Thermal Dynamics PCH-100XL, PCM-100XL Instruction Manual

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PLASMA

CUTTING TORCH

• Model PCH-100XL Hand Torch

• Model PCM-100XL Machine Torch

Instruction Manual

January 15, 2001 Manual No. 0-2583

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

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

Plasma Cutting Torch Model PCH-100XL & PCM-100XL Instruction Manual Number 0-2583

Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711

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

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: January 15, 2001

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

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

1.01 Notes, Cautions and W arnings ........................................................................ 1

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

1.03 Publications..................................................................................................... 2

1.04 Note , Attention et A vertissement ..................................................................... 3

1.05 Precautions De Securite Importantes.............................................................. 3

1.06 Documents De Ref erence............................................................................... 5

1.07 Declaration of Conf ormity................................................................................ 7

1.08 Statement of W arranty..................................................................................... 8

SECTION 2:

INTRODUCTION & DESCRIPTION..................................................................................... 9

2.01 Scope of Manual ............................................................................................ 9

2.02 General Description........................................................................................ 9

2.03 Specifications & Design Features................................................................... 9

2.04 Options And Accessories ............................................................................. 10

2.05 Introduction to Plasma .................................................................................. 10

SECTION 3:

INSTALLA TION PR OCEDURES ........................................................................................ 13

3.01 Introduction .................................................................................................. 13

3.02 Site Location................................................................................................. 13

3.03 Unpacking ..................................................................................................... 13

3.04 Setting Up Hand Torch.................................................................................. 13

3.05 Setting Up Machine Torch............................................................................. 13

3.06 Connecting Torch.......................................................................................... 14

3.07 Gas Connection ........................................................................................... 14

SECTION 4:

OPERATION ...................................................................................................................... 17

4.01 Introduction .................................................................................................. 17

4.02 Functional Overview..................................................................................... 17

4.03 Getting Started ............................................................................................. 17

4.04 Torch P arts Selection.................................................................................... 17

4.05 Cut Quality ................................................................................................... 18

4.06 Operating the System................................................................................... 19

4.07 Hand Torch Operation................................................................................... 20

4.08 Machine Torch Operation.............................................................................. 21

4.09 Recommended Cutting Speeds.................................................................... 22

4.10 Gouging........................................................................................................ 22

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE .................................................................................. 25

5.01 Introduction .................................................................................................. 25

5.02 General Torch Maintenance.......................................................................... 25

5.03 Common Operating Faults............................................................................ 25

5.04 Inspection and Replacement Consumable Torch Parts................................. 26

5.05 Troubleshooting Guide.................................................................................. 27

5.06 Servicing Machine Torch Components ......................................................... 28

5.07 Servicing Hand Torch Components .............................................................. 29

5.08 Torch And Leads Troubleshooting................................................................. 30

SECTION 6:

PARTS LISTS.....................................................................................................................33

6.01 Introduction .................................................................................................. 33

6.02 Ordering Information .................................................................................... 33

6.03 Replacement Hand Torch P arts.................................................................... 34

6.04 Replacement Machine Torch P arts ............................................................... 36

6.05 Options and Accessories.............................................................................. 38

6.06 Complete Assembly Replacement................................................................ 39

6.07 Spare Parts Kits ........................................................................................... 40

APPENDIX I: CUTTING SPEED CHARTS ................................................................................ 41

APPENDIX II: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM............... 42

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A pr ocedure which, if not properly followed, may cause damage to the equipment.

WARNING

A pr ocedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-571 1 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different pr ocesses. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

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

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

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

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

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

Date: May 1, 2000 1 GENERAL INFORMATION

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

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

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

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

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To pr otect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

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

PLASMA ARC RAYS

Plasma Arc Rays can injur e your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly pr otected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pr otect your skin from the arc rays and sparks.

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

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

• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY -TOE FOOTWEAR, obtainable fr om the American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 2 Date: Ma y 1, 2000

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. A WS Standar d A6.0, WELDING AND CUTTING CONT AINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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

10. NFPA Standar d 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standar d W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American W elding Society Standar d A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HA VE HELD HAZARDOUS SUBST ANCES, obtainable fr om the American Welding Society, 550 N.W . LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédur e en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

Date: May 1, 2000 3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-571 1 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (V oir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PA S couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper . Le gas hydrogène accumulé explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’éner gie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 4 Date: Ma y 1, 2000

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons

ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur . Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculair e.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12 400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L ’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAV AIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AY ANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

Date: May 1, 2000 5 GENERAL INFORMATION

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymar ch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDA TIONS DE PRA TIQUES SURES POUR LA PRÉP ARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 6 Date: Ma y 1, 2000

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2

W est Lebanon, New Hampshir e 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical r equirements among them ar e:

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

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

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

ated accessories.

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

manufacturing process. This is to ensure the pr oduct is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured pr oduct meets or exceeds all design specifications.

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

Manufacturers responsible repr esentative: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: May 1, 2000 7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal shall, upon notification ther eof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standar d industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or r eplacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A P AR TICULAR PURPOSE.

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

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years fr om date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years fr om date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year PCH/M-62 & PCH/M-102 Torches 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. T ransportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective May 1, 2000

GENERAL INFORMATION 8 Date: Ma y 1, 2000

SECTION 2:

PCH-100XL (90˚) Hand Torch

PCH-100XL (70˚) Hand Torch

A-01365

INTRODUCTION &

DESCRIPTION

2.03 Specifications & Design Features

The following applies to the PCH/M-100XL Torch only:

A. Torch Configurations

2.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the PCH/M-100XL Torch. Service of this equipment is restricted to Thermal Dynamics trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed.

2.02 General Description

NOTE

Refer to Section 2.05, Introduction To Plasma, for a more detailed description on plasma theory.

The PCH/M-100XL Torch provides cutting capacity of up to 1 inch (25.4 mm) at 70 amperes. In the torch, a single torch lead provides compressed air or nitr ogen (N2) from a single source to be used as both the plasma and secondary gas. The air flow is divided inside the torch head. Single-gas operation provides a smaller sized torch and inexpensive operation.

Plasma torches are similar in design to the common automotive spark plug. They consist of negative and positive sections which are separated by a center insulator. Inside the torch, the pilot arc is initiated in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas flows through the small orifice in the torch tip, which is focused on the metal to be cut.

1. Hand Torch PCH-100XL PCH-100XL is available with torch heads at 70°

and 90° to the torch handle. The hand torches include a torch handle and torch switch assembly.

Figure 2-1 PCH-100XL Hand Torches

2. Machine Torch PCM-100XL PCM-100XL Machine Torch is supplied with a

metal mounting tube with rack and pinion assembly.

PCM-100XL Machine Torch

Shown with Rack and Pinion

Mounting Assembly

Manual 0-2583 9 INTRODUCTION & DESCRIPTION

A-01363

Figure 2-2 PCM-100XL Machine Torch

B. Torch Leads Lengths

25 ft (7.6 m) or 50 ft (15.2 m)

C. Current Rating

70 Amps Max., DC, Straight Polarity

D. Duty Cycle

40% on 1 inch (25.4 mm) material

E. Cutting Range

Most materials up to 1 inch (25.4 mm) at 5 IPM (inches per minute)

F. Pierce Rating

3/8 inch (9.53 mm) on carbon steel

G. Transfer Distance

3/8 in (9.5 mm)

H. Gouging

3/16 inch (4.76 mm) wide x 1/8 inch (3.18 mm) deep with one single pass at 20 IPM(inches per minute)

I. Bevel Cut Capability

0° to 45° on 1/2 inch (13 mm) material

J. Torch Parts

Gas Distributor, Electrode, Tip, Shield Cup

K. Parts-In-Place (PIP)

Torch Head has built-in contacts

3.03 in

(77 mm)

3.16 in

(80 mm)

1.16 in

(29 mm)

1.38 in

(35 mm)

A-00933

8.21 in

(209 mm)

7.66 in

(195 mm)

1.16 in

(29 mm)

1.16 in

(29 mm)

6.54 in (166 mm) Min. 15 in (381 mm) Max.

16.96 in (431 mm)

Figure 2-3 Torch Dimensions

2.04 Options And Accessories

These items can be used to customize a standard system for a particular application or to further enhance performance (refer to Section 6 for ordering information).

L. Gas Requirement

1. Single Plasma/Secondary Gas Compressed Air or Nitrogen (N2)

2. Pressure 70 psi (4.8 bar)

CAUTION

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

3. Total Flow Cutting or Gouging: 406 scfh (192 lpm)

M. Dimensions

Figure 2-3 shows the overall dimensions of the three types of PCH/M-100XL Torches.

• Spare Parts Kits - Kits contain replacement frontend torch parts. Spare parts kits are available for standoff cutting, drag cutting, or gouging.

• Circle Cutting Guide - This device provides precise cutting capability with a hand torch. The guide fits both the 70° and 90° hand torches. The kits include roller guides and pivots that attach to the torch.

2.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is defined as a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging process use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.

While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.

In a Thermal Arc Plasma Cutting Torch a cool gas such as air or nitrogen (N2) enters Zone B (refer to Figure 2-4), where a pilot arc between the electrode and the

INTRODUCTION & DESCRIPTION 10 Manual 0-2583

torch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

Power

Supply

Workpiece

Figure 2-4 Typical Torch Head Detail

A-00002

D. High Frequency

Because direct current (DC) alone is not sufficient to strike and maintain the pilot arc, high frequency is also used. The high frequency jumps between the tip and electrode with the DC following.

E. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through a pilot wire.

F. Interlocks

One pressure switch acts as an interlock for the gas supply. If supply pressure falls below minimum requirements the pressure switch will open, shutting off the DC power, and the GAS indicator will go off. When adequate gas supply pressure is available the pressure switch will close, allowing power to be resumed for cutting.

G. Parts-In-Place (PIP)

By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C (Figure 2-4). Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.

Zone A (Figure 2-4) is used as a secondary gas that cools the torch. This gas assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag-free cut.

B. Gas Distribution

The single gas used is internally split into plasma and secondary gases.

The plasma gas flows into the torch through the negative lead, through the gas distributor , ar ound the electrode, and out through the tip orifice.

The secondary gas flows down around the outside of the torch gas distributor , and out between the tip and shield cup around the plasma arc.

C. Pilot Arc

The torch head has built-in contacts called Parts-InPlace (PIP). These two contacts are made through the canted coiled spring inside the shield cup when it is installed. The torch will fail to operate if these contacts are not made.

Torch Switch

To Control

Cable Wiring

PIP Pin

Shield Cup

PIP Pin

A-00458

Figure 2-5 Parts-In-Place (PIP) Diagram

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

Manual 0-2583 11 INTRODUCTION & DESCRIPTION

INTRODUCTION & DESCRIPTION 12 Manual 0-2583

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

• PCH/M-100XL Spare Parts Kit including:

(5) Cutting Tips (3) Electrodes (1) Canted Coil Spring (1) O-Ring (1) Lubricant

This Section describes installation of the PCH/M-100XL Torch. These instructions apply to the Torch and Leads Assemblies only; installation procedures for the Power Supply, Options, and Accessories are given in Manuals specifically provided for those units.

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Setting Up Torch

4. Connecting Torch 5 Gas Connection

6. Operator Training

3.02 Site Location

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

Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.

3.03 Unpacking

NOTE

(1) 7/32 Nut Driver (1) Utility Box

• PCH/M-100XL Instruction Manual (Catalog No. 0-

2583)

B. Options and Accessories

Options and Accessories are or dered and packaged separately from the torch components.

C. Unpacking Procedure

1. Unpack each item and remove all packing material.

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

3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping company before proceeding with system installation.

3.04 Setting Up Hand Torch

The hand torch is factory assembled and requires no special set up. The proper torch parts (shield cup, tip, gas distributor, and electrode) must be installed for the type of operation. Refer to Section 4.04, Torch Parts Selection for more information.

Torches ordered as part of a system are factory assembled to the power supply and are packaged in one shipping carton.

Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping. Components are packaged as follows:

A. Torch and Leads

T or ches and leads are packaged together. Spare parts for new torches are packed in a spare parts kit box.

Included with each torch is:

• PCH/M-100XL Torch with parts installed and leads attached. PCH-100XL hand torches include a handle assembly with torch switch. PCM-100XL machine torches include a metal mounting tube with rack and pinion assembly with remote pendant.

Manual 0-2583 13 INSTALLA TION PROCEDURES

3.05 Setting Up Machine Torch

WARNING

Disconnect primary power at the source before disassembling the torch or torch leads.

Metal mounting tubes with rack and pinion assemblies are standard for machine tor ches.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to align the torch perpendicular to the surface of the workpiece (Figure 3-1).

Rack and

Pinion Mounting

Assembly

CAUTION

The torch parts must correspond with the type of operation. Refer to Section 4.04, Torch Parts Selection.

Square

A-00934

Workpiece

Figure 3-1 Machine Torch Set-Up

3. The proper torch parts (shield cup, tip, gas distributor, and electrode) must be installed for the type of operation. Refer to Section 4.04, T orch Parts Selection for more information.

3.06 Connecting Torch

WARNING

3. In machine type operations the Machine Torch (PCM-100XL) has an extra cable connector supplied at the control cable connector. This connector allows connection to a remote pendant or CNC cable while using PIP connections in the T o rch Assembly . Connect the r emote pendant control cable to the lead connector provided on the Torch leads.

Remote Pendant/CNC

Cable Connector

Control

OK-To-Move

14 13

3 4

PIP

Circuit

Torch Control

Cable Connector

2 3

4 12 14 13

A-01366

Disconnect primary power at the source before disassembling the torch or torch leads.

1. Connect the torch lead connections to the Power Supply as described in the Manual supplied with the Power Supply.

Control Cable

Pilot Lead

Gas Lead

Torch Lead

Assembly

A-00935

Figure 3-2 Torch Lead Connections

2. Check the torch for proper parts assembly.

Figure 3-3 Remote Pendant Connector Diagram

3.07 Gas Connection

A. Connection

Connect the gas , compressed air or nitrogen (N2) only, to the Power Supply as described in the Manual supplied with the Power Supply.

CAUTION

Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.

B. Checking Air Quality

To test the quality of air, place a welding filter lens in front of the torch and turn on the gas. Any oil or moisture in the air will be visible on the lens. Do not initiate an arc!

INSTALLATION PROCEDURES 14 Manual 0-2583

C. Filtering

An inline pneumatic dryer/evaporator type air filter , capable of filtering to at least 5 microns, is required when using air from a compressor. This type filter will insure that moisture, oil, dirt, chips, rust particles, and other contminants from the supply hose do not enter the torch. For highly automated applications, a refrigerated drier may be used.

NOTE

Do not use an air line filter with high pressure gas cylinders.

Manual 0-2583 15 INSTALLA TION PROCEDURES

INSTALLATION PROCEDURES 16 Manual 0-2583

SECTION 4:

OPERATION

4.01 Introduction

This Section provides a description of the PCH/M-100XL Torch Assembly followed by operating procedures.

4.02 Functional Overview

The PCH/M-100XL Torch is designed to operate with the Pak Master 100XL Cutting System to provide a plasma cutting system which can cut most metals from gauge thickness up to 1 inch (25.4 mm). Using standard torch parts the torch can be used for plasma arc gouging upto 1/8 inch (3.18 mm) deep on a single pass.

4.03 Getting Started

E. Purge System

On the Power Supply place the ON/OFF switch to the ON position. An automatic gas pur ge (pre-flow) will remove any condensation that may have accumulated in the torch and leads while the system was shut down. The torch cannot be activated during the purge cycle (pre-flow). After the purge is complete, if the RUN/SET switch is in SET position, gas will flow . If the switch is in RUN position there will be no gas flow.

F. Current Output Level

At the Power Supply set the desired current output level to a maximum of 70 amperes. For drag cutting set the control at 35 amps or less only.

G. Pressure Settings

Place the RUN/SET switch to the SET position. Adjust gas pressure control for 70 psi ±3 (4.8 bar ±2).

This procedure should be followed at the beginning of each shift:

WARNING

Disconnect primary power at the source before assembling or disassembling stacked modules, individual modules, torch parts, or torch and leads assemblies.

A. Torch Parts

Check the torch for proper assembly. Install proper torch parts for the desired application (refer to Section 4.04, Torch Parts Selection).

B. Input Power

Check the power source for proper input voltage. Close main disconnect switch or plug unit in to supply primary power to the system.

C. Work Cable

Check for a solid work cable connection to the workpiece.

D. Gas Supply

H. Ready for Operation

Return the RUN/SET switch to RUN position.

The system is now ready for operation.

NOTE

Refer to Appendix II for a typical detailed block diagram of Sequence Of Operation.

4.04 Torch Parts Selection

Depending on the type of operation to be done determines the torch parts to be used.

Torch parts:

Shield Cup, Cutting Tip, Electrode and Gas Distributor

Type of operation:

Drag cutting, standoff cutting or gouging

The following torch parts are installed from the factory:

• Shield Cup

• Cutting T i p

• Electrode

• Gas Distributor

Select desired single gas supply. Make sure gas sources meet requirements (refer to Secton 2.03-K, Gas Requirements). Check connections and turn gas supply on.

Manual 0-2583 17 OPERATION

Refer to Figure 4-1 for the various torch parts.

Torch Head Assembly (70˚ Hand Torch Shown)

Standard Shield Cup

Catalog No. 8-7500

Hi-Vis Shield Cup (Black)

Catalog No. 8-7525

Cutting Tip, Air/N2

55 Amp (0.047 in)

Catalog No. 8-7504

Drag Cutting Tip, Air/N2

35 Amp (0.039 in)

Catalog No. 8-7503

Electrode

Catalog No. 8-7502

Gas Distributor

Catalog No. 8-7501

Castle Shield Cup

Catalog No. 8-7507

Cutting Tip, Air/N2

70 Amp (0.052 in)

Catalog No. 8-7505

Gouging Tip, Air

(0.073 in Orifice)

Catalog No. 8-7506

Gouging Gas Distributor

Catalog No. 8-7508

A-01362

Electrode

A-00937

Gas

Distributor

Tip

Shield Cup

Figure 4-2 PCH/M-100XL Torch Parts

2. Tilt the tor ch head to r emove the tip and gas distributor.

3. Using a 7/32 inch (5.5 mm) nut driver remove the electrode.

4. Install the desired electrode, gas distributor and tip

for the operation into the torch head.

NOTE

Be careful not to overtighten the electrode when reinstalling.

5. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

4.05 Cut Quality

Figure 4-1 Torch Parts Selection

T o change the torch parts for a dif ferent operation use the following procedure:

NOTE

The tip and gas distributor are held in place by the shield cup. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup from the torch head.

OPERATION 18 Manual 0-2583

NOTE

Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.

Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in Figure 4-3:

H. Various Materials and Thicknesses

Kerf Width

Cut Surface Bevel Angle

Top

Spatter

Top Edge Rounding

Dross

Build-Up

Cut Surface

Drag Lines

A-00007

Figure 4-3 Cut Quality Characteristics

A. Cut Surface

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

B. Nitride Build-Up

Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. These buildups may create difficulties if the material is to be welded after the cutting process.

The following table defines the cut quality on various materials and thicknesses:

Tab le 4-A C ut Quality on Various Mate rials

Material Type of Type of Cut

Th ickness Material Gas Characteristics

Carbon Steel Air G ood - Ex cellent

Gage

1 inch

(25.4mm ) Aluminum A ir Good - Excellent

S tainless A ir Good - Excellent

Nitrogen Good

Description of Cut Characteristics: Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x

tip orifice diameter), little or no dross, smooth cut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

tip orifice diameter), some dross (easily removed), medium-smooth cut surface, slight top edge rounding.

4.06 Operating the System

C. Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A per fectly perpendicular cut would result in a 0° bevel angle.

D. Top-Edge Rounding

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

E. Bottom Dross Build-up

Molten material which is not blown out of the cut area and re-solidifies on the plate. Excessive dross may require secondary clean-up operations after cutting.

F. Kerf Width

The width of the cut (or the width of material removed during the cut).

G. Top Spatter (Dross)

Top Spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice has become elongated.

WARNINGS

Disconnect primary power at the source before disassembling the power supply, torch, or tor ch leads.

Frequently review the Important Safety Precautions at the front of this manual. Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

NOTE

Handle torch leads with care and protect them fr om damage.

Manual 0-2583 19 OPERATION

A. Piloting

Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life.

B. To rch Standoff

Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally result in a more square cut.

be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

4.07 Hand Torch Operation

A. Drag or Standoff Cutting With Hand Torch

C. Edge Starting

For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near(not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal. Establish the cutting arc as quickly as possible.

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left (Refer to Figure 4-4). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Left Side

Cut Angle

Right Side Cut Angle

1. The torch can be comfortably held in one hand or steadied with two hands. Choose the technique that feels most comfortable and allows good control and movement. Position the index finger or thumb to press the control switch on the torch handle.

CAUTION

The tip should never come in contact with the workpiece except during drag cutting operations. The output current should be set to 35 amps or less when drag cutting.

2. Depending on the type of cutting operation, do one of the following:

a. For edge starts, hold the torch perpendicular to

the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.

b. For standoff cutting, hold the torch 1/8 - 3/8 in

(3 - 9 mm) from the work

c. For drag cuts install the drag cutting tip and set

the output current to 35 amps or less. Keep the torch in contact with the workpiece during the cutting cycle.

Figure 4-4 Side Characteristics Of Cut

E. Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often

OPERATION 20 Manual 0-2583

A-00512

4. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it.

Torch

Standoff

Shield Cup

A-00938

Distance 1/8" - 3/8"

Figure 4-5 Standoff Distance

3. W ith the torch in starting position, pr ess and hold the control switch. After an initial gas purge, the pilot arc will come on and remain on until the cutting arc starts.

4. Once on, the main arc remains on as long as the control switch is held down, unless the torch is withdrawn from the work or torch motion is too slow . If the cutting ar c is interrupted, the pilot arc comes back on automatically.

5. T o shut off the tor ch simply release the thumb control switch. When the switch is released a ten second post-flow will occur. If the torch switch is closed during the post-flow, the cutting arc will restart immediately when the torch is brought within range of the workpiece.

C. Castle Shield Cup With Straight Edge

NOTE

Other common terms for the Castle Shield Cup are Crown or Standoff Shield Cup.

The castle shield cup can be used with a non-conductive straight edge to make straight cuts by hand (refer to Figure 4-6). The castle shield cup functions best when cutting relatively smooth metal surfaces that are solid.

WARNING

The straight edge must be non-conductive.

Torch

Castle Shield

Cup

Non-Conductive

Straight Edge Cutting Guide

A-00939

Standoff

Distance 1/8"

B. Piercing With Hand Torch

2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete.

3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the workpiece after the pierce is complete.

Manual 0-2583 21 OPERATION

Figure 4-6 Using Castle Shield Cup With Straight

Edge

4.08 Machine Torch Operation

A. Cutting With Machine Torch

The machine torch can be activated by remote contr ol pendant or by a remote interface device such as CNC. For best results, 70 Amp Cutting T ip (Catalog # 8-7505) should be used.

1. Use a square to check that the torch is perpendicular to the workpiece to obtain a clean, vertical cut.

Rack and

Pinion Mounting

Assembly

Shown with

Rack and Pinion

Mounting Assembly

Square

Direction of Torch Travel

Standoff Distance

A-00934

Workpiece

Figure 4-7 Checking Alignment

2. To start a cut at the plate edge, position the center of the torch along the edge of the plate (refer to Figure 4-8)

B. Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate ( Figure 4-8). The arc can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece surface. This arc is generally recommended for the best cut using air plasma on stainless or aluminum.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A five degree leading arc is generally recommended for air plasma on mild steel.

Straight Arc

Trailing Arc

A-01364

Leading Arc

Figure 4-8 Machine Torch Operation

For optimum smooth surface quality, the travel speed should be adjusted so that only the leading edge of the arc column produces the cut. If the travel speed is too slow , a rough cut will be pr oduced as the arc moves from side to side in search of metal for transfer.

T ravel speed also af fects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the approriate Control Module Operating Manual for any Corner Slowdown (CSD) adjustments that may be required.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

OPERATION 22 Manual 0-2583

C. Piercing With Machine Torch

To pierce with a machine torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch.

When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff should be reduced to the recommended 1/8 - 1/4 inch (3 - 6 mm) dis-

tance for optimum speed and cut quality. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it.

4.09 Recommended Cutting Speeds

WARNING

Disconnect primary power to the system before disassembling the torch, leads, or power supply .

Cutting speed depends on material, thickness, and the operator’s ability to accurately follow the desired cut line. The following factors may have an impact on system performance:

• Torch parts wear

• Air quality

• Line voltage fluctuations

• Torch standoff height

• Proper work cable connection

NOTE

This information represents realistic expectations using recommended practices and well-maintained systems. Actual speeds may vary up to 50% from those shown.

Refer to Appendix I, Cutting Speed Charts, for complete chart data.

4.10 Gouging

WARNING

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch is activated.

A. Gouging Parameters

Gouging performance depends on parameters such as torch travel speed, current level, lead angle (the angle between the torch and workpiece), and the distance between the torch tip and workpiece (standoff).

B. Tor ch T ravel Speed

Optimum torch travel speed for gouging is 20 inches per minute (0.5 meters per minute) at 3/16 inch (4.7 mm) standoff. Travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

C. Current Setting

Current settings depend on torch travel speed, mode of operation (hand or machine torch), and the amount of material to be removed.

D. Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 70 amps, the recommended lead angle is 35° (refer to Figure 4-9). At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

Torch Head

CAUTIONS

Sparks from plasma gouging can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Check torch parts. The torch parts must correspond with the type of operation. Refer to Section 4.04, Torch Parts Selection.

Manual 0-2583 23 OPERATION

35˚

Standoff Height

1/8 - 1/4"

Workpiece

A-00941

Figure 4-9 Gouging Angle and Standoff Distance

E. Standoff Distance

The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge. Standoff distances greater than 1/4 inch (6 mm) may result in minimal metal removal or loss of transferred main arc.

F. Slag Build-up

Slag generated by gouging on materials such as carbon and stainless steels, nickels, and alloyed steels, can be removed easily in most cases. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build-up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build-up is most often a result of improper travel speed, lead angle, or standoff height.

OPERATION 24 Manual 0-2583

SECTION 5:

CUSTOMER/OPERATOR

WARNINGS

SERVICE

5.01 Introduction

This Section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than Thermal Dynamics Trained personnel.

WARNINGS

Disconnect primary power at the source before disassembling the torch or torch leads.

Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

CAUTION

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads (refer to Section 5.06, Servicing Machine Torch Components, or Section 5.07, Servicing Hand T or ch Components) and cleaned more thor oughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

CAUTION

Dry the torch thoroughly before r einstalling.

B. Checking Center Insulator

The center insulator separates the negative and positive sections of the torch. If the center insulator does not provide adequate resistance, current which is intended for the pilot arc may be dissipated into the torch head, resulting in torch failure.

Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.

NOTE

Handle torch leads with care and protect them fr om damage.

5.02 General Torch Maintenance

A. Cleaning To rch

Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

1. Remove the shield cup, tip, gas distributor, and electrode from the torch. Disconnect the tor ch leads from the power supply to isolate the torch from power supply circuits.

2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch fittings. Infinite resistance (no continuity) should be found. If continuity is found, refer to Section 5.08, Torch and Leads T roubleshooting.

5.03 Common Operating Faults

The following lists the more common cutting faults and what is the possible cause:

Manual 0-2583 25 SER VICE

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting current too low f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high d. Work cable disconnected

Remove the consumable torch parts per the following procedure:

NOTE

The tip and gas distributor are held in place by the shield cup. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed.

1. Unscrew and remove the shield cup fr om the torch.

NOTE

Slag built up on the shield cup that cannot be removed may effect the performance of the system.

Torch Head Assembly (70˚ Hand Torch Shown)

e. Worn torch parts f. Non-Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts d. Improper cutting current f. Non-Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time d. Air flow too low (incorrect pressure) e. Improperly assembled torch f. Non-Genuine Thermal Dynamics Parts

Electrode

A-00937

Gas

Distributor

Tip

Shield Cup

Figure 5-1 PCH/M-100XL Consumable Parts

2. Inspect the cup for damage. Wipe it clean or r eplace if damaged.

3. Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Clean or replace the tip if necessary.

Good Tip

Worn Tip

5.04 Inspection and Replacement Consumable T o rch Parts

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

SER VICE 26 Manual 0-2583

A-00942

Figure 5-2 Tip Wear

4. Remove the gas distributor and check for excessive wear, plugged gas holes, or discoloration. Replace if necessary.

5. Remove the electrode using 7/32 inch (5.5 mm) nut driver. Refer to Figure 5-3 and check the face of the electrode for excessive wear.

New Electrode

2. Torch switch activated during pre-flow

a. Release torch switch and wait at least 20 sec-

onds before activating switch again

3. Parts-In-Place (PIP) not satisfied.

a. Check canted coiled spring inside shield cup

4. Faulty torch parts

A-00943

Worn Electrode

Figure 5-3 Electrode Wear

6. Reinstall the electrode, gas distributor and tip into the torch head.

NOTE

Be careful not to overtighted the electrode when reinstalling.

7. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.

5.05 Troubleshooting Guide

Troubleshooting

This Sub-Section covers troubleshooting that requires dissasembly and electronic measurements. It is helpful for solving many of the common problems that can arise with this torch assembly.

How to use this Guide

The following information is a guide to help the Customer/Operator determine the most likely causes for various symptoms.

a. Inspect torch parts and replace if necessary. Re-

fer to Section 5.04, Inspection and Replacement Consumable Torch Parts

5. Gas pressure too high

a. Set pressure to 70 psi (4.8 BAR).

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

7. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached to

power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against

torch head (do not overtighten)

3. Parts-In-Place (PIP) not satisfied.

a. Check canted coiled spring inside shield cup

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your symptom, check the causes (easiest listed first) then remedies. Repair as needed being sure to verify that unit is fully operational after any repairs.

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN/SET switch in SET position

a. Place RUN/SET switch to RUN position.

Manual 0-2583 27 SER VICE

4. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

5. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

C. Low cutting output with no control

1. Incorrect setting of current control on power supply

a. Check and adjusted to proper setting.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

2. Torch is being moved too fast across workpiece

a. Return for repair or have qualified technician

repair per Service Manual.

D. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Incorrect setting of current control on power supply

a. Check and adjusted to proper setting.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

E. Erractic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix I, Cut-

ting Speed Charts).

4. Excessive oil or moisture in torch

a. Reduce cutting speed (refer to Appendix I, Cut-

ting Speed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.18 mm) from clean sur-

face while purging and observe oil or moisture buildup (do not activate torch)

5.06 Servicing Machine Torch Components

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

A. Removing Machine Torch Head

1. Unscrew the retaining nut fr om the mounting tube and slide the mounting assembly up over the leads.

2. Pull the mounting adaptor from the torch head assembly. Slide the positioning tube, adaptor, and retaining nut back over the leads to expose the negative/plasma lead connection, pilot lead connection, and two PIP (parts-in-place circuit) connectors.

a. Hold torch 1/8 inch (3.18 mm) from clean sur-

face while purging and observe oil or moisture buildup (do not activate torch)

F. No gas flow

1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 BAR).

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

G. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

SER VICE 28 Manual 0-2583

Pinion Assembly

Positioning Tube

Bushing

Machine

Torch Head

Mounting Adaptor

Retaining Nut

A-00944

Figure 5-4 Torch Mounting Assembly (PCM-100XL)

3. Disconnect the negative/plasma and pilot leads and the PIP connectors to allow removal of the torch head.

Sheath

Negative/Plasma Lead Connection

Parts-In-Place (PIP)

Wires

Pilot Lead

Connection

A-00945

Figure 5-5 Torch Head Removal (PCM-100XL)

B. Reassembling Machine Torch Assembly

1. Connect the two PIP lead connectors, the negative/ plasma and pilot leads.

NOTE

Tape the PIP lead connectors to the leads covering.

2. Slide the mounting adaptor and retaining nut down and push the adaptor securely onto the back of the torch head.

3. Slide the mounting assembly down and thread the retaining nut onto the mounting tube.

5.07 Servicing Hand Torch Components

WARNING

Disconnect primary power to the system before disassembling the torch or torch leads.

Connectors From

Torch Switch

Torch Control

Switch

Torch Handle

A-00947

Figure 5-6 Removing Torch Control Switch

2. Carefully cut and remove the heat shrink from the leads and handle being careful not to damage the wires under the heat shrink.

3. Remove the electrical tape from the leads and the end of the leads sheathing.

4. Slide the leads sheathing back to expose the torch switch connectors.

5. Remove the electrical tape securing the two connectors together .

6. Disconnect the torch switch leads. One lead goes to one side of the parts-in-place (PIP) circuit. The second lead goes to the control cable.

7. Disconnect the remaining PIP connector.

NOTE

The torch switch connectors are made to fit into its matching connector.

8. With a twisting motion, pull the torch from the handle far enough for the ends of the PIP wires to be removed from the handle.

9. Remove the screw and star washer securing the pilot control wire lead to the head assembly.

A. Removing Torch Switch and Torch Head

Assembly

The removal of the torch switch or torch head assemblies require disassembly of the torch handle and leads per the following procedure:

1. Roll the torch switch sheath back over the handle to expose the heat shrink covering the torch switch connectors.

Manual 0-2583 29 SER VICE

Negative/Plasma Lead Connection

Torch Switch

Control Cable

Wires

Torch

Switch

Parts-In-Place (PIP)

Wires

Pilot Lead

Connection

A-00946

Figure 5-7 Torch Head Removal (PCH-100XL)

10. Disconnect the negative (plasma) lead from the torch head.

1 1. Remove the defective torch head assembly.

12. Remove the torch handle and switch from the leads.

13. If the torch switch is defective, remove the switch from the torch handle.

B. Installing To rch Switch and Torch Head

Assembly

T o install the tor ch switch or torch head assembly use the following procedure:

To Control

Cable Wiring

PIP Pin

Shield Cup

PIP Pin

A-00458

Figure 5-8 Torch Switch and PIP Schematic

7. T ape the two control cable connector leads together .

8. Pull the leads sheathing over the three connectors and secure with electrical tape to the torch leads.

9. Pull the heat shrink tube back over the connectors and onto the end of the torch handle tube. Shrink the tubing into place.

10. Roll the torch switch sheath back over the handle.

5.08 Torch And Leads Troubleshooting

WARNINGS

Disconnect primary power to the system before disassembling the torch or torch leads.

DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.

1. Slide the replacement heat shrink tube over the leads.

2. Slide the torch handle with torch switch and sheathing over the torch leads.

3. Connect the negative (plasma) lead to the replacement torch head assembly.

4. Insert the screw through the pilot control wir e lead lug and then install the star washer before securing it to the head assembly.

5. Feed the torch switch leads through the handle and install the torch head on the handle.

NOTE

The torch switch connectors are made to fit into its matching connector.

6. Connect the two torch switch leads and the PIP leads to the mating connectors in the leads assembly.

A. Checking Center Insulator

The center insulator separates the negative and positive charged sections of the torch. If the center insulator does not provide adequate resistance, current which is intended for the pilot arc may be dissipated into the torch head, resulting in torch failur e.

1. Remove the shield cup, tip, gas distributor, and electrode from the torch.

2. Disconnect the torch leads from the power supply to isolate the torch from power supply circuits.

3. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch fittings.

If infinite resistance (no continuity) is found the center insulator is okay. Proceed to paragraph B, Checking Pilot and Switch Control Wires.

If there is continuity between the two torch quick disconnect fittings proceed to Step 4.

SER VICE 30 Manual 0-2583

4. Remove the torch head from the leads (r efer to Section 5.06, Servicing Machine T orchComponents or Section 5.07, Servicing Hand Torch Components).

This completes the checks for the proper operation of the center insulator of the torch head and leads. Proceed to paragraph 'C' to check pilot and switch control wires..

5. With the torch head disconnected from the leads, measure the resistance between negative cathode body of the torch head (where the electrode seats) and the positive anode body of the torch head (the outer threads where the shield cup seats).

Infinite resistance (no continuity) should be measured between negative and positive sections of the torch head.

If any current can flow through the center insulator , the torch head is faulty and must be r eplaced.

If the torch head is okay, the problem is in the leads assembly . Pr oceed to paragraph "B' to check torch lead assembly.

B. Checking Torch Lead Assembly

Check the torch leads by measuring the resistance between the positive pilot lead connector and the negative/ plasma lead fitting.

If continuity is found, replace the torch leads. If no continuity is found, the torch leads are probably

good. The torch leads should be tested further for insulation breakdown if no other fault can be found. To test the torch leads for insulation breakdown use the following procedure:

WARNINGS

C. Checking Pilot and Switch Control Wires

1. Disassemble the torch head and leads to expose the torch head connections. Refer to Section 5.06, Servicing Machine Torch Components or Section

5.07, Servicing Hand Torch Components.

2. Visually check that the PIP wires, torch switch wir es, pilot lead connection, and negative/plasma lead connections are properly connected and in good condition (no shorts or arcing).

Torch Switch

To Control

Cable Wiring

PIP Pin

Shield Cup

PIP Pin

A-00458

Figure 5-9 Torch Switch and PIP Schematic

If problems are evident, repair or replace as required.

If there are no visual problems then proceed to Step 3.

3. Check the pilot and switch control wires for opens from one end of the torch leads to the other.

If open replace torch leads.

This procedure should be performed only by a quali-

to other components in the torch leads.

fied electronic technician.

If shorted then replace torch leads.

4. Check the pilot and switch control wires for shorts

a. Remove the shield cup, tip, gas distributor, and

5. Carefully reassemble the torch and leads.

electrode from the torch head assembly if not already done.

b. Connect a Hi-Pot Tester capable of producing

2500VAC between the positive pilot lead and the plasma (negative) lead fittings.

c. Increase the output of the Hi-Pot Tester to a maxi-

mum of 2500VAC.

If the voltage drops to 0VAC then the insulation between the torch leads is breaking down and the leads must be replaced.

Carefully reassemble the components and recheck the completed assembly per paragraph 'A', Step 3 to confirm that the components have been properly assembled.

D. Torch Leads Replacement

1. Disconnect the torch gas, pilot control wire and torch control cable connections from the power supply.

2. Pull the defective leads from the power supply.

3. Remove the torch head assembly as described Section 5.06 Servicing Machine Head Components, or Section 5.07 Servicing Hand T orch Components.

5. Connect the replacement torch lead gas, pilot control wire and torch contr ol cable connection to the power supply.

7. Install the torch head assembly onto the replacement leads.

Manual 0-2583 31 SER VICE

SER VICE 32 Manual 0-2583

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable components. T or ch Assemblies ar e field serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows:

Section 6.03: Replacement Hand Torch Parts Section 6.04: Replacement Machine Torch Parts Section 6.05: To rch Options And Accessories Section 6.06: Complete Assembly Replacements Section 6.07: Spare Parts Kits

NOTE

Parts listed without item numbers are not shown, but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your authorized distributor . Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the parts list for each type item. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor.

Manual 0-2583 33 PARTS LISTS

6.03 Replacement Hand Torch Parts

Item # Qty Description Catalog #

1 Shield Cup Assemblies (All include item #3)

1 1 Standard Shield Cup 8-7500

1a 1 Castle Shield Cup Assembly 8-7507

1 Shield Cup Body (Includes item #3) 8-7498 1 Castle Shield Cup Heat Shield (Copper) 8-7499

1b 1 Copper Shield Cup Assembly 8-7496

1 Shield Cup Body (Includes item #3) 8-7498 1 Shield Cup Heat Shield (Copper) 8-7497

1c 1 Hi-Vis Shield Cup (Black) 8-7525

2 1 O-Ring 8-0532 3 1 Spring, Canted Coil 9-7501 4 1 Tip, Cutting, Air/N2, 0.052" Orifice, 70 Amps 8-7505

1 Tip, Cutting, Air/N2, 0.047" Orifice, 55 Amps 8-7504 1 Tip, Drag, Air/N2, 0.039" Orifice, 35 Amps 8-7503 1 Tip, Gouging, Air, 0.073" Orifice 8-7506

5 1 Distributor, Gas 8-7501

1 Distributor, Gas, Gouging 8-7508 6 1 Electrode, Air/N2 8-7502 7 1 Assembly, Torch Head (Includes items #8 - 10)

1 PCH-100XL 70° Torch Head 8-7510

1 PCH-100XL 90° Torch Head 8-7511 8 2 O-Ring 8-0533 9 1 #6-32 x 1/16 Phillips Pan Head Screw See Note

10 1 #6 Internal Star Washer See Note 11 1 Lead Assembly, Cable

Unshielded Leads, Complete

25 ft (7.6m) Length 4-0010 50 ft (15.2m) Length 4-0011

Shielded Leads For EMC Power Supplies Only, Complete

25 ft (7.6m) Length 4-0810

50 ft (15.2m) Length 4-0811 12 1 Handle 9-5636 13 1 Assembly, Tor ch Switch 9-7502 14 1 Sheath, Handle 8-1322

NOTE: Item can be purchased locally.

PARTS LISTS 34 Manual 0-2583

Shield Cup

Body

Heat Shield

(Copper)

Castle Shield

Cup Assembly

A-00948

Shield Cup

Body

Hi-Vis Shield

Heat Shield

Cup (Black)

(Copper)

Copper Shield

Cup Assembly

Manual 0-2583 35 PARTS LISTS

6.04 Replacement Machine Torch Parts

Item # Qty Description Catalog #

1 Shield Cup Assemblies (All include item #3)

1 1 Standard Shield Cup 8-7500

1a 1 Copper Shield Cup Assembly 8-7496

1 Shield Cup Body (Includes item #3) 8-7498 1 Shield Cup Heat Shield (Copper) 8-7497

1b 1 Hi-Vis Shield Cup (Black) 8-7525

2 1 O-Ring 8-0532 3 1 Spring, Canted Coil 9-7501 4 1 Tip, Cutting, Air/N2, 0.052" Orifice, 70 Amps 8-7505

1 Tip, Cutting, Air/N2, 0.047" Orifice, 55 Amps 8-7504 1 Tip, Drag, Air/N2, 0.039" Orifice, 35 Amps 8-7503 1 Tip, Gouging, Air, 0.073" Orifice 8-7506

5 1 Distributor, Gas 8-7501

1 Distributor, Gas, Gouging 8-7508 6 1 Electrode, Air/N2 8-7502 7 1 Assembly , Torch Head, PCM-100XL (Includes items #8 - 10) 8-7512 8 1 O-Ring 8-0533 9 1 #6-32 x 1/16 Phillips Pan Head Screw See Note

10 1 #6 Internal Star Washer See Note 11 1 Lead Assembly, Cable

Unshielded Leads, Complete

25 ft (7.6m) Length 4-0012 50 ft (15.2m) Length 4-0013

Shielded Leads For EMC Power Supplies Only, Complete

25 ft (7.6m) Length 4-0812

50 ft (15.2m) Length 4-0813 12 1 Tube, Positioning, 4A/5A, With Rack (includes Item #13) 8-5005 13 1 Positioning Tube End Cap (Molded) 8-4204 14 1 Nut, Retaining, Positioning Tube Adapter 8-4018 15 1 Insulating Sleeve Adapter 9-5637

1 Pinion Assembly includes: 7-2827 16 1 Torch Holder Sleeve 7-2896 17 1 Pinion Gear-Short 8-6074 18 1 Handwheel (T o r ch Holder) 9-4514 19 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515 20 1 Calibrated Torch Holder Bushing (Includes item #24) 9-4366 21 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 22 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 23 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 24 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note

NOTE: Item can be purchased locally.

PARTS LISTS 36 Manual 0-2583

Shield Cup

Body

Hi-Vis Shield

Heat Shield

Cup (Black)

(Copper)

Copper Shield Cup Assembly

Manual 0-2583 37 PARTS LISTS

A-00949

6.05 Options and Accessories

Qty Description Catalog #

1 Remote Pendant Contr ol includes: 7-3114

1 Switch Handle 8-1662

1 Switch Plate 8-1712

1 Eyebolt 1/4-20 x 1/2" Long 9-3096

1 Paddle Switch 9-4229

1 Cord Grip 9-4428

1 23/5 AWG Coil Cord 8-4246

1 Plug, 14 Pin 9-3294

1 Cable Clamp for #93294 9-3295

1 Circle Cutting Guide 7-7501

PARTS LISTS 38 Manual 0-2583

6.06 Complete Assembly Replacement

Description Catalog #

Hand Torches with Leads:

Unshielded Leads

PCH-100XL 70° Hand Torch, 25 ft (7.6 m) Leads 2-0001 PCH-100XL 70° Hand Torch, 50 ft (15.2 m) Leads 2-0002

PCH-100XL 90° Hand Torch, 25 ft (7.6 m) Leads 2-0003 PCH-100XL 90° Hand Torch, 50 ft (15.2 m) Leads 2-0004

Shielded Leads For Use With EMC Power Supplies Only

PCH-100XL 70° Hand Torch, 25 ft (7.6 m) Leads 2-0801 PCH-100XL 70° Hand Torch, 50 ft (15.2 m) Leads 2-0802

PCH-100XL 90° Hand Torch, 25 ft (7.6 m) Leads 2-0803 PCH-100XL 90° Hand Torch, 50 ft (15.2 m) Leads 2-0804

Machine Torches with Leads, Rack & Pinion Mounting Assembly:

Unshielded Leads

PCM-100XL Machine Torch, 25 ft (7.6 m) Leads 2-0005 PCM-100XL Machine Torch, 50 ft (15.2 m) Leads 2-0006

Shielded Leads For Use With EMC Power Supplies Only

PCM-100XL Machine Torch, 25 ft (7.6 m) Leads 2-0805 PCM-100XL Machine Torch, 50 ft (15.2 m) Leads 2-0806

Manual 0-2583 39 PARTS LISTS

6.07 Spare Parts Kits

Qty Description Catalog #

1 Cutting, Air, Spare Parts Kit Includes: 5-0001 1 Lubricant 8-4025 1 Box, Utility 8-3141 1 Nut Driver, 7/32" 8-4220 3 Electrode, Air/N2 8-7502 5 Cutting Tip, Air/N2, 0.052" Orifice, 70 Amp 8-7505 2 Tip, Drag, Air/N2, 0.039" Orifice, 35 Amps 8-7503 1 Canted Coil Spring 9-7501 1 O-Ring 8-0532

PARTS LISTS 40 Manual 0-2583

APPENDIX I: CUTTING SPEED CHARTS

Ai r Plasm a Cu t t i ng Speed Dat a Ch art Type To rch: PCH/M-100XL Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasm a Gas Press Flow (SCFH ) Pierce Pierce Height

Inches

1/16 1.59 8-7505 100 70 350 8.89 0.19 4.76 70 4.8 84 360 0 0.20 5.08 1/8 3.18 8-7505 105 70 140 3.56 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 1/4 6.35 8-7505 105 70 70 1.78 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 3/8 9.53 8-7505 105 70 40 1.02 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 1/2 12.70 8-7505 110 70 28 0.71 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 3/4 19.05 8-7505 120 70 8 0.20 0.19 4.76 70 4.8 84 360 NA NA NA

1 25.40 8-7505 120 70 5 0.13 0.19 4.76 70 4.8 84 360 NA NA NA

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm PSI BAR Plasm a Total Delay (Sec) Inches mm

Ai r Plasm a Cu t t i ng Speed Dat a Ch art Type To rch: PCH/M-100XL Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasm a Gas Press Flow (SCFH ) Pierce Pierce Height

Inches

1/8 3.18 8-7505 105 70 175 4.45 0.19 4.76 70 4.8 84 360 0 0.20 5.08 1/4 6.35 8-7505 105 70 100 2.54 0.19 4.76 70 4.8 84 360 0 0.20 5.08 3/8 9.53 8-7505 110 70 50 1.27 0.19 4.76 70 4.8 84 360 0 0.20 5.08 1/2 12.70 8-7505 120 70 25 0.64 0.19 4.76 70 4.8 84 360 NA NA NA 3/4 19.05 8-7505 125 70 5 0.13 0.19 4.76 70 4.8 84 360 NA NA NA

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm PSI BAR Plasm a Total Delay (Sec) Inches mm

Ai r Plasm a Cu t t i ng Speed Dat a Ch art Type To rch: PCH/M-100XL Type Materi al : Stainl ess Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasm a Gas Press Flow (SCFH ) Pierce Pierce Height

Inches

1/8 3.18 8-7505 105 70 80 2.03 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 1/4 6.35 8-7505 105 70 60 1.52 0.19 4.76 70 4.8 84 360 0.1 0.20 5.08 3/8 9.53 8-7505 105 70 28 0.71 0.19 4.76 70 4.8 84 360 0.2 0.20 5.08 1/2 12.70 8-7505 110 70 15 0.38 0.19 4.76 70 4.8 84 360 NA NA NA 3/4 19.05 8-7505 125 70 8 0.20 0.19 4.76 70 4.8 84 360 NA NA NA

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm PSI BAR Plasm a Total Delay (Sec) Inches mm

Manual 0-2583 41 APPENDIX

APPENDIX II: TYPICAL SYSTEM SEQUENCE OF

OPERATION BLOCK DIAGRAM

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

gas flows to set pressure.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed.)

post-flow, pilot arc will immediately restart.

If torch is within transfer distance (3/8 in) of

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (15 seconds)

NOTE - If torch is activated during

workpiece, main arc will transfer.

After post-flow:

GAS indicator off.

APPENDIX 42 Manual 0-2583

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-000926

Thermal Dynamics PCH-100XL, PCM-100XL Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual