Thermal Dynamics PakMaster 100 XL plus Bedienungsanleitung

Plasma Cutting

Power Supply

PAKMaster®100 XLTM Plus

A-02464

Operating Manual

February 10, 2003 Manual No. 0-2748

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-

ating, 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.

Plasma Cutting Power Supply

PAK Master®100XLTM Plus

Operating Manual Number 0-2748

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 permission 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: February 10, 2003

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 andWarnings ..................................................................... 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 ofWarranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION .............................................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description of System..................................................................... 2-1

2.03 Specifications / Design Features .................................................................. 2-1

2.04 Power Supply Options and Accessories ...................................................... 2-2

SECTION 3:

INSTALLATION ................................................................................................................. 3-1

3.01 Introduction .................................................................................................. 3-1

3.02 Site Selection ............................................................................................... 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Lifting Options .............................................................................................. 3-1

3.05 Input Power Connections ............................................................................. 3-2

3.06 InputVoltage Selection ................................................................................. 3-2

3.07 Primary Input Power Cable Connections ...................................................... 3-3

3.08 Gas Connections ......................................................................................... 3-4

3.09 ConnectingTorch Leads............................................................................... 3-6

3.10 Ground Connections For Mechanized Applications ...................................... 3-9

3.11 Tip Saver / Drag Cut Sensing Circuit.......................................................... 3-11

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Operating Controls ....................................................................................... 4-1

4.02 Sequence Of Operation................................................................................ 4-4

4.03 Preparations for Operating ........................................................................... 4-5

4.04 Cut Quality ................................................................................................... 4-6

TABLE OF CONTENTS (continued)

SECTION 5:

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

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

5.02 GeneralMaintenance ................................................................................... 5-1

5.03 Common Operating Problems ...................................................................... 5-2

5.04 TroubleshootingGuide ................................................................................. 5-4

5.05 Power Supply Parts Replacement ................................................................ 5-6

SECTION 6:

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

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

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

6.03 Complete Power Supply Replacement ......................................................... 6-2

6.04 Replacement Parts....................................................................................... 6-2

6.05 Options and Accessories ............................................................................. 6-2

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

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

APPENDIX 3: MAINTENANCE SCHEDULE ............................................................................A-3

APPENDIX 4: SYSTEM SCHEMATIC.......................................................................................A-4

May 14, 2002 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

properfunctionof cardiac pacemakers,hearingaids,

or other electronic health equipment. Persons who

work near plasma arc cutting applications should

consult their medical health professional and the

manufacturer of the health equipment to determine

whether a hazard exists.

To prevent possible injury, read, understand and

followall warnings, safety precautionsandinstruc-

tions before using the equipment. Call 1-603-298-

5711 or your local distributor if you have any ques-

tions.

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

inyourworkplace, refertoitem 1 in Subsection 1.03,

Publications in this manual.

• Usespecialequipment,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.

• Thisproduct, whenused for weldingor cutting, pro-

duces 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 May 14, 2002

• 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,referto item9inSubsection 1.03, Publications.

• Disconnectpower sourcebeforeperforming any ser-

vice 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 mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Donot cut or weld oncontainersthat may have held

combustibles.

• Providea firewatchwhenworking in an areawhere

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut underwa-

ter or while using a water table. DO NOT cut alu-

minum alloys underwater or on a water table un-

less the hydrogen gas can be eliminated or

dissipated. 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.

• Noiselevelsshould be measuredto be surethe 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 workpiece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainablefromthe Superintendent ofDocuments,

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

ANDGAS WELDINGANDCUTTING, obtainable from

the Superintendent of Documents, U.S. Government

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 theAmeri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

May 14, 2002 1-3 GENERAL INFORMATION

6. ANSI StandardZ49.2,FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS StandardA6.0, WELDINGAND 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, CUTTINGAND 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. CSAStandard 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 SocietyStandardAWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDINGAND CUTTING OF CONTAIN-

ERSAND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from theAmerican 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

GENERAL INFORMATION 1-4 May 14, 2002

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

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.

Serialnumbersareunique with each individual piece of equipmentanddetailsdescription,partsused to manufacture a unit

and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA(Canadian StandardsAssociation) standard C22.2 number 60 forArc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related

industry standards, and performs as specified. 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.

Manufacturers responsible representative: Giorgio Bassi

Managing Director

Thermal Dynamics Europe

Via rio Fabbiani 8A

40067 Rastignano (BO)

Italy

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