief

Gas/Power Lead Torch Lead Assembly

Gas/Power Lead Connection

A-00929

Figure 3-8 Torch Leads Connections

7. Connect the Torch Control Cable to the Torch Control Connection. 8. Remove the top nut and washer from the Pilot Stud.

Torch Leads Assembly

9. Place the lug of the Pilot Control Wire onto the stud and secure with the nut and washer removed in Step 8. 10. Close the access panel and turn the latching screw .

Strain Relief Nut

A-00930

3.10 Work Cable And Ground Connections

A. Electromagnetic Interference (EMI)
High frequency pilot arc initiation generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF may interfere with other electronic equipment such as CNC controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems:

Figure 3-7 Torch Strain Relief Nut

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B. Creating an Earth Ground

1. Install a ground wire (not included) between the system and a solid earth ground (also called star ground). To create a solid earth ground, drive a 1/2 in (12 mm) diameter copper rod approximately 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. The required depth will vary depending on location. Locate the rod as close as possible to the power supply. The work table should be connected to the same earth ground as the power supply. 2. Connect the control device (CNC) to a separate earth ground similar to the ground rod described above. The ground cable should be at least 12 gauge wire. 3. To minimize RF interference, position torch leads as far as possible (at least 1 ft or 0.3 m) from any CNC components, drive motors, control cables, or primary power lines. 4. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference. 5. Make sure work cable and ground cables are properly connected.

A-01349

Work Cable And Clamp

Make a solid work cable connection to the workpiece or cutting table

Figure 3-9 Power Supply Work Cable Connection

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INSTALLATION PROCEDURES

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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 operating procedures.

2. Access Panel A panel to gain 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.

4.02 Functional Overview

The Power Supply provides a degree of operating flexibility and the use of simple controls.

4.03 Operating Controls

This subsection provides specific functional descriptions of the Power Supply operating controls and indicators.

B. Control Panel
4
CURRENT 40 50

A. Front and Side Panel

1. Control Panel All operator controls, except gas pressure adjustment, are located on this panel. Power ON/OFF and RUN/ SET switches; CURRENT control; LED indicators for AC Power, TEMP, GAS, and DC.
1
30 60 20 15
ON AC TEMP GAS DC RUN

5 6 7

70

1
OFF SET
A-01353

Figure 4-2 Operating Controls

3

1. Current Control Adjustment to set the desired output current between 15-70 amps. For drag cutting applications set the control between 15 - 35 amps. Unit has an automatic fold-back circuit that limits current to 35 amps during drag cutting.

A-01352

2. ON/OFF Power Switch

4

ON position supplies AC power to activate all system control circuits. OFF position deactivates control circuits. 3. RUN/SET Switch

Figure 4-1 Front and Side Panel Connections

RUN position is used for torch operation. SET position used for setting gas pressure and purging lines.

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4. AC Power Indicator Green LED indicator will blink ON then OFF for approximately eight seconds and then stay ON after the ON/OFF power switch is set to ON. Indicates operating power is present in the unit.. 5. TEMP Indicator Normally OFF. Yellow LED indicator will come 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 LED indicator will come ON when the input gas pressure is set to 45 psi (3.1 BAR or 310 kPa) or higher. Indicator will be OFF when the pressure falls below 45 psi (3.1 BAR or 310 kPa). 7. DC Indicator Green LED indicator will come ON while the torch switch is pressed.

3. Gas/Power Lead Connection Connects the torch gas/negative lead to the unit.

D. Rear Panel
1. Gas Input Input connection for nitrogen (N2) or air input.

WARNING This unit not to be used with oxygen (O2).

C. Torch Panel Bulkhead

The torch panel bulkhead is located under the access panel. 1. Pilot Lead Stud Connects the pilot control wire on the torch to the unit.
1

1 2 3

A-01151

Figure 4-4 Rear Panel

2. EMC Primary Input Power Cable and Strain Relief
3
A-00923

Figure 4-3 Torch Panel Connections

2. Control Cable Connector Connects the torch switch to the unit. In machine torch applications connects the torch switch on the pendant to the unit.

EMC primary input power cable and strain relief. Input power cable is capable of handling upto 460 VAC, three-phase, input voltage designed for this unit. 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.

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4. Place RUN/SET switch to SET mode. a. Gas solenoid opens and gas flows to set pressure. b. GAS indicator turns ON. NOTE GAS indicator will not come ON if the gas pressure is set below 45 psi (3.1 BAR or 310 kPa) at the Regulator/Filter Assembly. 5. Place RUN/SET 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)

2 3

4
A-01152

a. Power supply enabled. b. DC indicator turns ON. c. Pilot relay closes. 8. Pilot arc is established

Figure 4-5 Rear Panel With Optional Two Stage Filter Installed
4. Optional Two Stage Air Line Filter The optional filter will remove moisture and contaminants from the air stream when using compressed air. The filter is capable of filtering to at least 5 microns.

9. Move Torch within transfer distance of workpiece. a. Main arc transfer. b. Pilot arc OFF. 10. Complete cutting operation NOTE If the torch is lifted from the workpiece, while still having torch switch activated, the main arc will stop and the pilot arc will automatically restart. 11. Release or deactivate the torch switch. a. Main arc stops. b. Pilot arc stops (power supply enable signal removed). NOTE If torch is activated during post-flow, pilot arc will immediately restart. If torch is within 3/8 in (9.53mm) transfer distance of workpiece, main arc will transfer.

4.04 Sequence Of Operation

The following is a typical sequence of operation for this cutting system. Refer to Appendix II for a block diagram. 1. Close main power source disconnect. a. AC power is available at the Power Supply. 2. Place RUN/SET 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 LED blinks ON and OFF for eight seconds then stays ON. b. Fans turn on.

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12. Gas will flow for 15 seconds (post-flow). a. Gas solenoid closes b. Gas flow stops. c. GAS indicator turns OFF. 13. 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. 14. Place the main power disconnect to open. a. Main AC power is removed from the system.
A-00925

Make a solid work cable connection to the workpiece or cutting table

4.05 Preparations for Operating

Follow this set-up procedure each time the system is operated:

Figure 4-6 Work Cable Connection To Workpiece

E. Torch Connection
WARNING Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Check that the torch is properly connected.

F. Purge the System (Gas Pre-Flow)

Move the ON/OFF switch to ON position. To start the pre-flow move the RUN/SET switch to SET position for a minimum of 20 seconds. The pre-flow gas purge will remove any moisture that may have accumulated in the torch and leads while the system was shut down. The torch cannot be activated during pre-flow.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate front end torch parts. The torch parts (shield cup, tip and electrode) must correspond with the type of operation (cutting or gouging). Refer to the Instruction Manual supplied with the Torch Assembly for proper parts selection.

G. Select Output Current

Select the desired current output level for the operation. 15 to 70 amps for standoff cutting and gouging 15 to 35 amps for drag cutting

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, Specifications/Design Features. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system.

H. Set Operating Pressure

Move the RUN/SET switch to SET position. Adjust the gas pressure to 70 psi (4.8 BAR or 482 kPa).

I. RUN/SET Switch
Set the RUN/SET switch to RUN position. The system is now ready for operation.

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.

4.06 Cut Quality

Cut quality requirements differ depending on application. 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 operation.

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.

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The following cut quality characteristics are illustrated in Figure 4-7 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 perpendicular 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 workpiece. 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 Spatter
G as A ir N i tr o g e n

C ar b o n S teel G ood E x c ellent G ood

T y p e o f M a t e r ia l S t a in le s s A lu m in u m S teel G ood G ood E x c ellent E x c ellent G ood G ood

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 removed), 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 parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Top Edge Rounding Dross Build-Up

Cut Surface Drag Lines

A-00007

Figure 4-7 Cut Quality Characteristics

Cut quality will vary on different types of and material thicknesses. The following table shows the cut quality that can be expected from this equipment for materials with a thickness from gage to 1 inch (25.4mm):

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OPERATION

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SECTION 5: CUSTOMER/OPERATOR SERVICE

5.01 Introduction
This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than Thermal Dynamics Trained personnel. For major troubleshooting and parts replacement procedures refer to PAK Master 100XL Power Supply (EMC) Service Manual 0-2612.

5.03 Common Operating Problems

WARNINGS Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operators body comes into contact with the workpiece while the torch is activated.

5.02 General Maintenance

CAUTION WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. NOTE The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. CAUTION 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. To clean the unit, open the enclosure (refer to Section 5.05-A, Opening Enclosure) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used. Handle torch leads with care and protect them from damage. Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

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 workpiece with the front of the tip at the edge of the workpiece 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. Establish 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

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the other. Viewed along the direction of travel, the right side of the cut is more square than the left (Refer to Figure 5-1). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.
Left Side Cut Angle

d. Work cable disconnected e. Worn torch parts 3. Excessive Dross Formation a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts

Right Side Cut Angle

d. Improper cutting current 4. Short Torch Parts Life a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time

A-00512

d. Air flow too low (incorrect pressure) e. Improperly assembled torch

Figure 5-1 Side Characteristics Of Cut

E. Dross
Generally when dross is present on carbon steel, it is referred 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 removed. 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 scrapping, 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.

5.04 Troubleshooting Guide

A. General
Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment.

WARNING 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 troubleshooting techniques.

B. Basic Troubleshooting
This manual covers a basic level of troubleshooting that requires limited dissasembly 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 section in the order presented. For major troubleshooting and parts replacement procedures refer to PAK Master 100XL Power Supply (EMC) Service Manual 0-2612.

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 2. Main Arc Extinguishes a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high

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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 position. 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, Input Power Connections) 3. Actual input voltage does not correspond to voltage selection inside unit a. Check actual line voltage vs. voltage selection (inside of unit) 4. Customer's main power line fuse(s) blown a. Check main power panel fuse(s) and replace as required. 5. Unit internal fuse blown or loose a. If blown, double check input voltage vs. voltage selection (indide of unit) and replace fuse per Section 5.05-B. If fuse blows again, return unit to an authorized service center. 6. Faulty components in unit a. Return 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 condition. 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 beyond duty cycle limit. 4. Input line voltage is below 75% of rated level a. Check and connect to proper input power line 5. Input voltage of 460 V applied to 208/230/240 V AC AC or 380/415 V Models AC a. Check input line voltage and correct as required. 6. 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 switch in SET position a. Move switch to RUN position. 2. Switch activated during 2 second pre-flow a. Release switch and wait at least 2 seconds before activating switch again 3. Faulty torch parts a. Inspect torch parts and replace if necessary (refer to Instruction Manual supplied with torch). 4. Gas pressure too high or too low a. Set pressure to 70 psi (4.8 BAR or 482 kPa). 5. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. D. AC Power indicator ON; Fans operating; No cutting output 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.

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SERVICE

E. Low cutting output with no control 1. Incorrect setting of CURRENT control a. Check and adjusted 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 adjusted to proper setting. 3. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. G. Erractic 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. AC Power indicator ON; Cutting output available; Fans not operating, 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. AC POWER indicator ON; Fans operate; No gas flow 1. Gas not connected or pressure too low a. Check source for at least 70 psi (4.8 BAR). 2. Faulty components in unit a. Return for repair or have qualified technician repair per Service Manual. J. Torch cuts but not adequately 1. Current set too low a. Increase current setting. 2. Torch is being moved too fast across workpiece a. Reduce cutting speed (refer to Instruction Manual supplied with torch.

3. Excessive oil or moisture in torch a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch)

5.05 Power Supply Parts Replacement

WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply.

A. Left Side Panel Removal

1. Using a phillips head screw driver remove the five screws which secure the left side panel (viewed from front of unit) to the frame assembly.

Left Side Panel

A-01560

Screws (5 Places)

Ground Wire

Figure 5-1 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 groun wire. 2. Carefully pull the Left Side Panel up and away from the unit to gain access to the inside of the unit. 3. To reinstall the left side panel do the following: 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.

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Manual 0-2611

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 and behind the EMC Filter on the left side of the unit. 3. Replace the fuse (0.8 amp, 600V). 4. Reinstall the left side panel per paragraph "A" above.
Internal Fuse 0.8 Amps, 600V

A-01561

EMC FIlter

Figure 5-2 Internal Fuse Location

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SECTION 6: PARTS LISTS

6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable components. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 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 Thermal Dynamics product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Dynamics without proper authorization 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 authorized Thermal Dynamics distributor.

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PARTS LISTS

6.03 Complete Power Supply Replacement

Power supply includes: CE Input Power Cable, Work cable, pressure regulator/air filter, air hose and fittings, and operating manual. Description PAK Master 100XL Power Supply (CE) Qty 1 Catalog # 3-0850

6.04 Options and Accessories

Qty 1 1 1 1 1 1 1 Description Two Stage Air Filter Kit Replacement Elements First Stage Second Stage Smart Cart Interface Cable - For Use With Machine Torches Only 25 foot (7.62m) 50 foot (15.24m) Circle Cutting Attachment 8-5557 8-5558 7-7501 9-1021 9-1022 7-7777 Catalog # 7-7500

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APPENDIX I: INPUT WIRING REQUIREMENTS

In p u t V o ltag e (V o lts) 208 230 240 380 415 460 F r eq . (H z ) 50/60 50/60 50/60 50/60 50/60 50/60 P o w er In p u t 3-P h (kV A ) 12.8 13.2 12.8 14.2 14.2 15.2 C u r r en t 3-P h (A m p s) 35.6 33.2 30.7 21.5 19.8 19.1 S u g g ested S iz es (S ee N o tes) F u se (A m p s) 3-P h 45 40 35 25 25 25 W ir e (m m ) 3-P h 10 10 10 10 10 10
2

Line V oltages w ith S ugges ted C irc uit P rotec tion and W ire S iz es

NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. Cable size is de-rated based on the Duty Cycle of the equipment. The suggested sizes are based on flexible power cable with power plug installations. For hard-wired installations refer to local or national codes. Cable conductor temperature used is 167 F (75 C). 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.

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APPENDIX

APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM)

ACTION Close external disconnect switch. RESULT Power to system.

ACTION ON/OFF switch to ON. RESULT AC indicator blinks for 8 seconds then steady on. Fans on. Power circuit ready.

ACTION RUN/SET switch to SET. RESULT Gas solenoid open, gas flows to set pressure. GAS indicator on.

ACTION RUN/SET switch to RUN. RESULT Gas flow stops. GAS indicator off.

ACTION ACTION Protect eyes and activate torch RESULT Gas flows (2 seconds). After gas pre-flow: DC indicator on. Pilot relay closes. Pilot arc established Torch moved away from work (while still activated). RESULT

PILOT ARC

Main arc stops. Pilot arc automatically restarts.

ACTION Torch moved within transfer distance of workpiece. RESULT 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 ACTION ON/OFF switch to OFF RESULT RESULT All indicators off. Power supply fans off. No power to system. Open external disconnect. Main arc transfer. Pilot arc off.

A-00926

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APPENDIX

APPENDIX III: SYSTEM SCHEMATIC

A-01564

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A-01564

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APPENDIX