Thermal Dynamics PakMaster 100 XL plus Operating Manual
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Thermal Dynamics PakMaster 100 XL plus Operating Manual

Thermal Dynamics PakMaster 100 XL plus Operating Manual

Air plasma cutting power supply
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A-02464
Manual No. 0-2748
August 23, 1999

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Summary of Contents for Thermal Dynamics PakMaster 100 XL plus

  • Page 1 A-02464 Manual No. 0-2748 August 23, 1999...
  • Page 2 While the information contained in this Operating Manual WARNING represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. ® Pak Master 100XL Plus Air Plasma Cutting Power Supply...
  • Page 3 Record Serial Numbers For Warranty Purposes Purchase Date Power Supply Torch...

  • Page 5: Table Of Contents

    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 ................
  • Page 6 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................31 6.01 Introduction ....................31 6.02 Ordering Information ..................31 6.03 Complete Power Supply Replacement ............32 6.04 Replacement Parts ..................32 6.05 Options and Accessories ................32 APPENDIX I: INPUT WIRING REQUIREMENTS ..............33 APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ...........

  • 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

    • Install and maintain equipment according to NEC • To protect your eyes, always wear a welding hel- code, refer to item 9 in Subsection 1.03, Publica- met or shield. Also always wear safety glasses with tions. side shields, goggles or other protective eye wear. •...

  • Page 9: Note, Attention Et Avertissement

    8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PRO- AVERTISSEMENT CESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, Toute procédure pouvant provoquer des blessures obtainable from the National Fire Protection Asso- de l’opérateur ou des autres personnes se trouvant ciation, Batterymarch Park, Quincy, MA 02269...
  • Page 10 • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des INCENDIE ET EXPLOSION revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous Les incendies et les explosions peuvent résulter des scories coupez ou soudez tout métal pouvant contenir un chaudes, des étincelles ou de l’arc de plasma.

  • Page 11: Documents De Reference

    • Utilisez la nuance de lentille qui est suggèrée dans 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA le recommendation qui suivent ANSI/ASC Z49.1: PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro...
  • Page 12 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.

  • 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: Introduction

    ® A. Power Supply Technical Specifications 100XL PLUS Air Plasma Cutting Power Supply only. Ser- vice of this equipment is restricted to Thermal Dynamics The following specifications apply to the Power Supply trained personnel; unqualified personnel are strictly cau- only: tioned against attempting repairs or adjustments not cov- ered in this manual, at the risk of voiding the Warranty.

  • Page 16: Power Supply Options And Accessories

    10. Overall Dimensions D. Smart Cart Overall dimensions are with handle, lead wrap Steel cart on easy rolling 10" pneumatic tires to pro- bracket, and Gas Regulator/Filter Assembly installed. vide maximum mobility for the power supply. Handle is 3/4" tubing with hooks for storage of torch leads. 19"...

  • Page 17: Installation Procedures

    vide sufficient clearance in front of the unit to allow ac- SECTION 3: cess to the front panel controls (minimum 6 inches or 0.15 INSTALLATION PROCEDURES CAUTION Operation without proper air flow will inhibit 3.01 Introduction proper cooling and reduce duty cycle. NOTE 3.03 Unpacking Depending on how the system was ordered, some...

  • Page 18: Input Power Connections

    • If using a fork lift vehicle, place and secure unit on a proper skid before transporting. Left Side • This unit has a handle mounted on top of the enclo- Panel sure for hand lifting only. Be sure unit is lifted and transported safely and securely.

  • Page 19: 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 20: 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 21 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 insure that moisture and debris from the supply hose does of the torch and turn on the gas.

  • Page 22: Connecting Torch Leads

    E. Using High Pressure Gas Cylinders 1. Refer to the following when using high pressure gas cylinders as the gas supply: Access Panel CAUTION Pressure should be set at 100 psi (6.9 bar) at the high pressure gas cylinder regulator. a.

  • Page 23: Work Cable And Ground Connections

    4. Feed the end of the torch leads through the hole in the B. Creating an Earth Ground front panel in the following order: 1. Install a ground wire (not included) between the sys- • Control Cable tem and a solid earth ground (also called star ground). To create a solid earth ground, drive a 1/2 in (12 mm) •...

  • Page 24: Tip Saver/Drag Cut Sensing Circuit

    3.11 Tip Saver/Drag Cut Sensing Circuit This power supply is equipped with a Tip Saver/Drag Cut Sensing Circuit which cuts current back to 35 amps if the tip touches the workpiece. The purpose of this is to prolong the life of the tip. If the user does not want the current to be decreasedwhen the tip touches the workpiece, the sensing circuit can be defeated by closing switch SW1-1 on the Gate/Logic PC...

  • Page 25: Operation

    3. Torch Leads Input SECTION 4: Hole in the front panel to feed the torch leads through OPERATION to the internal bulkhead connections. 4. Work Cable and Clamp 4.01 Introduction Work cable with clamp (factory Installed). This section provides a description of the Power Supply 5.
  • Page 26 3. RUN/SET/LATCH Switch 2. Control Cable Connector RUN position is used for general torch operation Connects the torch switch to the unit. In machine torch (torch switch must be held). SET position used for applications connects the torch switch on the pendant setting pressure and purging gas lines.

  • Page 27: Sequence Of Operation

    Primary input power cable strain relief for the pri- mary power cable (see Note) capable of handling the 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.

  • Page 28: Preparations For Operating

    5. Place RUN/SET/LATCH switch to RUN mode. a. Gas solenoid closes a. Gas flow stops. b. Gas flow stops. b. GAS indicator turns OFF. c. GAS indicator turns OFF. 6. Protect eyes and press or activate torch switch 14. Place the ON/OFF power switch on the front panel of the unit to OFF a.

  • Page 29: Cut Quality

    B. Check primary power source as follows: I. RUN/SET Switch 1. Check the power source for proper input voltage. Make Set the RUN/SET/LATCH switch to RUN position. sure the input power source meets the power require- The system is now ready for operation. ments for the unit per Section 2.03-A-4, Specifications/ Design Features.
  • Page 30 Kerf Width Cut Surface Bevel Angle Spatter Top Edge Rounding Dross Build-Up A-00007 Cut Surface Drag Lines Figure 4-9 Cut Quality Characteristics Cut quality will vary on different types of and material thicknesses. The following table shows the cut quality that can be ex- pected from this equipment for materials with a thick- ness from gage to 1 inch (25.4mm): T yp e o f M ater ial...

  • Page 31: Customer/Operator Service

    Weekly or Every 30 Cutting Hours: SECTION 5: 1. Check fan for proper operation and adequate air CUSTOMER/OPERATOR flow. SERVICE 2. Vacuum dust and dirt out of the entire machine. CAUTION 5.01 Introduction Do not blow air into the power supply during clean- This section describes basic maintenance procedures per- ing.

  • Page 32: Common Operating Problems

    3. Disconnect gas supply hose from barbed fitting. B. Torch Standoff 4. Turn the Cover counterclockwise and remove it Improper standoff (the distance between the torch tip and from the Filter Housing. The Filter Element is lo- workpiece) can adversely affect tip life as well as shield cated inside the Housing.

  • Page 33: Troubleshooting Guide

    Dross present on top of the plate (top spatter), is normally caused by a slow torch travel speed or too high of a torch WARNING standoff distance. F. Common Cutting Faults There are extremely dangerous voltage and power 1. Insufficient Penetration levels present inside this unit.
  • Page 34 3. Customer's main power line fuse(s) blown 4. Faulty components in unit a. Check main power panel fuse(s) and replace as a. Return for repair or have qualified technician required. repair per Service Manual. 4. Actual input voltage does not correspond to voltage D.

  • Page 35: Power Supply Parts Replacement

    H. AC Power indicator ON; Cutting output avail- A. Left Side Panel Removal able; Fans not operating, 1. Using a phillips head screw driver remove the five 1. Fan blades blocked screws which secure the left side panel (viewed from front of unit) to the frame assembly. a.
  • Page 36 Internal Fuse A-01354 0.8 Amps, 600V Figure 5-4 Internal Fuse Location SECTION 5: SERVICE Manual 0-2748...

  • Page 37: Parts Lists

    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 ser- vice, contact your Thermal Dynamics distributor. Mate- rials returned to Thermal Dynamics without proper au- thorization will not be accepted.

  • Page 38: Complete Power Supply Replacement

    6.03 Complete Power Supply Replacement Power supply includes: Work cable, pressure regulator/air filter, air hose and fittings, and operating manual. Description Catalog # PAK Master 100XL PLUS Power Supply 208/230VAC, Single-Phase with Input Cable & Molded Plug 3-0056-1 460VAC, Three-Phase without Input Cable & Plug 3-0056-2 6.04 Replacement Parts Description...

  • Page 39: 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 40: 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 41 This Page is Blank Manual 0-2748 APPENDIX...

  • Page 42: Appendix Iii: System Schematic

    APPENDIX III: SYSTEM SCHEMATIC INRUSH INRUSH A-02465 APPENDIX Manual 0-2748...
  • Page 43 OK TO MOVE 8/23/99 08/23 AC EC 8397 A-02465 Manual 0-2748 APPENDIX...
  • Page 44 APPENDIX Manual 0-2748...

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