Thermal Dynamics Pak Master 25 Operating Manual
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Thermal Dynamics Pak Master 25 Operating Manual

Thermal Dynamics Pak Master 25 Operating Manual

Thermal dynamics air plasma cutting system
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R
EUROPEAN
Air Plasma Cutting System
For 110VAC Systems
The System Includes:
®
• Pak Master
25™ EMC Power Supply
• EMC PCH-25 Torch with Leads
• Input Power Cable
• Work Cable with Clamp
Operating Manual
Manual No. 0-2577
October 31, 2002

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Summary of Contents for Thermal Dynamics Pak Master 25

  • Page 1 EUROPEAN Air Plasma Cutting System For 110VAC Systems The System Includes: ® • Pak Master 25™ EMC Power Supply • EMC PCH-25 Torch with Leads • Input Power Cable • Work Cable with Clamp Operating Manual Manual No. 0-2577 October 31, 2002...
  • Page 3 The publisher does not assume and hereby disclaims any liabil- ity to any party for any loss or damage caused by errors or omissions in the Pak Master 25 EMC Air Plasma Cutting System (110VAC) Operating Manual, whether such errors result from negligence, accident, or any other cause.
  • Page 4 Record Serial Numbers For Warranty Purposes Purchase Date Power Supply Torch...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION ......................i Notes, Cautions and Warnings ................. i Important Safety Precautions .................. i Publications ......................ii Note, Attention et Avertissement ................iii Precautions De Securite Importantes ..............iii Documents De Reference ..................v Declaration of Conformity ..................vii Statement of Warranty ..................
  • Page 6 TABLE OF CONTENTS (continued)

  • Page 7: General Information

    GENERAL INFORMATION GASES AND FUMES Notes, Cautions and Warnings Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high- •...

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding cir- PLASMA ARC RAYS cuit. • 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 ATTENTION USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards In- stitute, 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 respect de la procédure en question.
  • Page 10 • Utilisez un appareil respiratoire à alimentation en • Réparez ou remplacez toute pièce usée ou air si l’aération fournie ne permet pas d’éliminer la endommagée. fumée et les gaz. • Prenez des soins particuliers lorsque la zone de tra- •...

  • Page 11: Documents De Reference

    • Portez des gants de soudeur et un vêtement protecteur 2. Norme ANSI Z49.1, LA SÉCURITÉ DES approprié pour protéger votre peau contre les OPÉRATIONS DE COUPE ET DE SOUDAGE, étincelles et les rayons de l’arc. disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W.
  • Page 12 12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards 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...

  • Page 13: Declaration Of Conformity

    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.

  • Page 14: Statement Of Warranty

    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.

  • Page 15: Section 1: Introduction & Description

    1.1 SYSTEM DESCRIPTION ® The PAK MASTER 25™ • PAK MASTER 25™ EMC Model - The Power Supply provides European Air Plasma 20 amps maximum output cutting current from a standard 110 Cutting System volt, 50/60Hz AC single phase input service. All electrical, Includes: pilot, and gas control circuitry is included.

  • Page 16: System Options And Torch Parts

    • The Leads Storage Kit (Catalog # 7-0253) - Provides a place to store the EMC Pak Master 25 Torch Leads and is designed to be mounted on the top of the Pak Master 25 EMC Model Power Supply. • Air Line Filter - Removes damaging contaminants and mois- ture from the air stream when using compressed air.

  • Page 17: Section 2: Installation

    SECTION 2: INSTALLATION 2.1 UNPACKING AND CHOOSING A LOCATION What's Included with Included with each system is: the Power Supply (1) Work Cable with Clamp (Attached) (1) 14 AWG Single-Phase Input Power Cable (Attached) (1) Operating Manual ..........Cat. No. 0-2577 (1) Spare Parts Kit - Includes: (5) Standard Tips ..........

  • Page 18: Electrical Connections

    2.2 ELECTRICAL CONNECTIONS Disconnect primary power at the source before disassembling WARNING the power suply, torch or torch leads. Power Requirements The unit will operate from single phase 110V ±10%, 50/60 Hz. The service should be fused for 15 amps. Input power connections can be made directly to a properly NOTE fused disconnect or by using a plug which conforms to the...

  • Page 19: Gas Connections

    2.3 GAS CONNECTIONS Gases Compressed Air or Nitrogen (N Only Pressure 50 psi (2.8 BAR) Flow 125 scfh (59 lpm) CAUTION Maximum input gas pressure must not exceed 125 psi (8.6 BAR). WARNING This cutting system must not be used with Oxygen (O CAUTION Air supply must be free of oil, moisture, and other contaminants.
  • Page 20 Do not use an air line filter with high pressure gas cylinders. Using Shop Air To use shop air from a compressor, refer to Figure 2-B and: 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.

  • Page 21: Secton 3: Operation

    SECTON 3: OPERATION 3.1 OPERATING CONTROLS AC Power AC Power TEMP Gas Pressure Gas Pressure WORK Cable Switch Indicator Indicator Indicator Indicator Gauge Control Cable OPERATING INPUT POWER AC POWER PRESSURE WORK 50 PSI (3.4 BAR) PRESSURE TORCH ® ® CURRENT Made in the USA Note: Handle Not Shown...

  • Page 22: Getting Started

    3.2 GETTING STARTED Disconnect primary power at the source before disassembling WARNING the power supply, torch, or torch leads. Follow this set-up procedure each time the system is operated: Check Torch Parts 1. Check the torch for proper assembly and appropriate front end torch parts (see Section 4.5, Replacing Consumable Torch Parts).

  • Page 23: Sequence Of Operation

    3.3 SEQUENCE OF OPERATION ACTION ACTION ACTION ACTION RUN/SET Switch to SET RUN/SET switch ON/OFF switch RESULT Plug in to RUN to ON. Gas solenoid open, Power Cord RESULT gas flows to set Gas flow stops. RESULT pressure. RESULT GAS indicator off. Gas indicator ON Power circuit ready.

  • Page 24: Cut Quality

    3.4 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 second- ary cleaning operation.
  • Page 25 TYPE OF MATERIAL MATERIAL THICKNESS Carbon Steel Stainless Steel Aluminum Good - Excellent Good - Excellent Good - Excellent Gage to 1/4 in. Nitrogen (Aluminum to 3/16 in.) Good Good Good Table 3-A Cut Quality on Various Materials and Material Thicknesses Description of Cut Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice Characteristics...

  • Page 26: Operating The System

    3.5 OPERATING THE SYSTEM Disconnect primary power at the source before disassembling WARNING the power supply, torch, or torch leads. Frequently review the Important Safety Precautions at the beginning of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no WARNING part of the operator’s body comes into contact with the work- piece while the torch is activated.
  • Page 27 Common Cutting Faults Problem Possible Cause 1. Cutting speed too fast 2. Torch tilted too much Insufficient 3. Metal too thick Penetration 4. Worn torch parts 5. Cutting current too low 1. Cutting speed too slow 2. Torch standoff too high from workpiece Main Arc 3.

  • Page 28: Operating With A Hand Torch

    3.6 OPERATING WITH A HAND TORCH Cutting with a 1. The torch can be comfortably held in one hand or steadied Hand Torch with two hands. Choose the technique that feels most com- fortable and allows good control and movement. Position the index finger or thumb to press the control switch on the torch handle.

  • Page 29: Recommended Cutting Speeds

    3.7 RECOMMENDED CUTTING SPEEDS Cutting speed depends on material, thickness, and the operator’s Recommended Cutting Speeds ability to accurately follow the desired cut line. The following factors may have an impact on system performance: • Torch parts wear • Air quality •...
  • Page 30 Material Thickness Cut Speed (IPM) Amps Gas / Pressure Stand Off ALUMINUM 24 gauge Air / 50 psi Drag - 1/8" 22 gauge Air / 50 psi Drag - 1/8" 1/16" (1.6 mm) Air / 50 psi Drag - 1/8" 3/32"...

  • Page 31: Section 4: Customer/Operator Service

    SECTION 4: CUSTOMER/OPERATOR SERVICE 4.1 POWER SUPPLY SPECIFICATIONS Controls • ON/OFF Switch • RUN/SET Switch • Output Current Control • Pressure Regulator Control Panel Indicators LED Indicators: AC Power, GAS, DC, TEMP Pressure Gauge Input Power 110 VAC (±10%), 50/60 Hz, 15 Amp Single Phase Output Power Continuously variable from 12 to 20 Amps maximum 375 VDC...

  • Page 32: Torch Specifications

    4.2 TORCH SPECIFICATIONS Configuration 70º or 90° Hand Torch Current Rating 20 Amps Maximum, DC Straight Polarity Duty Cycle 100% Cutting Range Most materials up to 1/4 in (6.4 mm) Pierce Rating 1/8 in (3.2 mm) Transfer Distance 1/8 in (3.2 mm) Consumable Parts Gas Distributor, Electrode, Tip, Shield Cup Gases...

  • Page 33: Replacement Torches And Leads

    Address all inquiries to your authorized Thermal Dynamics distributor. If a Thermal Dynamics product must be returned for service, contact your Thermal Dynamics distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted.

  • Page 34: Basic Troubleshooting Giuide And Maintenance

    4.4 BASIC TROUBLESHOOTING GIUIDE AND MAINTENANCE Basic troubleshooting of the Pak Master 25 EMC Model Plasma General Cutting System can be performed without special equipment or knowledge, and without opening the enclosure. This basic troubleshooting guide covers input power, gas sup- ply, and torch problems.
  • Page 35 SYMPTOM POSSIBLE CAUSE REMEDY A. AC indicator not lighted. 1. Circuit Breaker open. 1. Reset Breaker. Use 15 Fan does not turn. amp or greater service. 1. Unit is overheated. 1. Make sure the unit has B. AC indicator lighted. not been operated (TEMP) indicator lighted.

  • Page 36: Replacing Consumable Torch Parts

    4.5 REPLACING CONSUMABLE TORCH PARTS Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply. DO NOT TOUCH internal torch parts while the AC indicator on WARNING the front panel of the power supply is lit. The tip, gas distributor, and electrode are held in place by the NOTE shield cup.

  • Page 37: General Torch Maintenance

    4.6 GENERAL TORCH MAINTENANCE Even if precautions are taken to use only clean air with a torch, Cleaning the Torch eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

  • Page 38: Servicing Torch Head Components

    4.7 SERVICING TORCH HEAD COMPONENTS Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply. NEVER touch any internal torch parts while the AC indicator WARNING light on the front panel of the control module is lit. Tools Required (1) No.
  • Page 39 Handle O-Ring (position in rear groove) Mounting Screws Position PIP wires in notches in back of split holder Align notch on pilot lead with notch in split holder PIP Pin Assemblies A-00782 Figure 4-E Disassembling the Split Holder Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply.
  • Page 40 Replacing the 5. Position both PIP leads through the notch where the nega- PIP Assembly tive/plasma lead exits the holder. (continued) 6. Position the torch head inside the holder. Align the notch on the pilot lead with the corresponding tab on the split holder. Make sure the negative/plasma fitting is securely inserted in the groove in the holder.
  • Page 41 Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply. Reassembling the Refer to Figure 4-D and: Torch Handle and 1. Connect the plasma and pilot lead connections at the torch Switch Assembly head. 2. Place the torch head in the handle and carefully return the torch switch and button to their proper position.

  • Page 42: Replacing Torch And Leads

    4.8 REPLACING TORCH AND LEADS Disconnect primary power to the system before disassembling WARNING the torch, leads, or power supply. Open Power Supply Refer to Figure 4-G and: Enclosure 1. Swing the handle into the forward position before removing any hardware. 2.
  • Page 43 The torch bulkhead is located directly behind the torch lead LocateTorch panel strain relief. Refer to Photo 4-A and: Bulkhead 1. Remove the nylon screw holding the protective insulating sheet to the bulkhead. 2. Loosen the torch lead strain relief nut inside the front panel. Replace Leads Do not remove the strain relief from the leads.
  • Page 44 CUSTOMER/OPERATOR SERVICE Manual 0-2577...

  • Page 45: Section 5: Parts Lists

    SECTION 5: PARTS LISTS 5.1 REPLACEMENT COMPLETE ASSEMBLIES Description Qty. Catalog # Complete PM 25 EMC Model 110V Systems: Power Supply, PCH-25 Torch (70 degree) 12.5 ft (3.8 m) Leads 1-0280 Power Supply, PCH-25 Torch (70 degree) 25 ft (7.6 m) Leads 1-0281 Power Supply, PCH-25 Torch (90 degree) 1-0282...

  • Page 46: Replacement Hand Torch Parts

    5.2 REPLACEMENT HAND TORCH PARTS Item # Description Catalog # Assembly, PIP (Parts-In-Place) Pins and Wire 9-6290 O-Ring 8-0533 Holder, Torch, Split, PCH25 70° Two Parts w/Screws 9-6259 Holder, Torch, Split, PCH25 90° Two Parts w/Screws 9-6260 Assembly, Basic Head, PCH25 70° 9-5807 Assembly, Basic Head, PCH25 90°...

  • Page 47: Miscellanous Parts

    5.3 MISCELLANOUS PARTS Description Catalog # Air Regulator/Gauge Assembly (see note) For units with rev letter 'F' or earlier 9-6283 For units with rev letter 'G' or later 9-6898 Cover, Grey, No Labels 9-6284 Torch Parts Label 9-6285 Warning Label 9-6286 PakMaster 25 Labels, Side (2 Required) 9-6287...

  • Page 48: Appendix I: System Schematic

    APPENDIX I: SYSTEM SCHEMATIC A-00801 APPENDIX Manual 0-2577...
  • Page 49 A-00801 APPENDIX Manual 0-2577...

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