Miller QUICK CUT 5000 Owners manual

AUTO

ARC)~

January

Effe

1989

ctlve

Wit

FORM:OM.143

ii

Seria

No.

JJ5I

527

8269

MODEL:

QUICK

CUTTM

5000

OWNERS.

IMPORTANT:

special
installing,

instructions

operation

operate,

understand

647

TC-125

Read

emphasis

operating,

are

of

welding

maintain

or

these

and

understand

the

on

or

for

maintaining

use

only

equipment.

this

instructions.

safety

by

unit.

the

material

persons

Do

Contact

this

not

entire

trained

allow

your

contents

throughout

equipment.

and

experienced

untrained

distributor

MANUAL

and

in

to

the

not

with

before

these

safe

install,

fully

of

the

This

persons

if

this

manual,

unit

you

manual,

do

MILLER

A

Miller

Group

Box

P0

Appleton,

414-734-9821

Tel.

ELECTRIC

Ltd.,

Company

1079

WI

54912

USA

Mfg.

PRINTED

IN

Co.

U.S.A.

ERRATA

SHEET

After

data

to

the

Add

A~

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Add

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steel

although

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curve

Table

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cutting

within

increase

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manual

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following

CAUTION:



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Do

TO

2-1.

Rated

Duty

30

120

2-5.

Output

40%

At

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Amperes

At

Volts

speed

the

capabilities

the

speeds

in

speed

cause

rapid

was

printed,

In

at

this

the

later

CAUTION

INCORRECT

air

or

only

not

use

SECTION

nitrogen

other

any

2

-

Specifications

Maximum

Open-

~

370

Speed

of

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(Chart

may

optimum

of

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chart

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refinements

manual.

beginning

PLASMA

for

the

or

gas

INTRODUCTION

Rated

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38

2-1)

the

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speed

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tip

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CAUTION:
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z

z

z

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7-

ELECTRICAL

insufficient

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parts.

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25-31
25-35
25-36
25-38
25-39

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27-1
27-3

27-13

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7-2.

7-3.

7-4.

7-5.

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Parts

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Page

6

TABLE

OF

CONTENTS

Section

SECTION

SECTION

SECTION

No.

-

1

SAFETY

1-1.

1-2.

1-3.

1-4.

2-1.

2-2.
2-3.
2-4.

3-1.

3-2.
3-3.

3-4.

Introduction

General

Arc

Standards

2-INTRODUCTION

Duty

General

Receiving-Handling

Description

3INSTALLATION

Location
Air

Input

Electrical

RULES

Precautions

Welding

Booklet

Index

Cycle

Information

Filter/Regulator

Voltage

Input

And

Installation

Changeover

Connections

Safety

And

Switch

Connections

Page

No.

1

1

4

5

7

7

8

8

8

8

9

9

SECTION

SECTION

SECTION

4-1.

4-2.

4-3.

4-4.

4-5.

4-6.

5-1.
5-2.

5-3.

6-1.
6-2.
6-3.
6-4.

6-5.

6-6.

6-7.

6-8.

4-

OPERATOR

Power

Ready

Metal

Thickness
Gas/Air

Trigger

5-

Plasma

Cutting
Shutting

6-

Routine

Shield

Torch

Spark

Overload

Safety

Circuit

Switch/Breaker

Light

Switch

Control

Switch

Hold

SEQUENCE

Arc

Problems

Down

MAINTENANCE

Maintenance

Cup.

And

Gap

Protection

Shutdown

Board

Troubleshooting

CONTROLS

Switch

OF

Cutting

And

Tip,

Work

Lead

Handling

Power

And

OPERATION

(PAC)

And

Recommendations

&

TROUBLESHOOTING

Electrode

Inspection

Devices

Precautions

On

Light

Inspection

And

Connections

And

Replacement

11
11
11
11
11
11

12

13

13

13

14

15
16

16
16

17

17

SECTION

7-

Diagram

ELECTRICAL

7-1.

Circuit

DIAGRAMS

Diagram

19

24262728

Section

SECTION

SECTION

No.

8-

8-1.
8-2.

8-3.

8-4.

8-5.

8-6.

8-7.

9

Figure

Figure

Figure
Figure
Figure
Figure

Figure

PLASMA

General

Definitions

ARC

CUTTING

High-Frequency

Location

General

Guidelines

Power

Installation

PARTS

9-1.
9-2.

9-3.

9-4.

9-5.

9-6.
9-7.

Installation

For

Sources

Guidelines

LIST

Main

Assembly

Capacitor

Terminal

Front

Panel

Pilot

Unit

Rectifier

Torch,

Assembly

Model

Installation

Assembly

Assembly,

Assembly

Radiation

Procedures

Checklist

.

APT-3000

(PAC)

Of

Plasma

Output

INSTALLATION

Arc

Cutting

GUIDELINES

(PAC)

Page

20
20

21
21
21

22

23

29

30

31

No.

LIST

OF

Table

Table
Table

CHARTS

2-1.
6-1.

6-2.

AND

TABLES

Specifications

Maintenance

Schedule

Troubleshooting

7

13
18

SECTION

1



SAFETY

RULES

1-1.

INTRODUCTION

We

learn

by

sonal

experience,

harmful,

others

Safe

welding

search,

evolved

tion,

wasteful,

teach

practices

and

development,

reliable

and

servicing

equipment

the safe

for

son

Some
technical

rules.

Read

tempting

Comply

ticular

personal

Failure

ous

based

are

volumes

and

to

with

equipment

safety

observe

to

or

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equipment

These

1-General

ting;

Reference

are

cedures

in

most

The

Health

safe

and

2-Arc

available

also

than

Standards

the

complete.

National

Administration,

inspection

ment

installation,

GENERAL

1-2.

DIfferent

and

radiatIon

this

manufacturers

(MSDSs)

ary

A.

Wear

use

shirt

avoid

to

Wear

shields

arc

fluxes

manual,

for

measures

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Burn

protective

in

welding,

collar

entry

helmet

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welding

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unwise.

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you.

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common

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understand

install,

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welded

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both

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1

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the

at

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into

source

oxygen

in

opened

is

safe

before

decomposed

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or

OM-296

arc

prod

can

where

cut

or

cutting

Page

also

or

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a

if

or

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1

where

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trichioroethylene

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BE

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through

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goggled

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if:

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containing

or

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NIOSH,SAFETYAND

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OM-296

Page

6

Rated

At

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120

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INTRODUCTION

2-1.

SpecificatIons

At

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installation,

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on

mm)

THE

AND

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DUTY

power

duty

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SAFETY

and

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TC-125

CYCLE

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OM-296

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la

to

7

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maintenance

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DESCRIPTION

2-4.

unit

negative)

the

isadirect

Plasma

single-phase

metals

Arc

This

APT-3000

APT-3000M

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duty

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high

electrically

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perature

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information

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1/4

30

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Description

current,

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electrical

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process.

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to

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LOCATION

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OM-296

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ELECTRIC

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828

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11

Page

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shield

Remove

4.

5.

inspect

cent

CUP,

REPLACEMENT

not

Do

Turn

Allow

touch

off

power

from

plug

SURFACES

cooling

damage

Inspect

whenever

shield

significantly

If

tip

replace

genuine

off

from

a

cup

oversize,

replacement

torch

parts,

power

receptacle.

shield

cup.

clean,

dry

(see

tip

using

in

hole

tip.

replace

AND

TIP,

ELECTRIC

live

electrical

source,

receptacle

or

servicing.

can

period

AND

TIP

torch.

cup,

cutting

reduced.

electrode

or

the

at

both

proceed

source,

cloth,

Figure

6-1).

supplied

If

hole

tip

ELECTRODE

(Figure

SHOCK

and

before

cause

before

ELECTRODE

and

tip,

speed

replacement

same

parts.

follows:

as

and

remove

off

wipe

wrench.

is

tip

(see

deformed

Figure

in

INSPEC

6-1

kill.

can

parts.

remove

inspect

severe

burns.

servicing.

electrode

thickness

or

becomes

Be

time.

input

contact

surface

or

6-1).

And

input

ing,

WEAR

weekly

has

to

sure

power

on

50

per

6.

Inspect

depth

move

7.

Reinstall

Reinstall

8.

ceptacle,

Figure

end

electrode

of

and

replace

tip

input

and

6-1.

electrode

of

exceeds

electrode

shield

and

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mm)

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And

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volts

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erosion

mm),

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ac

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rip

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in.

supplied

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Electrode

S.OO93

Electrode

re

re

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Torch

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~2Iectrode

Figure

6-2.

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And

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Air/Torch

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()

Replacement

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And

Arc/

Pilot

Detector

I

Lead

ShIeld

Cup

3

4

Detector

Lead

2

OM-296

Page

14

TORCH

6-3.

CONNECTIONS

WARNING:

a

NIFICANT

of





plug

ing,



less

power.

minutes.

Measure

touching

HOT



WORK

AND

(Figure

ELECTRIC

DC

Input

power.

Do

Turn

touch

not

off

power

from

receptacle,

maintaining,

Internal

within

Lesser

voltage

60

voltage

parts.

any

SURFACES

Allow

cooling

LEAD

6-3)

VOLTAGE

live

electrical

source,

and

or

servicing.

will

decrease

seconds

voltages

on

input

cause

can

period

INSPECTION

SHOCK

exists

remove

WAIT

after

remain

may

before

can

kill;

after

removal

parts.

input

be

fore

inspect

50

to

volts

removal

for

of

up

capacitors

severe

burns.

servicing.

AND

SIG

power

input

two

to

before

4.

Disconnect
shield

cup

5.

Disconnect

iT.

strip

6.

Disconnectwork

7.

Remove

B.

Relnstallatlon

1.

Route

2.

nect

Route

or

lief,

a.

b.

torch

new

work

to

new

and

connect

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nector.

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terminal

arc/shield

pilot

detector

torch

leadfromwork

cable

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work

lead

(+)

output

torch

torch

pilot

1

on

lead

switch

leads

and

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through

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cable

and

cable

and

cable

arc/shield

iT.

cup

2

from

leads

And

leads

leads

to

air/torch

cup

detector

terminal

3

and4from

(+)

from

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strain

lead1and

strip

outputterminal.

unit.

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relief,

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follows:

as

(-)

output

detector

IT.

terminal

and

con

strain

con

1

lead

re

to

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1.

2.

3.

should

lead

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Turn

from

plug

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Loosen
from

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clamp,

Of

off

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receptacle.

lower

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cable

air/torch

Torch

necessary

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source,

panel

clamp,

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output

proceed

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to

replace

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as

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and

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door.

disconnect

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the

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input

torch

Terminals

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power

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2:

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or

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4.

5.

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Torch

Detector

Cup

Arc/Shield

Connect

c.

IT.

on

d.

Connect

ii.

on

Connect

e.

iT.

on

Secure

Close

Reinstall

torch

and

input

ceptacle,

5witch

Lead

Lead

Detector

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shield

torch

torch

cable

secure

power

and

resume

Connections

Connection

Lead

detector

cup

switch

switch

and

leads

lower

front

plug

operation.

Connection

PB1

PB1

into

lead

lead

lead

in

panel

200/230

Torch

2

3

4

strain

access

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to

terminal

to

terminal

to

terminal

relief.

volts

door.

ac

Strip

2

3

4

re

iT

Plasma

Torch

Cutting

And

Cable

Work

And

Clamp

Lead

Figure

6-3.

Lower

Front

Panel

VIew

With

Relief

Access

Work

(+)

Terminal

Door

Output

Open

OM-296

18-t25

Page

646

15

SPARK

6-4.

WARNING:

AA

NIFICANT

of



Do



plug

ing,



Internal

less

power.

minutes.



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touching

MOVING



HOT



Allow

Troubleshooting

fied

This

behind

tory,

spark

come

lows:

1.

2.

3.

4.

5.

6.

7.

8.

is

unit

the

and

gap

necessary

off

Turn

from

plug

Remove

Loosen

Place

C.

point
Apply

gauge

Tighten

Reinstall

Reinstall

ceptacle,

~

Figure

OM-296

Page

GAP

Input

not

Turn

from

(Figure

ELECTRIC

DC

power.

touch

off

power

receptacle,

VOLTAGE

live

source,

6-4)

SHOCK

exists

electrical

remove

WAITbefore

and

maintaining,orservicing.

will

on

can

moving

can

period

be

to

a

spark

spark

is

not

in.

the

and

decrease

after

mayre

input

cause

parts.

cause

before

performed

gap

gap

recommended.

mm).

(1.2

spark

gap,

remove

voltage

within60seconds

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voltages

voltage

parts.

any

PARTS

away

a

cooling

with

panel.

from

The

Keep

SURFACES

persons.

provided

front

readjustment

is

to

adjust

0.047

source,

setting

power

receptacle.

half

left

screw

feeler

slight

held

is

screw

left

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and

16

of

A.

gauge

pressure

firmly

A.

half

of

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6-4.

Spark

wrapper

of

in

wrapper

from

proper

against

gap.

onto

into

plug

200/230

operation.

Gap

Adjustment

can

after

parts.

input

50

to

removal

main

forup

capacitors

serious

severe

servicing,

only

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at

set

was

If

it

should

proceed

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unit.

thickness

B

point

unit,

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SIG-

kill;

removal

power

inspect-

volts

of

input

to

two

before

Injury.

burns.

by

quaIl-

located

the

fac-

Normal

be
fol-

as

power

between

feeler

so

ac

re-

TA124

812

OVERLOAD

6-5.

WARNING:

~.

Do



Turn

power

maintaining,

INCORRECT

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or

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would
tive.

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follows:

1.

2.

3.

4.

5. Install

6.

7.

type,

Fl

protects

overload.

be

off,

replace

Turn

off

from

plug

Depress

wise.

Pull

out

free.

Insert

Depress

til

cover

Reinstall

fuse

new

fuse

ceptacle,

SAFETY

6-6.

A.

Shield

Should

stalledonthe

the

unit

READY

and

properly

check

by

loosening

light.

ating

source

Service

B.

Tip

TO

prevent

and
READY

pletely

check

off,

Section

AIr

C.

To

prevent

pressure,
pressure

Should

Cup

the

shield

would

light

shield

the

If

READY

properly.

and

Station

Leakage

injury

electrode

light

inoperative.

and

6-2,

Pressure

damage

this

switch

air

pressure

PROTECTION

ELECTRIC

touch

not

off

power

from

plug

or

FUSE

replacement

only

and

rating

control

the

Should

unit

the

and

Fl

correct

,

power

source,

receptacle.

rotate

and

with

fuse

fuse

with

and

is

secure.

input

and

cover

into

fuse

rotate

power

resume

SHUTDOWN

Detector

cup

torch,the

be

completely

turned

be

installed

the

light

If

contact

cup

shield

READY

according

detector

turns

the

immediately.

Detector

from

coming

turn

would

Should

replace

if

necessary.

unit

the

Switch

to

is

protectedbynormally

located

S5

drop

SHOCK

electrical

live

source,

receptacle

servicing.

can

damage

Parts

(see

circuitofthe

Fl

would

fuse

fuse

holder

fuse

plug

open,

the

problem,

and

holder

when

holder

holder

into

the

be

cover

operation.

DEVICES

CIrcuit

be

removed

READY

light

inoperative.

check

circuit

and

the

remains

nearest

CircuIt

contact

and

the

and

torch

in

the

that

to

observing

detector

shock

the

READY

electrode

air

a

preset

off,

cup

off,

light

electric

in

off,

tip

the

below

(Figure

4-1)

can

kilt.

parts.

and

before

fuse

remove

unit.

of

input

inspecting,

same

size,

List).

source

power

READY

completely

and

proceed

remove

cover

fuse

cover

200/230

Section

for

input

couriterclock

holder

cover.

back

clockwise

not

or

would

shield

proper

on,

properly

turn

6-2.

the

circuit

turnoff

cup

Factory

caused

with

each

unit

would

light

according

due

to

insufficient

PL2

tight

inopera

power

cover

into

unit.

un

volts

ac

and

off,

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is

the

clean

Weekly

operation

READY

is

oper

power

Authorized

the

by

the

other,

be

com

be

turned

closed

as

is

re

in-

tip

to

air

air

pressure/regulator.

value,

S5

would

the

open,

be

completely

turned

(see

D.

This

TP1
TP1

READY

pletely

run.

mal

minutes

6-7.

oft,

Table

Thermal

unit

and

or

inoperative.

Should

shutdown,

CIRCUIT

A~

4A

READY

light

inoperative.

check

air

6-2.

Troubleshooting).

ProtectIon

is

protected

TP2

located

TP2

open,

would

light

READY

the

a

cooling

will

be

required.

BOARD

WARNING:
NIFICANT
of

input

power.



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ing,

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less

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minutes.



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

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CAUTION:

(ESD)

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BEFORE

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shielding



Perform

touch

not

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from

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any

PARTS

away

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a

can

on

handling

carriers

would

turnoff,

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filter/regulator

by

normally

in

the

power

thermal

turn

The

off,

fan

shutdown

and

motor

light

period

HANDLING

ELECTRIC

DC

VOLTAGE

live

power

voltage

source,

or

servicing.

will

voltages

voltage

the

and

supply

the

FM

be

turned

of

SHOCK

exists

electrical

remove

and

WAiTbefore

decrease

after

may

on

input

parts.

can

cause

from

moving

can

cause

cooling

period

ELECTROSTATIC

damage

properly

circuit

or

work

only

before

circuit

grounded

circuit

boards.

boards

packages.

at

static-safe

a

and

the

unit

would

READY

air

closed

would

unit

would

off

would

light

compressor

thermostats

circuit.

occur,

continue

due

Should

be

to

a

approximately

PRECAUTIONS

can

kIll;

after

removal

parts.

input

power

inspect

50

to

volts

removal

remain

capacitors

serious

for

up

Injury.

of

to

before

parts.

severe

burns.

servicing.

DISCHARGE

boards.

wrist

in

proper

static-

work

be

the

com

to

ther

five

SIG

or

input

two

strap

area.

INCORRECT

plugs



Be

aligned.

EXCESSIVE

board.



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ment

plugs

6-8.

TROUBLESHOOTING

WARNING:

AA

NIFICANT
of

input



Do



Turn

plug

ing,



Internal

less

power.

minutes.



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touching

MOVING



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HOT



Allow

Troubleshooting

fied

It

is

assumed

to

Section

ing

with

the

function

working

The

remedies

this

circuit
dures.
these
ized

tion,

instructions.

properly

following

for

power

source.

diagram

If

the

procedures,

Service

strictly

INSTALLATION

plugs

cIrcuIt

are

can

sure

damage

that

PRESSURE

minimal

only

when

disconnectingorconnecting

and

removingorinstalling

pressure

(Table

ELECTRIC

DC

VOLTAGE

power.

touch

not

off

from

maintaining,

within60seconds

Lesser

live

electrical

power

receptacle,

voltage

source,

and

or

servicing.

will

voltages

voltageoninput

parts.

any

PARTS

away

SURFACES

a

cooling

persons.

that

the

of

3

of

until

table

some

while

trouble

Station.

follow

this

is

Use

contact

the

can

from

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to

unit

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manual,

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designedtodiagnose

of

the

troubles

this

table

performing

is

remedied

not

the

In

all

cases

manufacturers

or

board.

properly

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break

and

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6-2)

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parts.

remove

WAIT

decrease

after

remain

may

input

before

to

removal

for

50

capacitors

cause

serious

parts.

cause

performed

properly

before

the

the

severe

servicing.

only

installed

operator

power

source

developed.

and

that

in

conjunction

may

develop

troubleshooting

after

nearest

of

equipment

performing

Factory

procedures

and

cIrcuit

move

board

SIG

kill;

removal

power

inspect

volts

of

input

to

up

before

injury.

burns.

by

quali

accord

is

familiar

was

provide

with

proce

Author

malfunc

or

two

in

the

and

OM-296

Page

17

Table

6-2.

Troubleshooting

TROUBLE

Unit

completely

POWER

ative;

and

PL1
PL2

both

POWER

fan

off;

not

run.

not

Does

FM

runs;

PL1

light

PL2

light

No

high

READY

POWER

PL1

on.

moper-

ON

READY

oft.

ON

motor

cut;

light

light

FM

does

motor

fan

POWER

READY

and

both

on.

frequency.

PL2

light

ON

light

light

PL1

ON

off;

POWER

Line

switch/breaker

disconnect

position.

Line

fuse

or

Power

cord

receptacle.

Work

clamp

switch

Torch

switch

Torch

Fl

Fuse

Shield

contact

open.

cup

surface

not

switch

circuit

not

plug

connected.

not

PBI

PB1

tight

dirty.

CAUSE

in

breaker

secure

lead

connections.

lead

connections.

shield

or

CB1

the

tnpped.

OFF

open.

in

power

cup

Contact

.

line

Place

position.

Check

breaker.

Secure

Connect

and

workpiece.

Check,

connections

Check,

connections

Check

6-5.

and

Check,

Section

(see

Factory

disconnect

replace

power

work

clean,

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clean,

(see

replace

clean,

6-2).

Authonzed

cord

clamp

and

tighten

Section

and

tighten

Section

and

tighten

REMEDY

switch

line

fuse

plug.

to

clean,

Fl

according

shield

Service

in

or

bare

torch

6-3).

torch

6-3).

the

reset

switch

switch

to

cup

Station.

ON

circuit

metal

lead

lead

Section

torch

on

at

Fan
POWER

and

both

does

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on.

ON

not

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light

light

PU

PL2

Shield

Electrode

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(thermal

Insufficient

Specifications

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Dirty

Fan

detector

cup

touching

TP1

shutdown).

air

pressure

for

air

pressure

air

filter/regulator.

FM.

motor

lead

connections.

inside

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torch.

open

Table

tip

and/or

requirements).

adjustment.

Check,

lead

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6-2).

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minutes

2-1.

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Section

Clean

manufacturers

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Section

air

5-1).

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instructions

FM.

shield

Section

electrode

of

approximately

6-6).

compressor.

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according

detector

cup

6-3).

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4

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OM-296

Page

18

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48

~~23OV.

-Tn

SECTION

GENERAL

8-1.

The

following

installation

(PAC)

The

importance

emphasized

high-frequency

have

shown

tion

was

authorized

suitable

take

instructions

these

interference

plasma

ice

Department

technical

ing

Many

processes

open-circuit

to

trode

maximum

cutting

several

takes

to

spark

the

pilot,

current
sent

at

In

order

practice

the

output

using

by

frequency

will

be

DEFINITIONS

8-2.

A.

High-Frequency

(PAC)

In

the

plasma

be

may

of

arc

an

The

energyfromthe

the

torch

well

and

B.

Cutting

circuit

The

electrode,

C.

Output

Output

cutting

Electrode

D.

information

the

of

equipment

of

since

plasma

that,

fault.

at

FCC

services

steps

that

arc

cutting

personnel

information.

voltages

work

the

open-circuit

(FAG)

jump

power

thousand

the

creating

follow

can

low

power

to

provide

to

superimpose

of

a

plasma

high-frequency

voltage

discussed

used

Sources

arc

for

initiating

Power

outage,

electrode

insulated

CIrcuIt

consists

arc,

pilot

Terminals

terminals

current

and

Terminal

PLASMA

8-

is

necessary

high-frequency

described

correct

a

case

in

most

In

the

to

clear

could

might

(PAC)

and

applications

without

in

installation

histories

arc

cutting

cases,

event

occurs,

the

serve

as

be

caused

equipment.

will

assist

sufficient

making

situation.

voltage

volts

between

path

the

is

of

hazards

source

gap

initial

an

without

frequencies.

these

higher

a

high

arc

cutting

techniques.

be

this

AssIsted

a

source

section.

(PAC)

the

cutting

the

can

in

cutting

reinitiating

high-frequency

via

a

good

connecting

of

all

and

the

are

pilot

cable.

attachments

work

terminals.

terminals

arc.

ARC

make

to

plasma

instruction

this

interference

of

arc

cannot

(PAC)

an

inadequate

interference

that

the

a

by

of

to

jump

(OCV)

not

to

cause

the

ionization,

voltages,

is

user

guide

the

The

the

processes

direct

sufficient

torch

required

In

such

in

high-frequency

Factory

user

from

contact.

of

a

plasma

an

electrode

that

would

that

is

it

open-circuit

(PAC)

power

The

resulting

of

interference

Plasma

process,

cutting

quality,

high

arc

and,

arc.

source

low

connected

which

Arc

mustflowto

impedance,

provide

CUTTING

a

proper

cutting

manual.

be

over

to

due

equipment

installa

with

to

cases,

minimizing

Serv

supply

by

require

elec

the

The

arc

this.

the

be

pre

source

It

and

arc

on

for

electrical

common

voltage

high-

and

Cutting

frequency

in

the

case

the

to

the

(PAC)

E.

The

lead

F.

The

workpiece

G.

A

to

rent

H.

The

directions

and

I.

Bonding

to

less
and

J.

Depending

these

tion,

earth

K.

A

INSTALLATION

Pilot

Arc

arc

pilot

is

connected.

Work

work

Cutting

device

control

to

used

the

Cutting

cutting

the

cutting

Bonding

refers

of

the

any

cause

Figure

Grounding

terms

or

bonding,

.The

Receiver

receiver

Terminal

terminal

Terminal

terminal

is

connected.

Torch

in

the

position

and

arc,

Zone

zone

from

the

to

objects

current

8-4).

the

on

is

commonly

terms

is

any

electromagnetic

munications

L.

Conduction

Conduction

via

ergy

M.

HIgh

High

frequency

tinuous

N.

High-Frequency

purposes.

is

the

electrical

an

Frequency

or

pulsed,

(PAC)

High-frequency

to

fers

requiring

0.

Interference

Interference

of

high-frequency

P.

Radiation

any

of

the

high

frequency.

is

the

is

the

is

the

terminal

the

plasma

of

the

to

direct

the

is

space

midpoint

arc

(see

Figure

connecting

be

to

flow

between

(Earthing)

practices

of

parts

be

may

energy

used

device

and

transmission

conductor

radio

is

assisted

used

Assisted

frequency

to

plasma

plasma

unwanted

energy.

GUIDELINES

terminal

arc

electrode,

the

within

between

to

which

to

cutting

flow

of

50

the

which

(PAC)

to

plasma

ft.

8-6).

metallic

the

at

within

usedtoindicate

of

objects

same

potential

them

(see

jurisdictions,

the

apparatus

interchangeabiy.

normally

converting

start

arc

and

used

it

of

high-frequency

or

conducting

energy,

a

plasma

Plasma

arc

culling

cutting

(PAC)

problematic

the

transfer

(15

power

Figure

the

for

receiving

to

useful

either

arc.

Arc

(PAC)

processes

reception

the

pilot

cutting

process

cur

gas.

in

all

m)

source

together

regard

8-3

of

one

connec

the

to

com

en

medium.

con

Cutting

re

The

trode

OM-296

electrode

lead

or

20

Page

terminal

cutting

is

torch

the

terminaltowhich

connected.

is

the

elec

Radiation

through

is

the

space.

transmission

of

high-frequency

energy

HIGH-FREQUENCY

8-3.

RADIATION

Installations

the

power

diation.

at



disruption



in

major

A.

Direct
the

Such

the

receiving

sensitive

causes

Direct

radiation

power

considered

B.

Direct

attachment

Any

source

is

capable

high-frequency

cutting

tant

C.

Line

Most

quency

by

radiation

diation

D.

circuitisthe
have

to

Conduction

power

reradiation

from

Reradiatlon

Radiation

energy

is

grounded

mediate

radiated.

ence.

vicinity,

This

high

using

source

will

radiation,

device,

of

communications

electronic

of

high-frequency

Radiation

is

that

be

Radiation

direct

the

to

of

acting

source.

to

Radiation

energy.

major

the

only

And

lines

are

which

from

these

when

small

torch

the

the

from

metal

cutting

objects

conducted

beatroublesome

can

frequency

produce

if

the

signal

can

cause

controls

From

radiation

radiation

From

output

as

Since

source

proper

Radiation

capable

cause

may

power

compared

work

and

circuit

unshielded

or

as

some

strength

an

or

can

and

radiation

The

Power

emanating

the

from

from

The

Cutting

terminals

antenna

an

direct

of

radiation,

attached.

torch

of

conducting

interference

lines.

to

cables

can

some

an

integral

part

high-frequency

is

sufficient

inconvenience

cause

systems.

malfunction

The

follows:

as

are

four

Source

power

the

directly

power

line

source.

from

is

not

Circuit

of

the

power

and

radiation

From

radiating

from

it

is

impor

The

Power

the

high-fre

directly

up

in

the

and

of

interfer

such

by

by

Normally,

that

caused

leads.

or

be

picked

wiring

distance,

source

of

ra

or

Plasma

Cutting

Power

8-5.

A.

Position

gether

ble.

or

ra

B.

(PAC)

When

operation,
securely

good

un

im

re

ing.

manufacturer,

Plasma

Arc

(PAC)

Source

Figure

tion

Pickup

~

Keep

wires

8-1.

Requirements

in

GENERAL

Torch

and

the

And

torch

as

close

High-Frequency

Power

the

contact

Except

Arc

Power

Sources

plasma

all

service

fastened,

around

for

changes

the

Cutting

Source

\



unshielded

all

of

out

The

Vicinity

INSTALLATION

Cables

Work

and

work

floor

the

to

Assisted

arc

cutting

doors

and

adequately

the

and

source

power

(PAC)

Place

leadsonfloor

on

boards,

3/4

in.

I

to

and

the

ungrounded

weldIng

To

Minimize

Of

The

PROCEDURES

Or

Leads

cables

or

orground

Plasma

(PAC)

and

covers

entire

perimeter

adjustments

should

and

keep

(19-25

mm)

,

zone.

Cutting

leads

plane

Arc

power

must

bonded

of

allowedbythe

be

not

or

them

apart.

Ground

S.0084

Reradla

Zone

close

as

as

Cutting

source

be

closed,

to

ensure

the

modified.

to

possi

in

is

open

LOCATION

8-4.

Locate

as

ground

tion

should

amount

phone,

tors)

tallic
which

quency

cellaneous

in

some

ciency,

Figure

the

possible.

connection

the

of

be

of

communications,

located

conductors

will

energy

grounded,

other

and

8-1).

source

power

iocated

miscellaneous

pick

Also

power

within

up,

consider

when

source.

in

the

in

the

conduct,

an

transmitted

the

in

wiring

metallic

rigid

material

having

grounded

closetothe

as

the

selecting

Ideally,

area

wiring

and

other

cutting

cutting

or

by

cutting

conduit,

an

50

at

nearness

site

a

the

where

there

(lighting,

unshielded

zone.

Ungrounded,

zone

can

reradiate

the

cutting

should

zone

copper

equivalent

ft.

(15

m)

cutting

of

a

forthe

power

is

a

power,

act

as

antennas

the

circuit.

be

enclosed

braid,

shielding

intervals

process

suitable

installa

source

limited

tele

conduc

me

re

high-f

All

mis

eff

(see

Electrical

Input

Supply

8-2.

This

with

ft.

General

(Earthing)

ground

No.

toawater

or

(3

m)

Figure

C.

Grounding

is

It

recommended

or

i

grounded.

workpiece

ground

within

rod

10

Cables

12

of

the

Rules

For

Or

Leads

The

that

the

must

be

AWG

or

pipe

workpiece.

Torch

Workpiece

workpiece

made

by

smaller

which

wire

enters

grounding

OM-296

And

be

to

the

S-0085

Work

firmly

driven

a

earth

Page

the

21

D.

Metal

Installation

within

a

suitably

building

quency

sources

can

radiation.

in

Grounded

Buildings

of

a

plasma

bonded

effective

be

an

Wherever

such

places.

Copper

arc

and

cutting

grounded

means

possible,

(PAC)

(earthed)

of

reducing

power

high-fre

install

source

metal

power

metallic

rigid

rial

havinganequivalent

wound,

of

the

ing

be

grounded

tance

tween

conduit,

flexible,

miscellaneous

at

electrical
conduit

sections

Copper

metallic

50

connections

copper

ft.

(15

Strap

braid,

shielding

conduit

wiring

intervals.

m)

(see

Figure

Coupling

in

must

is

the

or

some

capability

not

suitable).

cutting

Good

be

maintained

8-4).

other

(spirally

Shield

zone

low

mate

must

resis

be

FIgure

However,

metal

that

(earthed).
good
building.

any

the

(as
pieces).

should

vals.

grounded

of

not

E.

ting

when

building,

the

building

This

electrical

During

having

type

reinforcing

welding

by

For

be

bolted

All

windows

copper

than

more

ShIeldIng

Zone

Ungrounded,

antennas

act

can

reradiate

cutting

pipes
telephone,

within

OM-296

as

the

circuit.

be

must

communications,

the

cutting

22

Page

Bonding

8-3.

Grounding

Of

Panels

the

precautions

can

ground

the

metalinthe

and

each

metal

or

and

screen

1/4

Of

MIscellaneous

metallic

high-frequency

This

grounded,

zone

Metal

power

is

be

construction

structural

piece

source

properly

accomplished

rods

around

of

buildings,

welded

doorways

or

in.

(6.4

conductors

which

will

means

that

and

must

must

metaltoall

togetheratfrequent

galvanized

mm)

energy

be

Metal

Panels

Of

Metal

And

Bonding

Building

is

installed

be

taken

bonded

by

the

of

a

structure,

steel

is

bonded

adjacent

should

mesh.

Wiring

in

the

pick

up,

transmitted

all

ungrounded

that

all

and

other

enclosed

Panels

within

be

to

and

grounded

placing

several

periphery

new

building

be

sure

that

together

other

adlacent

metal

panels

covered

be

hardware

in

The

cutting

conduct,

and/or

by

lighting,

power,

conductors

in

grounded,

sooig

sure

of

the

inter

with

cloth

Cut

zone

the

water

a

of

all

Figure

F.

The

connected

this

supply

8-4.

Power

plasma

manual,

conductors

completely
equivalent

the

power

cord.

shielding,

power

source.

entrance

Shielding

throughout

electrical

good

the

and

ing

Line

Input

Power

Suppivi

Line

Fuse

And

Switch

Receptacle

Figure

8-6.

PLASMA

1.

8-5.

GUIDELINES

ARC

Locate

connected

possible.

2.

Shield

connection

source

ments

Bonding

Method

Service

arc

to

If

cutting

the

line

the

unit

(PAC)

input

is

equipped

serving

up

The

solid

extend

location

should

source.

5Oft.(15m)

Ground

(PAC)

CUTTING

the

workpiece,

input

the

of

Section

in

solid,

to

metallic

and

is

,o

Conduit

Power

FOR

power

plasma

by

8-5F).

enclosed

shielding,

should

its

length

contact

power

Is

~

InstallationOfPlasma

the

equipment

to

the

line

as

specified

(see

For

power

power

supply

with

the

power

metallic

the

point

conduit,

the

entire

in

the

building

be

electrically

should

be

provided

Plasma

eta

c

______

Source

INSTALLATION

(PAC)

so

POWER

that

the

can

leads

arc

the

manufactures

Conduit

source

as

a

power

source

conduit,

of

connection

distance

connected

between

Arc

Power

________

Arc

ground

be

kept

to

up

cutting

Sections

should

instructed

cord,

should

or

equivalent

from

the

to

power

continuous

so

the

shield

Cutting

Source

Cutting

SOURCES

lead,

short

as

the

point

(PAC)

power

require

be

the

be

or

with

the

that

(PAC)

S

-002

OF

when

in

in

1

as

of

3.

Be

point

and

within

not

equivalent

lead

tory.

suitable.

4.

Keep

gether

5.

Adjust

given

Secure

6.

ing.

Visualize

7.

(15

power

and

a.

b.

c.

Use

8.

10

cold

that

sure

least

at

that

the

the

cutting

used,

covered

Spirally

torch

and

spark

in

this

all

the

radius

m)

source

Figure

Have

all

munication
in

grounded

cutting

Ground

wires,

Be

sure

phone

driven

ft.

(3

m)

water

the

conduit

ft.

50

(15

conduit

zone.

be

sure

shielding

cable,

wound,

and

work

to

close

as

setting

gap

manual.

service

and

cutting

centered

and

the

and

8-6),

unshielded

wires

shieldsorrelocated

zone.

all

large

or

support

there

that

within

wires

ground

less

or

pipes

from

as

system

from

m)

system

If

that

efficiency.

the

or

flexible

cablesorleads

the

access

zone

cutting

proceed

power,

within

metallic

wires

are

the

rods

the

the

ground

the

is

one

metallic

rigid,

the

shielding

Copper

equivalent,

metallic

ground

the

to

doors

as

a

sphere

on

a

point

torch

as

the

cutting

within

external

no

cutting

which

ground

for

continuous

is

power

complete

conduit
used

sleeving,

is

conduit

as

as

plane

minimum

before

with

between

Figure

(see

follows:

lighting,

objects,

the

enter

and

zone

outside

long

cutting

power

zone.

the

connection,

the

workpiece.

to

a

source,

run

is

has

satisfac

is

not

close

to

possible.

setting

operat

50

ft.

a

the
8-1

com

placed

the

guy

zone.

ortele

ground

or

Power

Be

Arc

sure

Plasma

9.

tight.

If

the

10.

be

ing,

8-7.

INSTALLATION

All

items

stallation.

may

terference

1.

Is

equipment

8-5D,

2.

Are

ac

Sections

3.

Are

torch

properly

4.

Are

ground

tions

5.

Is

equipment

tions

Point

Center

Figure

that

sure

source

that

not

power

Complete

with

authorized

and

8-5E,

input

power

8-5B,

and

installed

connections

8-5C,

8-6.1,

8-6.5

and

~-

8-6.

all

ground

is

the

building

GUIDELINES

be

necessary

the

necessary

properly

8-6.1)?

connections

8-6.2,

work

cables

(see

8-6.4,

properly

8-6.6)?

CuttIng

connections

operated

is

or

FCC

services.

located

and

8-6.3)?

or

Sections

properly

8-6.10,

and

set

up

Zone

clean

are

within

properly

practical

itemstoeliminate

(see

properly

leads

adjusted

a

CHECKLIST

Sections

and

8-5A

and

made

and

8-6.11)?

metal

build

grounded.

for

each

made

equipment

8-6.4)?

(see

(see

S.0022

and

in
in

8-4,

(see

Sec

Sec

OM-296

Page

23

SECTION

0

N

I-

I

I-

0

9-

PARTS

LIST

.c,)

E

C)

(n

4

C)

1~

a)

C.,

C.,

LI.

\



0)

C)

L.

LI.

\

OM-296

Page

24

Item

No.

Dia.

Mkqs.

Part

No.

Description

Quantity

Figure

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
32

33
34

35

36

37

38

39

40

9-1

DCV1

T2

AS1

S4

S5

FM

TI

Zi

125134
125135

+125

125133

125130

125111
125106

125110

125109

125105

125115

125108

125276

125107

125128

125092

+125

125021
125293
125118
125137
125119
125120
125132

125131

125093
125091

125122

125083

125124
124729

125125

125136

125084
125127
125126
125114

125129

125123

125121

+125

125045
125042

125043

125044
125145

125030

Main

SCREW

NUT

CASE

113

GROMMET

SUPPORT
CIRCUIT

DC

CIRCUIT

CIRCUIT

TRANSFORMER,

TERMINAL,

CIRCUIT

LABEL,

CIRCUIT

HOSE,
VALVE,

117

PANEL,
LABEL,

SCREW
COVER
SCREW

SWITCH,
BUSHING,

FITTING

FITTING,

PRESSURE

FAN

BRACKET,

TRANSFORMER,

BASE

LABEL,

CAPACITOR

SCREW

STABILIZER

LEG,

TERMINAL

FRONT

HOSE

PILOT
RECTIFIER
BRACKET

116

REGULATOR/FILTER



REGULATOR/FILTER



HOSE,



BRACKET,



GAUGE,

TORCH,

Assembly

CARD

POWER

CARD
CARD

CARD

warning

CARD

air

88

rear

warning

toggle

pipe

MOTOR,

warning

rubber

PANEL

CLAMP

UNIT

air

model

ASSEMBLY

SOURCE,

ASSEMBLY
ASSEMBLY

control

15

amp

2

ASSEMBLY

electric

ASSEMBLY

volts

way

2

dc

primary

SPDT

strain-relief

-

brass

SWITCH,

200

volts

-

fan

mtg

motor

power

general

ASSEMBLY

ASSEMBLY,

ASSEMBLY

(Figure

ASSEMLBY

mtg

air

0-1

9-5)

-

air

PST

60

APT-3000

2

amp

15

volts

pole

shock

changeover

15

amp

tee

air

3100

ac

-

main

can

250

rpm

kill

etc

200-230

volts

precautionary

(Figure

output

(Figure

ASSEMBLY

9-2)

(Figure

(Figure

9-6)

(consisting

9-3)

9-4)

filter/regulator

(Figure

9-7)

2

2

2

1

20

1

1
1

1
1
1
1

2

1
1
1

1

volts

ac

1

2

1

13

1
1

1
1

1

1
1
1
1

1

10

1

4

1

1

1
1
1

1

of)

1

1
1
1
1
1

+When
BE

ordering

SURE

TO

a

component

PROVIDE

originally

MODEL

AND

displaying

SERIAL

NUMBER

a

precautionary

WHEN

the

label,

ORDERING

label

should

REPLACEMENT

also

be

ordered.

PARTS.

OM-296

Page

25

2

1

5

item

No.

Figure

1
2

3

4

5
6
7
8

BE

SURE

OM-296

9-2

Page

Dia.

Mkgs.

RI

C1,13

R2

TO

26

PROVIDE

Part

No.

125

125

125 167

125

169

125170
125171

172

125

174

125
125

173

125168

MODEL

Figure

CapacItor

BRACKET,

RESISTOR

BAR

BUS

BAR

BUS

CAPACITOR,

RESiSTOR,

BRACKET,

INSULATOR

AND

SERIAL

9-2.

CapacItor

Description

Assembly

-

capacitor

mtg

electrolytic

-

component

NUMBER

20

cement

mtg

(Fig

1800

watt

WHEN

Assembly

Item

9-1

uf

8.2K

ORDERING

400

ohm

31)

volts

ac

REPLACEMENT

Quantity

1

1
1
1

2

1

1
1

PARTS.

2

8

9

10

11

12

Item

No.

Figure

1

2

3

4

5

6
7
8
9

10

11

12

13

14

15
16
17

SURE

BE

Dia.

Mkgs.

9-3

R13

~R12

C14

C15,16,17

RV1

PROVIDE

TO

Part

No.

125

126

125
125
125
125
125
125
125
125
125
125186

125
125

125
125183
125182

125184

125185

MODEL

9-3.

Assembly,

15

mtg

pipe

cement
cement

15

6

175

176
056
177
174
115
179
180
152

FIgure

Terminal

TERMINAL,
BRACKET,
FITTING,
RESISTOR,
RESISTOR,

TERMINAL,

TERMINAL,

CAPACITOR,

CAPACITOR,

RESISTOR,46OvoItsO.6watt

FASTON

187

188

181

FASTON

TERMINAL,

TERMINAL,

TERMINAL,

30

STOPPER

BINDER

INSULATOR

SUPPORT

AND

SERIAL

TermInal

Descnption

4

amp

-

component

-

brass

40

20

2

amp

4

amp

pole

600

amp

metanzed

ceramic

NUMBER

Assembly,

Output

(Fig

pole

9/16-18

watt
watt

UNF

6.8K

8.2K

pole

film

0.047

0.01uf400

receptacle

tab

volts

ac

WHEN

ORDERING

9-1

ohm
ohm

uf

volts

1

pole

Output

Item

volts

630

ac

35)

dc

REPLACEMENT

PARTS.

OM-296

Quantity

1

1
1
1

1

1
1
I

3

1
1
1
1
1

1

1
1

27

Page

11I1113I311I413331

6

iT

16

3

2

9

1

7

8

Item

No.

FIgure

9-4

1

2
3

4

5
6

7

8

9

10

11

12

13

14

15
16

17

18

Re~mmended

SURE

BE

OM-296

Page

Dia.

Mkgs.

Fl

R15

S1,2,3

CB1

PL1

LED1

PROVIDE

TO

28

Spare

Part

No.

125

*125

106

125

125 140

125141

125

125

125
125283

125

125148
125
125284
125
125280

125281
125282

097922

Parts.

MODEL

138

172

275

Front

FUSE,

HOLDER,

NAMEPLATE

114

PANEL,

INSULATOR

142

RESISTOR,

143

SWITCH,

CIRCUIT

112

NUT
SHAFT

147

DOOR,access-front

144

LAMP,

SCREW

146

LAMP,

NUT

WASHER

RiNG

KNOB

AND

FIgure

Panel

5

amp

fuse

front

toggle

PROTECTOR,

indicator

indicator

SERIAL

9-4.

Front

Descnption

Assembly

250

volts

250

volts

carbon

SPST3

220

15

NUMBER

0.3

vofts

mamp

Panel

(FIg

ac

ac

watt

amp

2P.50

ac,

dc,

WHEN

Assembly

9-1

Item

5K

ohm

30

volts

amp

red

lens

green

-,

ORDERING

36)

250

lens

dc

volts

ac

REPLACEMENT

Quantity

.

.

.

.

PARTS.

2

.3

.4

Item

No.

FIgure

2
3

4

5

6

7

8

9

BE

SURE

Mkgs.

9-5

R10,11

Dia.

05

C18

CR1

13

R9

RB

TO

PROVIDE

Part

No.

125

125
125
125
125

125
125
125

125161

125103

MODEL

123

166

164

165

115

162

085

163

Unft

PIlot

DIODE,

high

CAPACITOR,

RELAY,

enclosed

TERMINAL,

RESISTOR,

COUPLING

BRACKET

RESISTOR,
RESISTOR,

AND

SERIAL

Figure

(Fig

-

speed

film

15

WW

COIL

cement

cement

NUMBER

9-5.

Descnption

Item

9-1

2.5

20uf400

24

volts

2P

amp

60

watt

5

watt

20

Pilot

38)

amp

dc

12

watt.

WHEN

volts

SPST

ohm

100

3.3K

Unit

600

dc

ohm

ohm

ORDERING

volts

5

REPLACEMENT

Quantity

1

1

I
1
2

1

1

1
1

PARTS.

OM-296

Page

29

5

4

.7

8

1

18

13

3

5

17

Item

No.

Figure

1

2

3

4

5

6
7
8
9

10

11

12

.

13

14

15

16

17

18

Dia.

Mkgs.

9-6

C2-10

C11,12

R5
R7

D3,4

CT2

TMI

SR2

R6

TP1

SRi

R3,4

Part

No.

125

125
125

125
125159

125

125
125160
125
125

125

125154
125
125

125157

125158
125

125

125

FIgure

121

149

150

152

RectIfier

RESISTOR,

RESISTOR,

CAPACITOR,

Assembly

BUSBAR

089

090

DIODE,

CURRENT

high

TRANSFORMER

BUSBAR

TRANSISTOR

086

DIODE

088
153

CAPACITOR,

MODULE,

BINDER

155

SUPPORT,mtg-capacitor

156

RESISTOR,

SUPPORT

HEATSINK

095

THERMOSTAT,

DIODE

087
151

RESISTOR,WW53watt3.3

MODULE,

9-6.

Description

cement

WW

53

ceramic

-

speed

MODULE,

50

film

0.047

cement

NC

75

RectIfier

9-1

(Ag

40

watt

10

watt

0.01Ut400

12

amp

100

amp

uf~1000

10

watt

amp,8U0

Assembly

Item

400

ohm

ohm

600

amp

1200

volts

vofts

10

ohm

vo1ts~

ohm

16

39)

volts

volts

600

dc.~

.

.

ac

volts

.:~

Quantity

1

1

9

2

2

1

2

1

1

2

1
1
I
1

1

1

1

2

BE

OM-296

SURE

Page

TO

30

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERiN~G

R~PLACEMENT

-.

PARTS.

.

14-~

2 3

4

.6

7

8

Rem

No.

Figure

1

2

3

4

5

6

7
8
9

10

11

12
13
14

9-7

Dia.

Mkgs.

Part

No.

125

125071

125070

125

125
125
125
125
125

125

125
125
125
125
125

069

068

294

075
074
076

080
078

079

077

073
072

030

1~

10

Figure

Torch,

CUP

TIP
ELECTRODE

TORCH

INSULATING
SWITCH
TORCH

SHRINKABLE

HEAT

HOSE

PILOT

TORCH

POWER

TORCH

WRENCH

SHEATH

AND

Model

BODY

COVER

SWITCH

DETECTIVE

SWITCH

CABLE

HANDLE

9-7.

Torch,

Description

APT-3000

TUBE

LEAD

ASSEMBLY

TUBE

Model

LEAD

.9

APT-3000

Quantity

1

1
1
1

1

1
1
1
1
1

1

1

1

1

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-296

Page

31