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Thermal Dynamics Pak Master 100XL Operating Manual Download Page 1

Manual No. 0-2581

December 15, 1998

PAK MASTER

®

 100XL

Air Plasma Cutting

Power Supply

Operating Manual

A-01355

Summary of Contents for Pak Master 100XL

Page 1: ...Manual No 0 2581 December 15 1998 PAK MASTER 100XL Air Plasma Cutting Power Supply Operating Manual A 01355...

Page 2: ......

Page 3: ...rmal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 1996 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole o...

Page 4: ...STALLATION PROCEDURES 11 3 01 Introduction 11 3 02 Site Selection 11 3 03 Unpacking 11 3 04 Lifting Options 12 3 05 Input Power Connections 12 3 06 Input Voltage Selection 13 3 07 Input Power Cable Co...

Page 5: ...31 6 01 Introduction 31 6 02 Ordering Information 31 6 03 Complete Power Supply Replacement 32 6 04 Options and Accessories 33 APPENDIX I INPUT WIRING REQUIREMENTS 35 APPENDIX II SEQUENCE OF OPERATION...

Page 6: ......

Page 7: ...ng 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...

Page 8: ...ped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as recommended in Subsec tion 1 03 item 4 1 03 Publications Refer to the f...

Page 9: ...TISSEMENT L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Il faut communiquer aux op rateurs et au person nel TOUS les...

Page 10: ...rs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous...

Page 11: ...COMBUSTIBLES disponible aupr s de laAmerican Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies NFPA LES SYSTEMES GAZ AV...

Page 12: ...ardsAssociation standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974...

Page 13: ...for Thermal products shall be as follows with the exception of CutMaster 80XL Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 year...

Page 14: ...GENERAL INFORMATION 8...

Page 15: ...igned to work with the Model PCH M 100XL Plasma Torches Torches will provide a maximum 1 inch 25 4 mm cut capacity Hand torches are available in 70 and 90 con figurations Machine torches are available...

Page 16: ...ir line filter is available The filter will remove moisture and contaminants from the air stream when using compressed air The filter is capable of filtering to at least 5 microns The filter assembly...

Page 17: ...cient 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...

Page 18: ...e input For any other input voltage the Power Supply must be internally reset NOTE Refer to Section 3 06 Input Voltage Selection for procedure A Input Voltage Selection The Power Supply is factory wir...

Page 19: ...ng the voltage selection block to the terminal block 3 Pull the voltage selection block up and out from the terminal block 4 Turn the voltage selection block to the desired voltage to be used Use 220V...

Page 20: ...3 5 Primary Power Cable Connections Three Phase Operation Single Phase Operation Single phase operation requires a 2 conductor cable with ground a Locate the single phase jumper wire connected betwee...

Page 21: ...d other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting performance and rapid electrode wear An air li...

Page 22: ...lpm 6 Slide the gas supply hose over the barb fitting installed in Step 2 7 Secure the gas supply hose to the Barb fitting with the adjustable hose clamp NOTE Supply hose must be at least 4 hose 1 4...

Page 23: ...rference EMI commonly called RF noise This RF may interfere with other elec tronic equipment such as CNC controllers etc To mini mize RF interference follow these grounding procedures when installing...

Page 24: ...INSTALLATION PROCEDURES 18 Manual 0 2581 Make a solid work cable connection to the work piece or cutting table Work Cable And Clamp A 01349 Figure 3 13 Power Supply Work Cable Connection...

Page 25: ...front panel to feed the torch leads through to the internal bulkhead connections 4 Work Cable and Clamp Work cable with clamp factory Installed 5 Torch Leads and Spare Parts Kit Storage Area Bracket...

Page 26: ...ed under the access panel 1 Pilot Lead Stud Connects the pilot control wire on the torch to the unit 2 1 3 A 00923 Figure 4 3 Torch Panel Connections 2 Control Cable Connector Connects the torch switc...

Page 27: ...S indicator turns ON NOTE GAS indicator will not come ON if the gas pres sure is set below 45 psi 3 1 BAR or 310 kPa at the Regulator Filter Assembly 5 Place RUN SET switch to RUN mode a Gas flow stop...

Page 28: ...s pressure and flow requirements refer to Section 3 08 Gas Connections Check connection and turn gas supply on D Work Cable Connection Check for a solid and clean work cable connection to the workpiec...

Page 29: ...lties if the material is welded after the cutting process Kerf Width Cut Surface Bevel Angle Top Edge Rounding Cut Surface Drag Lines Dross Build Up Top Spatter A 00007 Figure 4 7 Cut Quality Characte...

Page 30: ...OPERATION 24 Manual 0 2581...

Page 31: ...rch or torch leads Frequently review the Important Safety Precau tions page 1 Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s bo...

Page 32: ...tting current too low 2 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c Cutting current too high d Work cable disconnected e Worn torch parts 3 Excessive Dros...

Page 33: ...ucted air flow and correct con dition 2 Fan blocked a Check and correct condition 3 Unit is overheated a Allow unit to cool down for about 5 minutes Make sure the unit has not been operated be yond du...

Page 34: ...cian repair per Service Manual J Torch cuts but not adequately 1 Current set too low a Increase current setting 2 Torch is being moved too fast across workpiece a Reduce cutting speed refer to Instruc...

Page 35: ...el per paragraph A above 2 Locate the internal fuse above the input power con tactor on the left side of the unit 3 Replace the fuse 0 8 amp 600V 4 Reinstall the left side panel per paragraph A above...

Page 36: ...SERVICE 30 Manual 0 2581...

Page 37: ...t 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 wit...

Page 38: ...ply includes Work cable pressure regulator air filter air hose and fittings and operating manual Description Qty Catalog PAK Master 100XL Power Supply 208 230VAC Single Phase With 50 Amp Input Plug an...

Page 39: ...ter Kit 7 7500 Replacement Elements 1 First Stage 9 1021 1 Second Stage 9 1022 1 Smart Cart 7 7777 Interface Cable For Use With Machine Torches Only 1 25 foot 7 62m 8 5557 1 50 foot 15 24m 8 5558 1 57...

Page 40: ...PARTS LISTS 34 Manual 0 2581...

Page 41: ...Wire Sizes Based on National Electric Code and Canadian Electrical Code NOTES Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements Cable size is de...

Page 42: ...orch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to syst...

Page 43: ...Manual 0 2581 37 APPENDIX...

Page 44: ...APPENDIX 38 Manual 0 2581 APPENDIX III SYSTEM SCHEMATIC A 01360...

Page 45: ...Manual 0 2581 39 APPENDIX A 01360 B EC 8055 HAS 11 23 98...

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