PakMaster 100XL Plus Operating Manual (0-2811)_Jun2003

7/26/2019 PakMaster 100XL Plus Operating Manual (0-2811)_Jun2003

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June 26, 2003 Manual No. 0-2811

Operating Manual

Automated Plasma

Cutting Power SupplyPAK Master 100XL Plus

A-02751


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WARNINGS

Read and understand this entire Manual and your employers safety prac-tices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents theManufacturer's best judgement, the Manufacturer assumes no liability forits use.

Automated Plasma Cutting Power SupplyPak Master100XL PlusOperating Manual Number 0-2811

Published by:Thermal Dynamics Corporation

82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711www.thermal-dynamics.com

Copyright 2000 byThermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permission ofthe publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to anyparty 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 26, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________


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TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-21.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference ............................................................................ 1-5

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

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

SECTION 2:INTRODUCTION .............................................................................................................. 2-1

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

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

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

2.04 Power Supply Options and Accessories ....................................................... 2-3

SECTION 3:INSTALLATION ................................................................................................................. 3-1

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

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

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

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

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

3.06 Input Voltage Selection ................................................................................. 3-2

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

3.08 Gas Connections ......................................................................................... 3-43.09 Connecting Torch Leads ............................................................................... 3-6

3.10 Ground Connections For Mechanized Applications ...................................... 3-8

3.11 Tip Saver/Drag Cut Sensing Circuit ............................................................ 3-10

3.12 External Control Connections..................................................................... 3-10

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

4.05 Cut Quality .................................................................................................. 4-5


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TABLE OF CONTENTS (continued)

SECTION 5:

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

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

5.02 General Maintenance ................................................................................... 5-1

5.03 Common Operating Problems ...................................................................... 5-25.04 Troubleshooting Guide ................................................................................. 5-4

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

SECTION 6:

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

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

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

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

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

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

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

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

APPENDIX III: POWER SUPPLY CNC INTERFACE DIAGRAM ............................................... A-3

APPENDIX IV: DATA TAG INFORMATION ................................................................................A-4

APPENDIX V: SYSTEM SCHEMATIC ...................................................................................... A-6


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Date: November 15, 2001 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warningsare used to highlight important information. These high-lights are categorized as follows:

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, maycause damage to the equipment.

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in the oper-ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO YOURHEALTH.

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with theproper function of cardiac pacemakers, hearingaids, or other electronic health equipment. Per-sons who work near plasma arc cutting applica-

tions should consult their medical health profes-sional and the manufacturer of the healthequipment to determine whether a hazard exists.

To prevent possible injury, read, understand andfollow all warnings, safety precautions and in-structions before using the equipment. Call 1-603-298-5711 or your local distributor if you have anyquestions.

GASES AND FUMES

Gases and fumes produced during the plasma cuttingprocess 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 arcdepend on the kind of metal being used, coatingson the metal, and the different processes. You mustbe very careful when cutting or welding any met-als which may contain one or more of the follow-ing:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper Selenium

Beryllium Lead SilverCadmium Manganese Vanadium

Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

For information on how to test for fumes and gasesin your workplace, refer to item 1 in Subsection 1.03,Publications in this manual.

Use special equipment, such as water or down draftcutting tables, to capture fumes and gases.

Do not use the plasma torch in an area where com-bustible or explosive gases or materials are located.

Phosgene, a toxic gas, is generated from the vaporsof chlorinated solvents and cleansers. Remove allsources of these vapors.

This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects and, in some cases, cancer. (California Health& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc processuses and produces high voltage electrical energy. Thiselectric energy can cause severe or fatal shock to the op-erator or others in the workplace.

Never touch any parts that are electrically liveor hot.


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GENERAL INFORMATION 1-2 Date: November 15, 2001

Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.

Repair or replace all worn or damaged parts.

Extra care must be taken when the workplace ismoist or damp.

Install and maintain equipment according to NEC

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

Disconnect power source before performing anyservice or repairs.

Read and follow all the instructions in the Operat-ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, orthe plasma arc.

Be sure there is no combustible or flammable ma-terial in the workplace. Any material that cannotbe removed must be protected.

Ventilate all flammable or explosive vapors fromthe workplace.

Do not cut or weld on containers that may haveheld combustibles.

Provide a fire watch when working in an area wherefire hazards may exist.

Hydrogen gas may be formed and trapped underaluminum workpieces when they are cut under-water or while using a water table. DO NOTcutaluminum alloys underwater or on a water tableunless the hydrogen gas can be eliminated or dis-sipated. Trapped hydrogen gas that is ignited willcause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-cesses can cause noise levels to exceed safe limits. Youmust protect your ears from loud noise to prevent per-

manent loss of hearing. To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect othersin the workplace.

Noise levels should be measured to be sure the deci-bels (sound) do not exceed safe levels.

For information on how to test for noise, see item 1in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.The plasma arc process produces very bright ultra violetand infra red light. These arc rays will damage youreyes and burn your skin if you are not properly protected.

To protect your eyes, always wear a welding hel-met or shield. Also always wear safety glasses withside shields, goggles or other protective eye wear.

Wear welding gloves and suitable clothing to pro-tect your skin from the arc rays and sparks.

Keep helmet and safety glasses in good condition.Replace lenses when cracked, chipped or dirty.

Protect others in the work area from the arc rays.Use protective booths, screens or shields.

Use the shade of lens as suggested in the followingper ANSI/ASC Z49.1:

Minimum Protective SuggestedArc 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 clearlyseen. Experience has shown that lighter filtersmay be used when the arc is hidden by the work-piece.

1.03 Publications

Refer to the following standards or their latest revisionsfor more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR1910, obtainable from the Superintendent of Docu-ments, U.S. Government Printing Office, Washington,D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable from the American Welding So-ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainablefrom the Superintendent of Documents, U.S. Govern-ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-PATION AND EDUCATIONAL EYE AND FACE PRO-TECTION, obtainable from American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MENSSAFETY-TOE FOOTWEAR, obtainable from the Ameri-can National Standards Institute, 1430 Broadway, NewYork, NY 10018


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6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from American National Standards Institute, 1430Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-tainable from American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,obtainable from the National Fire Protection Associa-tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN CYLINDERS, obtainable from theCompressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-ING AND CUTTING, obtainable from the CanadianStandards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHYobtainable from the National Welding Supply Associa-tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-TION FOR WELDING AND CUTTING OF CONTAIN-ERS AND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots note, attention, etavertissement sont utiliss pour mettre en relief desinformations caractre important. Ces mises en reliefsont classifies comme suit :

NOTE

Toute opration, procdure ou renseignementgnral sur lequel il importe dinsister davantageou qui contribue lefficacit de fonctionnementdu systme.

ATTENTION

Toute procdure pouvant rsulterlendommagement du matriel en cas de non-respect de la procdure en question.

AVERTISSEMENT

Toute procdure pouvant provoquer des blessuresde loprateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de laprocdure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENTS

LOPRATION ET LA MAINTENANCE DUMATRIEL DE SOUDAGE LARC AU JETDE PLASMA PEUVENT PRSENTER DESRISQUES ET DES DANGERS DE SANT.

Coupant larc au jet de plasma produit de lnergielectrique haute tension et des missionsmagntique qui peuvent interfrer la fonctionpropre dun pacemaker cardiaque, les appareilsauditif, ou autre matriel de sant electronique.

Ceux qui travail prs dune application larc aujet de plasma devrait consul ter leur membreprofessionel de mdication et le manufacturier dematriel de sant pour dterminer sil existe desrisques de sant.

Il faut communiquer aux oprateurs et au person-nel TOUS les dangers possibles. Afin dviter lesblessures possibles, lisez, comprenez et suivez tousles avertissements, toutes les prcautions de scuritet toutes les consignes avant dutiliser le matriel.Composez le + 603-298-5711 ou votre distributeurlocal si vous avez des questions.

FUME et GAZ

La fume et les gaz produits par le procd de jet deplasma peuvent prsenter des risques et des dangers desant.


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Eloignez toute fume et gaz de votre zone de respira-tion. Gardez votre tte hors de la plume de fumeprovenant du chalumeau.

Utilisez un appareil respiratoire alimentation en airsi laration fournie ne permet pas dliminer la fumeet les gaz.

Les sortes de gaz et de fume provenant de larc deplasma dpendent du genre de mtal utilis, desrevtements se trouvant sur le mtal et des diffrentsprocds. Vous devez prendre soin lorsque vouscoupez ou soudez tout mtal pouvant contenir un ouplusieurs des lments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre slniumbryllium manganse vanadium

Lisez toujours les fiches de donnes sur la scurit

des matires (sigle amricain MSDS); celles-cidevraient tre fournies avec le matriel que vousutilisez. Les MSDS contiennent des renseignementsquant la quantit et la nature de la fume et des gazpouvant poser des dangers de sant.

Pour des informations sur la manire de tester lafume et les gaz de votre lieu de travail, consultezlarticle 1 et les documents cits la page 5.

Utilisez un quipement spcial tel que des tables decoupe dbit deau ou courant descendant pourcapter la fume et les gaz.

Nutilisez pas le chalumeau au jet de plasma dans unezone o se trouvent des matires ou des gaz combus-tibles ou explosifs.

Le phosgne, un gaz toxique, est gnr par la fumeprovenant des solvants et des produits de nettoyagechlors. Eliminez toute source de telle fume.

Ce produit, dans le procder de soudage et de coupe,produit de la fume ou des gaz pouvant contenir deslments reconnu dans Ltat de la Californie, quipeuvent causer des dfauts de naissance et le cancer.(La scurit de sant en Californie et la code scuritSec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs lectriques peuvent blesser ou mme tuer. Leprocd au jet de plasma requiert et produit de lnergielectrique haute tension. Cette nergie lectrique peutproduire des chocs graves, voire mortels, pour loprateuret les autres personnes sur le lieu de travail.

Ne touchez jamais une pice sous tension ou vive;portez des gants et des vtements secs. Isolez-vousde la pice de travail ou des autres parties du circuitde soudage.

Rparez ou remplacez toute pice use ouendommage.

Prenez des soins particuliers lorsque la zone de tra-vail est humide ou moite.

Montez et maintenez le matriel conformment auCode lectrique national des Etats-Unis. (Voir la page5, article 9.)

Dbranchez lalimentation lectrique avant tout tra-vail dentretien ou de rparation.

Lisez et respectez toutes les consignes du Manuel deconsignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent rsulter des scorieschaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, desscories chaudes pouvant mettre le feu aux matires com-bust ib le s ou prov oq uer lexplo si on de fu mesinflammables.

Soyez certain quaucune matire combustible ou in-flammable ne se trouve sur le lieu de travail. Protgeztoute telle matire quil est impossible de retirer de lazone de travail.

Procurez une bonne aration de toutes les fumesinflammables ou explosives.

Ne coupez pas et ne soudez pas les conteneurs ayantpu renfermer des matires combustibles.

Prvoyez une veille dincendie lors de tout travail dansune zone prsentant des dangers dincendie.

Le gas hydrogne peut se former ou saccumuler sousles pices de travail en aluminium lorsquelles sontcoupes sous leau ou sur une table deau. NE PAScouper les alliages en aluminium sous leau ou surune table deau moins que le gas hydrogne peut

schapper ou se dissiper. Le gas hydrogne accumulexplosera si enflamm.

RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent blesservos yeux et brler votre peau. Le procd larc deplasma produit une lumire infra-rouge et des rayons


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ultra-violets trs forts. Ces rayons darc nuiront vosyeux et brleront votre peau si vous ne vous protgezpas correctement.

Pour protger vos yeux, portez toujours un casque ouun cran de soudeur. Portez toujours des lunettes descurit munies de parois latrales ou des lunettes deprotection ou une autre sorte de protection oculaire.

Portez des gants de soudeur et un vtement protecteurappropri pour protger votre peau contre lestincelles et les rayons de larc.

Maintenez votre casque et vos lunettes de protectionen bon tat. Remplacez toute lentille sale oucomportant fissure ou rognure.

Protgez les autres personnes se trouvant sur la zonede travail contre les rayons de larc en fournissant descabines ou des crans de protection.

Utilisez la nuance de lentille qui est suggre dans lerecommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggereCourant Arc Protective Numro Numro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs sappliquent ou larc actuel est observclairement. Lexperience a dmontrer que les filtresmoins foncs peuvent tre utiliss quand larc estcach par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de loue.Les procds de soudage larc de plasma peuventprovoquer des niveaux sonores suprieurs aux limitesnormalement acceptables. Vous d4ez vous protger lesoreilles contre les bruits forts afin dviter une pertepermanente de loue.

Pour protger votre oue contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protgez galement les autres personnes

se trouvant sur le lieu de travail. Il faut mesurer les niveaux sonores afin dassurer que

les dcibels (le bruit) ne dpassent pas les niveauxsrs.

Pour des renseignements sur la manire de tester lebruit, consultez larticle 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les plusrcentes ayant t faites celles-ci pour de plus amplesrenseignements :

1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DEPROTECTION DE LA SANT, 29CFR 1910,

disponible auprs du Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

2. Norme ANSI Z49.1, LA SCURIT DESOPRATIONS DE COUPE ET DE SOUDAGE,disponible auprs de la Socit Amricaine deSoudage (American Welding Society), 550 N.W.LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SCURIT ET LA SANT LORS DESOPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superin-tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AU TRA-VAIL ET DANS LES ECOLES, disponible de lInstitutAmricain des Normes Nationales (American Na-tional Standards Institute), 1430 Broadway, New York,NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponible auprsde lAmerican National Standards Institute, 1430Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRVENTION DES INCENDIESLORS DE LEMPLOI DE PROCDS DE COUPE ETDE SOUDAGE, disponible auprs de lAmerican Na-tional Standards Institute, 1430 Broadway, New York,NY 10018

7. Norme A6.0 de lAssociation Amricaine du Soudage(AWS), LE SOUDAGE ET LA COUPE DECONTENEURS AYANT RENFERM DES PRODUITSCOMBUSTIBLES, disponible auprs de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

8. Norme 51 de lAssociation Amricaine pour la Pro-tection contre les Incendies (NFPA), LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENEPOUR LE SOUDAGE, LA COUPE ET LESPROCDS ASSOCIS, disponible auprs de la Na-tional Fire Protection Association, Batterymarch Park,Quincy, MA 02269


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9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprs de la National Fire Pro-tection Association, Batterymarch Park, Quincy, MA02269

10. Norme 51B de la NFPA, LES PROCDS DECOUPE ET DE SOUDAGE, disponible auprs de laNational Fire Protection Association, Batterymarch

Park, Quincy, MA 0226911. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMS EN CYLINDRES,disponible auprs de lAssociation des GazComprims (Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. Norme CSA W117.2, CODE DE SCURIT POURLE SOUDAGE ET LA COUPE, disponible auprsde lAssociation des Normes Canadiennes, Stan-dards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LASCURIT DU SOUDAGE, disponible auprs delAssociation Nationale de Fournitures de Soudage(National Welding Supply Association), 1900 ArchStreet, Philadelphia, PA 19103

14. Norme AWSF4.1 de lAssociation Amricaine deSoudage, RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRPARATION LA COUPE ETAU SOUDAGE DE CONTENEURS ET TUYAUXAYANT RENFERM DES PRODUITSDANGEREUX , disponible auprs de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTIONRESPIRATOIRE, disponible auprs de lAmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018


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1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

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 forthe enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unitand 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.

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

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-turing process. This is to ensure the product is safe, when used according to instructions in this manual and relatedindustry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensurethe 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 ourarea of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing DirectorThermal Dynamics EuropeVia rio Fabbiani 8A40067 Rastignano (BO)Italy


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1.08 Statement of Warranty

LIMITED WARRANTY:Thermal DynamicsCorporation (hereinafter Thermal) warrants that its products will be free of defects inworkmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermalproducts as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,and maintained in accordance with Thermals 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 Thermals soleoption, 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 APARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, butnot limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) forservice interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to anycontract, 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 anywarranty, 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 THESAFETY 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 fromdate 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 dateof sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, andwith 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 anauthorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the furtherlimitations 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 YearBut Not Limited To, Starting Circuit,Contactors, Relays, Solenoids, Pumps,Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 YearExchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 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 repairfacility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation chargesto send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at thecustomers risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001


15/52

Manual 0-2811 2-1 INTRODUCTION

SECTION 2:INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions,and basic maintenance procedures for the PAK Master

100XL Plus Automated Plasma Cutting Power Supplyonly. Service of this equipment is restricted to properlytrained personnel; unqualified personnel are strictly cau-tioned against attempting repairs or adjustments not cov-ered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understand-ing of the characteristics and capabilities of this equip-ment will assure the dependable operation for which itwas designed.

2.02 General Description of System

The Automated System includes a Power Supply, Torch& Leads and Work Cable & Ring Terminal.

The Power Supply provides 80 amp maximum outputand includes all control circuitry, electrical and gas in-puts and outputs, pilot circuitry, torch leads receptacleand a work cable with ring terminal.

NOTE

The power supply can be ordered in various con-figurations with various options factory installed.

A-02750

Torch and

Leads

Work Cable andRing Terminal

Power Supply

Figure 2-1 Pak Master 100XL Plus AutomatedSystem

Various torches are available with the Power Supply. TheMachine Torch is available in a 180 configuration. Torchleads are available in 25 ft (7.6 m), or 50 ft (15.2 m) lengthswith fittings for simple installation. Spare Parts Kits areavailable for the torches which provide an assortment ofreplacement torch parts.

NOTES

Refer to Section 2.04 for a list of power supply op-tions and accessories.

2.03 Specifications/Design Features

A. Power Supply Technical Specifications

The following specifications apply to the Power Supplyonly:

1. Front Panel Controls

ON/OFF Switch, RUN/SET/LATCH Switch and

Output Current Control2. Front Panel Indicators

AC , TEMP , GAS , DC

3. Rear Panel

Input Power Cable Strain Relief, Gas Connection, GasRegulator/Filter Assembly, Two Stage Air Filter, CNCConnector

4. Input Power

Can be configured for the following input power:208/230/240 VAC (10%), 50/60 Hz, Single or Three-Phase

380/415 VAC (10%), 50/60 Hz, Three-Phase

460 VAC (10%), 50/60 Hz, Single or Three-Phase


16/52

INTRODUCTION 2-2 Manual 0-2811

5. Output Power

Continuously variable from 15 to 80 Amps maximum

6. Duty Cycle (Refer to NOTE)

Ambient

Temperature

Duty Cycle 40% 60% 100%

Current 80 Amps n/a 60 Amps

DC Voltage 112 vdc n/a 112 vdc

PakMaster 100XLP (Automated)

Duty Cycle

104F

(40C)

NOTE

The duty cycle will be reduced if the primary in-put voltage (AC) is low or the DC voltage is higherthan shown in the chart.

7. Cut Capacity (Mild Steel)

Production:3/8 inch (9.5 mm)

Genuine: 1 inch (25.4 mm)

Severance: 1-1/4 inch (31.8 mm)

8. Pilot Circuitry

Capacitive Discharge (CD), Pulsed DC

9. Weight

68 lbs ( 31 kg) w/work lead

75 lbs ( 34 kg) w/work lead, torch & lead

10. Overall Dimensions

19" (482 mm) High x 10.5" (267 mm) Wide x 24.8"(630 mm) Long

Overall dimensions are with Handle, Gas Regulator/Filter Assembly and Two Stage Air Filter installed.

B. Gas Regulator/Filter AssemblySpecifications

The following specifications apply to the Gas Regulator/

Filter Assembly only:1. Gas regulator maximum gauge pressure

160 psi (11 bar)

2. Maximum input gas pressure

125 psi (8.6 bar)

3. Filter

Coalescent type filter

C. Two Stage Air Line Filter Specifications

The following specifications apply to the Two Stage AirLine Filter Assembly only:

NOTE

The two stage air line filter is for use on systemsusing compressed air.

1. Air Flow

15 scfm (425 lpm)

NOTE

Depending on the moisture in the air source theweep drain on the bottom of the Filter should beleft open 1/4 turn at all times. The weep drain willallow 10 scfh (10.7 lpm) of air to escape using 100psi line pressure in the closed position. This willallow water, oil and contamination to escape fromthe filter.

2. Maximum input pressure

250 psi (17.2 bar)

3. Dew Point

10 to 35 F (-12 to 1.7 C) @ Atmospheric Pressure

4. Filtration

5 micron


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Manual 0-2811 2-3 INTRODUCTION

2.04 Power Supply Options andAccessories

NOTE

Refer to Section 6, Parts Lists, for part numbersand ordering information.

The following are accessories that are available for thispower supply:

A. Single Stage Air Line Filter Kit

A Single Stage In-Line Air Filter which is a pneumaticdryer/evaporator that installs in the plasma or sec-ondary compressed air line. Filters moisture, oil, dirt,chips, rust particles, and other contaminants.

B. High Pressure Regulators

High pressure regulators are available for air and ni-trogen. The regulators are used to set the proper pres-

sure for the type gas being used.C. 575V Transformer

This step-down transformer allows the power sup-ply to operate with 575 VAC three-phase input power.

D. Computer Control Cable (CNC)

The interface cable is available in two lengths, 25 ft(7.6 m) and 50 ft (15.2 m). The cable is used to inter-face the power supply with an auxiliary control de-vice to provide OK-To-Move, ON/OFF signals andstandoff control signals.

E. Single-Phase Input Power Cable (220 VAC)

Input power cable with molded plug for applicationsusing single-phase 220 VAC input power.

F. Multi-Purpose Cart

Rugged steel cart on easy-rolling rear wheels andfront-mounted swivel casters. Provides maximummobility for the power supply and can also serve asa display cart. Top shelf is 12 " (305 mm) x 20 (508mm). Steel handle is 30" (762 mm) high.


18/52

INTRODUCTION 2-4 Manual 0-2811


19/52

Manual 0-2811 3-1 INSTALLATION

SECTION 3:INSTALLATION

3.01 Introduction

NOTE

Depending on how the system was ordered, somePower Supply options may already be installed.

If option(s) have been factory installed some of theinstructions may not apply. It is recommendedthat all subsections be read for general informa-tion.

This section describes installation of the Power Supplyand connecting the Torch.

These instructions apply to the Power Supply only; in-stallation procedures for the Torch, Options, and Acces-sories are given in Manuals specifically provided for thoseunits.

The complete installation consists of:

1. Site selection

2. Unpacking

3. Connections to Power Supply

a. Input Power

b. Gas

c. Work Cabled. Torch Leads

4. Grounding

5. Operator training

3.02 Site Selection

Select a clean, dry location with good ventilation and ad-equate working space around all components.

NOTE

Review Important Safety Precautions (Section 1)to be sure that the selected location meets all safetyrequirements.

The power supply is fan cooled by air flow through thefront panel to the rear panel. Air flow must not be ob-structed. Provide at least 2 feet (0.6 m) in the rear and atleast 6 inches (0.15 m) on each side for clearance. Providesufficient clearance in front of the unit to allow access tothe front panel controls (minimum 6 inches or 0.15 m).

CAUTION

Operation without proper air flow will inhibitproper cooling and reduce duty cycle.

3.03 Unpacking

Each component of the system is packaged and protectedwith a carton and packing material to prevent damageduring shipping.

1. Unpack each item and remove all packing material.

NOTE

The Cutting Spare Parts Kit is shipped in the TorchLeads Storage Area on the side of the Power Sup-ply.

2. Locate the packing list(s) and use the list to identifyand account for each item.

3. Inspect each item for possible shipping damage. Ifdamage is evident, contact your distributor and/orshipping company before proceeding with system in-stallation.

3.04 Lifting Options

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-ener-gized supply line before moving unit.

This unit is equipped with one handle mounted onto thetop of the enclosure for hand carrying purposes.

WARNING

FALLI NG EQUI PMENTcan cause serious per-sonal injury and equipment damage.

Lift unit with the handle on top of the enclosure.

Only persons of adequate physical strength shouldlift the unit.

Use hand cart or similar device of adequate capac-ity.

If using a fork lift vehicle, place and secure unit ona proper skid before transporting.


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INSTALLATION 3-2 Manual 0-2811

This unit has a handle mounted on top of the enclo-sure for hand lifting only. Be sure unit is lifted andtransported safely and securely.

WARNING

HANDLEis not for mechanical lifting.

3.05 Input Power Connections

The Power Supply accepts input voltages from 208V to460V. Input can be 50 or 60 Hz, single-phase or three-phase. Depending on how the Power Supply was orderedthe Power Supply is factory wired for 230V single-phaseor 460V three-phase input. For any other input voltage,the Power Supply must be internally reset.

NOTE

Refer to Section 3.06, Input Voltage Selection forprocedure.

A. Input Voltage Selection

The Power Supply is factory-wired for 230V single-phaseor 460V three-phase input depending on the order. Forany other input voltage, the Power Supply must bechanged using the procedure in Section 3.06.

B. Electrical Connections

The power source must conform to local and national elec-tric codes. Recommended circuit protection and wiringrequirements are shown in Appendix I.

C. Opening Power Supply Enclosure

The left side panel of the Power Supply must be removedto gain access to the input power connections and theinput voltage selection.

WARNING

Disconnect primary power at the source before as-sembling or disassembling the Power Supply, torch

parts, or torch and leads assemblies.

1. Remove the five screws which secure the left sidepanel (viewed from front of unit) to the frame assem-bly.

Left SidePanel

Screws(5 places)

A-02761

Figure 3-1 Removing Left Side Panel

NOTE

There is a ground wire connection to the Left SidePanel on the inside of the unit.

2. Carefully pull the Left Side Panel up and away fromthe unit to gain access to the inside of the unit.

3.06 Input Voltage Selection

NOTE

For power supplies to use 575 VAC input power,

the unit must be setup for 460V three-phase op-eration and the 575V Transformer Accessory mustbe installed.

The Power Supply has three voltage settings; 208/230/240VAC, 380/415VAC, or 460VAC. Power Supplies arefactory-wired for 230V single-phase or 460VAC three-phase input depending on the order. Input voltage se-lection is accomplished by switching an internal buss barand connector inside the Power Supply. Also, for single-phase operation a jumper wire must be properly installed.

WARNING

Disconnect primary power at the source before as-sembling or disassembling the power supply, torchparts, or torch and leads assemblies.

To change the voltage selection use the following proce-dure as required:


21/52


1. Pull the single wire voltage selection plug from theconnector mounted on the internal center chassis.

380-415V/460V

220V

460V

380-

415V

220V

380-

415V

460V

220V

380-415V/460V

220V

Voltage SelectionPlug (220V)

Voltage SelectionPlug (460V)

Voltage SelectionPlug (380-415V)A-01361

Figure 3-2 Voltage Selection Plug

2. Loosen the screws securing the voltage selection block

to the terminal block.3. Pull the voltage selection block up and out from the

terminal block.

4. Turn the voltage selection block to the desired volt-age to be used. Use 220V for units using 208/230/240V input and 380-415V/460V for 380/415V or 460Vinput power.

5. Slide the voltage selection block onto the terminalblock and tighten all the screws.

NOTE

All screws must be tightened even if not used onthe terminal block.

380-415V/460V

220V

460V

380-

415V

220V

208/230/240VAC

380-

415V

460V

220V

380-415V/460V

220V

380-415V/460VAC

Voltage SelectionBlock

A-01347

Figure 3-3 Voltage Selection Block Installation

6. Move the voltage selection plug to the desired inputconnector for 220V (208/230/240V), 380/415V, or460V input power operation.

3.07 Primary Input Power CableConnections

Units ordered as 230V, single-phase, will have a six footpower input cable and plug factory installed. For all otherunits, a cable must be provided by the end user. Recom-mended cable sizes are specified in Appendix I.

A. Primary Power Cable ConnectionProcedure

1. Route the primary power cable through the strain re-lief fitting in the rear panel of the Power Supply andtighten strain relief screws.

AC Input Power

Cable Strain Relief

AC Input

Power CableA-00912

Figure 3-4 AC Input Power Cable Strain Relief

2. Connect the input cable inside the Power Supply forthe type of operation as follows:

Three-Phase Operation

Three-phase operation requires a 3-conductor cablewith ground.

a. Locate the ground stud and remove the topnut and washer.

b. Install a lug terminal on the ground wire.

c. Place the ground wire onto the ground studand secure with the nut and washer.

d. Insert the other three wires into the L1, L2, andL3 terminals on the contactor.

e. Tighten all set screws.

f. Verify unused jumper wire is connected onlyto the L3 terminals.

NOTE

The jumper wire from L1 to L4 must not be re-moved.


22/52


L1

L2

L3Input

Contactor

AC InputPower Cable

GND

Unused Jumper

L3 to L3 (storage)

A-02670

Figure 3-5 Primary Power Cable Connections -

Three-Phase Operation

Single-Phase Operation

Single-phase operation requires a 2-conductor cablewith ground.

a. Locate the single-phase jumper wire connectedbetween the two L3 terminal lugs on the in-put contactor.

b. Move one end of the jumper wire from termi-nal lug L3 to L2 at the contactor.

NOTE

The jumper wire from L1 to L4 must not be re-moved.

Single PhaseJumper Wire

(L2 to L3)

Input Contactor

A-00914

L3

L2

Figure 3-6 Single Phase Jumper Wire Installation

c. Locate the ground stud and remove the topnut and washer.

d. Install a lug terminal on the ground wire.

e. Place the ground wire onto the ground studand secure with the nut and washer.

f. Insert the other two wires into the L1 and L2

terminals on the contactor.g. Tighten all set screws even the ones not used.

AC InputPower Cable

L1

L2

GND

Input Contactor

A-00915

Figure 3-7 Primary Power Cable Connections -Single-Phase Operation

3.08 Gas ConnectionsA. Gas Requirements

WARNING

This unit not to be used with oxygen (O2).

Gases: Compressed Air or Nitrogen (N2) Only

Pressure: 70 psi (4.8 bar)

CAUTION

Maximum input gas pressure must not exceed 125psi (8.6 bar)

Flow: Cutting - 400 scfh (188.7 lpm)

Gouging - 400 scfh (188.7 lpm)


23/52


B. Checking Air Quality

To test the quality of air, place the RUN/SET/LATCHswitch to SET position, place a welding filter lens in frontof the torch and turn on the gas. Any oil or moisture inthe air will be visible on the lens. Do not initiate an arc!

CAUTION

Air supply must be free of oil, moisture, and othercontaminants. Excessive oil and moisture maycause double-arcing, rapid tip wear, or even com-plete torch failure. Contaminants may cause poorcutting performance and rapid electrode wear.

C. Gas Connections

The gas supply is connected to the Two Stage Air LineFilter Assembly installed on the rear of the unit. The con-nection is the same for compressed air or high pressuregas cylinders.

Connect the gas supply as follows:

1. Connect the gas line to the Regulator / Filter As-sembly inlet port as shown. The illustration showstypical fittings as an example. Other fittings maybe used. Install the fittings and tighten.

NOTE

Supply hose must be at least #4 hose (1/4 in or 6mm I.D.).

Two Stage Filter

Assembly

1/4 NPT to

#4 (6mm) Hose

Fitting

#4 (6mm) Gas

Supply Hose

Hose Clamp

A-02744

Figure 3-8 Gas Connection To Two Stage FilterAssembly

D. Optional Air Line Filter Installation

Filtering is required when using air from a compressor toensure that moisture and debris from the supply hose donot enter the torch. Although the unit is standard withthe Two Stage Air Filter there is an Optional Single-StageFilter Assembly that may be used. Install the OptionalSingle-Stage Filter as follows:

1. Remove the air hose connected between the TwoStage Air Filter OUT port and the Regulator/Fil-ter Assembly.


NOTE


A-02753

1/4 NPT to

#4 (6mm)

Hose Fitting

Dry Air Filter

Assembly

#4 (6mm)

Gas Supply

Hose

Hose Clamp

Figure 3-9 Gas Connection to Optional Single-StageFilter Assembly


24/52


E. Using High Pressure Gas Cylinders

Refer to the following when using high pressure gas cyl-inders as the gas supply:

CAUTION

Pressure should be set at 100 psi (6.9 bar) at thehigh pressure gas cylinder regulator.

Refer to the manufacturers specifications forinstallation and maintenance procedures forhigh pressure gas regulators.

Examine the cylinder valves to be sure theyare clean and free of oil, grease or any foreignmaterial. Momentarily open each cylindervalve to blow out any dust which may bepresent.

The cylinder must be equipped with an ad-justable high-pressure regulator capable ofoutlet pressures up to 100 psi (6.9 bar) maxi-mum and flows of up to 300 scfh (141.5 lpm).

1. Remove the air hose connected between the TwoStage Air Filter OUT port and the Regulator/Fil-ter Assembly.


NOTE


3.09 Connecting Torch Leads

WARNING

Disconnect primary power at the source before as-sembling or disassembling the power supply, torchparts, or torch and leads assemblies.

The Torch Leads must be properly installed to the PowerSupply for proper operation. Make all torch connectionsto the Torch Bulkhead Panel as follows:

NOTE

Equipment ordered as a system will have the Torchfactory connected to the Power Supply.

1. Turn the screw latch securing the front access panelto the power supply front panel.

Access

Panel

ScrewLatch

A-02467

Figure 3-10 Front Access Panel

2. Lift up the access panel for access to the torch bulk-head panel.

CAUTION

This system is designed for use with the PCM-102Automated Torch or the SL100 Machine Torchonly. Do not connect any other torch to this powersupply.


25/52


A. PCM-102 Torch Installation

1. Remove the retaining nut from the Strain Relief.

Strain ReliefNut

Strain Relief

Torch LeadsAssembly

A-02760

Figure 3-10 Torch Strain Relief Nut

2. Feed the end of the torch lead and the Strain Re-lief into the hole in the unit.

3. Tighten the Strain Relief Nut to secure the StrainRelief to the Power Supply.

Adapter

(Supplied With

Power Supply)

Pilot Lead

Torch Lead

Assembly

Gas/Power

Lead

Adapter

Connector Pilot Lead Stud

Gas/Power Lead

Connection

A-02747

PIP Circuit &

Shield Connectors

Figure 3-11 Torch Leads Connections

4. Connect the torch Negative/Plasma Lead to thebulkhead connection inside the Power Supply.

5. Connect the PIP and Shield Cables to the matingconnectors on the Adapter supplied on the PowerSupply.

6. Remove the top nut and washer from the PilotStud.

7. Place the lug on the Pilot Control Wire onto thestud and secure with the nut and washer removedin the above Step.

8. Tighten the Strain Relief onto the Torch Leads.

9. Check the torch for proper parts assembly.

10. Close the access panel and turn the latching screw.

B. SL100 Torch Installation

Torches with shielded leads and ATC connectors connectto a shielded ATC Adapter which connects to the powersupply bulkhead. Torches with shielded leads and O2Bfittings connect directly to the power supply bulkhead.Bulkhead connections are the same in both applications.

WARNING

Disconnect primary power at the source before dis-

assembling the torch or torch leads.

Strain ReliefNut

Strain Relief

Shielded ATC Adapter

Pilot Lead

Negative/PlasmaLead

Torch ControlConnectors

ShieldConnector

ShieldConnector

A-03677

Strain Relief Nut Removal

1. Remove the Strain Relief Nut from the Strain Re-

lief. Inside the Power Supply Bulkhead area, routethe connectors on the free end of the Adapter orTorch Leads through the Strain Relief Nut.

2. Fit the ATC Adapter or Torch Leads end and theStrain Relief into the hole in the unit.

3. Secure the Strain Relief with the retaining nut re-moved earlier.


26/52


4. Connect the ATC Adapter or Torch Leads Nega-tive / Plasma Lead to the bulkhead connectioninside the Power Supply.

5. Remove the top nut and washer from the PilotStud.

6. Connect the pilot lead terminal to the stud andsecure with the nut and washer removed previ-ously.

7. Connect the ATC Adapter or Torch Leads connec-tors to the power supply adapter.

WARNING

The Shielded ATC Adapter includes two connec-tors that are not used and must be taped out of theway to prevent contacting the Negative / Plasmaor Pilot Leads.

8. Tighten the Strain Relief onto the or Torch LeadsATC Adapter leads.

9. In applications using the torches with ATC Con-nectors,connect the torch leads male connectorto the ATC female receptacle. The connectorsshould push together with a very small amountof pressure. Secure the connection by turning thelocking nut clockwise until it stops. DO NOT usethe locking nut to pull the connection together.Do not use tools to secure the connections.

A-03627

12

ATC Male

Connector

ATC Adapter

Female Receptacle

Torch Leads

To

Power Supply

Torch Connection - Torch Leads with ATC MaleConnector, Power Supply with ATC Adapter

10. Check the torch for proper consumable parts.

CAUTION

The torch parts must correspond with the type ofoperation. Refer to the torch manual for details.

3.10 Ground Connections ForMechanized Applications

A. Electromagnetic Interference (EMI)

Pilot arc initiation generates a certain amount of electro-magnetic interference (EMI), commonly called RF noise.This RF noise may interfere with other electronic equip-ment such as CNC controllers, remote controls, heightcontrollers, etc. To minimize RF interference, follow thesegrounding procedures when installing mechanized sys-tems:

B. Grounding1. The preferred grounding arrangement is a single point

or Star ground. The single point, usually on thecutting table, is connected with 1/0 AWG (European50 mm2) or larger wire to a good earth ground (referto paragraph C, Creating An Earth Ground). Theground rod must be placed as close as possible to thecutting table, ideally less than 10 ft (3.0 m), but nomore than 20 ft (6.1 m).

NOTE

All ground wires should be as short as possible.

Long wires will have increased resistance to RFfrequencies. Smaller diameter wire has increasedresistance to RF frequencies, so using a larger di-ameter wire is better.

2. Grounding for components mounted on the cuttingtable (CNC controllers, height controllers, plasma re-mote controls, etc.) should follow the manufacturersrecommendations for wire size, type, and connectionpoint locations.

For Thermal Dynamics components it is recom-mended to use a minimum of 10 AWG (European 6mm2) wire or flat copper braid with cross section equal

to or greater than 10 AWG connected to the cuttingtable frame. The connection point must be clean baremetal; rust and paint make poor connections. For allcomponents, wires larger than the recommendedminimum can be used and may improve noise pro-tection.

3. The cutting machine frame is then connected to theStar point using 1/0 AWG (European 50 mm2) orlarger wire.


27/52


4. The plasma power supply work cable (see NOTE) isconnected to the cutting table at the single point Starground.

NOTE

Do Not connect the work cable directly to theground rod.

5. Make sure work cable and ground cables are prop-erly connected. The work cable must have a solidconnection to the cutting table. The work and groundconnections must be free from rust, dirt, grease, oiland paint. If necessary grind or sand down to baremetal. Use lock washers to keep the connections tight.Using electrical joint compound to prevent corrosionis also recommended.

6. The plasma power supply chassis is connected to thepower distribution system ground as required by elec-trical codes. If the plasma supply is close to the cut-ting table (see NOTE) a second ground rod is not usu-

ally needed, in fact it could be detrimental as it canset up ground loop currents that cause interference.

When the plasma power supply is far away from theground rod and interference is experienced, it mayhelp to install a second earth ground rod next to theplasma power supply. The plasma power supplychassis would then be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supplybe within 20 - 30 ft (6.1 9.1 m) of the cuttingtable, if possible.

7. The plasma control cable should be shielded with theshield connected only at the cutting machine end.Connecting the shield at both ends will allow groundloop currents which may cause more interference thanwith no shield at all.

C. Creating An Earth Ground

1. To create a solid, low resistance, earth ground, drive a1/2 in (12 mm) or greater diameter copper clad groundrod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so thatthe rod contacts moist soil over most of its length.Depending on location, a greater depth may be re-

quired to obtain a low resistance ground (see NOTE).Ground rods, typically 10 ft (3.0 m) long, may bewelded end to end for greater lengths. Locate the rodas close as possible to the work table. Install a groundwire, 1/0 AWG (European 50 mm2) or greater, betweenthe ground rod and the star ground point on the cut-ting table.

NOTE

Ideally, a properly installed ground rod will have aresistance of three ohms or less.

To test for a proper earth ground, refer to the follow-ing diagram. Ideally, the reading on the multimetershould be as follows:

For 115VAC: 3.0 VAC For 230VAC: 1.5 VAC

A-02971

+ _

Meter set toVAC setting

Machine

Earth Ground

Neutral

Line (Hot)

100WLight Bulb

115 or 230VAC

WARNING

Use extreme caution. This

test uses live voltage.

115VAC: 3.0 VAC230VAC: 1.5 VAC

V~V~

VR COM A

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft(6.1 9.1 m) does not generally increase the effective-ness of the ground rod. A larger diameter rod whichhas more surface area may help. Sometimes keepingthe soil around the ground rod moist by continuouslyrunning a small amount of water into it will work.Adding salt to the soil by soaking it in salt water may

also reduce its resistance. When these methods areused, periodic checking of the ground resistance is re-quired to make sure the ground is still good.


28/52


D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads asfar as possible from any CNC components, drive mo-tors, control cables, or primary power lines. If cableshave to pass over torch leads, do so at an angle. Donot run the plasma control or other control cables inparallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleedoff energy, which causes difficult starting and in-creased chance of RF interference.

3.11 Tip Saver/Drag Cut SensingCircuit

This power supply is equipped with a Tip Saver/DragCut Sensing Circuit which cuts current back to 35 amps ifthe tip touches the workpiece. The purpose of this is toprolong the life of the tip.

If the user does not want the current to be decreased whenthe tip touches the workpiece, the sensing circuit can bedefeated by closing switch SW1-1 on the Gate/Logic PCBoard. Slide top white toggle on SW1-1 to the right toclose circuit.

A-02569

Gate/Logic PC Board

SW1

1

2

ON

Figure 3-14 SW1 Switch Location

WARNING

Tip life will be considerably shortened if tip is re-peatedly touched to the workpiece without the TipSaver/Drag Sensing Circuit feature active.

3.12 External Control Connections

External control signal connections can be made to theRear Panel of the power supply. Connections can be madeto interface with CNC Controls, Standoff Control SC11or Remote Hand Pendant.

Depending on the option installed determines how the

option is connected to the Power Supply.A. Computer Control Interface (CNC)

NOTE

Used when Standoff Control SC11 are not used.

The computer control interface (CNC) allows an auto-mated system to interface with a computer or other con-trol device.

CNC cables can be interfaced to the Power Supply usingone of the following methods:

NOTE

Refer to Appendix III for CNC Interface Schematic.

Connector (J22) at the rear of the Power Supply

Internal terminal block in the Power Supply

Depending on the equipment ordered and the cables sup-plied connect the CNC cable per one of the following:

1. Using supplied CNC cable

Connect the supplied Power Supply/CNC Cableto the Power Supply rear panel connector J22

(CNC Control).


29/52


2. Using customer supplied CNC Cable

a. Remove the Left Side Panel from the PowerSupply as viewed from the front of the unit.

b. Remove the 7/8" knockout from the RearPanel and install a 1/2" NPT strain relief (notsupplied) into the hole.

CNC Knockout

A-02756

Rear Panel

1/2" (12.7 mm)Strain Relief

(Customer Supplied)

Figure 3-13 Rear Panel Knockout Location

c. Locate the internal terminal block (TB) on theFilter/Voltage Divider PC Board, located be-hind the Logic PC Board. The terminal block(TB) is plugged into a socket on the Filter/Volt-age Divider PC Board.

A-02762Logic PC Board

Internal Terminal

Block (TB)

Filter/Voltage Divider

PC Board

Figure 3-14 Internal Terminal Block Location

d. Feed the CNC cable through the strain reliefat the rear of the Power Supply, routing thecable above the Logic PC Board to the Termi-nal Block (TB).

A-02763

Internal TerminalBlock (TB)

CNC Cable Routing

Figure 3-15 Routing CNC Cable


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e. Remove the terminal block from the socket andconnect the CNC cable to the terminal block(TB) per the following chart (see NOTES afterchart):

TB

Connection

Description

1 Power Supply Output Voltage (ARC V +)

2 Power Supply Output Voltage (ARC V -)

3 High Side of START Signal (+15 vdc)

4 Low Side of START Signal (Common)

5 One Side of OK-To-Move Signal

6 Other Side of OK-To-Move Signal

ARC V. START OK TO

MOVE+

1 2 3 4 5 6

- + -

A-02754

Figure 3-16 Terminal Block Positions

NOTES

ARC V+ Power supply positive output voltage(work lead) connection to TB position 1 through a100k resistor.

ARC V- Power supply negative output voltage(torch electrode) connection to TB position 2through a 100k resistor.

START + signal at TB position 3, 15 vdc at 10 ma,must be brought low by connecting it to START -at TB position 4, using a switch or relay contact,to start the plasma torch.

OK-To-Move is a relay, rated at 115 VAC/28 vdcat 2A, connected to TB positions 5 and 6 whichcloses for the OK-To-Move signal when the cut-ting arc is on.

Make sure all connections to the Terminal Block(TB) are secure.

f. Reinstall the terminal block into the socket onthe Filter/Voltage Divider PC Board.

g. Secure the CNC cable by tightening the strainrelief.

h. Reinstall the Left Side Panel.

B. Optional Standoff Control SC11 Cable

The Standoff Control SC11 automatically finds height andmaintains torch standoff with a high speed torch liftermotor. The unit consists of a remote operator's control,torch lifter motor, and all cables required for installation.It is ordered and shipped separately. Refer to the Stand-off Control SC11 Instruction Manual for more informa-tion.

The standoff control remote cable connects to the recep-tacle J22 (CNC Control) on the rear panel of the PowerSupply.

J22

CNC Connector

A-02759

CNC or Remote HandPendant Control Cable

Figure 3-17 Standoff Or Hand Pendant ControlInterface Connection

C. Optional Remote Hand Pendant Control

For automated systems, the optional Remote Hand Pen-dant Control allows the operator to control system startand stop functions from a remote location.

Connect the Remote Hand Pendant cable connector tothe receptacle J22 (CNC Control) on the rear panel of thePower Supply.


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Manual 0-2811 4-1 OPERATION

SECTION 4:OPERATION

4.01 Introduction

This section provides a description of the Power Supplyoperating controls and procedures. Identification of theFront and Rear Panel components is followed by operat-ing procedures.

4.02 Operating Controls

This subsection provides specific functional descriptionsof the Power Supply operating controls and indicators.

A. Front and Side Panel

1. Control Panel

All operator controls, except gas pressure adjustment,are located on this panel. Power ON/OFF and RUN/SET/LATCH switches; CURRENT control; indicatorsfor AC Power, TEMP, GAS, and DC.

1

2

3

4

A-02748

Figure 4-1 Front and Side Panel Connections

2. Access Panel

A panel for access to the bulkhead area containingthe torch connections.

3. Torch Leads Input

Hole in the front panel to feed the torch leads throughto the internal bulkhead connections.

4. Work Cable and Clamp

Work cable with ring terminal (factory installed) forconnecting to work table.

B. Control Panel

1

2

3

4 5 67

A15

40

80

A-03454

60

Figure 4-2 Operating Controls

1. Current Control (A)

Adjustment to set the desired output current between15 to 80 amps. The unit has an automatic fold-backcircuit that limits current to 35 amps if torch tip con-tacts the workpiece.

2. ON / OFF Power Switch

ON position supplies AC power to activate all sys-tem control circuits. OFF position deactivates con-trol circuits.

3. RUN /SET /LATCH

Switch

RUN position is used for torch operation. SET posi-

tion used for setting gas pressure and purging lines.NOTE

The LATCH position is not used for automatatedsystem applications.

4. AC Power Indicator

Green indicator will blink ON then OFF for approxi-mately eight seconds and then stay ON after the ON/OFF power switch is set to ON. Indicates operatingpower is present in the unit.


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OPERATION 4-2 Manual 0-2811

5. TEMP Indicator

Normally OFF. Yellow indicator turns ON when theinternal temperature senors detect temperaturesabove normal limits. The unit should be allowed tocool before continuing operation.

6. GAS Indicator

Green indicator turns ON when the input gas pres-sure is set to 45 psi (3.1 bar) or higher. Indicator willbe OFF when the pressure falls below 45 psi (3.1 bar).

7. DC Indicator

Green indicator turns ON while the torch switch ispressed.

C. Torch Bulkhead Panel

The torch bulkhead panel is under the access panel.1. Pilot Lead Stud

Connects the pilot control wire on the torch to theunit.

2

1

3

A-00923

Figure 4-3 Torch Panel Connections

2. PIP/Shield ConnectorConnects the torch PIP circuit and shield wires to theunit with an adapter supplied with the Power Sup-ply.

3. Gas/Power Lead Connection

Connects the torch gas/negative lead to the unit.

D. Rear Panel

1. Gas Input

Input connection for air or nitrogen (N2) input.

WARNING

This unit not to be used with oxygen (O2).

A-02746

1

2

3

4

6

5

Figure 4-4 Rear Panel

2. Primary Input Power Cable Strain Relief

NOTE

Input power cable is supplied on units when or-dered for 230V single-phase operation.

Primary input power cable strain relief for the pri-mary power cable (see Note above) capable of han-dling the input voltage designed for this unit.

3. Gas Pressure Regulator/Filter Assembly

Pressure regulator to adjust the input gas pressure tothe Power Supply. An air line filter is supplied aspart of the pressure regulator.


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4. Two Stage Air Line Filter

The Two Stage Air Filter will remove moisture andcontaminants from the air stream when using com-pressed air. The filter is capable of filtering to at least5 microns.

5. CNC Connector (J22)

External connector provided for connection of CNCControl, Standoff Control SC11 or Remote Hand Pen-dant Control.

6. Knockout

Knockout provided that allows internal connectionof CNC Control to a Terminal Block.

7. Optional Single-Stage Filter Assembly

This optional in-line filter removes moisture and con-taminants from the air stream when using com-pressed air. The filter is capable of filtering to at least

0.85 microns.

1

2

3

7

A-02749

6

5

Figure 4-5 Rear Panel Showing Optional Single-Stage Filter

4.03 Sequence of Operation

The following is a typical sequence of operation for thiscutting system. Refer to Appendix II for a block diagram.

1. Close main power source disconnect.

a. AC power is available at the Power Supply.

2. Place RUN/SET/LATCH switch to RUN mode.3. Place the ON/OFF power switch on the front panel

of the Power Supply to ON.

a. AC Power indicator blinks ON and OFFfor eight seconds then stays ON.

b. Fans turn on.

4. Place RUN/SET/LATCH switch to SET mode.

a. Gas solenoid opens and gas flows to set pres-sure.

b. GAS indicator turns ON.

NOTE

GAS indicator will not come ON if the gas pres-sure is set below 35 psi (2.4 bar) at the Regulator/Filter Assembly.

5. Place RUN/SET/LATCH switch to RUN mode.

a. Gas flow stops.

b. GAS indicator turns OFF.

NOTE

Do Not use the LATCH position for automatedsystem applications.

6. Protect eyes and activate system (CNC start sig-nal or press Remote Pendant switch)

a. Gas pre-flows starts.

b. GAS indicator turns ON.

7. After gas pre-flow (approximately 2 seconds)

a. Power supply enabled.

b. DC indicator turns ON.

c. Pilot relay closes.

8. Pilot arc is established

9. Torch moves to within transfer distance of work-piece.

a. Main arc transfers to workpiece..

b. Pilot arc OFF.


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10. Complete cutting operation.

NOTE

If the torch is lifted from the workpiece, while stillhaving torch is activated, the main arc will stopand the pilot arc will automatically restart.

11. Stop system (CNC stop signal or release Remote

Hand Pendant switch)a. Main arc stops.

b. Pilot arc stops (power supply enable signal re-moved).

NOTE

If torch is activated during post-flow, pilot arc willimmediately restart.

If torch is within 3/8 in (9.5mm) transfer distanceof workpiece, main arc will transfer.

12. Gas will flow for 15 seconds (post-flow).a. Gas solenoid closes

b. Gas flow stops.

c. GAS indicator turns OFF.

13. Place the ON/OFF power switch on the frontpanel of the unit to OFF

a. AC Power indicator turns OFF.

b. Fans turn OFF.

14. Place the main power disconnect to open.

a. Main AC power is removed from the system.

4.04 Preparations for Operating

Follow this set-up procedure each time the system is op-erated:

WARNING

Disconnect primary power at the source before dis-assembling the power supply, torch, or torch leads.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate frontend torch parts. The torch parts (shield cup, tip and elec-trode) must correspond with the type of operation (cut-ting or gouging).

B. Check Primary Power Source

1. Check the power source for proper input voltage. Makesure the input power source meets the power require-ments for the unit per Section 2.03-A-4, Specifications/Design Features.

2. Connect the input power cable (or close the main dis-connect switch) to supply power to the system.

C. Gas Selection

Select desired gas (air or nitrogen). Make sure gas sourcemeets pressure and flow requirements (refer to Section3.08, Gas Connections). Check connection and turn gassupply on.

D. Work Cable Connection

Check for a solid and clean work cable connection to theworkpiece or cutting table. The area must be free frompaint and rust.

E. Torch Connection

Check that the torch is properly connected.

F. Power Supply On

Move the ON/OFF switch to ON position.

G. Select Output Current

Select the desired current output level for the operation:

15 to 80 amps for standoff cutting and gouging

15 to 35 amps for drag cutting

NOTE

At output settings over 35 amps, the power sup-ply automatically reduces output current to 35amps if the torch tip touches the workpiece.


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H. Set Operating Pressure

Move the RUN/SET/LATCH switch to SET position. Ad-just the gas pressure to 60 - 70 psi / 4.1 - 4.8 bar. Refer totorch manual for pressure setting details.

I. RUN/SET Switch

Set the RUN/SET/LATCH switch to RUN position.

NOTE

Do Not use the LATCH position for automatedsystem applications.

The system is now ready for operation.

4.05 Cut Quality

Cut quality requirements differ depending on applica-tion. For instance, nitride build-up and bevel angle maybe major factors when the surface will be welded aftercutting. Dross-free cutting is important when finish cut

quality is desired to avoid a secondary cleaning opera-tion.

The following cut quality characteristics are illustratedin Figure 4-6:

Cut Surface

The condition (smooth or rough) of the face of the cut.

Bevel Angle

The angle between the surface of the cut edge and a planeperpendicular to the surface of the plate. A perfectly per-pendicular cut would result in a 0 bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing fromthe initial contact of the plasma arc on the workpiece.

Dross Build-up and Top Spatter

Dross is molten material which is not blown out of thecut area and re-solidifies on the plate. Top spatter is drosswhich accumulates on the top surface of the workpiece.Excessive dross may require secondary clean-up opera-tions after cutting.

Kerf Width

The width of material removed during the cut.

Nitride Build-up

Nitride deposits which may remain on the surface of thecut when nitrogen is present in the plasma gas stream.Nitride buildups may create difficulties if the material iswelded after the cutting process.

Kerf Width

Cut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Figure 4-9 Cut Quality Characteristics

Cut quality will vary on different types of and materialthicknesses.

The following table shows the cut quality that can be ex-pected from this equipment for materials with a thick-ness from gage to 1 inch (25.4mm):

Type of M ater ia l

G asCa r bon

Steel

Stainless

Stee l

Aluminum

A ir Good -

Exce l len t

Good -

Exce l len t

Good -

Exce l len t

N i trogen G ood G ood G ood

Description of Cut Characteristics

Excellent- Minimum bevel (0 - 4), minimum kerf (2 xtip orifice diameter), little or no dross, smoothcut surface.

Good- Slight bevel (0 - 10), slightly wider kerf (2-1/2 xtip orifice diameter), some dross (easily re-moved), medium-smooth cut surface, slight top

edge rounding.Fair- Excessive bevel (over 10), wide kerf (over 2-1/2 x

tip orifice diameter), medium to heavy dross, roughcut surface, top edge rounding.

NOTES

Cut quality depends heavily on set-up and param-eters such as torch standoff, alignment with theworkpiece, cutting speed, gas pressures, and op-erator ability.


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Manual 0-2811 5-1 SERVICE

SECTION 5:SERVICE

5.01 Introduction

This section describes basic maintenance procedures per-formable by operating personnel. No other adjustmentsor repairs are to be attempted by other than properly per-sonnel.

For major troubleshooting and parts replacement pro-cedures refer to PAK Master 100XL Plus AutomatedPower Supply Service Manual 0-2812.

5.02 General Maintenance

WARNING

Disconnect primary power to the system before dis-assembling the torch, leads, or power supply.

To clean the unit, open the enclosure (refer to Section 5.05-A, Opening Enclosure) and use a vacuum cleaner to re-move any accumulated dirt and dust. The unit shouldalso be wiped clean. If necessary, solvents that are rec-ommended for cleaning electrical apparatus may be used.

This schedule applies to all types of non-li quid cooledplasma 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 tobe adjusted according to the operating environ-ment.

A. Maintenance Schedule

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damagedor worn.

2. Inspect torch for any cracks or exposed wires, re-place if necessary.

3. Check plasma and secondary supply and pres-sure/flow.

4. Purge plasma gas line to remove any moisturebuild-up.

5. Inspect input power cable for damage or exposedwires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate airflow.

2. Vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during clean-ing. Blowing air into the unit can cause metal par-ticles to interfere with sensitive electrical compo-nents and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace asrequired

2. Check cables and hoses for leaks or cracks, replaceif necessary.

3. Check all contactor points for severe arcing or pits,replace if necessary.

B. Two Stage Air Filter Element Replacement

NOTE

The Two Stage Air Filter has two Filter Elements.When the Filter Elements become dirty the PowerSupply will continue to operate but cut quality maybecome unacceptable.

1. Remove power from power supply.

2. Shut off air supply and bleed down system be-

fore disassembly before changing Filter Elements.

WARNING

Always turn off the air supply and bleed the sys-tem before disassembling the Filter Assembly asinjury could result.

3. Loosen the two bolts on the top of the Filter As-sembly enough to allow the Filter Elements tomove freely.

4. Note the location and orientation of the old FilterElements.

5. Slide out the old Filter Elements.

6. Slide the replacement Filter Elements into the Fil-ter Assembly the same as noted in Step 4 above.

7. Hand tighten the two bolts evenly, then torqueeach bolt to 20 - 30 in-lbs (2.3 - 3.4 Nm).

8. Slowly apply air pressure to the assembly check-ing for leaks.


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SERVICE 5-2 Manual 0-2811

C. Optional Single-Stage Filter ElementReplacement

NOTE

The Power Supply shuts down automatically whenthe Filter Element becomes completely saturated.The Filter Element can be removed from its hous-

ing, dried out, and reused. Allow 24 hours for El-ement to dry.

1. Remove power from power supply.

2. Shut off air supply and bleed down system be-fore disassembly to change Filter Element.

A-02476

FilterElement

(Cat. No. 9-7741)

Housing

Cover

BarbedFitting

Spring

Assembled FilterO-ring

Figure 5-1 Optional Single-Stage Filter Replacement

3. Disconnect gas supply hose.

4. Turn the Cover counterclockwise and remove itfrom the Filter Housing. The Filter Element is lo-cated inside the Housing.

5. Remove the Filter Element from the Housing andset Element aside to dry.

6. Wipe inside of housing clean, then insert the re-placement Filter Element cup side first, as shown

below.7. Replace Housing on Cover.

8. Reattach gas supply hose.

NOTE

If unit leaks between housing and cover, inspectthe "O" Ring for cuts or other damage.

5.03 Common Operating Problems

WARNINGS

Disconnect primary power at the source before dis-assembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precau-tions (page 1). Be sure the operator is equipped withproper gloves, clothing, eye and ear protection.Make sure no part of the operators body comes intocontact with the workpiece while the torch is acti-vated.

CAUTION

Sparks from the cutting process can cause damageto coated, painted, and other surfaces such as glass,

plastic and metal.NOTE

Handle torch leads with care and protect them fromdamage.

A. Piloting

Piloting is harder on parts life