Miller QUICK CUT 3000 Owners manual

AUTO

ARCJ~

October

Efte

1990

ctive

With

FORM:OM-143

Serial

No.

526

JK624482

MODEL:

QUICK

CUTTM

~,c

3000

OWNERS

IMPORTANT:

special

Installing,

instructions

operationofwelding

operate,

understand

SC-I

24

809

Read

emphasis

operating,

are

maintain

or

these

and

understand

the

on

or

for

use

only

equipment.

this

instructions.

the

safety

material

maintaining

by

persons

not

Do

unit.

Contact

entire

throughout

this

equipment.

trained

allow

your

contents

and

experienced

untrained

distributor

MANUAL

and

in

the

to

install,

not

with

before

these

safe

fully

of

the

This

persons

if

this

manual,

manual,

unit

you

do

MILLER

A

Miller

Group

P.O.

Box

Appleton,

Tel.

414-734-9821

ELECTRIC

Ltd.,

Company

1079

WI

54912

USA

Mfg.

PRINTED

IN

Co.

U.S.A.

RECEIVING-HANDLING

OM-295A

10/90

Before
age

claims

Assistance

from

ers

When

ways

Number.

unpacking

that

may

loss

for

distributor

the

Transportation

requesting

provide

SECTION

have

or

for

filing

the

Section

1-1.

1-2.

1-3.

1-4.

equipment,

occurred

or

settling

and/or

with

the

damage

Department.

information

Model

Description

No.



SAFETY

1

Introduction
General
Plasma

Standards

check

carton

during

shipment.

the

delivering

claims

equipment

about

this

and

RULES

Precautions

Arc

Cutting

Booklet

for

be

may

manufactur-

equipment,

Serial

TABLE

FOR

(PAC)

Index

dam-

any

File

any

carrier.

obtained

or

Style

OF

PLASMA

al

CONTENTS

Use

tion

mation

Model

Serial

Date

ARC

the

following

Serial

and

is

located

_________________________________

or

Style

Purchase

of

CUTTING

spaces

or

Style

on

No.

____________________

_____________________

(PAC)

the

to

Number

data

record

the

of

your

cardorthe

Page

Model

Designa

unit.

The

nameplate.

No.

1

1

4

5

infor

SECTION

SECTION

SECTION

SECTION

SECTION



2

SAFETY

2-1.

2-2.

General

Safety

3SPECIFICATIONS

3-1.
3-2.
3-3.

4-1.

4-2.

5-1.
5-2.

5-3.

DutyCycle
Cutting
Description

4

INSTALLATION

Loca
Electrical

5

OPERATOR

Power
Metal

Ready

6

SEQUENCE

PRECAUTIONS

Information

Alert

Symbol

Speed

OR

n

Connections

Input

CONTROLS

Switch/t3reaker

Switch

Light

OF

OPERATION

AND

And

Safety

And

Signal

RELOCATION

Power

And

SIGNAL

Words

On

WORDS

Light

6
6

7
7

8

8
8

9
9
9

6-1.
6-2.
6-3.

Plasma

Cutting

Arc

Problems

Shutting

Cutting

Down

(PAC)

And

Recommendations

11

11
11

Section

No.

Page

No.

SECTION

SECTION

SECTION

7

7-1.

7-2.

7-3.

7-4.

7-5.

7-6.

7-7.

7-8.
7-9.

7-10.

8

Diagram

Diagram
Diagram
Diagram
Diagram

9

MAINTENANCE

Routine

Air

Shield

Shield

Torch

Spark

Overload

Safety

Circuit

Maintenance

Filter/Regulator

Tip,

Detector

Work

And

Cup,
Cup

And

Gap

Protection

Shutdown

Board

Handling

Troubleshooting

ELECTRICAL

Circuit

8-1.

8-2.

Circuit

Circuit

8-3.

Circuit

8-4.

Circuit

8-5.

PLASMA

Diagram

Diagram

Diagram

Diagram
Diagram

ARC

DIAGRAMS

CUTTING

&

TROUBLESHOOTING

Electrode

Pin

Inspection

Lead

Inspection

Devices

Precautions

Control

For
For

Driver

For

High

Filter

For

(PAC)

Inspection

And

Replacement

And

Connections

Board

PCi

Board

PC2

Frequency

Board

PC4

INSTALLATION

And

Replacement

Board

PC3

GUIDELINES

12
13
13

14
14

16

17
17
17

18

21

22

24

25
25

SECTION

9-1.

9-2.

9-3.

9-4.
9-5.
9-6.

9-7.

10

Figure
Figure

Figure
Figure
Figure

Figure
Figure
Figure

Table

Chart

Table

Table

General
Definitions

High-Frequency

Location

General

Guidelines

Power

Installation

PARTS

10-1.

10-2.
10-3.

10-4.

10-5.
10-6.
10-7.

10-8.

3-1.
3-i.

7-1.
7-2.

Installation

For

Sources

Guidelines

LIST

Main

Assembly

Circuit
Rectifier
Pilot

Panel,

Terminal

Card/Resistor

Unit

Front

Capacitor

Torch,

APT-bOO

Specifications

Cutting

Maintenance

Speed

Troubleshooting

Radiation

Procedures

InstallationOfPlasma

Checklist

Assembly

Assembly

W/Components

Assembly,

Output

Assembly

LIST

OF

CHARTS

Schedule

AND

Arc

TABLES

Cutting

26

26
27
27

27

(PAC)

28

29

30
32
33
34
35

36

37
38

7

8

12

18

SECTION

1



SAFETY

RULES

FOR

PLASMA

ARC

CUlliNG

(PAC)

1-1.

We
sonal

harmful,

ers

Safe

welding

research,

evolved

tion,

INTRODUCTiON

learn

experience.

by

experience,

wasteful,

teach

you.

practices

and

cutting

development,

reliable

and

servicing

like

a

unwise.

and

developed

describedinthis

are

equipment

practices.

equipmentisimproperly

the

for

son

Some

technical

rules.

Read

tempting

Comply

ticular

personal

Failure

ous

injury

equipment

These

1-General

and

ting;

Reference

also

are

cedures

in

the

most

complete.

The

National

Health

inspection

ment

safe

practices

based

on

are

volumes

understand

and

to

install,

with

these

equipment

safety

observe

to

or

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safe

practices

common

to

operate,

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used

and

these

death.

be used

Precautions,

2-Plasma

standards.
available
than those

Standards

Arc

for

given

Index

Electrical

Administration,

requirements

installation,

use,

explain.

these

and

for

the

When

with

are

common

Cutting

Published

additional

in

Code,

local

and

Learning

child

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and

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may

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safe

safety

divided

safety

touching

Let

a

the

experience

experience

manual.

field

experience

safe

installation,

Accidents

not

alwaysbegiven.

sense;

or

confidence.

others

Itiswisertofollow

safe

practices

service

as

instruction

practices

the

applicable

of

others.

may

becomes

into

two

to

arc

welding

(PAC).

Standards

and

more

in

this

this

manual.

manual.

complete

They

ANSI

Occupational

industrial

also

service.

provide

codes,

basis

a

through

hot

in

occur

may

stove,

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the

use

opera

The

require

before

per

oth

From

have

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the

equipment.

the

to

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habit,

Sections:

and

on

safety

listed

are

Safety

and

for

equip

par

seri

the

cut

pro

the

and

local

manuals

a

Z49.1is

is

of

at

for

(protected

plates

for

weldingorcutting

the

tect

cover

place

1

-3A.2.

Avoid

oily

Hot

metal,

without

dled

Medical

a

qualified

shift

unless

treatment

Ear

plugs

confined

work

overhead.

Flammable

sons

intending

B.

Toxic

Severe

fumes,

that

welding

adequate

Z49.1

listed

from

eyes

glass

or

greasy

suchasthe

gloves.

aid

first

first

medical

of

flash

should

space.

hair

Fume

discomfort,

vapors,

or

ventilation

in

oxygen.

Lead

ing

duce
local

the

plied

used.

Metals

fumes

moved

or,

cadmium-,

-,

and

similar

harmful

exhaust

area

well

as

respirator.

coatedwith

should

from

the

if

necessary,

concentrationsoftoxic

ventilation

not

clear

(and

radiant

broken,

cover

chipping

by

when

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workpiece,

and

aid

A

eye

person

facilities

burns

be

worn

hard

treatment.

should

of

the

when

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should

preparations

weld

to

Prevention

cut.

or

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or

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cutting

Standards

materials,

oxygen

may

as

zinc-,

the

as

For

beryllium,

described

Index.

mercury-,

when

must

operator

orcontaining

be

heated

work

surface,

while

wearing

glass).

energy

or

pitted,

A

spark

should

First

be

closebyfor

are

eyes

working

be

should

death

or

enrichment

produce.

NEVER

welded

be

used,

must

both

materials

unless

cut

or

the

area

an

air-supplied

This

is

a

or

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metal.

flying

or

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ignite

may

be

never

aid

facilities

available

and

overhead

worn

be used

not

can

Prevent

ANSI

in

and

beryllium-bear

or

fumes.

or

wear

methods

for

immediate

skin

burns.

when

result

or

depletion

this

Standard

ventilate

cut,

may

Adequate

each

person

an

must

that

emit

air-sup

coating

is

well

ventilated

respirator.

MUST

to

pro

Re

See

them.

han

and

each

in

or

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by

per

from

with

with

pro

toxic

is

a

in

be

re

1-2.

Different

different

tion

consult

Sheets

GENERAL

the

to

the

(MSDSs)

metals

fumes,

cautionary

coatings

A.

Wear

use

Button

trousers

Wear

shields

on

Burn

Prevention

protective

in

welding

shirt

to

helmet

underneath

PRECAUTIONS

and

metal

gases,

Information

manufacturers

for

specific

measures

materials

concerning

cut

clothinggauntlet

or

cutting,

collar

avoid

entryofsparks

with

and

pocket

safety

and

hat,

coatings

and

radiation

In

this

manual,

Material

technical

with

this

gloves

and

high

flaps,

and

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or

appropriate

can

produce

levels.Inaddi

be

Safety

and

data

materials

any

equipment.

designed

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and

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slag.

filter

with

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glasses

sure

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shoes.

cuff

to

pre

or

for

less

side

or

in

Work

if

and,

necessary,

tor.

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leaks

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centration
confined

When

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source

space

to

if

opened

safe

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from

heat

and

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by

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a

gas

in

in

space

while

confined

a

large

dangerously.

space.

confined

a

left

possible

open.

prevent

downstream

or

reentering

chlorinated

of

the

arc

other

lung

and

while

only

wearing

space

quantities

valves

Check

it.

form

to

eye

can

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to

solvents

PHOSGENE,

irritating

it

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being

an

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should

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cylinders

gas

OFF

shut

sure

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gas

of

been

that

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decomposed

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products.

OM-295

ventilated

respira

avoided.

be

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gases

con

into

supply

in

the

a

at

accidentally

the

highly

The

space

toxic

ultra-

Page

is

1

violet

(radiant)

trichioroethylene

phosgene.

can

pors

phere,

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mospheres

trichioroethylene

C.

FIre

Causes

tibles

or

of

reached

heated

cylinders;

BE

AWARE

through

and

goggled

tances.

To

Keep

and

cause

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ustibles.

eas,

combustibles

and

cracks,

through

operator.

prevent

equipment

electrical

(in

short

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the

Avoid

and

heat;

snug-fitting,

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touching

not

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welded

work

should

shields.

Fire

watcher

guishing

ing

equipment

or

cutting

a.

appreciable

energy

and

DO

NOT

be

drawn

the

where

containing

or

and

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fire

and

the

by

material;

and

short

THAT

flying

along

wallorfloor

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fires

and

clean

parts)

circuits.

are

if

work,

practicable,

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least35feet

at

or

protect

fire-resistant

combustibles

or

on

be

protected

be

must

if:

construction)

b.

appreciable

feet

but

can

c.

openings

within

(concealed

35

feet

sparks

d.

combustibles

metal

Hot

work

ensure

have

been

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work

glowing

An

empty

produce

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never

been

cleaned

OM-295

Page

or

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supervisors

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partitions

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can

also

perchioroethylene

OR

welding

energy

even

CUT

minute

where

or

can

penetrate

WELD

into

the

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explosion

flame,

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circuits.

of

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pipes,

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slag

follows:

as

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out

travel

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explosion:

and

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of

in

the

area,

rooms,

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the

against

covers

cut.

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by

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within

are

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or

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in

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to

away

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on

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free

particles

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an

area

tanks,

dip

out

shields.

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with

reach

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opposite

ceilings,

heat-resistant

with

suitable

for

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35

feet

further

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by

sparks

in

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to

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before

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area

free

when

container

Standard

decompose

solvent

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slag

sight

to

atmos

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hot

can

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doors,

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to

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of

oil,

grease,

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fire

extin

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building

than

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roofs,

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by

operation

precautions

of

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that

or

F4.

has

1,

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listed

heated,

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at

of

slag,

and

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the

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can

cut.

ar

and

near

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to

or

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7

in

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ing

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the

on

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equipment

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smell

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castings

Index.

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carbon

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recommended

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with

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paragraph).

to

sight

determine

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may

as

gasoline).

D.

Standard

manual,

HANDLING

DERS,

1.

Regulator

regulator

any
with

Never

other

Remove

pair

indicate

External

Excessive

If

delivery

valve

Faulty

If

gauge

surized,

atmospheres.

contain

flammable

Compressed

precautions.

and

those

OF

listed

11

Pressure

relief

from

or

more

that

faulty

close

a

faulty

leaks.

gas

overpressure;

regulator

downstream

one

connect

than

(first

Creep.

pressure

closed.

Gauge.

pointer

returns

nor

COMPRESSED

in

Regulators

valve

equipment.

relief

a

regulator

for

cylinder

regulator:

does

Repair.

Do

NOT

attempt

manufacturers

to

pair
special

nel.

Cylinders

damage

Avoid

third
cuits.

to

ICC

assurance

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2.

a

rails,

They

serious

or

techniques

Cylinders

must

to

electrical

DOT

Identifying

marked

gas

content.

or

is

Notify

alter

name,

and

illegal

to

be

handled

their

walls,

circuit

electrical

can

produce

accident.

marking

of

safety

content.

gas

on

them;

supplier

number,

hazardous.

This

solvent

a

solubility)

dioxide,

containers

can

They

Never

dust,

Gas

Equipment

Comply

detailed

Standards

is

designed

devices.

the

which

from

valve).

continues

not

move

to

stop

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designated

and

tools

valves,

contact

wires,

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must

when

Use

do

not

if

unmarked.

other

or

includes

contents

Do

if

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or

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followed

and

in

F4.l.

NOT

depend

itissafetoweld

must

explode.

weld

or

gas,

with

CGA

in

Standard

GASES

Index.

to

it

is

not

Provide

to

a

cylinder

regulator

service

The

following

rise

to

off

stop

after

pin

Send

faulty

repair

used

are

carefully

and

to

or

safety

with

welding

circuit

cylinders

1-3C.)

be

each

on

the

cylinder

only

cylinders

color

on

rely

markings

thorough

steam

depend

by

purging

using

protective

shouldbecleaned

on

sense

cut.

or

be

vented

cut

or

liquid

precautions

protect

intended

such

containing

was

immediately

before

where

the

vapors

(such

in

P-I,SAFE

IN

CYLIN

only

to

protect

protection

designed.

for

this

the

gas

re

symptoms

with

downstream

when

pin

pressure

regulators

center,

trained

by

prevent

devices.

pres

release.

for

where

person-

leaks

and

re

including

or

that

arcs

cylinder.

is

properly

with

to

identify

NEVER

on

a

cutting

cir

lead

may

It

is

an

han

name

gas

DEFACE

cylinder.

or

of

air

of

It

MT,

Keep

keep

Empties:

mark

promptly.

Prohibited

other

roller.

Locate

over.

than

Never

or

use.

its

secure

Passageways

where

areas

Transporting

such

port

the

ground

or

magnets.

NOT

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sparks,

allow

where

Protect

falling

when

Stuck

cylinder

supplier.

your

Mixing

Never

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3.

Prohibited

for

the

follows:

as

for

inert

Use

ferrules

wire

nary

hoses

No

copper

to

tings

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off

hose

or

on,

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Protect

sparks,

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nections.
indicate

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ing

(1-2D3).

a

as

by

expose

slag,

contents

such

exposure

cylinders,

objects,

moving

Do

valve.

valve

gases.

refill

any

fittings

Hose

use.

specified

red

gases.

or

or

to

fittings.

tubing

splice

runs

long

ground

otherwise

hose

hose

slag,

hose

Immerse

leaks.

or

leaky

Do

valves

them

separate

Never

use

intended

cut

on

a

cylinder.

cylinders

work

and

may

be

they
cylinders.

platform

their

orcradle.

valves

cylinders

flame,

to

etc.,

exceed

exists.

particularly

weather.

and

cylinders.

NOT

use

cannot

that

Never

try

cylinder.

should

Never

gas.

for

clamps

other

never

use

A

general

fuel

gas,

designed

substitute)

splices.

hose.

to

prevent

to

keep

damaged.

to

prevent

from

damage

and

open

flame.

regularly

pressurized

hose

worn

NOT

tape.

closed,

a

cylinder

use,

so

areas.

struck.

With

a

or

caps,

to

that

may

130F

hammer

a

be

mix

to

be

hose

green

Uc~

kinks

it

from

kinks

by

for

leaks,

by

cutting

replace

from

NEVER

cannot

they

Keep

crane,

NOT

Do

or

arcs,

cause

Cool

valves,

Replace

or

opened

any

gases

modified

otherthan

hose

for

for

as

a

binding

only

and

being

and

sharp

wear,

hose

securely,

caps

FULLS,

or

cylinders

use

by

and

its

contents

as

a

support

be

a

secure

lift

cylinders

chains,

excessive

knocked

clear

rupture.

with

water

from

bumps,

securely

caps

wrench

identification

oxygen,

the

standard

abuse.

run

to

hand.

by

in

a

or

exchanged.

that

designed

and

hose

(not

to

brass

Suspend

over,

open

cylinder.

connect

stepped

tangles.

out

and

loose

bubbles

and

in

area

edges,

and

water;

return

for

or

of

sup

off

slings,

heat,

Do

not

spray

falls,

a

Notify

rule

is

black

ordi

f

it

by

con

splic

4.

Proper

Clean

cylinder

orifices

Except

outlet

with

Match
that

thatthe

and

for

hydrogen,

away

clean

a

regulator

the

regulator

regulator

CONNECT

to

a

gases

Tighten

nections,

Tighten.
retighten

Adapters.

plier)

use

and

Regulator

right-hand

by

(with

5.

Drain
fore

justing

sive

seat

engaged

Stand

Open

creases

reaches

lowing

seal

to

less

Use

safe

cylinder

connections.

clean

If

connection

using

Use

between

wrenches

two

LEFT-HAND

outlet

grooved

Pressurizing

regulator

opening

screw

compression

to

open

slightly

side

to

cylinder

slowly.

regulator

position:

stem

than

one

pressure

and

efficient

regulators.

Check

thereafter.
uid

leak.
bustible.

E.

Remove

mediately

in

F.

Close

G.

Rope

cutting

*Trademark

for

leaks

Brush

or

equivalent

Clean

off

User

ResponsibIlities

leaky

for

equipment

Leaving

supply

gas

Rope

Staging-Support

staging-support

operation;

Connections

valve

outlet

damage

from

lintless

a

regulator

seats

crack

people

cloth.

to

cylinder.

label

and

inlet

and

designed

and

containing

When

and

smooth

leaks,

adapter

and

to

tighten

threads.

hose)

for

nut

on

fitting

properly

CGA

a

cylinder

(or

threads

hex

Steps

residual

of

cylinder

in

(clockwise).

heat

on

pressurization.

on

of

regulator

valve

When

manifold

(or

at

high

single-stage

slowly

gauge

maximum),

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oxygen

against

repair.

manual.

turn

to

charts

recommended

on

with

per

soapy

defective

or

possible

permit

(available

first

soap

gallon

water

See

User

Equipment

at

source

should

rope

may

of

Proctor

&

Gamble.

of

impurities

before

cylinder

connecting

valve

momentarily,

sources

Before

cylinder

outlet

for

other

any

of

connecting,

marking

match.

a

particular

assembling

where

seats

disassemble,

wrench.

(available

if

and

for

one

marked

may

left-hand

fuel

suitable

regulator,

adapter

connections

oxygen

or

shank)

through

gas

valve)byturning

Draining

pressure

Leave

prevents

seat

adjusting

regulators.

while

opening

that

so

is

leave

and

leak.

quick

from

inert

regulator

pressurized

cylinder

gases,

For

fuel

emergency

your

pressure

pressurization

solution

of

after

equipment

(capfull

water).

dried

test;

Bubbles

from

Responsibility

Unattended

and

drain

gas.

not

be used

burn.

that

may

regulator.

pointing

ignition.

gas.

threaded

from

cylinder

Wipe

check

area,

NEVER

gas

necessary.

clean,

your

is

required.

RIGHT-

identified

be

threads

gas.

vent

exces

allowing

by

screw

valve.

pressure

(gauge

in

valve

open

gas,

open

shutoff.

supplier)

settings

and

regularly

of

Ivory

indicate

is

soap

for

OM-295

com

service

statement

welding

Page

clog

and

or

con

and

sup

be

ad

in

fol

fully

to

for

on

Liq

im

or

3

1-3.

Comply

Plasma

a

ries

bright

frared

pressed

PLASMA

Arc

careless

high

and

energy

with

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operator

currents

hot.

gases

unnecessary

accidents.

dards

A.

Burn

Comply

The

bright.

weight

burn

burn;

painful.

Precautions

referenced

Protection

with

electric

Its

radiation

clothing,

the

skin

those

from

DONT

CAUTIONS.

1.

Protective

Wear

long-sleeve

shoes

clothing

apron,

of

Bare
Button

ets

Protect

electric

A

shade
used

cut.

Protect

Cracked

worn;

Cracked,

IMMEDIATELY.

pitted,

Flash

helmet

helmet
started.

eyes

cause

area

Enclosed

rate

round

OM-295

(1-2A).

such

and

fire-resistant

untreated

skin

protection.

collar

to

prevent

2.

Eye

eyes

arc

and

without

properweiding

according

when

cutting.

filter

or

radiation

broken,

or

spattered.

goggles

to

give

be

not

Looking

(particularly

retinal

a

in

the

field

3.

Protection

cutting

room

or

the

operation

4

Page

CUTTING

ARC

precautions

properly

invites

at

significant

Sparks

fly,

radiates,

be

and

in

index.

used.

protects

are

may

risks

precautions

in

used

arc

can

from

reflect

eyes.

Skin

and

gas-shielded

GET

BURNED;

Clothing

clothing

As

necessary,

leather

as

cotton.

Wear

to

protect

entry

Head

from

chest

of

sparks.

Protection

exposure

protection.

helmet

to

ANSI

Place

with

or

a

helmet

pass

loose

plate

broken

can

Replace

with

side

shields

some

protection

lowered

at

bum

of

enclosed

an

a

high

that

vision.

of

Nearby

area.

with

over

arc

intensity

For

bay

(PAC)

in

1-1,

done,

trouble.

and

1-2,

isasafeprocess,

The

voltages.

fumes

workpieces

The

described

in

1-2.

cutting

damage

rise,

are

wise

himself

is

intense

eyes,

ultraviolet

operator

and

here

tight-colored

burns

resemble

arcs

are

more

COMPLY

in

addition

use

jacket

leggings.

dark,

and

to

orshield

Z49.1

over

clear

or

through

filter

clear

cover

the

momentarily

to

additional

or

sleeves,

Avoid

substantial

and

neck,

NEVER

arc.

containing

ANSI

and

face

before

cover

plate.

shield

plates

to

should

cause

must

plate

MUST

be

the

to

eyes

face

before

witi

gloves,

gas-shielded

leave

may

a

permanent

Personnel

production

is

best.

cutting,

in

open

low-reflective,

this

section.

equipment

The

hot,

arc

and

others

and

and

is

and

avoids

in

visibly

penetrate

surfaces,

acute

severe

WITH

hat,

protective

flame-proof

outer

garments

clothing.

button

Z87.

look

filter

a

1

pock

must

beginning

NOT

burns.

be

replaced

when

broken,

underthe

worn

should

cutting

unprotected

arc)

a

sepa

areas,

non-combusti

but

car

very

in

com

from

stan

light

and

sun

and

PRE

and

at

an

plate

be

to

be

the

is

can

dark

sur

ble

screens

ticularly
Viewing

Sons

Others

proper
Before

doors

B.

Comply

Generator

air.

C.

Comply

at

the

who

working

flash

starting

are

Toxic

with

Carbon

FIre

with

closed.

and

Equipments

equipment.

Loose

cause

Never

cause

rough

D.

Comply

E.

Exposed

ting

ment

conductor.
TOUCH

tection.

To

Wear

body

out

a

cannot

tween

metal

able

through

A

and

of

buildings,

cases,

electrode

source

Plasma

cording

must

Welding

cable

fire.

a

cut

on

violent

a

handling.

Compressed

with

Shock

hot

circuit,

can

fatally

awet

protect

dry

insulating

and

clothing

adequate

duckboard

dry

be

the

body

reduces

dangerous

the

voltage

will

conducting

any

conducting

electrical

workpieces,

is

1.

Grounding

arc

to

be

grounded

And

grounding

first

the

is

connection

or

panels.

level.

floor

Provide

cut.

will

be

looking

in

area.

goggles.

to

cut,

Prevention

Fume

precautions

engine

exhaust

monoxide

Explosion

precautions

rated

capacity.

overheat

It

may

connections

a

cylinder

rupture

Gas

precautions

Prevention

conductors

in

or

ungrounded,

shock

DO

NOT

surface

against

shock:

dry.

insulation

rubber

or

avoided.

and

an

the

electrical

and

Sweat,

body.

exist

between

object

objects

tools,

etc.

and

any

OFF.

the

cutting

the

equipment

National

according

Cutting.

lead

(green

for

free

Allow

proper

directly

that

See

make

sure

in1-2B.

be

must

kill.

can

Prevention

in

1

-2C.

not

Do
cables

may

other

or

leadtosuch

or

EquIpment

in1-2D.

other

or

electrically-HOT

SiT,

cutting

and

work

when

mat

sea

whose

electrical

a

person

STAND,

when

gloves

Never

against

electrically

resistance,

the

in

the

work

object

lethal

but

benches,

touch

possibly

include,

Never

metal

Equipment

must

Electrical

to

ANSI

or

that

Locate

green

grounding

with

should

air

shields

face

the

at

all

persons

that

screen

vented

overload

and

overheat

pressure

bare

metalinthe

body

LIE,

without

body

protection.

in

a

damp

dampness

water,

HOT

part

currents

cutting

work

circuit.

are

the

unless

be

Code,

Z49.1,

yellow

be

made.

circulation,

cut.

are

flaps

to

cause

or

vessel.

a

rupture

for

all

wearing

the

outside

arc

cutting

fire.

a

flash

par

per

or

bay

and

It

can

under

cut

equip

becomes

LEAN

suitable

ON,

OR

pro

Keep

with

area

shock.

Stay

sweat

or

moisture

or

be

orgrounded

and

could

en

flow

to

torch

electrode

Examples

not

limited

source

power

cutting

grounded

and

the

the

torch

power

ac

work

Safety

terminal

stripe).

This

a

on

to,

In

or

When

installing,

as

power

torto
to

carry

cally

Do

tying

the

HOT

NOT

ANY

source,

building

ground

by

GROUND

gas

Three-phase
equipment

available,

wires

ment

become

can

shock,

Before
ductors
connections.

If

line

a

equipment
ground

plug
ceptacle,
ground

prong

Never

plug

2.

Fully

torches

cracks

screws.

before

connect

the

of

ground

electrically

possibly

cutting,

are

touching

cord

for

leadtothe

is

added

the

prong

plug,

remove

with

broken

a

Plasma

insulated

with

on

pieces

connect

control,

ground.

currents

current

stray

connection.

to

flammable

or

electrical

installing.Ifonly

single-phase

the

line.

third

HOTa

3-phase

to

fatally.

check

ground

bare

with

a

ground

connection

grounded

for

connection

ground

only.

connect

the

Cutting

torches

protruding

lead

If

the

to

ground

oft

ground

Torches

screws.

missing

frames

the

worktable,

Conductors

safely.

Equipment

may

conduit,

liquid

Check

NOT

Do

wire,

(live)

dangerous

for

metal

lead

to

a

switchbox.

to

must

cord

line

a

grounded

prong

prong.

should

Do

or

of

each

unit,

and

must

shock,

such

phase

3-phase

possibly

ortoa

as

requirements

water

be

adequate

made

oil

circula

pipe

or

power

equipmenttoonly

connect

the

or

continuity.

of

equipment

is

provided

switchbox,

a

grounded

be

connected

comes

mating

from

be

used.

NOT

with

loose

the

equipment

condition

Be

sure

frames

with

connect

If

a

three-prong

mating

with

receptacle.

plug,

Do

torches

or

or

NOT

a

use

a

missing

such

electri

fatally.

car-

fuel.

of

is

two

equip

will

that

con

at

the
the

re

the

to

three-

a

use

use

with

whenever
switch

Never

ing

power

6.

Safety

should.notbedisconnectedorshunted

Before
shut

red-tag

power.

move

Do

not

gency,

burns,

Never

and

Power

plasma

1-4.

For

their

1.

the

closed

is

touch

the

in

object

contact

source

Safety

devices,

installation,

all

OFF

power,

switches)

Disconnect

115

all

disconnect

volts

power

open

it

must

flash

or

leave

equipment

disconnect

cutting

STANDARDS

more

information,

latest

revisions,

ANSI

Standard

AND

CUTTING,

Welding

FL

33126.

source

power

(pressed).

torch

with

OFF.

is

Devices

such

as

inspection,

and

to

prevent

cables

all
line-cord

circuit

be

disconnected,

switch

from

all

power

switch

power

and

Society,

isONand

electrode

or

tip

the

cutting

interlocks

remove

while

and

service

or

line

accidental

from

power

from

plugs

cutting.

guard

arcing.

unattended.

to

equipment

be

must

source.

BOOKLET

refer

to

the

available

INDEX

following

complyasapplicable:

Z49.1,

550

SAFETY

obtainable

N.W.

from

LeJeune

the

cutting

and
circuit

circuit

fuses

conduct

any

unless

breakers,

out.

of

equipment,

(or

turning

source,

and

receptacles.

in

an

If,

against

before

standards

IN

the

Rd,

shut

leaving.

near

WELDING

American

Always

torch

the

lock

or

of

ON

re

emer

shock,

OFF

the

or

Miami,

3.

Cables

Frequently

IMMEDIATELY

age.

worn

or

damaged

shock

from

be

cable

hot

4.

Terminals

5.

Cutting

though

recommended

a

control

taped

metal

and

have

as

before

sources

normally

torch

may

ble.

Keep

from

Terminals

should

Even

provided

still

source

Power

process

on-off

cutting

to

cable.

give

free

and

And

other

cables

REPLACE

insulation

resistance

of

sparks.

Other

exposed

inspect

bared

dry,

insulating

Torch

Disassembly

there

are

standard

equipment

safe

touching

for

used

are

equipped

of

the

cutting

electrode

for

Cables

oil

and

covers

several

practice

any

the

power

and

tip

wear,

those

to

cracks,

avoid
with

and

with

excessively

possibly

damaged

equivalenttooriginal

and

grease,

Exposed

parts

secured

safety

the

on

to

torch

parts.

Plasma

with

output.

become

Parts

of

before

shutdown

cutting

turn

Arc

devices

protected

electrical

operation.

torch,

off

the

Cutting

that

As

a

result,

electrically

dam

lethal

areas

Ca

units

devices

it

power

(PAC)

permit

the

HOT

IS

2.

3.

4.

5.

6.

NIOSH,

ING

tainable

U.S.

D.C.

OSHA,

29

dent

Office,

ANSI

PATIONAL
FACE

can

way,

ANSI

SAFETY

AND

from

Government

20402.

SAFETY

CFR

1910,

of

Documents,

Washington,

Standard

PROTECTION,

National

New

Standard

SAFETY-TOE

American

Broadway,

ANSI

Standard

THE

USE

ESSES,

Standards

NY

obtainable

10018.

AND

GAS

WELDING

the

Superintendent

AND

obtainable

Z87.1,

AND

Standards

NY

York,

Z41

FOOTWEAR,

NationaI~
New

York,

Z49.2,

OF

CUTTING

Institute,

HEALTH

AND

HEALTH

U.S.

20402.

PRACTICE

Office,

from

Government

Printing

D.C.

EDUCATIONAL

obtainable

Institute,

10018.

STANDARD

.1,

obtainable

Standards

NY

10018.

FIRE

AND

from

the

1430

Broadway,

IN

ARC

CUTTING,

of

Documents,

Washington,

STANDARDS,

the

Superinten

FOR

from

1430

FOR

Institute,

PREVENTION

WELDING

American

OM-295

WELD

Printing

OCCU

EYE

the

Ameri
Broad

MENS

fromihe

PROC

National

New

Page

ob

AND

1430

114

York,

5

7.

8.

9.

10.

American

RECOMMENDED
PREPARATION

CONTAINERS

OF

OUS

SUBSTANCES,

can

Welding

FL

ami,

NFPA

TEMS

331

Standard

FOR

PROCESSES,

Protection

Quincy,

NFPA

CODE,

tion

02269.

NFPA

MA

Standard

obtainable

Association,

Standard

PROCESSES,

Protection

Quincy,

MA

Welding

Society

SAFE

FOR

THAT HAVE

Society,

26.

OXYGEN-FUEL

51,

WELDING,

obtainable

Association,

02269.

70,

from

Batterymarch

51B,

obtainable

Association,

02269.

Standard

PRACTICES

WELDING

obtainable

N.W.

550

CUTTING,

from

Batterymarch

NATIONAL

National

the

CUTTING

from

Batterymarch

AND

HELD

from

LeJeune

AND

the

National

ELECTRICAL

Fire

Park,

Quincy,

AND

the

National

AWS

FOR

CUTTING

HAZARD

the

Ameri

Rd,

GAS

ALLIED

Protec

WELDING

F4.1,

THE

Mi

SYS

Fire

Park,

MA

Fire

Park,

11.

12.

13.

14.

15.

CGA

Pamphlet

PRESSED

from

the

Compressed

ferson

22202.

CSA
WELDING

Canadian

Sales,

Canada

NWSA

Davis

Standard

178

M9W

booklet,

RAPHY,

Supply
phia,

American

RECOMMENDED
ARC

Welding

FL

ANSI

RATORY

American

Association,

PA

CUTTING,

Society,

33126.

Standard

Broadway,

P-i,

GASES

Highway,

W117.2,

AND

CUTTING,

Standards

Rexdale

1

R3.

WELDING

obtainable

19103.

Welding

obtainable

550

Z88.2,

PROTECTION,

National

New

York,

HANDLING

SAFE

IN

CYLINDERS,

Gas

Association,

Suite

CODE

Association,

Boulevard,

the

from

Arch

1900

Society

PRACTICES

Standard

N.W.

LeJeune

PRACTICE

obtainable

Standards

NY

10018.

501,

Arlington,

FOR

obtainable

Rexdale,

SAFETY

National

Street,

FOR

from

the

FOR

Institute,

OF

COM

obtainable

1235

SAFETY

from

Standards

Ontario,

BIBLIOG

Welding

Philadel

AWS

C5.2,

PLASMA

American

Rd,

Miami,

RESPI

from

1430

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VA

IN

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the

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Information

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B.

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GENERAL

General

presented

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the

nameplate

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

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Power

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SECTION

INFORMATION

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on

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should

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unit

this

panel

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SAFETY

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PRECAUTIONS

SAFETY

to

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WORDS

SYMBOL

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OM-295

Page

6

SECTION

Table

SPECIFICATIONS

3-

3-1.

SpecIficatIons

Rated

Duty

10

80

Output

At

60%

Cycle

Amperes

At

Volts

DC

Maximum

Open-

Circuit

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380

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Hz

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15

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49

(22

Weight

lbs.

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OM-295

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CONDITION

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OM-295

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_7

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SECTION

ELECTRIC

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the

9

SECTION

6

SEQUENCE

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Arc

OM-295

Page

10

6-1.

A~

PLASMA

WARNING:
tion

ARC

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OM-295

Page

11

SECTION

7

MAINTENANCE

TROUBLESHOOTING

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months.

months.

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SA-126

SB-124

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Page

13

Cross

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five

OM-295

Page

19

NOTES

OM-295

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638

25

SECTION

9

PLASMA

ARC

CUTTING

(PAC)

INSTALLATION

GUIDELINES

9-1.

The
installation

(PAC)

The

emphasized

GENERAL

following

information

of

equipment

importance

since

high-frequency

cases,
event

curs,

the

serve

caused

equipment.

will

Many
open-circuit

trodetothe
maximum

cutting

takes

to

lot,

rent
at

In

practice

the

using

frequency

will

9-2.

A.

In

may

of

The

the

and

B.

The

electrode,

C.

Output

ting

D.

The

trode

OM.296

an

inadequate

that

interference

the

situation.

as

assist

processes

is

user

In

a

guide

the

by

high-frequency

The

the

user

voltages

work

open-circuit

(PAC)

several

jump

creating

can

low

power

order

output

power

thousand

the

gap

an

follow

without

fre.quencies.

to

provide

to

superimpose

of

a

plasma

high-frequency

voltage

be

discussed

DEFINITIONS

High-Frequency

(PAC)

the

an

torch

Cutting

Output

current

Electrode

Power

plasma

be

used

arc

outage,

energy

well

circuit

from

electrode

insulated

consists

pilot

terminals

electrode

lead

of

26

Page

arc

for

Circuit

Terminals

and

Terminal

terminal

the

is

the

high-frequency

described

of

correct

a

histories

case

equipment

installation

with

required

such

in

Factory

and

to

cases,

minimizing

Service

by

supplying

applications

sufficient

without

voltage

source

volts

between

initial

path

the

these

arc

the

of

hazards

higher

a

cutting

techniques.

be

can

in

this

Assisted

a

section.

Sources

cutting

initiating

(PAC)

the

reinitiating

the

high-frequency

via

a

good

connecting

of

all

attachments

and

arc,

are

pilot

cutting

work

the

terminals

arc.

is

the

torchisconnected.

necessary

plasma

in

this

instruction

installation

of

interference

have

shown

was

authorized

take

suitable

these

interference

plasma

Department

technical

of

to

jump

making

direct

(OCV)

is

not

sufficient

to

cause

torch

electrode

ionization,

that

voltages,

high

open-circuit

(PAC)

The

source

cutting

the

of

Plasma

process,

arc

cutting

source

quality,

cable.

terminals.

which

terminal

to

make

a

arc

manual.

that,

fault.

at

services

steps

be

in

to

cannot

FCC

instructions

that

might

arc

cutting

personnel

information.

processes

from

the

contact.

of

a

plasma

for

electrical

an

and

that

the

arc

would be

it

is

common

present

voltage

source

power

resulting

interference

Arc

Cutting

high

frequency

in

and,

low

connected

to

the

arc.

must

impedance,

provide

which

the

the

proper

cutting

over

due

to

most

In

the

oc

clear

could

be

(PAC)

require

elec

The

arc

this.

It

spark

the

pi

cur

on

by

high-

and

case

flow

to

to

the

cut

elec

E.

Pilot

The

pilot

lead

F.

The

connected.

is

Work

work

workpiece

G.

Cutting

A

device

control

the

H.

The

directions
and

I.

the

arc,

Cutting

cutting

the

Bonding

Bonding

the

cause

of

current

any

Terminal

Arc

terminal

arc

Terminal

terminal

is

connected.

Torch

in

used

position

and

to

direct

Zone

zone

from

cutting

refers

to

objects

flow

9-4).

J.

Grounding

the

Depending

these

tion,

earth.The

K.

Receiver

A

receiver

tromagnetic

cations

L.

Conduction

Conduction

ergy

M.

High

High

tinuous

N.

High-Frequency

on

is

terms

or

bonding,

terms

is

any

energy

purposes.

is

via

electrical

an

Frequency

frequency

or

pulsed,

commonly

the

(PAC)

High-frequency

fers

quiring

0.

Interference

of

high-frequency

P.

Radiation

through

of

to

Interference

Radiation

any

high

is

space.

the

frequency.

is

the

the

the

is

is

the

the

plasma

of

the

electrode,

flow

the

is

the

the

arc

space

midpoint

Figure

(see

connecting

tobeat

the

between

(Earthing)

practices

of

parts

be

may

device

is

assisted

plasma

transmission

used

normally

and

converting

transmission

conductor

radio

frequency

used

to

Assisted

plasma

arc

unwanted

energy.

terminal

terminaltowhich

arc

of

within50ft.

between

to

cutting

to

transfer

plasma

the

which

(PAC)

gas.

9-6).

metallic

same

them

within

used

of

objects

potential

(see

Figures

jurisdictions,

to

indicate

the

apparatus

interchangeably.

used

for

receiving

it

useful

to

of

high-frequency

or

conducting

start

cutting

and

energy,

a

plasma

Plasma

arc

cutting

(PAC)

problematic

of

high-frequency

the

the

cutting

process

current

(15

m)

source

power

together

regardless

9-3

one

the

connec

to

communi

medium.

either

arc.

Arc

Cutting

(PAC)

processes

reception

energy

pilot

in

all

to

and

of

the

elec

en

con

re

re

to

to

9-3.

HIGH-FREQUENCY

RADIATION

Shielded

Wire

Installations

the

power

diation.

the

at

disruption

in

sensitive

major

A.

Direct

Direct

the

power

considered

Direct

B.

attachment

Any

source

using

source

Such

radiation,

receiving

of

communications

electronic

Radiation

source.

to

Radiation

is

capable

of

be

causes

radiation

high-frequency

is

cutting

tant

C.

Most

quency

by

diation
tion

D.

Radiation

grounded

mediate

radiated.

ence.

circuit

have

to

Conduction

Line

power

energy

reradiation

small

is

from

the

Reradiation

from

metal

vicinity,

This

only

lines

from

torch

can

high

frequency

will

produce

device,

controls

if

can

the

some

signal

cause

or

high-frequency

The

From

is

that

radiation

Radiation

direct

the

to

of

energy.

the

major

the

And

are

which

these

when

and

the

cutting

objects

conducted

be

acting

proper

may

compared

a

from

radiation

From

The

output

an

as

Since

source

torch

Radiation

capable

cause

power

work

cables

circuit

unshielded

or

some

troublesome

direct

as

an

integral

high-frequency

strength

inconvenience

an

cause

can

and

systems.

radiation

Power

are

Source

emanating

the

power

the

from

Cutting

terminals

antenna

of

of

power

Circuit

of
and

radiation

radiation,

attached.

From

conducting

interference

lines.

Normally,

caused

that

to

leads.

or

be

can

pickedupby
wiring

distance,

source

part

sufficient

is

malfunction

four

The

follows:

as

line

the

from

is

source.

power

directly

radiating

from

it

is

impor

Power

The

high-fre

directly

such

radia

by

in

the

and

of

interfer

of

ra

or

not,

the

or

ra

un

im

re

Ground

(15

/

Arc

Plasma

Cutting

Power

Figure

tion

9-5.

A.

Torch

Position

gether

ble.

B.

High-Frequency

(PAC)

When

operation,
securely

good

Except

(PAC)

Source

9-1.

Pickup

GENERAL

the

and

the

fastened,

contact

for

~

Keep

And

torch

as

Power

plasma

all

changes

manufacturer,

Arc

Plasma

Cutting

Power

(PAC).

Source

At50ft.

Intervals

m)

Center

-.

unshielded

all

wires

out

of

Requirements

The

In

close

service

around

the

Vicinity

INSTALLATION

Cables

Work

work

and

the

to

Assisted

Sources

arc

cutting

doors

and

the

and

.power

Place

on

boards,

in.

1

to

3/4

adequately

entire

source

leads

(19-25

11

Soft.

Point



and

the

floor

adjustments

and

ungrounded

cutting

Minimize

To

Of

Or

cables

or

ground

Plasma

(PAC)

and

covers

perimeter

should

floor

on

keep

mm)

zone.

The

PROCEDURES

Leads

or

or

them

apart.

,

Cutting

leads

plane

power

must

bonded

of

allowed

not

Reradia

as

Arc

source

be

to

the

be

modified.

as

4

-00

8

S

Zone

to

close

possi

Cutting

in

is

closed,

ensure

opening.

the

by

9-4.

Locate

as

ground

tion

LOCATION

the

possible.

connection

of

should

amount

phone,

tors)

tallic

which

communications,

located

conductors

will

quency

cellaneous

in

grounded,

other

some

ciency,

ure

9-1).

power

Also

the

power

located

be

miscellaneous

of

within

pick

energy

wiring

rigid

material

and

grounded

source

consider

when

source.

in

an

the

cutting

the

in

cutting

conduct,

up,

transmitted

in

the

cutting

metallic

having

50

at

thL

to

nearness

asLse

selecting

Ideally,

where

area

wiring

and

(lighting,

other

zone.

zone

reradiate

or

the

cutting

by

zone

conduit,

an

equivalent

ft.

(15

m)

the

cutting

of

the

for

site

a

the

power

there

unshielded

power,

Ungrounded,

act

can

should

copper

as

the

circuit.

beenclosed

shielding

intervals

process

suitable

a

installa

source

is

limited

a

conduc

antennas

high-fre

All

braid,

(see

tele

me

mis

effi

Fig

Electrical

Input

Supply

Rules

General

Figure

9-2.

Cables

C.

Grounding

is

It

recommended

or

grounded.

workpiece

10

rod

ft.

ground

within

This

with

or

(3

No.

to

m)

(Earthing)

that

a

of

12

water

the

must

AWG

ground

For

Leads

Or

The

the

be

made

smaller

or

which

pipe

workpiece.

Ground

Torch

And

Workpiece

workpiece

by

grounding

wire

enters

OM-295

S-0085

Work

be

firmly

driven

to

a

the.earth

Page

the

27

0.

Metal

Installation

within

a

suitably

building

quency

sources

can

radiation.

in

Grounded

Copper

Buildings

of

a

plasma

bonded

beaneffective

Wherever

such

places.

arc

and

cutting

grounded

means

possible,

(PAC)

(earthed)

of

reducing

power

install

source

metal

high-fre

power

rial

having

wound,

of

ing

be

grounded

tance
tween

an

flexible,

miscellaneous

the

at

electrical

conduit

Copper

equivalent

metallic

50

ft.

(15

connections

sections

(see

Strap

shielding

conduit

in

wiring

intervals.

m)

must

Figure

capability

is

not

suitable).

the

cutting

be

9-4).

zone

Good

low

maintained

Conduit

(spirally

Shield

must

resis

be

rounding

Bonding

Of

Figure

However,

metal
the

This

trical

During

having

ing

each

ing

metal

welded

or

and

screen

1/4

E.

when

building,

building

be

can

accomplished

ground

the

construction

metal

and

structural

piece

buildings,

together

doorways

or

galvanized

in.

(6.4

mm)

Shielding

Zone

ting

Ungrounded,

act

reradiate

cutting
pipes

as

must

antennas

the

circuit.

telephone,

within

the

cutting

metallic

rigid

OM-296

Page

28

Wire

Metal

Panels

9-3.

Grounding

the

Of

power

bonded

Metal

must

Panels

precautions

is

properly

by

rods

around

in

the

structure,

steel

of

metaltoall

adjacent

should

mesh.

Of

Miscellaneous

metallic

which

the

of

is

bonded

metal

at

frequent

be

covered

hardware

conductors

will

high-frequency

This

means

be

grounded,

communications,

zone

conduit,

and

must

copper

And

Building

source

be

and

placing

periphery

a

new

building

be

sure

together

other

adjacent

panels

intervals.

with

cloth

Wiring

in

pick

up,

energy

that

all

that

and

enclosed

be

or

braid,

Metal

Panels

Bonding

is

installed

takentobe

grounded

several

that

(earthed).

good

of

the

of

all

the

(as

pieces).

shouldbebolted

All

grounded

of

not

more

In

The

the

cutting

zone

conduct,

transmitted

ungrounded

all

lighting,

other

some

conductors

in

grounded,

other

S-SO

19

within

a

that

sure

elec

building.

type

any

reinforc

weld

by

For

windows

copper

than

Cut

can

and/or

the

by

water

power,

mate-

Figure

F.

The

connected

this

supply

9-4.

Power

plasma

manual.

conductors

completely
equivalent

the

power

cord.

shielding,

power

source.

entrance

Shielding

throughout

electrical

good

the

and

ing

Line

Input

Power

Supply

Ground

Figure

9-6.

1.

2.

9-5.

GUIDELINES

PLASMA
SOURCES

Locate

when
short

Shield

connectionofthe

source

ments

Coupling

Bonding

Service

arc

cutting

to

the

line

If

the

unit

serving

enclosed

shielding,

The

solid

should

extend

location

its

length

contact

power

Line

Fuse

Switch

Or

Receptacle

Installation

should

source.

Box

(PAC)

ARC

the

equipment

connected

as

possible.

the

line

input

as

specified

Section

(see

Method

(PAC)

input

is

equipped

in

solid,

to

up

metallic

the
in

and

should

is

provided

And

Power

FOR

CUTTING

the

to

plasma

by

For

power

supply

power

the

the

with

power

metallic

point

conduit,

entire

the

building

be

electrically

be

Plasma

Welding

Of

Plasma

Source

INSTALLATION

that

so

workpiece,

leads

power

arc

manufactures

the

9-5F).

Conduit

source

as

a

power

source

conduit,

of

connection

or

distance

to

connected

between

Arc

Cutting

Power

Arc

(PAC)

the

ground

can

to

up

cutting

S-0020

Sections

should

instructed

cord,

should

or

with

equivalent

from

the

power

continuous

that

so

the

shield

(PAC)

Source

S

Cutting

POWER

lead,

be

kept

the

point

(PAC)

power

require

the

the

-002

OF

be

in

be

in

I

1

1

as

of

3.

sure

at

that

used,

that

least

the

the

cutting

Be

point

and

within

not

equivalent

covered

lead

tory.

Spirally

suitable.

not

the

conduit

ft.

50

(15

conduit

zone.

be

sure

that

shielding

or

cable,

wound,

system

m)

system

If

the

efficiency.

the

flexible

is

from

the

is

one

metallic

rigid,

shielding

Copper

equivalent,

metallic

continuous

source,

power

complete

conduit

used

sleeving,

satisfac

is

conduit

to

run

has

is

is

a

Power

4.

5.

6.

7.

8.

Keep

gether

ble.

Adjust

given

Secure

ating.

Visualize

(15

power

9-1

and

Have

a.

munication

in

grounded

ting

b.

Ground

wires,

Be

c.

phone

Use

10

ft.

cold

torch

and

spark

in

all

radius

m)

source

all

zone.

sure

driven

(3

water

and

as

this

manual.

service

the

cutting

9-6),

unshielded

all

or

support

that

wires

ground

or

m)

pipes

work

close

setting

gap

centered

and

and

wires

shields

large

there

within

less

as

cables

the

to

and

access

zone

on

the

cutting

proceed

power,

within

relocated

or

metallic

wires

no

are

the

rods

from

the

the

ground

leads

or

ground

the

minimum

to

doors

a

as

sphere

a

point

torch
follows:

as

lighting,

the

cutting

objects,

within

the

external

cutting

which

enter

ground

for

close

as

planeaspossi

setting

before

between

(see

outside

with

and

zone

oper

50

a

Figures

com

placed

the

cut

long

cutting

power

zone.

connection,

the

zone.

tele

or

the

ground

workpiece.

to

the

guy

ft.

or

Center

9.

Be

tight.

If

10.

the

building,
grounded.

items

1.

2.

INSTALLATION

Is

9-50,

Are

9-7.

All

stallation.

terference

(see

3.

Are

ment

9-6.4)?

4.

Are

tions

Is

5.

Sections

Point

Figure

that

sure

power

be

be

not

may

Complete

authorized

with

equipment

9-5E,

ac

input

Sections

torch

and

properly

9-5C,

connections

9-6.1,

ground

equipment

9-6.5

9-6.

all

ground

source

sure

GUIDELINES

necessary

the

necessary

properly

and

9-6.1)?

power

9-5B,

work

installed

9-6.4,

properly

and

j

~

Cutting

connections

is

operated

that

the

or

FCC

services.

located

connections

9-6.2,

cables

(see

properly

9-6.10,

set

9-6.6)?

)

Cutting

Torch

Zone

clean

are

withinametal

building

practical

itemstoeliminate

(see

and

or

Sections

and

up

is

CHECKLIST

for

Sections

properly

9-6.3)?

leads

and

made

and

9-6.11)?

adjusted

properly

each

9-5A

(see

S

-002

and

in

in

9-4,:

made

equip

and

Sec

(see

2

OM-295

Page

29

SECTION

10

PARTS

LIST

0

c,J

a

V

>.

.0

E

a,
C,)

C,)

OM-295

Page

U-

30

Item

No.

Dia.

Mkgs.

Part

No.

Figure

10-1.

Description

MaIn

Assembly

Quantity

12

13

15

20

21

22

23
24

25
26

27

28
29

30

31
32

33

34

35

36
37

38

39

40

41

42

43

.44

45

46

47

10

11

14

16

17
18
19

1

2

3

4

5

6
7

8

9

Pci

PC2

CT2

Zi
Ti

FL1

FM

AC1

T2

PC3

S2

125134

125135

+125

125197

125199
125130
125196

10-2

Fig

10-3

Fig

125208
125205

125206

125200

125201
125202
125204
125203
125228
125209

125278

125277

125

*012642

125211

125210

125212

124729

125136
125127
125213

125194
125276

10-4

Fig

+125

125111

125129
125217
125218
125219
125224
125222
125
125
125226
129932

125227
125225
125137

10-5

Fig

10-6

Fig

10-7

Fig

126796

SCREW

NUT

113

CASE

CIRCUIT
CIRCUIT

SUPPORT

BRACKET

CIRCUiT

RECTIFIER
CURRENT

STABILIZER

TRANSFORMER,

NOISE

FAN

BRACKET,
PANEL,

BUSHING,

CABLE,

AIR

VALVE

~DlAPHRAGM

279

FILTER

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LEG,rbr

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PILOT

221

BRACKET

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PRESSURE

FITTING

FITTING,
FITTING,

2P~

FITTING,

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REGULATOR/FILTER

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SCREW
FRONT

TERMINAL

CAPACITOR

TORCH,

CARD
CARD

CARD/RESISTOR

ASSEMBLY

TRANSFORMER

FILTER,

MOTOR,

100V50/60

mtg-fan

rear

strain-relief

3c

power

COMPRESSOR,

PLATE

minat

gI

ISOLATOR,

warning

warning

UNIT

CARD

hose

air

SWITCH

pipe-brs
pipe-brs

pipe-brs

mtg-air

HOSE

air

pipe-brs

PANEL

ASSEMBLY,

ASSEMBLY

APT-i

ASSEMBLY

ASSEMBLY

power

250V

ac

motor

with

slo-blo

general

control

electric

ASSEMBLY

elb

tee

bushing

filter

elb

ASSEMBLY

000,

(Fig

ASSEMBLY

main
20A

2700/3100RPM

Hz

plug

(consisting

4A

rbr

of)

precautionary

shock

can

output

10-8)

kill

2
2
2

1

1

16

1

1
i
1
1
1

1

1
1

1

1
1

1

1

1

1

4

4

2

1

10

4

1

1
2
1
1
1

4

1
1
1

2

1
1
1
1
1
1
1

10

1
1
1
1

+When

ordering

*Re~mmended

SURE

BE

TO

a

component

Spare

PROVIDE

Parts.

MODEL

originally

AND

displaying

SERIAL

a

precautionary

NUMBER

WHEN

label,

ORDERING

the

should

label

REPLACEMENT

alsobeordered.

PARTS.

OM-295

Page

31

(tern

No.

Dia.

Mkgs.

Part

No.

Figure

10-2.

Description

CIrcuit

Card/Resistor

Assembly

(Fig

10-1

item

Quantity

8)

10

11

1

2

3

4

5

6

7

8
9

PC4

R12

R10,11

C9
C5

C6,7

R13

125110

125240

125241

125

239

125

238

125

237

125

236

125 152
125

188

125

187

125

186

CIRCUITCARDASSEMBLY

RES1STOR,WW2OWlOOohrn

RESISTOR,

BRACKET

TERMINAL,
CAPACITOR,
CAPACITOR,
CAPACITOR,

FASTON

FASTON

RESISTOR,

WW6OW1.6Kohm

6A

6P

ME

.22ut

MF

.47uf

.Olut

cer

TERMINAL,

TERMINAL,

460V

63OVDC

63OVDC

400

tab

receptacle

.6W

VAC

1

1

2

I

1

1

1

.

2

1
1

1

2

BE

OM-295

SURE

7

6.

Page

TO

32

5

PROVIDE

MODEL

Figure

AND

SERIAL

1.

10-2.

4

Circuit

NUMBER

0

..~

0

Card/Resistor

WHEN

ORDERING

Assembly

REPLACEMENT

PARTS.

SA-124

a

966

Item

No.

Dia.

Mkgs.

Part

No.

Figure

10-3.

Description

RectifIer

Assembly

(Fig

10-1

Item

Quantity

9)

10

11

12

13
14

1

2

3

4

5

6
7
8
9

C2
R5

R3

C3,4

D3,4

SRi

R4

TP1

01

D1,2

125153
125250

125251
125

249

125247

125245
125242
125243
125248

125244
125246

252

125

023

106
125166

CAPACITOR,
RESISTOR,

RESISTOR,

BRACKET

CAPACITOR,

DIODE,

DIODE

20A

BRIDGE,

RESISTOR,

THERMOSTAT,

HEATSINK

TRANSISTOR,

BAR

BUS

TERMINAL,
DIODE,

high-speed

film

cement
cement

film

1200V

cement

NC

100A

6A

2P

.047uf

20W
20W

.Oiuf

250A

7W

2.5A

1600VDC

400V

500V

1000VDC

ohm

10

ohm

3.3

10

ohm

600V

1

1
1
1

2

2

1
1
1
1
1
1
1

2

14

13

12,

11

Figure

10-3.

L

RectifIer

Assembly

SA-124

8

9

968

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-295

Page

33

item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Pilot

film

WW

24VDC

cement

cement

l5uf

60W

Unit

2.5A

SPST

5W
20W

(Fig

400

20

30

VDC

ohm

600V

3.3K

Figure

1
2
3

4

5

6
7

C8

R8,9

D5

CR1

R7
R6

125260

125

261

125263
125166
125165

125262

125103

CAPACITOR,

BRACKET,

RESISTOR,

DIODE,
RELAY,

RESISTOR,
RESISTOR,

10-4.

mtg-component

high-speed

end

ohm

10-1

ohm

Item

29)

1
1

2

1
1
1
1

3

BE

SURE

7

TO

PROVIDE

<

6

MODEL

AND

SERIAL

Figure

NUMBER

L

10-4.

Pilot

WHEN

Unit

ORDERING

5

REPLACEMENT

PARTS.

SA-124

1

969

OM-295

Page

34

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

10

12
13

14

11

15
16

25OVAC

3A

ADC

M

Front

w/Components

3OVDC

P

1

red

lens

green

20A

lens

25OVAC

10-5.

Figure

1

2
3

4

5

6

7

8

9

F2

Si

CB1

PL1

PL2

Fl

*125

106
125
125

125
125232
125
125233
125
125
125

125

125
106

125

*125

229

172

280

281

274

283

282

284
231

147

235
820

146
138

FUSE,

HOLDER,

NUT
WASHER

NAMEPLATE

SWITCH~

NUT

CIRCUIT
RING
SCREW

PANEL,

SHAFT

DOOR,

LAMP,
LAMP,
FUSE,

Panel,

25OVAC

3A

fuse

SPST

tgl

PROTECTOR,

front

access-front

11OVAC

neon

LED

15

5A25OVAC

(Fig

10-1

Item

45)

1

2
1
1

1

1
1

1
1

2

1
1
1
1
1

1

*Recommended

SURE

BE

TO

Spare

PROVIDE

Parts.

MODEL

Figure

AND

10-5.

SERIAL

Panel,

NUMBER

13

Front

w/Components

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-295

SA-124

971

Page

35

Item

No.

Dia.

Mkgs.

Part

No.

Figure

10-6.

Description

Terminal

Assembly,

Output

(FIg

10-1

Item

Quantity

46)

1

2

3

4

5

6
7
8

iT

Torch

Work

125175

125

125056

125
125
125182
125
125181

1

264

185

183

184

TERMINAL,
BRACKET,

FITTING,

SUPPORT

STOPPER

BINDER

INSULATOR

TERMINAL,

15A4P

mtg-component

30A

600

9/16

VAC

pipe-brs

1
1
I
1
1
1
1

P

1

3

a

1

BE

OM-295

SURE

Page

TO

36

8

7

6

PROVIDE

5

MODEL

C-

Figure

AND

SERIAL

10-6.

Terminal

NUMBER

6~~

a

4

Assembly,

WHEN

Output

ORDERING

REPLACEMENT

PARTS.

SA-124

970

Item

No.

Dia.

Mkgs

Part

.

No.

Figure

10-7.

Description

CapacItor

Assembly

(FIg

10-1

Item

47)

Quanfity

1

2



3

4

5

6
7

Cl
T3

Ri
R2

125
125256
125

125
125259
125
125

EDGING SADDLE

255

PANEL

258

BRACKET,

257

CAPACITOR,

COUPLING

254

RESISTOI~,

253

RESISTOR,

mtg-capacitor

40W

lOW

200VAC

200

8.2K

elctlt

COIL

cement
cement

4700uf

ohm

ohm

3

1
1
1
1
1
1

7

6

10-7.

Figure

Capacitor

Assembly

1

SA-124

5

967

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-295

Page

37

13

15

1

5

9

OM-295

Page

10~

p

9

SC-124

813-A

10-8.

Figure

38

Torch,

APT-i

000

Item

No.

Part

No.

Descnption

Quantity

BE

SURE

10

11

12

13

14

15

126

796

1

2

3

4

5

6
7

8

9

TO

PROVIDE

131
131

125032

125031
125033
125034
125

270

125078
125079
125

273
125269
125

268
125

074
125

266

125285

190

184

MODEL

FIgure

TORCH

ELECTRODE

TIP

CUP

WRENCH
POWER

PILOT

TORCH

HOSE

HEAT

SWITCH

TORCH
TORCH

INSULATING

10-8.

DETECTIVE

AND

SHEATH

SHRINKABLE

AND

SERIAL

Torch,

BODY,

CABLE

DETECTIVE

SWITCH

COVER

SWITCH

HANDLE

TUBE

APT-bOO

(consisting

PIN

ASSEMBLY

LEAD

TUBE

NUMBER

WHEN

of)

LEAD

ORDERING

REPLACEMENT

1

2

1

1

1
1
1
1
1
1
1

1

1

1

1

PARTS.

OM-295

Page

39

GUARD

is

equipped

bracket

the

of

with

the

fittings

over

AND

on

systems.

OPTION~

MOTOR

306)

(#042

This

filter

mounting

installation

an

rear

panel

plasma

is

to

plasma

air

cutting

equipped

match

systems,

of

flow

2~H.

ACCESSORIES

FILTER

AIR

with

will

that

the

top,

smaller,

The

in.

1/4

a

m

on

it

and

a

facilitate

or

side,

portab

ter

N

ports

rated

a

s

REPLACEMENT

ELEMENT

312)

(#042

four.

Carton

SDX-575

TRANSFO

of

STE

(#0423

Three-

75

V

ase,

or

460,

three-phase.

)

50/60

380

-DOWN

ER

FILTER

Hz.

Volt

power

Reduces

to

230

33
50

COVERS

ft.

(10

ft.

(15

hose

if

necessary.

CABLE

For

For

Protects

non-conductive

removed

m)

m)

and

zipper

torch

torch

cables.

and

(#118
(#042

Features

is

easily

678)

389)

4/90