Thermal Dynamics PakMaster™ 100 XL™ Plus Air Plasma Cutting Power Supply User manual

Brand: Thermal Dynamics

Model: PakMaster™ 100 XL™ Plus Air Plasma Cutting Power Supply

Category: Welding System

Type: User manual

This manual is also suitable for

PakMaster™ 100 XL™ Plus Air Plasma Cutting Power Supply (CE)

Manual No. 0-2784

August 23, 1999

Operating Manual

A-02464

Air Plasma Cutting

Power Supply (CE)

WARNING

Read and understand this entire Operating Manual and your

employer’s safety practices before installing, operating, or

servicing the equipment.

While the information contained in this Operating Manual

represents our best judgement, Thermal Dynamics Corporation

assumes no liability for its use.

Pak Master

100XL PLUS Air Plasma Cutting Power Supply(CE)

Operating Manual Number 0-2784

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

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 PLUS Air Plasma Cutting

Power Supply (CE) Operating Manual, 0-2784,whether such

error results from negligence, accident, or any other cause.

Printed in the United States of America

August 1999

Purchase Date

Power Supply

Torch

Record Serial Numbers For Warranty Purposes

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION .................................................................................................. 1

1.01 Notes, Cautions and Warnings ...................................................................... 1

1.02 Important Safety Precautions ........................................................................ 1

1.03 Publications ................................................................................................... 2

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

1.05 Precautions De Securite Importantes ............................................................ 3

1.06 Documents De Reference ............................................................................. 5

1.07 Declaration of Conformity .............................................................................. 7

1.08 Statement of Warranty ................................................................................... 8

SECTION 2:

INTRODUCTION ................................................................................................................. 9

2.01 Scope of Manual............................................................................................ 9

2.02 General Description of System ...................................................................... 9

2.03 Specifications/Design Features ..................................................................... 9

2.04 Power Supply Options and Accessories ...................................................... 10

SECTION 3:

INSTALLATION PROCEDURES ........................................................................................ 11

3.01 Introduction.................................................................................................. 11

3.02 Site Selection............................................................................................... 11

3.03 Unpacking ................................................................................................... 11

3.04 Lifting Options.............................................................................................. 11

3.05 Input Power Cable Connections................................................................... 12

3.06 Gas Connections......................................................................................... 12

3.07 Connecting Torch Leads .............................................................................. 14

3.08 Work Cable And Ground Connections ......................................................... 15

3.09 Tip Saver/Drag Cut Sensing Circuit ............................................................. 16

SECTION 4:

OPERATION ...................................................................................................................... 17

4.01 Introduction.................................................................................................. 17

4.02 Functional Overview .................................................................................... 17

4.03 Operating Controls ...................................................................................... 17

4.04 Sequence Of Operation ............................................................................... 19

4.05 Preparations for Operating........................................................................... 20

4.06 Cut Quality................................................................................................... 21

SECTION 5:

CUSTOMER/OPERATOR SERVICE.................................................................................. 23

5.01 Introduction.................................................................................................. 23

5.02 General Maintenance .................................................................................. 23

5.03 Common Operating Problems ..................................................................... 24

5.04 Troubleshooting Guide ................................................................................. 25

5.05 Power Supply Parts Replacement ............................................................... 27

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.....................................................................................................................29

6.01 Introduction.................................................................................................. 29

6.02 Ordering Information.................................................................................... 29

6.03 Complete Power Supply Replacement......................................................... 30

6.04 Replacement Parts ...................................................................................... 30

6.05 Options and Accessories............................................................................. 30

APPENDIX I: INPUT WIRING REQUIREMENTS ...................................................................... 31

APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ........................................... 32

APPENDIX III: SYSTEM SCHEMATIC....................................................................................... 34

Date: 6/22/99 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 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 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.

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.”

• Wear dry gloves and clothing. Insulate yourself from

the work piece or other parts of the welding cir-

cuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

GENERAL INFORMATION 2 Date 6/22/99

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publica-

tions.

• Disconnect power source before performing any ser-

vice or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have held

combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut 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

Documents, U.S. Government Printing Office, Wash-

ington, 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 WELD-

ING AND GAS WELDING AND CUTTING, obtain-

able from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402

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

CUPATION 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 MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the

American National Standards Institute, 1430 Broad-

way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES,

obtainable from American National Standards Insti-

tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

Date: 6/22/99 3 GENERAL INFORMATION

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 Asso-

ciation, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire Pro-

tection 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

WELDING AND CUTTING, obtainable from the Ca-

nadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W

1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-

PHY obtainable from the National Welding Supply

Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, REC-

OMMENDED SAFE PRACTICES FOR THE PREPA-

RATION FOR WELDING AND CUTTING OF CON-

TAINERS 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 RESPIRA-

TORY 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.

• Eloignez toute fumée et gaz de votre zone de respi-

ration. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en

air si l’aération fournie ne permet pas d’éliminer la

fumée et les gaz.

GENERAL INFORMATION 4 Date 6/22/99

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un

ou plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des

gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans

une zone où se trouvent des matières ou des gaz

combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou

“vive”; portez des gants et des vêtements secs.

Isolez-vous de la pièce de travail ou des autres par-

ties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la

page 5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel

de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail.

Protégez toute telle matière qu’il est impossible de

retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail

dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler

sous les pièces de travail en aluminium lorsqu’elles

sont coupées sous l’eau ou sur une table d’eau. NE

PAS couper les alliages en aluminium sous l’eau ou

sur une table d’eau à moins que le gas hydrogène

peut s’échapper ou se dissiper. Le gas hydrogène

accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de plasma

produit une lumière infra-rouge et des rayons ultra-vio-

lets très forts. Ces rayons d’arc nuiront à vos yeux et

brûleront votre peau si vous ne vous protégez pas

correctement.

• Pour protéger vos yeux, portez toujours un casque

ou un écran de soudeur. Portez toujours des lunettes

de sécurité munies de parois latérales ou des lu-

nettes de protection ou une autre sorte de protec-

tion oculaire.

• Portez des gants de soudeur et un vêtement

protecteur approprié pour protéger votre peau

contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protec-

tion en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant

des cabines ou des écrans de protection.

Date: 6/22/99 5 GENERAL INFORMATION

• Utilisez la nuance de lentille qui est suggèrée dans

le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé

clairement. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres

personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer

que les décibels (le bruit) ne dépassent pas les

niveaux sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus

récentes ayant été faites à celles-ci pour de plus amples

renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET

DE PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Docu-

ments, U.S. Government Printing Office, Washing-

ton, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine de

Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES

OPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent 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

l’Institut Américain des Normes Nationales (Ameri-

can National Standards Institute), 1430 Broadway,

New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES

INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS

DE COUPE ET DE SOUDAGE, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du

Soudage (AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES

PRODUITS COMBUSTIBLES, disponible auprès de

la American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

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. ivret 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

GENERAL INFORMATION 6 Date 6/22/99

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

Soudage, RECOMMANDATIONS DE PRA-

TIQUES 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 PROTEC-

TION RESPIRATOIRE, disponible auprès de

l’American National Standards Institute, 1430

Broadway, New York, NY 10018

Date: 6/22/99 7 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 Direc-

tive’ (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) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

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: Steve Ward

Director of Operations

Thermadyne UK

Chorley England

GENERAL INFORMATION 8 Date 6/22/99

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 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 XL Plus Series and 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).

Parts

XL Plus Series & Parts Parts

PAK Units, Power Supplies CutMaster 80XL 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

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 May 6, 1999

Manual 0-2784 9 SECTION 2: INTRODUCTION

SECTION 2:

INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions,

and basic maintenance procedures for the PAK Master

100XL PLUS Air Plasma Cutting Power Supply (CE) only.

Service of this equipment is restricted to Thermal Dynam-

ics trained personnel; unqualified personnel are strictly

cautioned against attempting repairs or adjustments not

covered in this manual, at the risk of voiding the War-

ranty.

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 100XL PLUS (CE) System includes a power supply,

PCH/M-80 torch & leads, work cable & clamp, and in-

put power cable.

The Power Supply provides 80 amp maximum output

and includes all control circuitry, electrical and gas in-

puts and outputs, pilot circuitry, torch leads receptacle,

input power cable, and a work cable with clamp.

NOTE

The power supply can be ordered in various con-

figurations with various options factory installed.

A-02462

Torch and Leads

Work Cable and Clamp

XL PLUS Power Supply

Figure 2-1 Pak Master 100XL Plus (CE) System

The PCH/M-80 torch provides a maximum 1 inch (25.4

mm) cut capacity. Hand torches are available in a 70°

and 90° configuration. Machine Torches are available in

180° configuration. Torch leads are available in 25 ft (7.6

m), or 50 ft (15.2 m) lengths with fittings for simple in-

stallation. Spare Parts Kits are available for the torches

which provide an assortment of replacement torch parts.

NOTES

For Torch information, refer to the PCH/M-80

Manual 0-2753.

Refer to Section 2.04 in this manual 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/LATCH Switch and

Output Current Control

2. Front Panel LED 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 80 Amps maximum

6. Duty Cycle

40% Duty Cycle at an output of 112VDC/80 amps

100% Duty Cycle at an output of 112VDC/60 amps

7. Cut Capacity (Mild Steel)

1 inch (25.4 mm); 1-1/4 inch (31.8 mm) severance

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. Weight

75 lbs ( 34 kg) w/work lead, filter & input power cable

82 lbs ( 37.2 kg) w/work lead, torch & lead, filter and

input power cable

SECTION 2: INTRODUCTION 10 Manual 0-2784

10. Overall Dimensions

Overall dimensions are with handle, lead wrap

bracket, and gas regulator/filter assembly installed.

19" (482 mm) High x 13" (330 mm) Wide x 24.75" (630

mm) Long

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

NOTE

Refer to Section 6, Parts Lists, for part numbers

and ordering information.

The following options and accessories available for this

power supply, but must be ordered separately:

A. Dry Air Filter Kit

An optional in-line filter for use on compressed air

shop systems. highly effective at removing moisture

and particulate matter from the air stream to at least

0.85 microns.

B. Two Stage Air Line Filter

An alternative to the Dry Air filter, this optional two

stage air line filter is for use on compressed air shop

systems. Filters moisture and contaminants to 5.0 mi-

crons. This filter assembly is pre-assembled at the fac-

tory and need only be attached to the power supply.

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. Smart Cart

Steel cart on easy rolling 10" pneumatic tires to pro-

vide 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.

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 25

ft. (7.6 m) cable. An extension cable of 25 ft. (7.6 m) can

be added to the standard hand pendant control to pro-

duce 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 drag-

ging without risk of touching tip.

Manual 0-2784 11 SECTION 3: INSTALLATION PROCEDURES

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 subsections be read for general informa-

tion.

This section describes installation of the Power Supply

and connecting the Torch.

These instructions apply to the Power Supply only; in-

stallation procedures for the Torch, Options, and Acces-

sories are given in Manuals specifically provided for those

units.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input Power

b. Gas

c. Work Cable

d. Torch Leads

4. Grounding

5. Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and ad-

equate working space around all components.

NOTE

Review Important Safety Precautions (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 ob-

structed. Provide at least 2 feet (0.6 m) in the rear and at

least 6 inches (0.15 m) 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 0.15

m).

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.

1. Unpack each item and remove all 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.

This unit is equipped with one handle mounted onto the

top of the enclosure for hand carrying purposes.

WARNING

FALLING EQUIPMENT can cause serious per-

sonal 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 capac-

ity.

SECTION 3: INSTALLATION PROCEDURES 12 Manual 0-2784

• 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.

3.05 Input Power Cable Connections

The 100XL PLUS Power Supply (CE) operates on three

phase, 380/415VAC, ± 10% 50/60Hz input.

CAUTION

The primary power source,power cable must all

conform to local electric code and the recommended

circuit protection and wiring requirements (refer

to table in 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 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 (N

) Only

Pressure: 70 psi (4.8 bar)

CAUTION

Maximum input gas pressure must not exceed 125

psi (8.6 bar)

Flow: Cutting - 400 scfh (188.7 lpm)

Gouging - 400 scfh (188.7 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

Air supply must be free of moisture, and other con-

taminants. Excessive and 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.

1. Locate the 1/4 NPT to #4 (6mm) hose barbed fitting

shipped inside the Torch Spare Parts Kit.

2. 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 insure that moisture and debris from the

supply hose does not enter the torch. We recom-

mend either the optional Dry Air Filter Kit or Two

Stage Filter Assembly to provide the necessary fil-

tering.

Manual 0-2784 13 SECTION 3: INSTALLATION PROCEDURES

3. Install the barbed fitting as shown below.

4. Tighten the barbed fitting.

5. Place an adjustable hose clamp (customer supplied),

1/4" (6.5mm) to 5/8" (15.9mm)) over the gas supply

hose.

Regulator/Filter

Assembly

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

Fitting

#4 (6 mm) Gas

Supply Hose

Hose Clamp

A-01149

Figure 3-2 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 Dry Air Filter

or Two Stage Air Line Filter be installed for improved

filtering. Gas connections to optional filters are shown in

Figures 3-3 and 3-4.

A-02607

1/4 NPT to

#4 (6mm)

Hose Fitting

Dry Air Filter

Assembly

#4 (6mm)

Gas Supply

Hose

Hose Clamp

Figure 3-3 Gas Connection to Optional Dry 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 3-4 Gas Connection To Optional Two Stage

Filter Assembly

E. Using High Pressure Gas Cylinders

1. Refer to the following when using high pressure gas

cylinders as the gas supply:

SECTION 3: INSTALLATION PROCEDURES 14 Manual 0-2784

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).

2. Slide the gas supply hose over the barb fitting installed

in Step 2.

3. Secure the gas supply hose inplace with the adjustable

hose clamp.

NOTE

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

mm I.D.).

3.07 Connecting Torch Leads

WARNING

Disconnect primary power at the source before as-

sembling 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

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.

Access

Panel

Screw

Latch

A-02467

Figure 3-5 Front Access Panel

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/M-

80 torch only. Do not connect any other torch to

this power supply. For information about torches,

refer to Manual 0-2753.

3. Remove the Strain Relief Nut from the Strain Relief

supplied on the end of the Torch Leads.

Strain Relief

Nut

Strain Relief

Torch Leads

Assembly

A-02514

Figure 3-6 Torch Strain Relief Nut

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Thermal Dynamics PakMaster™ 100 XL™ Plus Air Plasma Cutting Power Supply User manual

Brand: Thermal Dynamics

Model: PakMaster™ 100 XL™ Plus Air Plasma Cutting Power Supply

Category: Welding System

Type: User manual

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