Tweco 150XL User Manual
PLASMA CUTTING
POWER SUPPLY
CE PAK Master® 150XL
With Latch Circuit
M
T
M
T
A-03044
™
Operating Manual
June 14, 2001 Manual No. 0-2865
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
CE PAK Master150XL With Latch Cir cuit
Operating Manual Number 0-2865
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1999 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 14, 2001
Record the following information for Warranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMA TION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.0 2 Important Safety Precautions....................................................................... 1 - 1
1.03 Publications.................................................................................................. 1-2
1.0 4 Note, Attention et Avertissement.................................................................. 1- 3
1.0 5 Precautions De Securite Importantes ........................................................... 1-3
1.06 Documents De Reference............................................................................. 1-5
1.0 7 Declaration of Conformity ............................................................................. 1- 7
1.0 8 Statement of W arranty .................................................................................. 1-8
SECTION 2:
INTRODUCTION & DESCRIPTION ................................................................................... 2-1
2.0 1 Scope of Manual .......................................................................................... 2-1
2.0 2 Pow er Supply General Description ................................................................ 2- 1
2.0 3 Specifications/Design Features .................................................................... 2 -2
2.0 4 Po wer Supply Options and Accessories ....................................................... 2- 3
2.0 5 Theory Of Operation ..................................................................................... 2 -4
SECTION 3:
INST ALLATION PROCEDURES ........................................................................................ 3-1
3.01 Introduction................................................................................................... 3-1
3.0 2 Site Selection ............................................................................................... 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Transporting Options..................................................................................... 3-1
3.0 5 Input Pow er Cable Connections .................................................................... 3-2
3.0 6 Gas Connections .......................................................................................... 3- 2
3.07 Connecting T orch Leads ................................................................................ 3-5
3.0 8 Ground Connections For Mechanized Applications ....................................... 3 -7
3.0 9 Filling Pow er Supply Coolant......................................................................... 3-9
SECTION 4:
OPERATION...................................................................................................................... 4-1
4.01 Introduction................................................................................................... 4-1
4.02 Operating Controls........................................................................................ 4-1
4.03 Sequence of Operation ................................................................................. 4-3
4.04 Preparations for Operating ............................................................................ 4-4
4.0 5 Cut Quality ................................................................................................... 4- 5
4.0 6 System Operation......................................................................................... 4- 6
4.0 7 Optional Pow er Supply Settings.................................................................... 4- 7
TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE.................................................................................. 5-1
5.01 Introduction................................................................................................... 5-1
5.02 General Maintenance.................................................................................... 5-1
5.03 Common Operating F aults ............................................................................ 5-2
5.04 Common Operating Problems ....................................................................... 5-3
5.05 T roub leshooting Guide .................................................................................. 5-4
5.0 6 Pow er Supply Parts Replacement................................................................. 5- 6
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 P ower Supply Replacement .......................................................................... 6-2
6.0 4 Basic Replacement Parts ............................................................................. 6- 2
6.0 5 Options and Accessories.............................................................................. 6 - 2
APPENDIX 1: INPUT WIRING REQUIREMENTS..................................................................... A-1
APPENDIX 2: SEQ UENCE OF OPERATION BLOCK DIAGRAM ............................................. A-2
APPENDIX 3: GROUNDING DIAGRAM.................................................................................... A-3
APPENDIX 4: ROUTINE MAINTENANCE SCHEDULE ............................................................ A-4
APPENDIX 5: PO WER SUPPLY CNC INTERF A CE DIA GRAM ................................................A-5
APPENDIX 6: SCHEMATIC DIAGRAM..................................................................................... A-6
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A pr ocedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A pr ocedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
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 1-603298-571 1 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different pr ocesses. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
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 information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where 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.
• 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.”
Date: May 1, 2000 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.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating 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 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.
• 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.
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.
• T o protect your hearing fr om 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.
PLASMA ARC RAYS
Plasma Arc Rays can injur e 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 pr otected.
• 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.
• Wear welding gloves and suitable clothing to protect 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, 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 OCCUP ATION AND EDUCA TIONAL 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 fr om the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Date: Ma y 1, 2000
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
7. A WS Standard A6.0, WELDING AND CUTTING CONT AINERS WHICH HAVE HELD COMBUSTIBLES, obtainable 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 PROCESSES, 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 Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standar d 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
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
12. CSA Standard W1 17.2, CODE FOR SAFETY IN WELDING 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 Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standar d AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBST ANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute pr océdur e pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
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: May 1, 2000 1-3 GENERAL INFORMATION
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 + 603-298-571 1 ou votre distributeur
local si vous avez des questions.
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.
• 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.
• 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.
• 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 différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
• 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. (V oir 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.
• 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.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
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.
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
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 1-4 Date: Ma y 1, 2000
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
RAYONS D’ARC DE PLASMA
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 oculair e.
• 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:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro 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.
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
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.
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 Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AY ANT 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
Date: May 1, 2000 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, Batterymar ch
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, RECOMMANDA TIONS DE PRA TIQUES
SURES POUR LA PRÉP ARA TION 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-6 Date: Ma y 1, 2000
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshir e 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 Dir ective.
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 r equirements among them ar e:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Ar c welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-cir cuit boards used.
* CENELEC EN50199 EMC Product Standard for Ar c Welding Equipment.
* 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
manufacturing process. This is to ensure the pr oduct 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 pr oduct 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 repr esentative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: May 1, 2000 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 ther eof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standar d industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or r eplacement, 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
P AR TICULAR 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 fr om 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 fr om 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
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun 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, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
PCH/M-62 & PCH/M-102 Torches 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 1, 2000
GENERAL INFORMATION 1-8 Date: Ma y 1, 2000
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
150XL Plasma Cutting Power Supply (CE). 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.
2.02 Power Supply General
Description
Power Supply is designed to cut most metals up to 1-1/2
inches (38 mm) using air, nitrogen, or argon/hydrogen
as the plasma gas. This system is also capable of satisfying many gouging applications. The Power Supply is
ideal for hand applications and can also be used in mechanized applications.
The Power Supply provides 120 amp maximum output
current and includes all control circuitry, electrical and
gas inputs and outputs, pilot circuitry, torch leads receptacle and a 20 ft (6.1 m) work cable with clamp.
The torch used with the Power Supply is available in the
following configurations:
• 70° or 90° Hand Torch Head (PCH)
• 180° Machine Torch Head (PCM) with 1-3/8 inch
(34 mm) diameter Mounting Tube with Rack and
Pinion Assembly
Machine torch systems with unshielded leads include a
Remote Hand ON/OFF Pendant; machine torches with
shielded leads include a CNC Interface Cable.
NOTES
The power supply can be ordered in various configurations with various options factory installed.
Refer to the supplied Tor ch Instruction Manual for
more information on the Torch.
Refer to Section 2.04 for list of Power Supply Options and Accessories.
M
T
M
T
A-03044
Figure 2-1 Pak Master 150XL System
The Standard Coolant supplied with the Power Supply
can be used in ambient temperatures down to 10° F
(-12° C). If the ambient temperature will be below 10° F
(-12° C) then Super Coolant should be used. This coolant
can be used in areas where the ambient temperature dr ops
to -34° F (-36° C).
A. Typical System
A typical system configuration will contain the following:
• CE Power Supply
• 20 ft (6.1 m) Work Cable with Clamp
• Torch with Leads (torch type and leads length as
ordered)
• Torch Spare Parts Kit
• CNC Interface Cable or Remote Pendant Control
(depending on type of torch leads ordered)
• Standard Thermal Arc Coolant - 3 gallons (11.4 liters)
NOTE
Refer to Section 2.04 for complete list of Power Supply Options and Accessories.
B. Requirements to Complete System
To complete the system, the user needs to provide the
following:
• Primary Input Power Cable Plug
• Gas Supplies
Manual 0-2865 2-1 INTRODUCTION & DESCRIPTION
2.03 Specifications/Design Features
p
A. Power Supply Specifications
The following specifications apply to the Power Supply
only:
Ambient
erature
Tem
Duty Cy cle
Power Supply Duty Cycle
104° F
(40° C)
60% 100%
104° F
(40° C)
1. Front Panel Controls
• ON/OFF, RUN/SET and STANDARD/LATCH
Switches
• Output Current Control
• Work Cable Connection
• Torch Leads Connection
2. Front Panel LED Indicators
• AC
• TEMP
• GAS Pressure/Coolant Flow
• DC Output
3. Rear Panel
• Primary Input Power Cable with Filtering Beads and
Strain Relief
• Plasma Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressur e Adjustment
• Secondary Gas Regulator/Filter Assembly with Gas
Pressure Gauge and Pressur e Adjustment
• Two Stage Air Line Filter Assembly
• EMI Filter Assembly
4. Input Power (see NOTES)
Current
DC Voltage
7. Cut Capacity on Carbon Steel
• Genuine Cut Capacity: 1-1/2 inch (38 mm)
• Severance Cut: 1- 3/4 inch (44 mm)
• Pierce Rating: 5/8 inch (15.9 mm)
8. Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC
9. CNC Interface Signals
Start/Stop and OK-To-Move
10. Coolant Pressure
Internal Service Adjustable (Factory Only)
130 psi (8.8 bar) at zero flow
120 - 125 psi (8.2 - 8.5 bar) at 0.6 gpm (2.3 lpm)
11. Coolant Flow Rate
0.5 gpm (1.9 lpm) with 150 feet (45.7 m) of total torch
and torch leads at 70°F (21°C)
120 Amps n/a Amps
128 vdc n/a vdc
NOTE
380-415 VAC (±10%), 50/60 Hz, Three-Phase
NOTE
Refer to Appendix 1 for suggested input wiring
size, current ratings and circuit protection r equirements.
5. Output Power
Continuously variable from 30 to 120 amps (±5%)
6. Duty Cycle (see NOTE)
NOTE
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.
The flow rate varies with lead length, torch configuration, ambient temperature, amperage level,
etc.
12. Cooling Capacity
4,000 to 10,000 BTU
NOTE
Maximum value based on “free flow” condition.
13. Coolant Reservoir Capacity
2 gallons (Use Thermal Arc® coolant only)
Capable of handling a total of 150 feet (45.7 m) of
torch lead length
14. Overall Dimensions
Height: 45-3/8 inches (1.2 m)
Width: 24-1/2 in (0.6 m)
Depth: 35 inches (0.9 m)
INTRODUCTION & DESCRIPTION 2-2 Manual 0-2865
15. Weight
Power Supply with Torch: 275 lbs (125 kg)
2.04 Power Supply Options and Accessories
Shipping Weight: 350 lbs (158.8 kg)
16. Used With Torch
• PCH-120 Hand Torch
• PCM-120 Machine Torch
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas Regulator Maximum Gauge Pressure
Plasma: 160 psi (11.3 bar)
Secondary: 160 psi (11.3 bar)
2. Maximum Input Gas Pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
C. Gas Requirements
1. Plasma
Gases: Compressed Air, Nitr ogen, Argon/Hydr ogen
Operating Pressure: 65 psi (4.5 bar)
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for the
Power Supply:
A. High Pressure Regulators
High pressure regulators are available for air, nitrogen, and argon-hydrogen. The regulators are used
to set the proper pressure for the type of gas being
used.
B. CNC Interface Cable
NOTE
Accessory is for use with Shielded PCM Torch &
Leads.
The CNC Interface Cable is available in two lengths:
25 ft (7.6 m) and 50 ft (15.2 m). The cable is used to
interface the Power Supply with an auxiliary control
device to provide OK-T o-Move and ON/OFF signals.
C. Work Cable Kit
Power Supply is supplied with attached 20 ft (6.1 m)
work cable and clamp. Longer cables are available
as a user installed kit.
Cold Flow:
Cutting: 50 - 78 scfh (23.6 - 36.8 lpm)
Gouging: 85 - 95 scfh (40.1 - 44.8 lpm)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
2. Secondary
Gases: Compressed Air, Carbon Dioxide (C02), Nitrogen
Operating Pressure: 60 psi (4.1 bar)
Cold Flow:
Cutting: 340 scfh (160.4 lpm)
Gouging: 235 scfh (110.9 lpm)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar).
D. Remote Pendant Control
NOTE
Accessory is for use with Unshielded PCM Torch
& Leads.
Control used to manually start and stop cutting operations from a location up to 25 ft. (7.6 m) from the
Plasma Power Supply.
Manual 0-2865 2-3 INTRODUCTION & DESCRIPTION
2.05 Theory Of Operation
A. Plasma Arc Cutting and Gouging
Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma
gas to transfer an electric arc to a workpiece. The metal
to be cut is melted by the intense heat of the arc and then
blown away by the flow of gas.
With a simple change of torch parts, the system can also
be used for plasma arc gouging. Plasma arc gouging uses
the same process to remove material to a controlled depth
and width.
B. Input and Output Power
The unit converts AC input power to DC power for the
main cutting arc. The negative output is connected to
the torch electrode through the negative torch lead, and
the positive output connects to the workpiece through
the work cable.
C. Pilot Arc
When the torch is activated there is a 2 second (service
adjustable) gas pre-flow, followed by an uninterrupted
pulsed DC pilot arc established between the electrode and
tip. The pilot arc is initiated by a momentary high frequency pulse from the Power Supply. The pilot creates a
path for the main arc to transfer to the work. When the
main arc is established, the pilot arc shuts off. The pilot
automatically restarts when the main arc stops, as long
as the torch remains activated.
1. Parts-In-Place (PIP) Interlock
The Power Supply has a built-in parts-in-place interlock that prevents accidental torch starting
when torch parts are not properly installed. A flow
switch on the coolant return lead detects reduced
coolant flow caused by improper torch assembly.
If not satisfied, the switch interrupts power to the
tip and electrode.
2. Gas Pressure Interlock
A pressure switch acts as an interlock for the
plasma gas supply . If the plasma gas supply pr essure falls below minimum requirements the pr essure switch will open, shutting off the power to
the contactors, and the GAS indicator will go out.
When adequate plasma supply pressure is available the pressure switch will close, allowing power
to be resumed for cutting.
NOTE
There is no gas pressure interlock for secondary
gas.
D. Main Cutting Arc
The power supply converts the AC input power to DC
power for the main cutting arc. The negative output is
connected to the torch electrode through the negative
torch lead. The positive output is connected to the workpiece via the work cable and clamp connection.
E. RF Shielding
Machine torch systems using CNC Interface Cables are
shielded to minimize radio frequency (RF) interference
which results from the high frequency ar c initiation. These
shielded systems are designed with features such as a
wire for establishing an earth ground and shielded torch
and control leads. The CNC control signals are filtered
on an internal PC Board.
F. Interlocks
The system has several built-in interlocks to provide safe
and efficient operation. When an interlock shuts down
the system, the fault condition must be remedied and the
system recycled using the applicable control device.
INTRODUCTION & DESCRIPTION 2-4 Manual 0-2865
Loading...