Thermal Dynamics PAK Master 150XL Bedienungsanleitung

Service Manual

November 18, 2005 Manual No. 0-2825

A-02861

Automated Plasma

Cutting Power Supply

PAK Master

150XL™

WARNINGS

Read and understand this entire Manual and your employer’s safety practices 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

Pak Master®150XL

Service Manual Number 0-2825

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written per-

mission 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

this Manual, whether such error results from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: November 18, 2005

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:_______________________________________

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 ............................................................................. 1-5

1.07 Declaration of Conformity .............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

INTRODUCTION ................................................................................................................... 1

2.01 Scope Of Manual ............................................................................................. 1

2.02 General Service Philosophy ............................................................................. 1

2.03 Service Responsibilities ................................................................................... 1

SECTION 3:

DESCRIPTION ................................................................................................................... 3-1

3.01 Scope of Manual ........................................................................................... 3-1

3.02 Power Supply General Description ................................................................ 3-1

3.03 Specifications/Design Features ..................................................................... 3-2

3.04 Power Supply Options and Accessories ....................................................... 3-3

2.05 Theory Of Operation ...................................................................................... 3-3

SECTION 4:

SERVICE .......................................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-1

4.02 Periodic Inspection & Procedures ................................................................. 4-1

4.03 System Theory ............................................................................................. 4-3

4.04 Common Operating Problems ....................................................................... 4-5

4.05 Troubleshooting Guide - General Information ................................................. 4-6

4.06 Circuit Fault Isolation .................................................................................... 4-7

4.07 Main Input and Internal Power Problems ....................................................... 4-8

4.08 Pilot Arc Problems ....................................................................................... 4-10

4.09 Main Cutting Arc Problems ..........................................................................4-12

4.10 Test Procedures ........................................................................................... 4-13

SECTION 5:

REPLACEMENT PROCEDURES ...................................................................................... 5-1

5.01 Introduction ................................................................................................... 5-1

5.02 Anti-Static Handling Procedures ................................................................... 5-1

5.03 Parts Replacement - General Information ...................................................... 5-1

5.04 Major External Parts Replacement ............................................................... 5-2

5.05 Access Panel Parts Replacement ................................................................ 5-3

5.06 Left Side Center Chassis Parts Replacement ............................................... 5-4

5.07 Right Side Center Chassis Parts Replacement ............................................. 5-8

5.08 Base Parts Replacement ............................................................................. 5-13

5.09 Rear Panel Parts Replacement ....................................................................5-16

TABLE OF CONTENTS (Continued)

SECTION 6:

PARTS LISTS .................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-1

6.02 Ordering Information ...................................................................................... 6-1

6.03 Major External Replacement Parts ............................................................... 6-2

6.04 Access Panel Replacement Parts ................................................................ 6-3

6.05 Left Side Center Chassis Replacement Parts ............................................... 6-4

6.06 Right Side Center Chassis Replacement Parts ............................................ 6-6

6.07 Base Replacement Parts ............................................................................. 6-8

6.08 Rear Panel Replacement Parts ................................................................... 6-10

6.09 Options and Accessories ............................................................................ 6-12

APPENDIX 1: INPUT WIRING REQUIREMENTS ....................................................................... A-1

APPENDIX 2: SEQUENCE OF OPERATION (BLOCK DIAGRAM) ............................................ A-2

APPENDIX 3: POT/LED PC BOARD LAYOUT .......................................................................... A-3

APPENDIX 4: LOGIC PC BOARD LAYOUT ............................................................................... A-4

APPENDIX 5: GATE DRIVE PC BOARD LAYOUT..................................................................... A-6

APPENDIX 6: PILOT/OUTPUT PC BOARD LAYOUT AND WIRING CONNECTION DIAGRAM .. A-8

APPENDIX 7: CD PC BOARD LAYOUT .................................................................................. A-10

APPENDIX 8: INPUT PC BOARD LAYOUT ............................................................................. A-11

APPENDIX 9: FET PC BOARD LAYOUT ................................................................................. A-12

APPENDIX 10: CAPACITOR PC BOARD LAYOUT .................................................................. A-14

APPENDIX 11: CURRENT SENSOR PC BOARD LAYOUT ..................................................... A-15

APPENDIX 12: 36VAC CIRCUIT DIAGRAM ............................................................................. A-16

APPENDIX 13: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE

FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .................................................... A-17

APPENDIX 14: TYPICAL MECHANIZED SYSTEM GROUNDING DIAGRAM ........................... A-18

APPENDIX 15: POWER SUPPLY CNC INTERFACE DIAGRAM

WITHOUT STANDOFF CONTROL ................................................................................... A-19

APPENDIX 16: TYPICAL MECHANIZED SYSTEM CABLE INTERCONNECTION DIAGRAM ... A-20

APPENDIX 17: QUICK REFERENCE TO INTERCONNECTING CABLES AND HOSES .......... A-21

TABLE OF CONTENTS (Continued)

APPENDIX 18: FILTER/VOLTAGE DIVIDER PC BOARD LAYOUT .......................................... A-22

APPENDIX 19: SYSTEM SCHEMATIC for Units to Rev AH ..................................................... A-24

APPENDIX 20: SYSTEM SCHEMATIC for Units Rev AJ and Later ........................................... A-26

Date: November 15, 2004 1-1 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 in-

formation 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.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

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.”

GENERAL INFORMATION 1-2 Date: November 15, 2004

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

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

tions.

• Disconnect power source before performing any

service 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 ma-

terial 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.

PLASMAARC 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 Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-

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

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Office, Washington, D.C. 20402

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

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2004 1-3 GENERAL INFORMATION

6. ANSIStandard Z49.2,FIRE PREVENTIONIN THEUSE OF

CUTTINGAND WELDING PROCESSES, obtainable from

AmericanNational Standards Institute,1430 Broadway,New

York, NY 10018

7. AWS StandardA6.0, WELDING AND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable from American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

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 Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPAStandard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

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 WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society StandardAWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS 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 RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

1.04 Note, Attention et

Avertissement

Danscemanuel,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.

GENERAL INFORMATION 1-4 Date: November 15, 2004

FUMÉEet 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 respiration.

Gardezvotretête 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.

• Lessortes de gaz et de fumée provenantde l’arc de plasma

dépendent du genre de métal utilisé, des revêtements se

trouvantsur lemétaletdes différentsprocédés. Vousdevez

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 combus-

tibles 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.

• Ce produit, dans le procéder de soudage et de coupe,

produit de la fumée ou des gaz pouvant contenir des

éléments reconnu dans L’état de la Californie, qui

peuvent causer des défauts de naissance et le cancer. (La

sécuritéde santé enCalifornieet la codesécuritéSec. 25249.5

et seq.)

CHOCELECTRIQUE

Leschocs électriques peuvent blesseroumême tuer.Leprocédé

aujet de plasma requiertetproduit de l’énergie électriquehaute

tension.Cette énergieélectriquepeut produiredeschocs graves,

voire mortels, pour l’opérateur et les autres personnes sur le

lieude 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 parties 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

couperles alliages en aluminiumsousl’eau ou sur unetable

d’eau à moins que le gas hydrogène peut s’échapper ou se

dissiper. Legashydrogèneaccumuléexploserasienflammé.

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