Thermal Dynamics PAK Master 100XL Plus Operating Manual
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Thermal Dynamics PAK Master 100XL Plus Operating Manual

Thermal Dynamics PAK Master 100XL Plus Operating Manual

Automated plasma cutting power supply
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Automated Plasma
Cutting Power Supply
PAK Master 100XL Plus
A-02751
Operating Manual
June 26, 2003
Manual No. 0-2811

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  • Page 1 Automated Plasma Cutting Power Supply PAK Master 100XL Plus A-02751 Operating Manual June 26, 2003 Manual No. 0-2811...
  • Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety prac- tices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Automated Plasma Cutting Power Supply ®...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................... 5-1 5.01 Introduction ....................5-1 5.02 General Maintenance ................... 5-1 5.03 Common Operating Problems ..............5-2 5.04 Troubleshooting Guide ................. 5-4 5.05 Power Supply Parts Replacement ..............5-6 SECTION 6: PARTS LISTS ........................6-1 6.01 Introduction ....................

  • Page 7: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 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.

  • Page 13: Declaration Of Conformity

    1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 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.

  • Page 14: Statement Of Warranty

    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...

  • Page 15: Introduction

    208/230/240 VAC (±10%), 50/60 Hz, Single or Three- Phase 380/415 VAC (±10%), 50/60 Hz, Three-Phase Torch and Leads 460 VAC (±10%), 50/60 Hz, Single or Three-Phase A-02750 Work Cable and Ring Terminal Figure 2-1 Pak Master 100XL Plus Automated System Manual 0-2811 INTRODUCTION...
  • Page 16 5. Output Power C. Two Stage Air Line Filter Specifications Continuously variable from 15 to 80 Amps maximum The following specifications apply to the Two Stage Air Line Filter Assembly only: 6. Duty Cycle (Refer to NOTE) NOTE PakMaster 100XLP (Automated) The two stage air line filter is for use on systems using compressed air.

  • Page 17: Power Supply Options And Accessories

    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. Single Stage Air Line Filter Kit A Single Stage In-Line Air Filter which is a pneumatic dryer/evaporator that installs in the plasma or sec- ondary compressed air line.
  • Page 18 INTRODUCTION Manual 0-2811...

  • Page 19: Installation

    SECTION 3: CAUTION INSTALLATION Operation without proper air flow will inhibit proper cooling and reduce duty cycle. 3.01 Introduction 3.03 Unpacking NOTE Each component of the system is packaged and protected with a carton and packing material to prevent damage Depending on how the system was ordered, some during shipping.

  • Page 20: Input Power Connections

    • This unit has a handle mounted on top of the enclo- sure for hand lifting only. Be sure unit is lifted and Left Side transported safely and securely. Panel WARNING HANDLE is not for mechanical lifting. 3.05 Input Power Connections A-02761 The Power Supply accepts input voltages from 208V to 460V.

  • Page 21: Primary Input Power Cable Connections

    1. Pull the single wire voltage selection plug from the 3.07 Primary Input Power Cable connector mounted on the internal center chassis. Connections Units ordered as 230V, single-phase, will have a six foot Voltage Selection Voltage Selection power input cable and plug factory installed. For all other Plug (460V) Plug (220V) units, a cable must be provided by the end user.

  • Page 22: Gas Connections

    c. Locate the ground stud and remove the top nut and washer. Input d. Install a lug terminal on the ground wire. Contactor e. Place the ground wire onto the ground stud and secure with the nut and washer. f. Insert the other two wires into the L1 and L2 terminals on the contactor.
  • Page 23 B. Checking Air Quality D. Optional Air Line Filter Installation To test the quality of air, place the RUN/SET/LATCH Filtering is required when using air from a compressor to switch to SET position, place a welding filter lens in front ensure that moisture and debris from the supply hose do of the torch and turn on the gas.

  • Page 24: Connecting Torch Leads

    E. Using High Pressure Gas Cylinders 3.09 Connecting Torch Leads Refer to the following when using high pressure gas cyl- inders as the gas supply: WARNING CAUTION Disconnect primary power at the source before as- Pressure should be set at 100 psi (6.9 bar) at the sembling or disassembling the power supply, torch high pressure gas cylinder regulator.
  • Page 25 A. PCM-102 Torch Installation 7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed 1. Remove the retaining nut from the Strain Relief. in the above Step. 8. Tighten the Strain Relief onto the Torch Leads. Torch Leads 9.

  • Page 26: Ground Connections For Mechanized Applications

    4. Connect the ATC Adapter or Torch Leads Nega- 10. Check the torch for proper consumable parts. tive / Plasma Lead to the bulkhead connection inside the Power Supply. CAUTION 5. Remove the top nut and washer from the Pilot The torch parts must correspond with the type of Stud.
  • Page 27 4. The plasma power supply work cable (see NOTE) is NOTE connected to the cutting table at the single point “Star” Ideally, a properly installed ground rod will have a ground. resistance of three ohms or less. NOTE To test for a proper earth ground, refer to the follow- Do Not connect the work cable directly to the ing diagram.

  • Page 28: Tip Saver/Drag Cut Sensing Circuit

    D. Routing Of Torch Leads 3.12 External Control Connections 1. To minimize RF interference, position torch leads as External control signal connections can be made to the far as possible from any CNC components, drive mo- Rear Panel of the power supply. Connections can be made tors, control cables, or primary power lines.
  • Page 29 2. Using customer supplied CNC Cable d. Feed the CNC cable through the strain relief at the rear of the Power Supply, routing the a. Remove the Left Side Panel from the Power cable above the Logic PC Board to the Termi- Supply as viewed from the front of the unit.
  • Page 30 e. Remove the terminal block from the socket and f. Reinstall the terminal block into the socket on connect the CNC cable to the terminal block the Filter/Voltage Divider PC Board. (TB) per the following chart (see NOTES after g. Secure the CNC cable by tightening the strain chart): relief.

  • Page 31: Operation

    4. Work Cable and Clamp SECTION 4: Work cable with ring terminal (factory installed) for OPERATION connecting to work table. B. Control Panel 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 operat- ing procedures.
  • Page 32 D. Rear Panel 5. TEMP Indicator 1. Gas Input Normally OFF. Yellow indicator turns ON when the Input connection for air or nitrogen (N2) input. internal temperature senors detect temperatures above normal limits. The unit should be allowed to cool before continuing operation. WARNING 6.

  • Page 33: Sequence Of Operation

    4. Two Stage Air Line Filter 4.03 Sequence of Operation The Two Stage Air Filter will remove moisture and The following is a typical sequence of operation for this contaminants from the air stream when using com- cutting system. Refer to Appendix II for a block diagram. pressed air.

  • Page 34: Preparations For Operating

    10. Complete cutting operation. 4.04 Preparations for Operating NOTE Follow this set-up procedure each time the system is op- If the torch is lifted from the workpiece, while still erated: having torch is activated, the main arc will stop and the pilot arc will automatically restart. WARNING 11.

  • Page 35: Cut Quality

    H. Set Operating Pressure Nitride Build-up Nitride deposits which may remain on the surface of the Move the RUN/SET/LATCH switch to SET position. Ad- cut when nitrogen is present in the plasma gas stream. just the gas pressure to 60 - 70 psi / 4.1 - 4.8 bar. Refer to Nitride buildups may create difficulties if the material is torch manual for pressure setting details.
  • Page 36 OPERATION Manual 0-2811...

  • Page 37: Service

    For major troubleshooting and parts replacement pro- cedures refer to PAK Master 100XL Plus Automated Six Months or Every 720 Cutting Hours: Power Supply Service Manual 0-2812.

  • Page 38: Common Operating Problems

    C. Optional Single-Stage Filter Element 5.03 Common Operating Problems Replacement NOTE WARNINGS The Power Supply shuts down automatically when the Filter Element becomes completely saturated. Disconnect primary power at the source before dis- The Filter Element can be removed from its hous- assembling the power supply, torch, or torch leads.
  • Page 39 D. Direction of Cut F. Common Cutting Faults In the torch, the plasma gas stream swirls as it leaves the 1. Insufficient Penetration torch to maintain a smooth column of gas. This swirl ef- a. Cutting speed too fast fect results in one side of a cut being more square than the other.

  • Page 40: Troubleshooting Guide

    B. AC Power indicator ON; TEMP indicator ON For major troubleshooting and parts replacement pro- cedures refer to PAK Master 100XL Plus Automated 1. Airflow obstructed Power Supply Service Manual 0-2812. a. Check for obstructed air flow and correct con- C.
  • Page 41 C. Torch will not pilot when torch is activated (hand 3. Faulty components in unit pendant or CNC start signal) a. Return for repair or have qualified technician 1. RUN/SET/LATCH switch in SET position repair per Service Manual. a. Move switch to RUN position. G.

  • Page 42: Power Supply Parts Replacement

    B. Fuse Replacement 5.05 Power Supply Parts Replacement 1. Remove the left side panel per paragraph "A" above. 2. Locate the internal fuse above the input power WARNING contactor on the left side of the unit. 3. Replace the fuse. Refer to Section 6 for catalog Disconnect primary power to the system before dis- number.

  • Page 43: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provide a breakdown of all replaceable com- ponents. The parts lists are arranged as follows: Section 6.03 Complete Power Supply Replacement Section 6.04 Replacement Parts Section 6.05 Options and Accessories NOTE Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

  • Page 44: Complete Power Supply Replacement

    Power supply includes: Work cable and ring terminal, pressure regulator/air filter, two stage air filter and operating manual. Description Catalog # PAK Master 100XL Plus Automated Power Supply Without Input Plug and Cable 3-6862 6.04 Replacement Parts Description Catalog # Fuse (0.8 amp, 600V)

  • Page 45: Appendix I: Input Wiring Requirements

    APPENDIX I: INPUT WIRING REQUIREMENTS Input Power Input Current Input Suggested Sizes (See Notes) Voltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada) (Volts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph 50/60 18.9 17.3 50/60 18.9...

  • Page 46: Appendix Ii: Sequence Of Operation (Block Diagram

    APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) LATCH ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET/LATCH RUN/SET/LATCH switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops.

  • Page 47: Appendix Iii: Power Supply Cnc Interface Diagram

    APPENDIX III: POWER SUPPLY CNC INTERFACE DIAGRAM NOTE Cable connections from Cutting Machine Controller (CNC) to Plasma Power Supply. Cutting Machine CNC Cable Power Supply START/STOP Source 15 vdc, 10ma Black Blue Not Used Orange Not Used White 2A, 125 VAC Start Motion Green (OK-To-Move)

  • Page 48: Appendix Iv: Data Tag Information

    APPENDIX IV: DATA TAG INFORMATION West Lebanon, NH USA 03784 Manufacturer's Name and/or Logo, Location, Model and Revision Level, Serial Number Model: and Production Code Made in USA Type of Power Regulatory Standard Covering Supply (Note 1) This Type of Power Supply Output Current Type Duty Cycle Factor Output Range (Amperage/...
  • Page 49 This page left blank. Manual 0-2811 APPENDIX...

  • Page 50: Appendix V: System Schematic

    APPENDIX V: SYSTEM SCHEMATIC A-02765 APPENDIX Manual 0-2811...
  • Page 51 A-02765 Manual 0-2811 APPENDIX...

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