Plasma Cutting System PAK 10 Instruction Manual April 12, 2002 Manual No.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting 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.
Contents SECTION 1: GENERAL INFORMATION .................................................................................................... i 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ..........................................................................i Important Safety Precautions ............................................................................ i Publications ......................................................................................................
SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. PLASMA ARC RAYS • Repair or replace all worn or damaged parts. 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. • Extra care must be taken when the workplace is moist or damp.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédure en question. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 AVERTISSEMENT 8.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau. • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz. • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés.
ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement. 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 : • 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. 1.
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.
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.
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.
SPECIFICATIONS Pak 10 A-03289 Gas Hoses Gas Regulators Spare Parts Kit Work Cable Torch and Leads Figure 1-A Components of PAK 10 Cutting System 1 1 2 2 3 10 Thermal Arc PAK 3 4 A-03291 A-03290 Fig. 1-C Accessories Fig. 1-B Type 4B LO-AMP Gas Cooled Torches 1. 90° Hand cutting torch (PCH-4B 90°) 1. Cylinder Rack 2. 70° Hand cutting torch (PCH-4B 70°) 2. Torch Guide & Circle Cutting Attachment 3. Machine mounted cutting torch (PCM-4BT) 3. Leads Extension Package 4.
PAK 10 UNIT 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).
1.3. PLASMA CUTTING 1.4. THEORY OF OPERATION 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. The main components of the PAK 10 cutting system are illustrated in the block diagram (Figure 1-E) and their function is summarized below.
POS. (RED/YEL) SECONDARY GAS PRESS SOLENOID VALVES TORCH LEADS PLASMA GAS PRESS NEG.
2.2 INSTALLATION 2.1 UNPACKING The PAK 10 is skid-mounted and protected with a carton and padding material to prevent damage in shipment. 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 transparent plastic envelope, is packed in with the PAK 10 unit. 2 3 4 EQUIPMENT ASSEMBLY After removing the carton, turn the lifting eye (3, Fig.
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 obstructed. 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 requirements. 3. Check for possible loose connections and damage that may have occurred during shipment. 4.
5. Check the three phase power service to be used. Recommended fuse or circuit breaker sizes are given in Table 2-A. Power Transformer Line Voltages Accepted Fuse or Recommended Minimum Circuit Primary Breaker Wire size * Amperes 208 80 230 60 460 30 230 60 2 460 30 575 25 40 380 40 3 415 30 460 40 380 30 4 460 30 500 220 60 5 380 40 500 30 180 90 6 200 80 220 60 * From the National Electric Code, 1 4 6 10 6 10 10 8 10 10 8 10 10 6 8 10 4 6 6 1978 7.
1 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. INPUT SEC 1 3 2 4 PLASMA 2 4FU 3 5 5A 6 A-03360 1. INPUT cable bushing 2. SECondary gas connection fitting A-03361 3. PLASMA gas connection fitting l. Actuator for Interlock Switch (SW3) Figure 2-E Rear Panel Connections 2.
OPERATION 4 7 5 60 40 70 80 5A 20 10A 3 5 3 6 bar psi 60 40 4 2 1 4 2 5 1 6 bar psi PLASMA GAS 80 60 2FU 80 AMPERES D.C. 1FU 6 100 3 20 9 100 2 SECONDARY GAS TORCH AC POWER 90 100 50 ON DC POWER RUN 1 REMOTE CURRENT CONTROL SET OFF MIN. CURRENT Thermal Arc PAK 10 CUTTING SYSTEM 8 A-03309 Figure 3-A PAK 10 Control Unit Operating Controls 3.1 OPERATING CONTROLS 7. RUN/SET Switch (SW2) Move up to RUN position for torch operation.
3. Turn the ON/OFF switch ON (9, Figure 3-A). The amber “READY” light will come on. (If the gas supply is on, the gases will flow for two seconds). 4. Turn the RUN/SET switch to the SET position. Open the plasma gas supply valve at the source. Adjust the pressure regulator on the gas supply until the plasma gas pressure reads 30 psi (2.0 bar). 5. Purge for approximately 3 minutes by letting the plasma gas run.
MACHINE TORCH OPERATION When cutting with a machine torch, the torch must be at right angles to the plate to obtain a clean, vertical cut. Use a square, as shown in Figure 3-D, to align the torch. It is good to start a cut at a slow speed and increase the speed to obtain the desired cut quality. Table 3-B gives typical cutting speeds for various materials and material thicknesses.
Starting Pierce Continue Cut After Pierce WARNING It is not enough to simply move the ON/OFF switch on the unit to its OFF position when cutting operations have been completed. Always open the power supply disconnect switch 5 minutes after the last cut is made. A-01920 COMMON CUTTING FAULTS Figures 3-F and 3-G Piercing with Hand Torch When using a hand torch, tip the torch slightly to pierce so that blowback particles blow away from the torch tip rather than directly into it, as shown in Figure 3-F.
3.4 CUTTING CURRENT AND SPEED SELECTION The desired cutting current and the speed at which the torch is moved along the line of the cut depend on the thickness and composition of the workpiece. In hand cutting, the speed is usually determined by how fast the operator can comfortably and accurately follow the line of the cut. Most operators find that at speeds much above 30 ipm it is difficult to accurately follow the line of the cut. For machine cutting, faster speeds are often used. Refer to Table 3-B.
PAK 10 - SEQUENCE OF OPERATION System OFF System READY ACTION 1. Close external disconnect switch. Red AC POWER indicator ON. ACTION ACTION 1. RUN/SET switch to RUN. 1. RUN/SET switch to SET. 2. ON/OFF switch to ON. 2. Select cutting amps with CURRENT knob. RESULT RESULT 2. Coolant pressure switch closes. 1. Gas valves open, gases flow to purge system and allow setting of pressures. 1. Gas flow stops. 3. Gases flow. 2. Power circuits disabled. 2. Power circuits ready. 1.
Torch Disassembly and Inspection SERVICE The Service Section is divided into six parts: WARNING 4.1 Torch Maintenance Disconnect primary power before disassembling the torch. 4.2 Torch Leads and Leads Extension Packages 4.3 PAK Unit Maintenance 4.4 Gas Pressure Regulators Disassemble the torch parts as follows: 4.5 Trouble Shooting Guide 1. Pull off the shield cup (1) and inspect it for damage. Wipe it clean, or replace it if it appears to be damaged. 4.6 Test Procedures 4.
If the end of the electrode is badly pitted (cavity almost covers diameter) then that end of the electrode should no longer be used. Torch Assembly WARNING The electrode may then be reversed. When both ends are pitted, the electrode should be replaced. Do not attempt to repoint the electrode. Disconnect primary power before assembling the torch. NOTE Remove the liner assembly (4) and sleeve (6), in accordance with the following step, only if either appears to be damaged and requires replacement. 1.
6. PCH-4B: Install the back cap (14) and tighten it securely. CAUTION Use care to see that the back cap is turned all the way down to hold the collet (12) securely. On the machine torches this cap goes down inside and may seem tight, but still may not be holding the collet tightly. Arcing may result, welding the collet to the torch and causing irreparable damage. Use a ferrule (1) to secure the hose to the fitting or lock the hose in place with a twisted wire.
4.4 WARNING Disconnect primary power before installing the leads extension package. Do not turn on primary power to unit until all connections are made and insulators are in place. The leads that are furnished with the extension packages are the same as standard leads with the exception of the control switch leads for the hand torch. On the extension package the control switch leads terminate in a receptacle for the 2 prong “Twist-Loc” plug.
2 3 WARNING 4 Removing the cover of a PAK 10 with a Running Gear also removes the retaining Chains making the gas cylinders free standing. These cylinders must be restrained by some temporary means until the cover and the retaining bar are replaced and the retaining chains reconnected. 1 5 A-01894 6 When the external disconnect switch is closed, the red “AC POWER” light goes on and the fan starts. When the ON/OFF switch goes ON, the amber “READY” light goes on and the gases flow for two seconds.
When the torch switch is pressed, the gas and red “DC POWER” light should come on. If this does not happen, check as follows: 3. Shorted torch leads a. Repair or Replace. J. No spark can be seen in torch F. Gas does not flow when torch switch pressed 1. High frequency points shorted 1. Torch switch not connected a. Check wires to plug, switch, and receptacle. 2. Torch switch not closing a. Clean and dry area around high frequency points, adjust gap to 0.015". 2. Shorted capacitor C-1 a.
4. Current control circuit inoperative (A cutting arc can be established on very thin material if the torch is held very close) Q. Short torch parts life 1. Pilot arc remains on during cut a. Check CSR circuit (See R, Test Procedures). a. See next section (Problem M). Once the cutting arc is established, the cutting current should be equal to the setting of the CURRENT adjust knob (unless the remote current control is in use).
Tests requiring voltage measurements are marked with the warning symbol: All other tests are to be made with the primary power to the machine turned off. C. Relay 1CR has a 24 volt AC coil. The coil resistance should be approximately 80 ohms measured from pin A to pin B (on bottom of relay). Bottom Of Relay 1CR A-01900 NOTE A. The two time delay relays, TD1 and TD2, are interchangeable and can normally be checked by swapping them. They are the “delay on operate” type with a fixed 2 second delay. B.
2. High frequency protection for the diodes is provided by capacitors C-2, C-3, and C-4 which are installed between each side of the bridge rectifier and ground, and across the output of the bridge rectifier. These capacitors and their connections should be checked. K. The pilot arc resistor is located horizontally at the back of the unit. It should read 3.5 ohms. 3. Overheating of the diode can occur if air flow over the heat sink is inadequate or if the diode is not properly fastened to the heat sink.
Q. The best way to check the printed circuit control card is to replace it with one known to be good. The same card is used in the PAK 10, 22, 44 and 350. R. Watch the high frequency points during a cut. If the high frequency remains on, check the resistance of the toroid coil (See test G) and of the relay CSR. The coil of relay CSR should read about 3K ohms measured from pin A to pin B (bottom view same as time delay - See test C). S.
PARTS LISTS General Arrangement The Assembly Parts List consists of illustrated Parts Lists of the following: • Complete PAK 10 Cutting System • Equipment Board Assembly • Control P.C.
PAK 10 Cutting System Fig. Item No. 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 1 2 3 4 5 5 5 5 6 6 7 8 9 9 9 10 10 11 12 13 14 15 Parts Lists Qty.
11 (13) 4 12 14 15 1 2 9 8 10 3 5 6 7 A-03300 Figure 5-1 Complete PAK 10 Cutting System Manual No.
Equipment Board Assembly Fig. Item No. 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 Qty. 1 2 3 4 5 6 7 8 9 10 * 11 12 13 14 15 16 17 18 19 Catalog Number (1) (1) (1) (1) (1) (1) (1) (3) (3) (1) (1) (1) (1) (1) (2) (1) (1) (2) (1) (1) Description 9-3118 8-1459 8-1310 9-2390 8-0001 9-3117 8-1538 9-2504 8-1715 8-1951 9-2886 9-2847 9-3292 8-1373 9-3175 9-2848 9-2693 9-2694 9-2790 9-2780 Reference Designator EQUIP.
Control P.C. Board Assembly Fig. Item No. 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 1 2 3 4 5 6 7 8 9 10 11 Qty. (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) Catalog Number 9-2918 9-3l74 9-2687 9-3114 9-2689 9-3115 9-2688 9-3116 9-3119 9-3592 9-3568 Description Reference Designator PRINTED CIRCUIT BOARD COVER GROUNDING LEAD TRANSFORMER RECEPTACLE RESISTOR, 3.9K ohm BRACKET PRINTED CIRCUIT BOARD (Control Cir.
Control Bridge and Main Bridge Assemblies Fig. Item No. 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 5-4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 Parts Lists Qty.
8 9 10 4 3(SCR2) 16(D6) 11 2(D3) 13(D9) 14 (C8) 25 29 16(D4) 28 16(D5) 5 15 4 2(D2) 24 6 3(SCR1) 14(C4) 2(D1) 26 14(C3) 1 13(D7) 13(D8) 21 12 7 17 22 14(C2) 23 20 31 19 26 18 30 27 A-03303 Figure 5-4 Control Bridge and Main Bridge Assemblies Manual No.
Torch Connection Panel Assembly Fig. Item No. 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 5-5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Parts Lists Qty. (1) (1) (1) (2) (2) (2) (1) (2) (4) (1) (1) (1) (1) (1) (1) Catalog Number 9-2335 9-3157 8-0220 8-0260 9-3158 9-2023 8-0352 8-0257 9-3336 9-3160 9-3161 9-3162 Description Reference Designator SWITCH BRACKET TWIST-LOCK BASE O2B-1/4 NPT STR. ADAPTER 1/4 NPT BULKHEAD 1/4-1/8 NPT REDUCER BUSHING HIGH FREQ.
1 7 6 9 8 6 8 9 2 9 3 11 10 9 4 5 12 13 14 15 A-03304 Figure 5-5 Torch Connection Panel Assembly Manual No.
Pilot Resistor and Rear Panel Assembly Fig. Item No. 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 5-6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Parts Lists Qty. (1) (2) (2) (2) (2) (2) (2) (2) (2) (1) (1) (1) (1) (1) (1) (1) Catalog Number 9-2966 9-3163 8-0330 8-0256 9-2023 8-0354 8-1786 8-0312 8-0257 8-5118 9-2968 9-2391 9-3165 9-3402 9-3166 8-5119 Description Reference Designator RESISTOR, 3.
14 12 11 3 2 10 4 7 16 6 9 1 5 8 13 2 A-03305 Figure 5-6 Pilot Resistor and Rear Panel Assembly Manual No.
Front Panel Assembly Fig. Item No. 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 5-7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Parts Lists Qty.
3 4 17 1 18 2 15 12 16 7 10, 11 9, 11 14 (LT1) 14 (LT2) 6 13 8 5 A-03306 Figure 5-7 Front Panel Assembly Manual No.
Base Components Assembly Fig. Item No. 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 5-8 1* 2 3 4 5 6 7 8 9 10 11 12 12 12 12 12 12 12 12 13 Parts Lists Qty.
12 11 (13) 9 10 6 5 8 1(not shown assembled) 4 2 7 A-03307 3 Figure 5-8 Base Components Assembly Manual No.
Torch Leads, Leads Extension Packages, Torch Guide and Circle Cutting Attachment, Remote Control Assembly Fig. Item No. 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 5-9 1 1a 2 3 4 5 6 7 8 8 9 9 10 11* 12 13 14 15 16 17 17 17 17 18 20 21 22 23 Parts Lists Qty.
14 16 12,13 15 2 1a 11, 21 1 4 3 1a 10 5 1 23 6 22 8 14 9 16 20 7 18, 21 17 10 22 A-03308 Figure 5-9 Torch Leads, Leads Extension Packages, Torch Guide and Circle Cutting Attachment, Remote Control Assembly Manual No.
Series 4B Gas-Cooled Torches Fig. Item No. 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 5-10 1A 1B 2 2 2 2 3 4 5 6 7 8 9 10A 10B 10C 11 12 12a 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Parts Lists Qty.
1A 2 3 4 6 5 8 9 7 10B 11 12 13 14 1B 18 17 19 o 10 (70 ) 16 PCH-4B HAND TORCH 1 2 3 4 5 6 12a 7 13 8 9 10C 21 23 15 22 20 PCM-4B MACHINE TORCH 24 25 26 WRENCHES A-03263 Figure 5-10 Series 4B Gas-Cooled Torches Manual No.
Gas Pressure Regulators Fig. Item No. 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 5-11 * * * * 1 2 3 4 5 6 7 7 8 8 9 10 11 Qty.
