Thermal Dynamics Plasma Cutting System PAK 10 Manuel utilisateur

Marque: Thermal Dynamics

Modèle: Plasma Cutting System PAK 10

Catégorie: Système de soudage

Taper: Manuel utilisateur

Plasma Cutting

System

PAK 10

April 12, 2002 Manual No. 0-0515

Instruction Manual

WARNINGS

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

ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Plasma Cutting System PAK 10

Instruction Manual Number 0-0515

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

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

mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to

any party for any loss or damage caused by any error or omission in

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

any other cause.

Printed in the United States of America

Publication Date: April 12, 2002

Record the following information for Warranty purposes:

Where Purchased:_________________________________________

Purchase Date:____________________________________________

Power Supply Serial #:_____________________________________

Torch Serial #:_____________________________________________

Contents

SECTION 1:

GENERAL INFORMATION ....................................................................................................i

1.01 Notes, Cautions and Warnings ..........................................................................i

1.02 Important Safety Precautions ............................................................................i

1.03 Publications......................................................................................................ii

1.04 Note, Attention et Avertissement .....................................................................iii

1.05 Precautions De Securite Importantes.............................................................. iii

1.06 Documents De Reference ............................................................................... v

1.07 Declaration of Conformity ............................................................................... vii

1.08 Statement of Warranty................................................................................... viii

SPECIFICATIONS ........................................................................................................................ 1

1.1. DESCRIPTION OF EQUIPMENT ................................................................... 2

1.2. SPECIFICATIONS........................................................................................... 2

1.3. PLASMA CUTTING........................................................................................ 3

1.4. THEORY OF OPERATION.............................................................................. 3

INSTALLATION............................................................................................................................. 5

2.1 UNPACKING ................................................................................................... 5

2.2 EQUIPMENT ASSEMBLY ............................................................................... 5

2.3 EQUIPMENT INSTALLATION ......................................................................... 6

OPERATION................................................................................................................................. 9

3.1 OPERATING CONTROLS............................................................................... 9

3.2 PRE-OPERATION SET-UP ............................................................................. 9

3.3 OPERATION ................................................................................................. 10

3.4 CUTTING CURRENT AND SPEED SELECTION......................................... 13

SERVICE.................................................................................................................................... 15

4.1 TORCH MAINTENANCE .............................................................................. 15

4.2 TORCH LEADS AND LEADS EXTENSION PACKAGES .............................. 17

4.3 PAK UNIT MAINTENANCE ........................................................................... 18

4.4 GAS PRESSURE REGULATORS ................................................................. 18

4.5 TROUBLE SHOOTING GUIDE ..................................................................... 19

4.6 TEST PROCEDURES................................................................................... 21

PARTS LISTS ............................................................................................................................. 25

General Arrangement............................................................................................ 25

PAK 10 Cutting System ......................................................................................... 26

Equipment Board Assembly .................................................................................. 28

Control P.C. Board Assembly................................................................................. 29

Control Bridge and Main Bridge Assemblies ......................................................... 30

Torch Connection Panel Assembly ........................................................................ 32

Pilot Resistor and Rear Panel Assembly ............................................................... 34

Front Panel Assembly ........................................................................................... 36

Base Components Assembly ................................................................................ 38

Torch Leads, Leads Extension Packages, Torch Guide and

Circle Cutting Attachment, Remote Control Assembly .................................. 40

Series 4B Gas-Cooled Torches ............................................................................. 42

Gas Pressure Regulators...................................................................................... 44

Date: November 15, 2001 i GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation regarding the kind and amount of fumes

and gases that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection 1.03,

Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

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

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

GENERAL INFORMATION ii Date: November 15, 2001

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

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

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial in the workplace. Any material that cannot

be removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

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

D.C. 20402

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

CUTTING, obtainable from the American Welding So-

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

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

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

ment Printing Office, Washington, D.C. 20402

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

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

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

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 iii GENERAL INFORMATION

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS 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 SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

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

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

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

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

1.04 Note, Attention et

Avertissement

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.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

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.

GENERAL INFORMATION iv Date: November 15, 2001

• Eloignez toute fumée et gaz de votre zone de respira-

tion. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air

si l’aération fournie ne permet pas d’éliminer la fumée

et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un ou

plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des gaz

pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une

zone où se trouvent des matières ou des gaz combus-

tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

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

produit de la fumée ou des gaz pouvant contenir des

éléments reconnu dans L’état de la Californie, qui

peuvent causer des défauts de naissance et le cancer.

(La sécurité de santé en Californie et la code sécurité

Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”;

portez des gants et des vêtements secs. Isolez-vous

de la pièce de travail ou des autres parties du circuit

de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la page

5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de

consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail. Protégez

toute telle matière qu’il est impossible de retirer de la

zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans

une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous

les pièces de travail en aluminium lorsqu’elles sont

coupées sous l’eau ou sur une table d’eau. NE PAS

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.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de

plasma produit une lumière infra-rouge et des rayons

Date: November 15, 2001 v GENERAL INFORMATION

ultra-violets très forts. Ces rayons d’arc nuiront à vos

yeux et brûleront votre peau si vous ne vous protégez

pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou

un écran de soudeur. Portez toujours des lunettes de

sécurité munies de parois latérales ou des lunettes de

protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur

approprié pour protéger votre peau contre les

étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection

en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant des

cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le

recommendation qui suivent ANSI/ASC Z49.1:

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.

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.

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 Superin-

tendent 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 TRA-

VAIL ET DANS LES ECOLES, disponible de l’Institut

Américain des Normes Nationales (American Na-

tional Standards Institute), 1430 Broadway, New York,

NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES

LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET

DE SOUDAGE, disponible auprès de l’American Na-

tional Standards Institute, 1430 Broadway, New York,

NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage

(AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES PRODUITS

COMBUSTIBLES, disponible auprès de la American

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

33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection 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 Na-

tional Fire Protection Association, Batterymarch Park,

Quincy, MA 02269

GENERAL INFORMATION vi Date: November 15, 2001

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13.Livret NWSA, BIBLIOGRAPHIE SUR LA

SÉCURITÉ DU SOUDAGE, disponible auprès de

l’Association Nationale de Fournitures de Soudage

(National Welding Supply Association), 1900 Arch

Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

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

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 vii GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’

(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for

the enforcement of this Directive.

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

and date of manufacture.

National Standard and Technical Specifications

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

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

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

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

ated accessories.

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

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

industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure

the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our

area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director

Thermal Dynamics Europe

Via rio Fabbiani 8A

40067 Rastignano (BO)

Italy

GENERAL INFORMATION viii Date: November 15, 2001

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics

Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in

workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

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 Year 1 Year 1 Year

Exchanges, 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® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation

charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall

be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective November 15, 2001

Manual No. 0-0515 1 Specifications

Pak 10

Gas

Regulators

Gas Hoses

Spare Parts

Kit

Work Cable

Torch and Leads

A-03289

A-03290

Figure 1-A Components of PAK 10 Cutting System

Fig. 1-B Type 4B LO-AMP Gas Cooled Torches

1. 90° Hand cutting torch (PCH-4B 90°)

2. 70° Hand cutting torch (PCH-4B 70°)

3. Machine mounted cutting torch (PCM-4BT)

4. Remote control unit for machine mounted torch

Fig. 1-C Accessories

1. Cylinder Rack

2. Torch Guide & Circle Cutting Attachment

3. Leads Extension Package

SPECIFICATIONS

erm

al A

rc P

A-03291

Specifications 2 Manual No. 0-0515

1.1. DESCRIPTION OF

EQUIPMENT

A complete PAK 10 system includes a PCH-4B hand

torch and/or PCM-4BT machine torch with 25 foot or

50 foot (7.62 m or 15.24 m) leads, a spare parts kit, a

PAK 10, gas supply, pressure regulators, 10 foot gas

supply hoses and a 25 foot work cable with clamp.

Three 4B torches are available (Figure 1-B): 90° hand

torch (1), 70° hand torch (2), and a machine mounted

torch (3). The 4BT machine mounted torch is controlled

by a remote control assembly (4, Figure 1-B) with an

ON/OFF switch and a remote current control. An ini-

tial supply of parts for the 4B is in the spare parts kit

(Figure 1-A).

1.2. SPECIFICATIONS

TYPE 4B GAS COOLED TORCH

• Current Rating: 100 amperes maximum, DCSP, 80%

duty cycle

• Plasma Gas: Nitrogen (N2), 30 psi (2.2 kg/cm

), 15

SCFH (7.5 lpm); 65% Argon/35% Hydrogen, 40 psi

(2.8 kg/cm

), 30 SCFH

• Secondary Gas: Carbon dioxide (C0

), 50 psi (3.52

kg/cm

), 250 SCFH (125 lpm); compressed air, 50

psi (3.52 kg/cm

), 250 SCFH (125 lpm)

• Cutting Capacity (most metals): Maximum thick-

ness- 1 inch (25.4 mm); production cutting- 5/8 inch

(15.9 mm); piercing- 3/4 inch (19 mm)

• Weight: Hand torch PCH-4B- 1-3/4 lbs. (0.79 kg);

Machine mounted torch PCM-4BT- 3 lbs. (1.36 kg)

without leads

PAK 10 UNIT

Power Input: 20 KVA, 50/60 Hertz, 3-phase in one of

the following standard voltage/amperage combina-

tions:

1- 208/230/460 volts, 60/50/25 amps

2- 230/460/575 volts, 50/25/20 amps

3- 380/415/460 volts, 30/30/25 amps

4- 380/460/500 volts, 30/25/25 amps

5- 220/380/500 volts, 50/30/25 amps

6- 180/200/220 volts, 70/60/50 amps

Certain other special voltage combinations are avail-

able.

• Rated Output: 100 amperes DC straight polarity

• Current Control: 50 to 100 amps continuously ad-

justed by feedback circuit

• Control Circuit: 24 volt AC

• Plasma and Secondary Gas Pressures: Controlled

by pressure regulator at gas supply

• Weight: 615 lbs. (279 kg)

• Dimensions: Width- 26 inches (66 cm); Depth- 36

inches (91 cm); Height- 24 inches (61 cm)

ACCESSORIES AVAILABLE:

• A cylinder rack (1, Figure 1-C) that holds two gas

cylinders

• A torch guide and circle cutting attachment (2, Fig-

ure 1-C)

• Torch lead extension packages to extend the torch

leads in increments of 25 or 50 feet (3, Figure 1-C)

TORCH DIMENSIONS

AB CD

PCH-4B (70°) 16.00” (406 mm) 3.98” (100 mm) 1.25” (32 mm) 1.32” (34 mm)

PCH-4B (90°) 15.25” (390 mm) 3.98” (100 mm) 1.25” (32 mm) 1.32” (34 mm)

PCM-4BT 18.38” (467 mm) 8.12” (206 mm) 16.00” (406 mm) 0.69” (17 mm)

B MIN

C MAX

A-03292

Manual No. 0-0515 3 Specifications

1.3. PLASMA CUTTING

Plasma is a gas which has been heated to an extremely

high temperature and ionized so that the gas becomes

electrically conductive. The plasma cutting process uses

this plasma to transfer an electric arc to the workpiece.

The metal to be cut is melted by the heat of the arc and

then blown away.

In a plasma torch, a cool gas such as nitrogen (N2) en-

ters in Zone A, Figure 1-D. In Zone B a pilot arc be-

tween the electrode and the front of the torch heats and

ionizes the gas. An arc transfers to the workpiece

through a column of plasma gas in Zone C.

A-00002

Workpiece

Power

Supply

Figure 1-D Plasma Torch Operation

Plasma torches deliver a high concentration of heat to

a very small area. The stiff, constricted plasma arc is

shown in Zone C. Direct current straight polarity is

used for plasma cutting, as shown in the illustration.

Plasma cutting torches use a secondary gas, which as-

sists the high velocity plasma gas in blowing the mol-

ten metal out of the cut. This results in fast, clean, dross

(slag)-free cuts. In the PAK l0 system, the secondary

gas also cools the cutting torch. CO

or compressed air,

supplied by either a cylinder or plant air system, is nor-

mally used as the secondary gas.

1.4. THEORY OF OPERATION

The main components of the PAK 10 cutting system

are illustrated in the block diagram (Figure 1-E) and

their function is summarized below.

PLASMA AND SECONDARY GASES

Plasma and secondary gases flow through the PAK unit

to the cutting torch at pressures set at the external regu-

lators. The pressure of each gas is indicated on the front

panel gauges. Solenoid valves turn the gases on and

off. The gas pressure interlocks shut the system down

if the plasma gas pressure falls below 25 psi (1.7 bar) or

the secondary gas pressure drops below 30 psi (2.0 bar).

The plasma gas flows through the green/black lead,

around the electrode and gas distributor, and out

through the tip orifice.

The secondary gas flows through the red/yellow torch

lead, down the outside of the torch liner, through the

holes at the base of the liner and out around the plasma

arc.

PILOT ARC

When the torch is started, the pilot arc contactor closes

and an arc is established between the electrode and

cutting tip. The pilot arc makes a path for transferring

the main arc to the work.

HIGH FREQUENCY

Because direct current alone is not sufficient to strike

and maintain the pilot arc, high frequency is superim-

posed on the direct current.

CUTTING ARC

The main bridge rectifier converts the 3-phase AC

power to DC power for the pilot and main cutting arcs.

The negative output is connected to the torch electrode

through the torch lead. The positive output is connected

to the workpiece (through the work cable) and, through

a contactor and resistor to the torch tip.

CURRENT CONTROL

The desired cutting current is set on the CURRENT

ADJUST knob. A control circuit stabilizes cutting cur-

rent against fluctuations due to changes in line volt-

ages, material thickness, torch standoff and travel

speed. Changing the amount of saturating current in

the reactor changes the amount of AC power supplied

to the main bridge rectifier. The amount of saturating

current is controlled by a comparator which compares

the actual cutting current to the amperage selector po-

tentiometer setting.

Specifications 4 Manual No. 0-0515

Figure 1-E Block Diagram of PAK 10 Cutting System

GAS PRESSURE

INTERLOCK

POWER

TRANS-

FORMER

SATURABLE

REACTOR

COMPARATOR

PILOT ARC

HIGH FREQUENCY

PILOT ARC

CONTACTOR

AMPERAGE

SELECTOR POT

SOLENOID

VALVES

SECONDARY

GAS

PLASMA

GAS

3-PHASE

AC POWER

CONTROL

CIRCUITS

SECONDARY GAS PRESS

PLASMA

GAS PRESS

MAIN BRIDGE

RECTIFIER

MAIN

CONTACTOR

SCR CONTROL

BRIDGE

RECTIFIER

WORK

CURRENT

SENSING COIL

(TOROID

TRANSFORMER)

PAK 10 POWER SUPPLY AND CONTROL UNIT

AMP

POS.

(RED/YEL)

TORCH

LEADS

CUTTING

TORCH

(-)

(+)

SHUNT

A-03293

NEG.

(GR/BLK)

Manual No. 0-0515 5 Installation

INSTALLATION

2.1 UNPACKING

The PAK 10 is skid-mounted and protected with a car-

ton and padding material to prevent damage in ship-

ment. The casters, lifting eye, gas hoses, work cable,

torch, torch leads and miscellaneous parts are packed

separately.

One copy of the PAK 10 Instruction Manual, in a trans-

parent plastic envelope, is packed in with the PAK 10

unit.

A-03356

1. Washer-head cover screws

2. Cover Assembly

3. Lifting eye

4. Access door fasteners

5. Lead connection access door assembly

6. Interlock switch actuator

7. Casters

8. Work cable receptacle

Figure 2-A Power Supply and Control Unit with

Access Door Open

2.2 EQUIPMENT ASSEMBLY

After removing the carton, turn the lifting eye (3,

Fig. 2-A) all the way into the threaded socket on top

of the unit and tighten it securely. The lifting eye

may then be used to lift the unit for removal of the

skids and installation of the casters (7). If no crane

or hoist is available for lifting, a fork lift or jack may

be used. Use care so that the base of the unit will

not be damaged. Lift the unit and remove the two

skids which are secured to the base assembly with

four bolts and hex nuts. Install the two swivel cast-

ers (7) at the front of the unit using four 5/16-18 x

3/4 inch cap screws and four 5/16-18 locknuts in

each. Install the two fixed casters at the rear in the

same manner. Lower the unit onto the casters and

remove the lifting device.

Installation 6 Manual No. 0-0515

2.3 EQUIPMENT INSTALLATION

Select a clean, dry location with good ventilation and

adequate working space. Be sure that the air flow into

the unit (from underneath) and out the back is not ob-

structed. A source of 3 phase power and a source of

gases with pressure regulators are required.

Review PRECAUTIONS in the first section of this

manual to be sure that location meets all safety require-

ments.

Most users prefer nitrogen (N2) as the plasma gas and

carbon dioxide (C0

) as the secondary gas, since it is

easy to obtain good quality cuts with this combination.

Argon/Hydrogen (Ar/H

) (65% argon-35% hydrogen)

is sometimes preferred as the plasma gas when cutting

1/2" to 1" thick aluminum to improve cut finish and

reduce smoke and fumes. Compressed air (free of dirt

and oil) may also be used as the secondary gas.

A-03357

Figure 2-B Internal Packing Material

NOTE

A typical 50 lb. CO

cylinder is capable of deliv-

ering 35 SCFH on a continuous basis. There-

fore, the manifolding of several CO

cylinders

may be necessary to obtain the required torch flow

rate, depending on application and duty cycle.

Connect the unit as follows:

1. Remove the top of the unit as follows:

a. Remove the screws holding the cover.

b. Open the lead connection access door (5, Fig-

ure 2-A).

c. Lift off the cover of the unit.

2. Remove the paper band (1, Figure 2-B) stapled

around the main terminal board.

3. Check for possible loose connections and damage

that may have occurred during shipment.

4. Check the transformer (Figure 2-C) to be sure that

it is set up for the available power. Three terminals

(Figure 2-C) are provided for each phase. As shown

in Figure 2-C, to connect the unit for 460 volts, the

three wires from the input terminals attach to the

three terminals marked 460. For other voltages, the

three wires are connected to the appropriately

marked terminals.

Voltage Connections -

Transformer

A-03358

Figure 2-C Transformer Voltage Connections

CAUTION

Input voltage of the available three phase power

source must correspond to one of the three oper-

ating voltages of the PAK 10. If not properly

connected, damage to the equipment may result.

Manual No. 0-0515 7 Installation

5. Check the three phase power service to be used.

Recommended fuse or circuit breaker sizes are given

in Table 2-A.

Power

Trans-

former

Line

Voltages

Accepted

Fuse or

Circuit

Breaker

Amperes

Recommended

Minimum

Primary

Wire size *

208

230

460

230

460

575

380

415

460

380

460

500

220

380

500

180

200

220

* From the National Electric Code, 1978

Table 2-A Line Voltages, Circuit Protection &

Recommended Wire Size

NOTE

Larger wires may be required if the length is over

25 feet.

6. With the primary power disconnect switch open,

connect the electrical ground and primary power

leads to the terminals on the upper right hand side

(facing the unit from the front.) Recommended wire

sizes are given in Table 2-A. The leads are led

through the “INPUT” fitting in the back (1, Figure

2-E). A proper ground connection must be made to

the brass stud as shown (2, Figure 2-D). The other

leads are attached to terminals L1, L2, and L3 (1,

Figure 2-D).

WARNING

Do Not Turn on Power Until Step 10.

7. Connect the gases to be used to the fittings on the

back of the unit (2 & 3, Fig. 2-E). Pressure regula-

tors for use with PAK units and specifically cali-

brated for use with nitrogen (Cat. #9-2722), argon/

hydrogen (Cat. #9-3053), carbon dioxide (Cat. #9-

2759), and compressed air (Cat. #9-3022) are avail-

able from Thermal Dynamics. The gas supplies

must be equipped with adjustable pressure regula-

tors capable of being set between 0 and 60 psi (0-4.1

bar) and of delivering 15 Standard Cubic Feet per

Hour (SCFH) (7 lpm) of N2 and 250 SCFH (118 lpm)

of C0

or compressed air.

A-03359

1. Primary Lead Terminals

2. Ground Terminal

Figure 2-D Primary Lead Connections

Installation 8 Manual No. 0-0515

4FU

INPUT

PLASMA

SEC

A-03360

1. INPUT cable bushing

2. SECondary gas connection fitting

3. PLASMA gas connection fitting

Figure 2-E Rear Panel Connections

8. Check the torch to see that it is properly assembled

(Refer to Section 4.1.).

a. Pass the torch leads and control wire through

the bushing on the front panel (5, Figure 2-F)

and connect them to the appropriate fittings.

b. If the torch is machine-mounted, the remote

control assembly plug must also be inserted in

the remote current control jack.

9. Re-install the cover of the unit (the leads access door

must be open). Start the sheet metal screws but do

not tighten them until the cover is lined up.

Carefully close the leads access door, making sure

that the switch actuator (1, Figure 2-F) enters its slot

and activates the interlock switch. When the cover

is properly positioned, tighten the screws.

WARNING

Do Not Operate the Unit unless all parts of the

enclosure are in place. This is important for

proper cooling as well as safety.

10. The work cable (Figure 1-A) is equipped with a

twist-lock plug on one end and a work clamp on

the other. The plug fits into the work receptacle on

the front of the unit (8, Figure 2-A) and the clamp

attaches to the workpiece. The unit is now ready

for operation.

A-03361

l. Actuator for Interlock Switch (SW3)

2. Negative (-) torch lead fitting

3. Positive (+) torch lead fitting

4. Torch control switch receptacle

5. Torch lead insulating bushing

6. Remote current control jack

Figure 2-F Torch Connection Access Door and

Panel

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Thermal Dynamics Plasma Cutting System PAK 10 Manuel utilisateur

Marque: Thermal Dynamics

Modèle: Plasma Cutting System PAK 10

Catégorie: Système de soudage

Taper: Manuel utilisateur

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