PLASMA CUTTING
POWER SUPPLY
PAK Master® 38XL
Used With PCH-42 RPT SureLok™ Torch
A-01721
Instruction Manual
June 21, 2002
Manual No. 0-2872
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.
Plasma Cutting Power Supply
PAK Master® 38XL
Instruction Manual Number 0-2872
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
Copyright 2001 by
Thermal Dynamics Corporation
All rights reserved.
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: June 21, 2002
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
1.02
1.03
1.04
1.05
1.06
1.07
1.08
Notes, Cautions and Warnings ..................................................................... 1-1
Important Safety Precautions ....................................................................... 1-1
Publications .................................................................................................. 1-2
Note, Attention et Avertissement .................................................................. 1-3
Precautions De Securite Importantes ........................................................... 1-3
Documents De Reference ............................................................................ 1-5
Declaration of Conformity ............................................................................. 1-7
Statement of Warranty .................................................................................. 1-8
SECTION 2:
INTRODUCTION & DESCRIPTION .................................................................................. 2-1
2.01
2.02
2.03
2.04
Scope of Manual .......................................................................................... 2-1
General Description ..................................................................................... 2-1
Specifications & Design Features ................................................................. 2-1
Options And Accessories ............................................................................. 2-2
SECTION 3:
INSTALLATION PROCEDURES ....................................................................................... 3-1
3.01
3.02
3.03
3.04
3.06
Introduction .................................................................................................. 3-1
Site Location ................................................................................................ 3-1
Unpacking Procedure ................................................................................... 3-1
Electrical Connection ................................................................................... 3-1
Torch Connection ......................................................................................... 3-3
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01
4.02
4.03
4.04
Introduction .................................................................................................. 4-1
Operating Controls ....................................................................................... 4-1
Getting Started ............................................................................................. 4-2
Recommended Cutting Speeds .................................................................... 4-3
SECTION 5:
SERVICE ......................................................................................................................... 5-1
5.01
5.02
5.03
5.04
5.05
5.06
5.07
5.08
5.09
Introduction .................................................................................................. 5-1
General Maintenance ................................................................................... 5-1
Common Operating Faults ........................................................................... 5-1
Troubleshooting Guides ................................................................................ 5-2
Basic Troubleshooting Guide ........................................................................ 5-2
Advanced Troubleshooting Guide ................................................................. 5-3
Troubleshooting Flow Charts ........................................................................ 5-4
Test Procedures ......................................................................................... 5-11
Power Supply Component Replacement Procedures ................................. 5-14
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS .................................................................................................................... 6-1
6.01
6.02
6.03
6.04
6.05
Introduction .................................................................................................. 6-1
Ordering Information .................................................................................... 6-1
Power Supply Replacement Parts ................................................................ 6-2
Complete Assembly Replacement ............................................................... 6-4
Options and Accessories ............................................................................. 6-4
APPENDIX 1: SEQUENCE OF OPERATION BLOCK DIAGRAM ............................................. A-1
APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE ............................................................ A-2
APPENDIX 3: RECOMMENDED CUTTING SPEEDS .............................................................. A-3
APPENDIX 4: NON-CE SYSTEM SCHEMATIC ........................................................................ A-4
APPENDIX 5: CE SYSTEM SCHEMATIC ................................................................................. A-6
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
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.
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
NOTE
• 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 metals which may contain one or more of the following:
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
Antimony
Arsenic
Barium
Beryllium
Cadmium
A procedure which, if not properly followed, may
cause damage to the equipment.
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
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 information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
• 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.
1.02 Important Safety Precautions
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
WARNINGS
• Do not use the plasma torch in an area where combustible 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.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS 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. 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
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: November 15, 2001
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects 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 operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
1-1
GENERAL INFORMATION
• 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, Publications.
PLASMA ARC 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 helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Disconnect power source before performing any
service or repairs.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Read and follow all the instructions in the Operating Manual.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
FIRE AND EXPLOSION
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
• Be sure there is no combustible or flammable material 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.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (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.
GENERAL INFORMATION
Minimum Protective
Shade No.
Suggested
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.
• 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 underwater 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 dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
Arc Current
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 Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 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. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
1-2
Date: November 15, 2001
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
AVERTISSEMENT
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
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.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
1.05 Precautions De Securite
Importantes
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
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.
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
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.
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS 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
Il faut communiquer aux opérateurs et au personnel 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.
1.04 Note, Attention et
Avertissement
Dans ce manuel, 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.
Date: November 15, 2001
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
1-3
GENERAL INFORMATION
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête 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.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine
argent
arsenic
baryum
béryllium
cadmium
chrome
cobalt
cuivre
manganèse
mercure
nickel
plomb
sélénium
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.
• 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 travail 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 travail 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 combustibles ou provoquer l’explosion de fumées
inflammables.
• 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.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• 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 sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
• 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
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
1-4
Date: November 15, 2001
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Nuance Minimum
Protective Numéro
Nuance Suggerée
Numéro
Moins de 300*
8
9
300 - 400*
9
12
400 - 800*
10
14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
Date: November 15, 2001
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
1-5
GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
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. Livret 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
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
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. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION
1-6
Date: November 15, 2001
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.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used 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 Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192
when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing 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:
Date: November 15, 2001
Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
1-7
GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
PAK Units, Power Supplies
XL Plus &
CutMaster Series
Parts
Cougar/Drag-Gun
Parts
All Others
Labor
Main Power Magnetics
3 Years
1 Year
2 Years
1 Year
Original Main Power Rectifier
3 Years
1 Year
2 Years
1 Year
Control PC Board
3 Years
1 Year
2 Years
1 Year
All Other Circuits And Components Including,
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Consoles, Control Equipment, Heat
Exchanges, And Accessory Equipment
1 Year
Torch And Leads
Maximizer 300 Torch
SureLok Torches
1 Year
All Other Torches
180 Days
180 Days
180 Days
180 Days
90 Days
90 Days
90 Days
None
Repair/Replacement Parts
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. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: November 15, 2001
GENERAL INFORMATION
1-8
Date: November 15, 2001
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.03 Specifications & Design
Features
A. Pak Master 38XL Power Supply
The following applies to the Pak Master 38XL Power Supply only:
2.01 Scope of Manual
1. Controls
This manual contains descriptions, operating instructions
and maintenance procedures for the Pak Master 38XL
Plasma Cutting System. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs
or adjustments not covered in this manual, at the risk of
voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
• AC POWER on/off Switch
• CURRENT Output Control
• PRESSURE Regulator Control with Pressure Gauge
2. Control Panel Indicators
AC
GAS
DC
OVER TEMP
3. Input Power
• 120/220 VAC (±10%), 50/60 Hz, Single-Phase
Domestic unit supplied with 10 ft (3 m) Input
Power Cable and Molded Plug
2.02 General Description
The Power Supply provides a system which can cut most
metals from gauge thickness up to 3/8 inch (9.5 mm).
• 220 VAC (±10%), 50/60 Hz, Single-Phase
CE unit supplied with 10 ft (3 m) CE Input
Power Cable without Plug
The Power Supply provides 29 amps maximum output
cutting current (limited to 20 Amp on 120VAC service).
All electrical, pilot, and gas control circuitry is included.
• 100/200 VAC (±10%), 50/60 Hz, Single-Phase
Japan unit supplied with 10 ft (3 m) Input
Power Cable without Plug
4. Output Power
Continuously variable from 12 to 29 Amps maximum.
Limited to 20 Amps maximum with 100 VAC and
120 VAC units using 20 Amp service.
5. Open Circuit Voltage (OCV)
375 vdc
6. Duty Cycle (see NOTE)
NOTE
A-01721
The duty cycle will be reduced if the primary input voltage (AC) is low or the DC voltage is higher
than shown in the chart.
Power Supply Duty Cycle
Manual 0-2872
2-1
Ambient
Temperature
104° F
(40° C)
104° F
(40° C)
104° F
(40° C)
Duty Cycle
40%
60%
100%
Current
29 Amps
n/a Amps
n/a Amps
DC Voltage
92 vdc
n/a vdc
n/a vdc
INTRODUCTION & DESCRIPTION
7. Work Lead
13. Power Supply Dimensions
10 ft. (3.0 m) with clamp
8. Cut Capacity
TOP
PANEL
Maximum cut capacity on Mild Steel
17.6 in
(448 mm)
• 1/4 inch (6.4 mm) @ 20A setting on 100 VAC &
120 VAC Units
• 3/8 inch (9.5 mm) @ 29A setting on 120 VAC, 200
VAC & 220 VAC Units
9. Pilot Circuitry
17 in
(432 mm)
Capacitor Discharge (CD), Pulsed DC
END
PANEL
10. Gas Connection
1/4 NPT Gas Fitting
SIDE PANEL
11. Gas Requirements
A-01671
9.75 in
(248 mm)
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. Contaminants may cause poor
cutting performance and rapid electrode wear.
a. Type Gas
Compressed Air or Nitrogen (N2) Only
2.04 Options And Accessories
The following accessories are available for this Power
Supply. Refer to Section 6, Parts Lists, for part numbers
and ordering information.
A. Single Stage Air Line Filter Kit
A Single Stage In-Line Air Filter which is a pneumatic
dryer/evaporator that installs in the compressed air
supply line. Filters moisture, oil, dirt, chips, rust particles, and other contminants.
WARNING
This cutting system must not be used with Oxygen (O2).
B. High Pressure Regulators
b. Operating Pressure
High pressure regulators are available for air and nitrogen. The regulators are used to set the proper pressure for the type gas being used.
50 psi (3.4 bar)
NOTE
CAUTION
Regulators should not be installed with In-Line Air
Filters.
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
c. Flow
190 scfh (90 lpm)
scfh = standard cubic feet per hour
12. Weight
49 lbs (22.3 kg)
INTRODUCTION & DESCRIPTION
2-2
Manual 0-2872
SECTION 3:
INSTALLATION
PROCEDURES
3.03 Unpacking Procedure
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove any packing material.
3.01 Introduction
This section describes installation of the Power Supply.
These instructions apply to the Power Supply, Torch and
Leads Assemblies only; installation procedures for the
Options and Accessories are given in manuals specifically
provided for those units.
The complete installation consists of:
1. Site Selection
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system installation.
3.04 Electrical Connection
A. Power Requirements
2. Unpacking
1. Domestic Units
3. Electrical Connection
• Using 120 VAC Service
4. Gas Connections
5. Torch Connections
Unit will operate on single phase 120VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps. If
fused at 20 amps, the Power Supply Current
Control must be set for 20 amps or less. Using
a 15 amp circuit is insufficient for proper operation of this Power Supply.
6. Operator Training
3.02 Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
• Using 220 VAC Service
CAUTIONS
Unit will operate on single phase 220VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 20 amps.
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
2. CE Units
To prevent entry of cutting or other metal debris,
the power supply must not be operated in the horizontal position. Operate the power supply in the
vertical position only with the handle in the upright position.
Unit will operate on single phase 220VAC ±10%,
50/60 Hz input power. The electrical service must
be fused for at least 20 amps.
3. Japan Units
The power supply is cooled by air flow through the end
and side panels. Air flow must not be obstructed. Provide at least 12 inches (300 mm) clearance on each side.
Provide sufficient clearance above unit to allow access to
top panel controls (minimum 12 inches or 300 mm).
• Using 100 VAC Service
Unit will operate on single phase 100VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps. If
fused at 20 amps, the Power Supply Current
Control must be set for 20 amps or less. Using
a 15 amp circuit is insufficient for proper operation of this Power Supply.
NOTE
Review the safety precautions in Section 1 of this
manual to be sure that the location meets all safety
requirements.
• Using 200 VAC Service
Unit will operate on single phase 200VAC
±10%, 50/60 Hz input power. The electrical
service must be fused for at least 30 amps.
Manual 0-2872
3-1
INSTALLATION PROCEDURES
B. Input Voltage Selection
D. Power Connections
Input voltage selection switch is available on Domestic and Japan Units only.
CAUTION
The primary power source, power cable, and plug
all must conform to local electrical codes and recommended circuit protection and wiring requirements.
WARNING
Do not switch input voltage when unit is powered
ON.
• Domestic 220 VAC Service Only
Remove the 120V Plug that comes with the unit.
The attached AC input power cable is three conductor, 12 AWG. The input power connections
can be made directly to a properly fused disconnect or by using a plug which conforms to the recommended ratings.
Set Input Voltage Selection Switch to the correct
input voltage. This switch is located on the end
panel of the unit, near the bottom.
Domestic
Japan
• CE 220 VAC Service Only
The attached AC input power cable is three conductor, 14/3 AWG. The input power connections
can be made directly to a properly fused disconnect or by using a plug which conforms to the recommended ratings.
• Japan 200 VAC Service Only
A-03262
A-03261
The attached AC input power cable is three conductor, 12 AWG. The input power connections
can be made directly to a properly fused disconnect or by using a plug which conforms to the recommended ratings.
C. Extension Cords
Extension cords can be used only with the following units:
• 120 VAC Domestic Units
3.05 Gas Connection
• 100 VAC Japan Units
Extension cords must meet National Electric Code guidelines. Extension cords must have the same rating as the
electrical service (20A for 20A service; 30A for 30A service) and must have three-prong plugs. Refer to the following table for recommended cord sizes:
Extension Cord Wire Gauge Requirements
Cord Length
20A Service 30A Service
50 ft (15.2 m) or Less
12
10
100 ft (30.5 m)
10
8
150 ft (45.7 m)
8
6
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
This subsection includes information for connecting the
gas supply to the Power Supply. The information is
grouped in paragraphs for different type gases and options per the following:
A. Using Shop Air
B. Using High-Pressure Gas Cylinders
Refer to the appropriate paragraph(s) for the desired application to be used.
INSTALLATION PROCEDURES
3-2
Manual 0-2872
A. Using Shop Air
B. Using High Pressure Gas Cylinders
An air line filter, capable of filtering to at least 5 microns,
is required when using air from a compressor to insure
that moisture and debris from the supply hose does not
enter the torch.
NOTE
Do not use an air line filter with high pressure gas
cylinders.
To use air or nitrogen from a high pressure gas cylinder:
CAUTION
1. Connect the gas supply hose to the female 1/4
NPT gas input fitting at the front panel of the
power supply.
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. Contaminants may cause poor
cutting performance and rapid electrode wear.
NOTE
For a secure seal, apply thread sealant to the fitting threads, according to the maker's instructions.
Do Not use Teflon tape as a thread sealer, as small
particles of the tape may break off and block the
small gas passages in the torch.
Install the Optional Air Line Filter and connect the gas
supply per the following procedure:
AIR FLOW
Top Panel
Gas Fitting
A-01658
A-01657
AIR FLOW
Supply Hose From
Gas Cylinder Regulator
Filter Cap
Top Panel
Gas Fitting
Figure 3-2 High Pressure Gas Cylinder Connection
Air Line Filter
Assembly
2. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign material. Momentarily open each cylinder valve to
blow out any dust which may be present.
3. Each cylinder must be equipped with an adjustable high-pressure regulator capable of pressures
up to 50 psi (3.5 bar) minimum and flows of up to
190 scfh (90 lpm).
Figure 3-1 Shop Air Gas Connection
NOTE
DO NOT use teflon tape on gas fittings.
NOTE
1. Connect the air line filter assembly to the female
1/4 NPT gas input fitting at the front panel of
the power supply. The air filter is supplied with
1/4 NPT gas couplings. A quick disconnect fitting is recommended on the filter body cap to allow easy connection to the compressed air source.
Refer to the manufacturer’s specifications for installation and maintenance procedures for high
pressure gas regulators.
4. Connect the gas supply hose to the high-pressure
regulator at the gas cylinder.
5. Set the tank regulator to 75 psi (5.3 bar). This is
the required output pressure for the tank regulator.
2. Connect the air supply hose to the inlet fitting on
the air line filter body cap.
CAUTION
6. Use the regulator on the front of the power supply to adjust the operating gas pressure to the unit.
When connecting a gas fitting to the filter cap, hold
the cap flats with a wrench. Over tightening the
cap on the filter body can damage the filter cartridge or cap gasket.
Manual 0-2872
3-3
INSTALLATION PROCEDURES
6. Remove the nylon screw holding the protective
insulating sheet to the bulkhead.
3.06 Torch Connection
The Torch is installed to the Power Supply when ordered
as part of the system. Use the following procedure only
if the Power Supply and Torch were ordered separately:
Nylon Screw
1. Open the Power Supply per Section 5.08-A.
Bulkhead
Area
2. Locate the torch bulkhead directly behind the
torch lead panel strain relief.
Bulkhead Area
A-03235
A-03237
Figure 3-4 Nylon Screw
7. Connect the Torch Negative Lead to the fitting in
the brass torch bulkhead.
Figure 3-3 Torch Bulkhead Location
NOTE
Note that all wires are outside the protective insulating sheet.
Torch Lead
Fitting
3. Remove the strain relief nut from the strain relief
on the Torch Leads Assembly.
Torch Negative
Lead
4. Feed the ends of the Torch Leads Assembly
through the hole in the Power Supply Panel.
5. Place the strain relief nut back over the end of the
Torch Leads and secure the strain relief to the
panel with the nut.
Bulkhead
A-03236
Figure 3-5 Negative Torch Lead Connection
INSTALLATION PROCEDURES
3-4
Manual 0-2872
8. Close the protective insulating sheet back over the
torch bulkhead and secure with the nylon screw
removed earlier (see CAUTION).
CAUTION
Be sure all wires are outside the protective insulating sheet when the nylon screw is reinstalled. High
voltage is present on the torch negative lead.
9. Connect the two torch control connectors and the
pilot wire to the Main PC Board Assembly connections.
Torch Control
Connectors
Pilot Wire
Connection
A-03234
Figure 3-6 Wiring Connections
10. Close the Power Supply by reinstalling the Power
Supply panel.
Manual 0-2872
3-5
INSTALLATION PROCEDURES
INSTALLATION PROCEDURES
3-6
Manual 0-2872
6. CURRENT Control
SECTION 4:
OPERATION
Adjusts output current from 12 to 29 amps.
Units (100 or 120 VAC) fused for 20A input power
should be limited to a maximum of 20 amps output.
4.01 Introduction
7. Pressure Gauge
This Section provides a description of the Power Supply
followed by operating procedures.
Displays input gas pressure to the torch.
8. PRESSURE Control
4.02 Operating Controls
OPERATING PRESSURE
50 PSI (3.4 BAR)
AC POWER
TM
OFF
10
8 11
6 7
1
9
INPUT POWER
Adjusts gas pressure from the regulator. Pull knob
out and turn clockwise to increase gas pressure to
desired level. Push Knob in to lock setting.
9. Input Power Cable
WORK
ON
Strain relief and input power cable for main AC
power to the unit.
PRESSURE
Gas
Electrode Distributor Tip
Torch Head Assembly
Standard
Shield Cup
20
OVER
AC
GAS
DC
Maximum
20A at 115V
TEMP
TORCH
Proper Assembly of Torch Head Components
REPLACEMENT
TORCH PARTS
0.1 in (2.5 mm)
Examine for elongated,
cratered, or oversized orifice
Part Description
Standard Electrode
Gas Distributor
Tip
Standard Shield Cup
GAS
SUPPLY
29
12
Check the electrode and tip for excessive wear.
Replace electrode if worn back more than 0.1"
(2.5 mm). Check tip orifice for out-of-round wear.
10. WORK Cable Input
CURRENT
Catalog No.
9-6506
9-6507
9-6501
9-6003
Recommended operating pressure for clean, dry
Air or Nitrogen is 50 PSI (3.5 BAR).
This system is not for use with Oxygen (O2).
Input for the work cable on the system.
Made in the USA
A-01672
2 3 4 5 12
11. TORCH Cable Input
Input for interfacing the Torch to the Power Supply.
Figure 4-1 Front Panel Controls and Indicators
12. Gas Input Fitting
Input gas fitting (1/4 NPT) to connect the desired
gas supply to the Power Supply.
1. AC POWER ON/OFF Switch
ON position supplies AC power to activate all system circuits. OFF position deactivates circuits.
2.
13. Input Power Selection Switch
NOTE
AC Indicator
Input voltage selection switch is available on Domestic and Japan Units only.
Green light indicates AC input power is present in
the system when the ON/OFF switch is in ON position. Indicator will flash for 3-5 seconds when first
turned on until the power circuits are ready.
3.
GAS Indicator
Green light indicates minimum gas pressure (35 psi
or 2.5 bar) flowing to the torch when torch is activated.
4.
Input Power selection switch to set the correct AC
input voltage for the Power Supply. The switch is
located on the end panel of the unit, near the bottom.
Domestic
Japan
13
13
DC Indicator
Green light indicates adequate DC power output for
main arc when the torch is activated.
A-01674
5.
A-01944
Figure 4-2 Input Power Selection Switch
OVER TEMP Indicator
Indication is off during normal operation. Yellow
light indicates overheating; unit must be allowed to
cool. The indicator will also flash momentarily if
the torch is shorted.
WARNING
Do not switch input voltage when unit is powered
ON.
Manual 0-2872
4-1
OPERATION
F. Checking Air Quality
4.03 Getting Started
To check the quality of the air, press then release torch
switch then place a welding filter lens in front of the
torch. Any oil or moisture in the air will be visible on
the lens. Do not initiate an arc!
This procedure should be followed at the beginning of
each shift:
WARNING
G. Current Output Level
1. Domestic Units
Disconnect primary power at the source before assembling or disassembling torch parts, or torch and
leads assemblies.
• For 220VAC, 20 Amp Input Circuits and
120VAC, 30 Amp Input Circuits:
At the Power Supply set the desired current
output level for the desired operation (12 to 29
amps).
A. Torch Parts
Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to
Manual supplied with the Torch for proper Torch
Parts Selection).
• For 120VAC, 20 Amp Input Circuits:
At the Power Supply set the desired current
output level between 12-20 amps. Setting
above 20 amps is likely to blow wall fuses or
circuit breakers.
NOTE
The power supply will not operate unless the torch
shield cup is fully seated against the PIP (Parts in
Place) pins in the torch head.
2. CE Units (220VAC, 20 Amp Input Circuit)
At the Power Supply set the desired current output level for the desired operation (12 to 29 amps).
B. Input Power
3. Japan Units
1. Check that Input Voltage Selection Switch is set
for proper input voltage (Domestic & Japan Units
only).
• For 200VAC, 30 Amp Input Circuit:
At the Power Supply set the desired current
output level for the desired operation (12 to 29
amps).
2. Make sure the power source meets circuit protection and wiring requirements per Section 3.04.
3. Plug unit in and close main disconnect switch to
supply primary power to the system.
• For 100VAC, 30 Amp Input Circuits:
Set desired current between 12-20 Amps. Setting above 20 Amps will cause excessive fuse
blowing and reduce the reliability of the unit.
C. Work Cable
Check for a solid work cable connection to the workpiece.
H. Pressure Settings
D. Gas Supply
Select desired gas supply, air or nitrogen (N2). Make
sure gas source meets the gas requirements (refer to
Section 2.03, Specifications & Design Features).
Check connections and turn gas supply on.
Press then release torch switch. While gas flows, adjust gas PRESSURE control to 50 psi (3.5 bar).
I.
The system is now ready for operation.
NOTE
E. Purge System
On the Power Supply place the ON/OFF switch to
the ON position. An automatic gas purge (PreFlow)
will remove any condensation that may have accumulated in the torch and leads.
OPERATION
Ready for Operation
4-2
Refer to Appendix 1 for a detailed block diagram of
the Sequence Of Operation.
Manual 0-2872
4.04 Recommended Cutting Speeds
Cutting speed depends on the type of material, material
thickness and operator ability to accurately follow the desired cut line. The following factors may have an impact
on system performance:
•
Torch parts wear
•
Air quality
•
Operator experience
•
Torch standoff height
•
Proper work cable connection
•
Alloy content of material
For complete cutting speed data refer to Appendix 3.
NOTE
The information represents realistic expectations
using recommended practices and well maintained
systems. Actual speeds may vary from those shown
in the chart depending on the alloy content of the
selected material.
Manual 0-2872
4-3
OPERATION
OPERATION
4-4
Manual 0-2872
SECTION 5:
SERVICE
To clean the unit, open the enclosure (refer to Section 5.08A, Opening Enclosure) and use a vacuum cleaner to remove any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.
5.01 Introduction
CAUTIONS
This section describes basic maintenance procedures that
can be performed by operating personnel, and advanced
procedures that can be performed by properly trained
personnel. No other adjustments or repairs other than
those described are to be attempted.
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
When cleaning care must be taken not to move or
damage the electronic components.
WARNINGS
B. Optional Single Stage In-Line Air Filter
Disconnect primary power at the source before disassembling the torch or torch leads.
Frequently review the Important Safety Precautions in Section 1. Be sure the operator is equipped
with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body
comes into contact with the workpiece while the
torch is activated.
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
NOTE
Refer to Section 6, Parts Lists, for replacement parts
and ordering information.
The Optional Single Stage In-Line Air Filter cartridge
should be replaced every 30 days, depending on the condition of the compressed air. If a noticeable drop in air
pressure occurs, the filter may have become filled with
contaminants and must be replaced.
Replace the cartridge per the following procedure:
1. Unscrew the filter cap from filter body.
Handle torch leads with care and protect them from
damage.
2. Slide the old cartridge out of the filter body.
3. Insert the new filter cartridge into the filter body.
The filter cartridge will go in only one way.
5.02 General Maintenance
4. Reinstall the filter cap and only hand tighten.
A. Cleaning Power Supply
The only routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.
Refer to Appendix 2, Maintenance Schedule, for specific
procedures.
WARNING
NOTE
Supply hoses must be at least #4 hose (1/4 inch or
6.4 mm minimum inside diameter).
5.03 Common Operating Faults
The following lists the more common cutting faults and
what is the possible cause:
1. Insufficient Penetration
a. Cutting speed too fast
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-Genuine Thermal Dynamics Torch Parts
Manual 0-2872
5-1
SERVICE
Basic troubleshooting is limited to non-power checks and
external Power Supply faults. Advanced troubleshooting requires fault isolation to the Power Supply or Torch,
Power Supply disassembly, voltage measurements and
major component replacement.
2. Main Arc Extinguishes
a. Cutting speed too slow or cutting current too high
b. Torch standoff too high from workpiece
c. AC line too low - reduce output current
The guides are as follows:
d. Work cable disconnected
Section 5.05 - Basic Troubleshooting Guide
e. Worn torch parts
Section 5.06 - Advanced Troubleshooting Guide
f. Non-Genuine Thermal Dynamics Torch Parts
Depending on the level of repair to be done, refer to the
desired troubleshooting guide.
3. Excessive Dross Formation
a. Cutting speed too slow (bottom dross)
5.05 Basic Troubleshooting Guide
b. Cutting speed too fast (top dross)
A. General
c. Torch standoff too high from workpiece
Basic troubleshooting of the Pak Master 38XL plasma cutting system can be performed without special equipment
or knowledge, and without opening the enclosure.
d. Worn torch parts
e. Improper cutting current
f. Non-Genuine Thermal Dynamics Torch Parts
This basic troubleshooting guide covers input power, gas
supply, and torch problems.
4. Short Torch Parts Life
For problems not covered here, refer to the Advanced
Troubleshooting Guide or contact your authorized distributor.
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
e. Improperly assembled torch
If a product must be returned for service, contact your
authorized distributor. Materials returned to the Manufacturer without proper authorization will not be accepted.
f. Output current too high
B. How to use this Guide
g. Torch tip contacting workpiece
The following information is a guide to help determine
the most likely causes for various symptoms.
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
h. Damaged or loose torch head components
This guide is set up in the following manner:
i. Non-Genuine Thermal Dynamics Torch Parts
X. Symptom (Bold Type)
5. Poor Pilot Starting
Any Special Instructions (Text Type)
a. Non-Genuine Thermal Dynamics Torch Parts
1. Cause (Italic Type)
b. Worn torch parts
a. Check/Remedy (Text Type)
c. Damaged or loose torch head parts
Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
the unit is fully operational after any repairs.
5.04 Troubleshooting Guides
There are two Troubleshooting Guides, Basic and Advanced, provided in this Instruction Manual. The Basic
Troubleshooting Guide uses symptom, cause, and remedy for fault isolation. The Advanced Troubleshooting
Guide uses Flow Charts and test procedures for fault isolation.
A. AC Indicator
OFF, Fan does not operate.
1. ON/OFF Switch not on.
a. Turn ON/OFF Switch to ON position.
2. No power from wall circuit.
a. Reset breaker or replace fuse. Refer to Section
3.04 for proper power requirements.
SERVICE
5-2
Manual 0-2872
E. AC indicator ON, OVER TEMP indicator dark,
B. Temperature (OVER TEMP) indicator
ON.
GAS indicator
1. Unit is overheated due to exceeding duty cycle.
ON. Torch does not pilot.
a. Allow to cool, reduce duty cycle.
1. Faulty torch parts
2. Unit is overheated due to obstructed air flow.
a. Inspect torch parts and replace if necessary per
Torch Manual supplied with Torch.
a. Provide at least 12 inch clearance around unit.
2. Gas pressure too high.
b. Clean unit (refer to Section 5.02).
3. Shorted torch; OVER TEMP Indicator lights momentarily then unit stops cutting or piloting.
a. Set pressure to 50 psi (3.5 bar).
F. Torch pilots but does not cut.
a. Check for proper torch parts assembly or
shorted torch head per Torch Manual supplied
with Torch.
1. Work lead not connected.
a. Make sure work lead is connected securely to
bare metal.
4. Input voltage too high.
2. AC input power too low
a. Check customer supplied voltage source. Refer to Section 2.03-A-3.
a. Use shortest service to breaker panel possible.
Refer to Section 3.04 for input power cable requirements.
C. AC Indicator blinks for 4 seconds when power is
turned on but no gas flows.
1. Gas not connected or turned on.
G. Gas flows continually even with power off.
1. Debris in solenoid holding piston open.
a. Check for proper gas supply.
a. Replace Solenoid.
2. Air filter or air line blocked.
a. Replace filter cartridge, check that air lines are
not kinked.
3. Torch leads or head blocked (Gas Pressure Indicator
lighted).
a. Check for twists or kinks in torch leads, check
torch parts. Check for plugged torch head.
4. Faulty gas solenoid or Main PCB.
5.06 Advanced Troubleshooting
Guide
A. General
The troubleshooting covered in this Instruction Manual
requires Power Supply disassembly and live measurements. It is helpful for solving the common problems
that may arise with the Power Supply Assembly.
a. Check for 24 VAC at J2-3 to J2-4 with torch
switch depressed. If present, replace solenoid,
otherwise repair or replace power supply.
WARNING
D. AC indicator ON, OVER TEMP indicator dark, no
gas flow when torch switch pressed.
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
1. Shield cup not properly installed on torch.
a. Check that shield cup is fully seated against
torch head.
2. Faulty Torch Switch or PIP Assembly in torch holder.
a. Refer to Torch Manual supplied with Torch.
3. Faulty Main PC Board
a. Replace Power Supply
Manual 0-2872
ON, gas flows, DC indicator
If major complex subassemblies are faulty, the assembly
must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each in
the order presented.
5-3
SERVICE
The guide has two sections as follows:
Section 5.07 - Troubleshooting Flow Charts
Section 5.08 - Test Procedures
Specific test procedures have been grouped together, and
are referenced by the flowcharts.
B. How to use this Guide
The following information is a guide to help the Service
Technician determine the most likely causes for various
failures. This guide is set up in the following manner:
1. Use flowchart(s) to isolate problem to possible
circuit(s).
2. Perform the test procedures as required as noted on
flowcharts.
3. Repair as needed being sure to verify that unit is fully
operational after any repairs.
5.07 Troubleshooting Flow Charts
The following pages are flow charts to be used to isolate
problems in the Plasma Cutting System.
SERVICE
5-4
Manual 0-2872
Chart #1: Main Power
AC Indicator OFF
on Front Panel
System
Operates
Properly?
No
AC POWER
Switch ON?
Power Cable
Plugged In?
Yes
Connect AC Power
Input Cable to
AC Source
No
Yes
Yes
No
Faulty AC Indicator
Replace Power Supply
Check Main
Power Disconnect
Place AC POWER
Switch to ON
Place Main Power
Disconnect to ON
No
Main Power
Disconnect ON?
Yes
Check Main Disconnect
Power Line Fuse
Install Proper
Fuse
No
Check Main Disconnect
Power Line Fuses For
Proper Amperage
Yes
Main Power
Line Fuse
Replaced
Once?
No
Main Power
Line FuseOkay?
Yes
No
Unplug Power Supply
From Main Power Source
Replace Main
Power Line Fuse
Yes
Unplug Power Supply
From Main Power Source
Proceed to Chart #2B
Proceed to Chart #2A
Manual 0-2872
5-5
SERVICE
Chart #2: Input Power Checks
B
NOTE
This Condition could also result if the input
line voltage was low or using an extension
cable and the user was using a high standoff
while cutting.
Check Input Diode Bridge on
Heatsink/PC Board Assembly
Per Section 5.08-A
A
Check 1/2A Fuse (F1) on the
Heatsink/PC Board Assembly
1/2A Fuse
Checks Okay?
Diode Bridge
Checks Okay?
Yes
(See Note)
Yes
Check FET Assemblies on
Heatsink/PC Board Assembly
Per Section 5.08-C
No
FET Assemblies
Check Okay?
Yes
No
Unplug J2 Connector on the
Heatsink/PC Board Assembly
Check Capacitor
PC Board Assembly on
Heatsink/PC Board Assembly
Per Section 5.08-D
Replace
Power Supply
Replace Fuse (F1) and
Apply AC Power to the
Power Supply
Capacitor PC
Board Assembly
Checks Okay?
AC Indicator
Comes ON?
No
Replace Capacitor
PCB per
Section 5.09-E
No
Yes
No
Yes
Replace
Pressure Gauge/Solenoid
Assembly
SERVICE
Unit
Operates
Properly?
Yes
5-6
Check unit for
proper operation
Replace Cover
and follow
operating procedures
Manual 0-2872
Chart #3: Temperature Indicator Checks
AC and Gas Indicators are ON
Temperature Indicator Either
ON or Blinks Once
When Torch Switch is Pressed
Temp Indicator
ON Steady
When Torch Switch
is Pressed
No
Proceed to Chart #4
(blinks once)
Yes
No
Fan
Operating?
No
Duty Cycle
Exceeded?
Allow Power Supply
To Cool
Yes
Yes
Temperature
Indicator Still
ON?
No
Use Proper
Operating Procedures
Yes
No
Temperature
Indicator ON?
Yes
Replace Power Supply
Assembly
Manual 0-2872
5-7
SERVICE
Chart #4: Shorted Torch or Resistor (R3) Checks
AC and Gas Indicators are ON
DC Indicator Blinks or Momentary ON
When Torch Switch is pressed
Check Pilot Wire
per Section 5.08-E
Pilot Wire
Check Correct?
No
Replace
Leads Assembly
Yes
Check Resistor (R3) Assembly
per Section 5.08-F
Resistor R3
Check Okay?
No
Replace Resistor (R3)
Assembly
per Section 5.08-F
Yes
Replace Power Supply
SERVICE
5-8
Manual 0-2872
Chart #5: Faulty Torch
B
A
AC Indicator ON
No GAS Flow When Torch
Switch is Depressed
AC and Gas Indicators are ON
DC Indicator OFF
When Torch Switch is Depressed
Gas Supply
Okay?
No
Connect
Gas Supply
Check Torch And Leads
per Torch Manual
Yes
Torch
Check Correct?
Check Torch Switch
per Section 5.08-G
No
Replace Torch
Yes
Replace Power Supply
Manual 0-2872
5-9
SERVICE
Chart #6: Possible Shipping Damage
CURRENT Control Knob Turns Completely
Around And Doesn't Stop At Minimum Or
Maximum Positions
Check Shaft Of CURRENT
Control Is Not Loose Or
Broken From PC Board
Is Control
Shaft Okay?
No
Make Claim
Against Freight Carrier
Replace Power Supply
Yes
Replace CURRENT Control
Knob per Section 5.09-A
SERVICE
5-10
Manual 0-2872
3. Set digital volt/ohm meter to diode test scale.
5.08 Test Procedures
4. Using the Figures for each test, check each diode
in the module. Each diode must be checked in
forward bias (plus to negative) and reverse bias
(negative to plus) direction.
The checks in these test procedures are all made with the
main power disconnected.
5. Connect the volt/ohm meter positive lead to the
anode of the diode and the negative lead to the
cathode of the diode for forward bias testing. A
properly functioning diode will conduct in the forward bias direction and indicate between 0.3 to
0.9 volts.
WARNING
Disconnect primary power to the system at the
source before opening the Power Supply.
A. Opening Power Supply
6. Reverse the meter leads across the diode for reverse bias testing. A properly functioning diode
will block in the reverse bias direction and depending on the meter function will indicate an
open or "OL".
1. Lay the unit down on its side (side without the
leads wrap) and remove the six screws on the side
of the unit and six screws on the ends of the unit.
(refer to Section 6.03 Power Supply Replacement
Parts, for exploded view of unit.)
NOTE
AC
AC
Do not remove the four screws holding the handle
to the case. Do not remove the single screw on the
bottom panel.
2. Slide the cover straight up and off the power supply. Pivot the cover over the torch lead, work lead,
and power cord and rest the cover beside the
power supply.
(
(+)
)
NOTE
(
Make certain not to strain the ground wire connection to the cover of the power supply.
)
B. Checking Input Diode Bridge
AC
(+)
Testing of diode modules requires a digital volt/ohm
meter that has a diode test scale or an analog VOM with
1X or X10 scale. Remember that even if the diode module checks good, it may still be bad. If in doubt, replace
the Power Supply.
AC
A-01274
Figure 5-2 Input Diode Diagram
1. Open the Power Supply per paragraph ‘A’ above.
2. Make a visual check of the Input Diode Bridge
for damage.
Input Diode
A-01273
Figure 5-1 Input Diode Location
Manual 0-2872
5-11
SERVICE
C. Checking FET Assemblies
1. Open the Power Supply per paragraph ‘A’ above.
A-00307
2. Using an ohmmeter set on the Rx1 scale make the
following checks:
0.75
Forward Bias
Diode Conducting
Capacitor
PC Board
Diode Test Symbol
Anode
VR COM
_
+
A
Wire #3
(-) Terminal
(+) Terminal
Cathode
Figure 5-3 Testing Diode Forward Bias
7. For an analog meter, use the meter set on X1 or
X10 scale to measure the resistance of each diode
in both directions. The readings should differ by
at least a factor of 10. If they do not differ (either
high or low in both directions) then replace the
diode module.
8. If the diode has visible damage or is shorted, the
diode is faulty. Replace the Power Supply.
A-03248
Figure 5-5 FET Assembly Check
A-00306
a. Measure from Capacitor PC Board (+) to Main
Transformer Wire #3. If the meter indicates a
short the FET Assemblies are faulty.
OL
b. Measure from Capacitor PC Board (-) to Main
Transformer Wire #3. If the meter indicates a
short the FET Assemblies are faulty.
Reverse Bias
Diode Not Conducting
Cathode
VR COM
_
+
A
Anode
Figure 5-4 Testing Diode Reverse Bias
SERVICE
5-12
Manual 0-2872
3. Using an ohmmeter set on the Rx1 scale make the
following checks:
D. Checking Capacitor PC Board
1. Open the Power Supply per paragraph ‘A’ above.
a. Measure from the Torch Block and the end of
the Pilot Wire. The meter should indicate an
open.
Capacitor PC
Board
b. Measure from Pilot Wire to torch tip. Should
measure short (less than 1 ohm).
4. Reinstall the Pilot Wire back onto the stud terminal on the Main PC Board.
F. Checking Resistor R3 (11k ohms)
1. Open the Power Supply per paragraph ‘A’ above.
2. Using a pair of needle nose pliers, remove the red
wire from the terminal on Resistor R3.
A-03249
Figure 5-6 Capacitor PC Board Location
2. Using an ohmmeter set on the Rx1 scale make the
following check:
a. Measure from Capacitor PC Board (+) to (-)
terminals. The meter should increase in resistance as the capacitors charge. If the meter
indication does not increase the Capacitor PC
Board is faulty.
E. Checking Pilot Wire
1. Open the Power Supply per paragraph ‘A’ above.
A-03250
Resistor (R3)
2. Remove the Pilot Wire from the stud terminal on
the Main PC Board.
Figure 5-8 Resistor R3 Location
3. Using an ohmmeter set on the Rx100 scale make
the following check:
a. Measure the Resistance of the Resistor R3. The
meter should indicate 11K ohms.
4. Reinstall the wire back onto the Resistor terminal.
5. Check that the other ends of both red and blue
wires are properly attached.
Pilot Wire
Connection
A-03243
Figure 5-7 Pilot Wire Location
Manual 0-2872
5-13
SERVICE
G. Checking Torch Switch
1. Open the Power Supply per paragraph 'A' above.
5.09 Power Supply Component
Replacement Procedures
2. Disconnect the Torch Control Connectors from the
wiring harness of the J3 connector on the Main
PC Board
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
A. Current Knob Replacement
1. Using a small blade screwdriver loosen the screw
securing the knob to the CURRENT Control adjustment shaft.
Torch Control
Connectors
2. Turn the CURRENT Control adjustment shaft
fully clockwise. This will represent the maximum
position.
3. Slide the replacement knob onto the shaft.
Connector
J3
4. Turn the knob so that the line on the knob points
towards the wide end of the current control symbol.
A-03245
5. Tighten the screw in the knob to secure the knob
to the shaft.
Figure 5-9 Torch Control Connectors Location
6. Turn the knob fully counterclockwise.
3. Using an ohmmeter set on the Rx1 scale make the
following check:
7. The line should now line up with beginning of
the CURRENT Control adjustment symbol.
a. Measure across the Torch Control Connectors.
The meter should indicate an open when the
Torch Switch is not pressed. When the Torch
Switch is pressed the meter should indicate a
short. If faulty, replace Torch & Leads or repair Torch components per Manual supplied
with the Torch.
8. Adjust the knob as required to align the minimum
and maximum reference points.
B. Fuse Replacement
The 1/2A Fuse is located on the Main PC Board inside
the Power Supply. The Fuse is next to the terminal block
on the left side of the Power Supply.
NOTE
NOTE
The Shield Cup must be installed to complete the
circuit through the Parts-In-Place (PIP) contacts.
Removal of the Fuse requires the use of a pair of
needle nose pliers.
4. Reconnect the Torch Control Connectors back to
the wiring harness of the J3 connector on the Main
PC Board.
Remove the Fuse per the following procedure:
1. Open the Power Supply per Section 5.08-A.
2. Using a pair of needle nose pliers carefully remove
the Fuse.
3. Replace the Fuse only with the properly rated and
type fuse. Fuse F1, is next to the Terminal Block
and is a 1/2 amp 250V fuse.
SERVICE
5-14
Manual 0-2872
D. Air Regulator Assembly Replacement
The Air Regulator Assembly includes the Air Regulator,
Pressure Switch, Pressure Gauge, and Solenoid Assemblies and is removed from the Power Supply as a complete assembly. Remove the assembly per the following
procedure:
1. Open the Power Supply per Section 5.08-A.
2. Disconnect the ground wire from the cover, and
set the cover aside.
Fuse
Location
3. Refer to paragraph 'G' below to disconnect the
Torch Leads from inside the Power Supply.
4. Disconnect the work cable from the stud terminal on the Main PC Board.
F1
Torch Control
Connectors
A-01704
Terminal
Block
Figure 5-10 Fuse F1 Location
Work Cable
Connection
4. Reinstall the Power Supply Cover.
C. AC POWER Switch Replacement
NOTE
Pilot Wire
Connection
Make sure power cord is unplugged.
1. Open the Power Supply per Section 5.08-A.
A-03246
2. Remove the two nuts securing ON/OFF Switch
to the panel.
Figure 5-12 Connection Locations
AC (Black)
5. Remove the AC input power and ground connections to the Main PC Board.
Blue Wire #3
6. Remove the four screws from the side of the Power
Supply and the single screw on the bottom of the
Power Supply.
7. Push back the regulator hose fitting clamp and
slide the complete Heatsink/Main PC Board Assembly back and up out of the way.
A-01705
AC (White)
Blue Wire #19
8. Remove retaining nut from front of the regulator
assembly, and remove complete assembly with
wiring.
Figure 5-11 Power Switch Connections
9. Remove the faulty Air Regulator, Pressure Switch,
Pressure Gauge, or Solenoid Assembly and install
the replacement assembly.
3. Remove wires from Switch.
4. Install the replacement AC Power Switch by reversing the above procedure.
Manual 0-2872
5-15
SERVICE
10. Install complete Air Regulator Assembly by reversing the above procedure.
5. Remove the two wires connected to the Pilot Resistor noting the locate of each.
6. Install the replacement Pilot Resistor by reversing the above procedure.
NOTE
Properly route the pressure switch and gas solenoid wires and secure with cable ties.
G. Torch and Leads Replacement Procedure
E. Capacitor PC Board Replacement
Procedure
1. Open the Power Supply per Section 5.08-A.
2. Locate the torch bulkhead directly behind the
torch lead panel strain relief.
1. Open the Power Supply per Section 5.08-A.
2. Remove the three nuts and star washers securing
the Capacitor PC Board to the Heatsink/PC Board
Assembly. The nuts are located at terminals (+),
(-), and (N).
Bulkhead Area
3. Pull the Capacitor PC Board up from the three
plastic PC Mounting Standoffs. Squeeze standoffs with needlenose pliers.
4. Remove the black pad on top of the capacitors
from the faulty Capacitor PC Board.
5. Install the replacement Capacitor PC Board by reversing the above procedure and noting the following:
a. Place the black pad removed from the faulty
PC Board on top of the capacitors on the replacement PC Board.
b. Refer to the following CAUTION and torque
the three nuts on terminals (+), (-), and (N) to
15 inch-lbs (1.695 Nm)
CAUTION
A-03237
Figure 5-13 Torch Bulkhead Location
NOTE
Note that all wires are outside the protective insulating sheet.
3. Loosen the torch lead strain relief nut inside the
front panel. Do not remove the strain relief from
the leads. Replacement torch leads are provided
with strain reliefs.
DO NOT over torque the nuts on the terminals as
the PC Board may be damaged.
F. Pilot Resistor Replacement Procedure
1. Open the Power Supply per Section 5.08-A.
2. Locate the Pilot Resistor near the Heatsink/PC
Board Assembly.
4. Disconnect the two torch control connectors and
the pilot wire from the Main PC Board Assembly
connections.
NOTE
There are two resistors mounted to this area, Pilot
Resistor (15 ohms) and Damping Resistor (30
ohms). The Pilot Resistor is mounted on the bottom.
3. Using a phillips screwdriver remove the two
screws securing the Pilot and Damping Resistors
to the Heatsink/PC Board Assembly.
4. Pull the Pilot Resistor out far enough to gain access to the two wiring connections.
SERVICE
5-16
Manual 0-2872
CAUTION
Be sure all wires are outside the protective insulating sheet as noted above when it is reinstalled. High
voltage is present on the torch negative lead.
Torch Control
Connectors
Torch Lead
Fitting
Torch Negative
Lead
Pilot Wire
Connection
A-03234
Figure 5-14 Wiring Connections
5. Remove the nylon screw holding the protective
insulating sheet to the bulkhead.
Bulkhead
Nylon Screw
A-03236
Bulkhead
Area
Figure 5-16 Negative Torch Lead Connection
7. Install the replacement Torch and Leads Assembly by reversing the above steps.
A-03235
Figure 5-15 Nylon Screw
6. Use a 3/8 inch (9.5 mm) open end wrench to
loosen the torch lead fitting from the brass torch
bulkhead. This fitting must be removed from the
Torch Lead and installed on the replacement lead.
Manual 0-2872
5-17
SERVICE
SERVICE
5-18
Manual 0-2872
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. Power Supply and Torch Assembly are field
serviceable, so a complete breakdown of parts is provided.
The parts lists are arranged as follows:
Section 6.03 Power Supply Replacement Parts
Section 6.04 Complete Assembly Replacements
Section 6.05 Options And Accessories
NOTE
Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers
shown.
B. Returns
If a product must be returned for service, contact your
authorized distributor. Materials returned without proper
authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the description column of the Parts List. Also include the model
and serial number of the torch. Address all inquiries to
your authorized distributor.
Manual 0-2872
6-1
PARTS LISTS
6.03 Power Supply Replacement Parts
Item #
Qty
1
1
Descript!ion
Catalog #
Cover, with Labels
Domestic and CE Units
9-4611
Japan Units
9-6380
2
1
Base, with Labels
9-4612
3
1
Knob
9-4146
4
1
Fuse, 1/2 Amp, 250V (F1)
9-6395
5
1
Air Regulator Assembly Includes:
9-6897
1
Air Regulator
8-4382
1
Pressure Gauge Kit
9-7018
1
Pressure Switch
9-1044
1
Solenoid With Wiring
9-4605
6
1
Handle (does not include screws/washers)
9-4606
7
1
Resistor (R3), 11K ohms, 40W
9-7701
8
1
ON/OFF Switch
8-4248
9
1
Capacitor PC Board Assembly
9-4607
10
1
Pilot Resistor (R1), 15 ohms 55W
9-6323
11
1
Work Cable with Clamp
10 ft (3 m) Length
9-6298
15 ft (4.6 m) Length
9-6595
20 ft (6.1 m) Length
9-6596
25 ft (7.6 m) Length
9-6597
9-7650
12
1
Leads Wrap (with label)
13
1
Torch and Leads Assembly
14
1
PCH-42R RPT 70° Hand Torch, 20 ft (6.1 m) Leads
7-4226
PCH-42R RPT 90° Hand Torch, 20 ft (6.1 m) Leads
7-4227
Voltage Selection Switch (Non-CE Units Only)
9-3325
The following items are not shown:
Gas Connector
1
1/4 NPT FEM Elbow
9-4595
1
Nipple, Hex, 1/4 NPT-1/4 NPT
9-4482
1
1
PARTS LISTS
AC Input Power Cord
Domestic and Japan Units
9-7651
With Ferrite Beads For CE Units
8-3162
Hardware (screws, washers) for cover, handle
6-2
9-6376
Manual 0-2872
12
1
9
Non-CE Units
6
14
7
4
11
8
CE Units
3
13
10
2
A-03259
5
Manual 0-2872
6-3
PARTS LISTS
6.04 Complete Assembly Replacement
Description
Catalog #
Domestic Systems including:
Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable and Work Lead with Clamp
70° Torch with 20 ft (6.1 m) Leads
90° Torch with 20 ft (6.1 m) Leads
1-3851
1-3853
Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable, Work Lead with Clamp and Optional
Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads
90° Torch with 20 ft (6.1 m) Leads
1-3951
1-3953
CE Systems including:
Power Supply, Torch with Leads (Unshielded), Spare Parts Kit, AC Input Power Cable with Filtering Beads,
Work Lead with Clamp and Optional Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads
90° Torch with 20 ft (6.1 m) Leads
1-8851
1-8853
Japan Systems including:
Power Supply, Torch with Leads, Spare Parts Kit, AC Input Power Cable, Work Lead with Clamp and Optional
Air Line Filter Installed
70° Torch with 20 ft (6.1 m) Leads
90° Torch with 20 ft (6.1 m) Leads
1-3951J
1-3953
Power Supply Only
120/220 VAC - Domestic Units
3-3850
220 VAC - CE Units
3-8850
100/200 VAC - Japan Units
3-3950J
6.05 Options and Accessories
Qty
1
Description
Catalog #
Single Stage In-Line Air Filter
7-0250A
Replacement Cartridge
7-0252
High Pressure Regulators
1
Air
9-3022
1
Nitrogen (N2)
9-2722
1
Torch Spare Parts Kit Includes:
5
Tip, Air
5
Electrode, 40A SureLok
1
Distributor, Gas
1
Shield Cup, Standard
1
Box, Utility
1
Adhesive Hang Tab
1
Label, Spare Parts Kit
PARTS LISTS
5-4204
6-4
Manual 0-2872
APPENDIX 1: SEQUENCE OF OPERATION BLOCK
DIAGRAM
ACTION
ACTION
Plug in
Power Cord
ON/OFF switch
to ON.
RESULT
RESULT
Power to system.
AC Indicator flashes for
3 seconds then stays on.
ACTION
RUN/SET Switch to SET
RESULT
Gas solenoid open,
gas flows to set
pressure.
Gas indicator ON
if above 35 psi
ACTION
RUN/SET switch
to RUN
RESULT
Gas flow stops.
GAS indicator off.
Power circuit ready.
Fan on.
ACTION
ACTION
Torch moved away
from work (while
still activated).
Protect eyes and
activate torch
RESULT
RESULT
Gas flows
GAS indicator ON
After gas pre-flow:
Main arc stops.
Pilot arc automatically restarts.
PILOT ARC
DC indicator on.
Power supply enabled.
Pilot arc established
ACTION
Torch moved within
transfer distance of
workpiece.
RESULT
Main arc transfer.
Pilot arc off.
ACTION
DC indicator still on.
Torch deactivated by torch
switch release.
RESULT
Main arc stops. Pilot stops.
(Power supply enable signal removed.)
DC indicator off.
ACTION
After post-flow:
ON/OFF switch
to OFF
Gas solenoid closes. Gas flow stops.
GAS indicator OFF.
RESULT
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (1/8 in) of
workpiece, main arc will transfer.
All indicators off.
Power supply
fan off.
ACTION
Unplug
Power Cord
RESULT
No power to system.
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Manual 0-2872
A-1
APPENDIX
APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE
This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.
NOTE
The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged or worn.
2. Inspect torch for any cracks or exposed wires, replace if necessary.
3. Check plasma and secondary supply and pressure/flow.
4. Purge plasma gas line to remove any moisture build-up.
5. Inspect input power cable for damage or exposed wires, replace if necessary.
Weekly or Every 30 Cutting Hours:
1. Check fan for proper operation and adequate air flow.
2. Blow or vacuum dust and dirt out of the entire machine.
CAUTION
Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.
Six Months or Every 720 Cutting Hours:
1. Check the in-line air filter(s), clean or replace as required
2. Check cables and hoses for leaks or cracks, replace if necessary.
3. Check all contactor points for severe arcing or pits, replace if necessary.
APPENDIX
A-2
Manual 0-2872
APPENDIX 3: RECOMMENDED CUTTING SPEEDS
NOTE
Cutting speeds are for use with PCH-42 RPT Torch.
Pak Master 38XL Cutting Speeds (Air Pressure @ 50 psi for all settings)
Recommended
Maximum Cut
Recommended
Cut
Speed @29
Material
Thickness
Cut
Speed @ 29
Amps
Speed @ 20 Amps
Amps
26 Gauge
250
310
385
20 Gauge
125
245
310
1/16"
85
140
208
Mild Steel
1/8 "
25
55
85
3/16 "
15
30
55
1/4 "
8
16
27
3/8 "
NR
10
14
24 Gauge
150
310
385
1/16"
40
80
115
Stainless Steel
1/8 "
25
44
70
3/16 "
10
19
27
1/4 "
NR
14
20
24 gauge
100
290
360
20 gauge
75
228
310
Galvanized Steel
18 gauge
65
172
233
16 gauge
45
140
203
1/16 "
150
223
280
3/32 "
25
105
172
Aluminum
1/8 "
10
60
85
3/16 "
NR
20
30
NR = Not Recommended
Manual 0-2872
A-3
Standoff
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/16"
drag-1/16"
drag-1/16"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/16"
drag-1/16"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
drag-1/8"
APPENDIX
APPENDIX 4: NON-CE SYSTEM SCHEMATIC
A-01675
APPENDIX
A-4
Manual 0-2872
NOTE
Refer to Appendix 5 for CE Power Supplies.
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Manual 0-2872
A-5
APPENDIX
APPENDIX 5: CE SYSTEM SCHEMATIC
A-01933
APPENDIX
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Manual 0-2872
NOTE
Refer to Appendix 4 for all other Power Supplies.
A-01933
Manual 0-2872
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APPENDIX
APPENDIX
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Manual 0-2872