Page 1
PLASMA ARC
CUTTING SYSTEM
SIGNATURE® PAK® 1250XR
TM
• PAK 1250 XR POWER SUPPLY
• PCH/M-52 T ORCH WITH WITH LEADS
• WORK CABLE WITH CLAMP
• TORCH SPARE PARTS KIT
• RUNNING GEAR WITH HANDLE
• AIR LINE FILTER AND REGULATOR
April 4, 2001 Manual No. 0-2377
Page 2
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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 Arc Cutting System Signature® PAK® 1250XR
TM
Operating Manual Number 0-2377
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1993 by
Thermal Dynamics Corporation
All rights reserved.
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: April 4, 2001
Record the following information for W arranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
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Contents
GENERAL INFORMATION.............................................................................................................i
Notes, Cautions and W arnings..................................................................................i
Important Safety Precautions ....................................................................................i
Publica tions..............................................................................................................ii
Note, Attention et Av ertissement ............................................................................. iii
Precautions De Securite Importantes...................................................................... iii
Documents De Reference ....................................................................................... v
Declaration of Conformity....................................................................................... vii
Statement of W arranty........................................................................................... viii
SECTION 1: SYSTEM DESCRIPTION........................................................................................ 1
1.1 GENERAL DESCRIPTION............................................................................... 1
1.2 POWER SUPPLY SPECIFICATIONS............................................................... 2
1.3 TORCH SPECIFICA TIONS .............................................................................. 3
1.4 SYSTEM ACCESSORIES................................................................................ 4
1.5 THEORY OF OPERATION ............................................................................... 4
SECTION 2: UNIT ASSEMBLY.................................................................................................... 7
2.1 UNPACKING THE SYSTEM............................................................................. 7
2.2 EQUIPMENT ASSEMBLY ................................................................................ 7
2.3 INSTALLA TION............................................................................................... 10
2.4 LIFTING THE PO WER SUPPLY..................................................................... 14
SECTION 3: OPERATION ......................................................................................................... 1 5
3.1 OPERATING CONTROLS.............................................................................. 15
3.2 PRE-OPERATION SET-UP ............................................................................ 16
3.3 CUTTING OPERATION.................................................................................. 17
3.4 GOUGING OPERATION ................................................................................ 21
3.5 GENERAL OPERATING NOTES ................................................................... 23
3.7 CUTTING SPEEDS........................................................................................ 24
3.8 SEQUENCE OF OPERATION........................................................................ 26
SECTION 4: MAINTENANCE.................................................................................................... 27
4.1 TORCH MAINTENANCE ................................................................................ 27
4.2 TORCH LEADS REPLACEMENT .................................................................. 28
4.3 POWER SUPPLY MAINTENANCE ................................................................ 30
4.4 TR OUBLESHOOTING GUIDE ....................................................................... 31
4.5 TEST PR OCEDURES.................................................................................... 35
SECTION 5: PARTS LISTS........................................................................................................ 37
5.1 SYSTEM COMPONENTS & ACCESSORIES ................................................ 38
5.2 FRONT PANEL COMPONENTS .................................................................... 40
5.3 REAR PANEL COMPONENTS ...................................................................... 41
5.4 BASE COMPONENTS ................................................................................... 42
5.5 UPPER EQUIPMENT PANEL COMPONENTS .............................................. 44
5.6 BULKHEAD COMPONENTS ......................................................................... 46
5.7 TORCH COMPONENTS ................................................................................ 47
5.8 TORCH ACCESSORIES ................................................................................ 48
5.9 TROUBLESHOOTING DIAGRAM ................................................................... 50
5.10 CNC INTERF A CE SCHEMATIC .................................................................... 51
5.11 SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 1).................... 52
SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 2)............................ 54
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GENERAL INFORMATION
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 procedure which, if not properly followed, may
cause damage to the equipment.
W ARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
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 1-603298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. Y ou 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 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: Ma y 1, 2000 (SPECIAL) i GENERAL INFORMATION
Page 6
• 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 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. T rapped hydrogen gas that is ignited will
cause an explosion.
NOISE
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly 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 protect 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.
Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
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.
• T o protect your hearing from loud noise, wear pr otective 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 Publications in this manual.
GENERAL INFORMATION ii Date: Ma y 1, 2000 (SPECIAL)
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 A TION AND EDUCATIONAL 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 from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
Page 7
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. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS 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 Standard 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 Standard 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 Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Note, Attention et Avertissement
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
A VERTISSEMENT
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.
Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au 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 + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
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: Ma y 1, 2000 (SPECIAL) iii GENERAL INFORMATION
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.
Page 8
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des 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.
• 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.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• 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. (Voir l'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.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’ état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’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.
• 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.
GENERAL INFORMATION iv Date: Ma y 1, 2000 (SPECIAL)
• 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.
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.
Page 9
• 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.
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. V ous dú4ez vous pr otéger 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 v.
Documents De Reference
1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL 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 TRAV AIL 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
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 A YANT 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, Batterymar ch Park,
Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
Date: Ma y 1, 2000 (SPECIAL) v GENERAL INFORMATION
10. Norme 51B de la NFP A, LES PROCÉDÉS DE COUPE
ET DE SOUDAGE, disponible auprès de la National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
Page 10
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 PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION vi Date: Ma y 1, 2000 (SPECIAL)
Page 11
Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds 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 product is safe, when used accor ding 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: Ma y 1, 2000 (SPECIAL) vii GENERAL INFORMATION
Page 12
Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry prac tice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PA R 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 belo w).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Y ear
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 To rch 1 Year 1 Year
PCH/M-62 & PCH/M-102 To rches 1 Year 1 Year
All Other To rches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 1, 2000
GENERAL INFORMATION viii Date: Ma y 1, 2000 (SPECIAL)
Page 13
SECTION 1: SYSTEM DESCRIPTION
1.1 GENERAL DESCRIPTION
R
Signature PAK 1250 XR
Power Supply
R
A-01451
Figure 1-A The Signature PAK 1250 XR Plasma Arc Cutting/Gouging System
Spare Parts Kit
PCH/M-52
Work Cable
and Clamp
Torch with Leads
The complete Signature PAK 1250 XR System includes:
• Signature PAK 1250 XR Power Supply
• PCH-52 Hand Torch (or) PCM-52 Machine Torch
• 25 ft (7.6 m) or 50 ft (15.2 m) Torch Leads
• PCH/M-52 Spare Parts Kit
• 25 ft (7.6 m) Work Cable and Clamp
• Running Gear and Handle
• Air Line Filter and Regulator Assembly
(or) High Pressure Gas Regulators
1
GENERAL INFORMATION
Page 14
1.2 POWER SUPPLY SPECIFICATIONS
Power Input
Output
Weight
The PAK 1250 XR is available in the following volt-amp
combinations:
Voltage Frequency Phase Amperage
200/220 60 Hz 3 74/68
200/220 50 Hz 3 74/68
200/220 50/60 Hz * 3 74/68
380/415 50 Hz 3 40/37
460 60 Hz 3 33
380/500 50 Hz 3 40/30
575 60 Hz 3 26
* 200V at 50 Hz, 220V at 60 Hz
Table 2-A (page 13) contains information on power input,
current ratings, circuit protection, and wire sizes.
Range I- 35 amps
Range II- 70 amps
Range III- 105 amps
Duty Cycle - 80%
Approximate Shipping Weight - 275 lbs. (125 kg)
22.5 in
(0.57 m)
R
27.0 in
(0.69 m)
A-01452
18.0 in
(0.46 m)
Figure 1-B Power Supply Dimensions
GENERAL INFORMATION
2
Page 15
1.3 TORCH SPECIFICATIONS
Torch Configurations
Torch Leads Lengths
Current Rating
Weight
Cutting Range
Gas Requirements
PCH-52 70° or 90° Hand Torch
PCM-52 180° Machine Torch
Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m).
Extendable in increments of 25 ft or 50 ft up to maximum
100 ft (30.4 m) with leads extension package (see Torch
Accessories, page 4)
105 Amps Maximum, Direct Current Straight Polarity
Hand and Machine Torch rated at 80% Duty Cycle
PCH-52 Hand Torch (no Leads) - Approx. 1.0 lb. (.45 kg)
Most materials up to 1.25 in (32 mm)
Pressure Hot Flow
Plasma Gas
Compressed Air, 40 psi For Cutting:
Argon/Hydrogen (2.8 bar) 22-28 SCFH
or Nitrogen (10.4-13.2 lpm)
For Gouging:
22-43 SCFH
(10.4-20.3 lpm)
Secondary Gas
Compressed Air 75 psi Cutting or Gouging
Nitrogen, or (5.2 bar) 470 SCFH
Carbon Dioxide (221 lpm)
PCH-52 70° Hand Torch
C
B
A
A - 9.38 in (238 mm)
B - 1.38 in (35 mm)
C - 3.00 in (76 mm)
PCH-52 90° Hand Torch
A - 8.78 in (223 mm)
C
B
A
B - 1.38 in (35 mm)
C - 2.87 in (73 mm)
PCM-52 180° Machine Torch
B
D
A -16.56 in (421 mm)
B - 1.38 in (35 mm)
C - 6.06 in (154 mm) Min.
C
A
A-01472
13.93 in (354 mm) Max.
D - 1.38 in (35 mm)
Figure 1-C Torch Dimensions
3
GENERAL INFORMATION
Page 16
1.4 SYSTEM ACCESSORIES
Power Supply Accessories
Torch Accessories
SC2/XR Standoff Control - For machine mounted torches,
the SC2/XR automatically maintains torch standoff by
controlling a customer-supplied torch lifter motor.
Cylinder Rack Running Gear - For transporting up to two
full-sized gas cylinders along with the system.
Computer Control Cable Kit - For interfacing the power
supply with a computer or auxiliary control device.
High Pressure Gas Regulators - Available for air, argon/
hydrogen, nitrogen, and CO2.
Service Parts Kit - Provides spare power supply parts for
service activities in remote areas.
Front Mount Regulator Kit - Allows convenient access to
air line regulators from front of unit.
See page 38 for ordering information.
Air/Multi-Gas Gouging Parts Kit - Everything needed to
add gouging capabilities to the cutting system.
Remote Pendant Control - For remote control operation of
machine torch systems.
Circle Cutter Attachment - Manual torch guide extends for
cuts from 2.25 in (57 mm) to 24 in (610 mm) in diameter.
Also available: 12 in (305 mm) extension rod
Leads Extension Packages - Available in 25 ft (7.6 m) or
50 ft (15.2 m) lengths. For extending leads up to a
maximum of 100 ft (30.5 m).
See page 37 for ordering information.
1.5 THEORY OF OPERATION
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 processes use this plasma to transfer an electric 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 severance of the
material, plasma arc gouging is used to remove metals to a
controlled depth and width.
In a plasma cutting torch, a cool gas such as air or nitrogen
(N2) enters Zone B (Figure 1-D), where a pilot arc between
the electrode and the 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.
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 1-D). Direct current (DC) straight polarity
is used for plasma cutting, as shown in the illustration.
4GENERAL INFORMATION
Page 17
1.5 THEORY OF OPERATION (continued)
,
Plasma Gas Flow
(continued)
Gas Distribution
Pilot Arc
The cutting torch also uses a secondary gas (Zone A,
Figure 1-D) which assists the high velocity plasma gas in
blowing the molten metal out of the cut and allowing a
fast, slag-free cut. The secondary gas also cools the torch.
Compressed air, supplied by either a cylinder or plant air
system, or CO2 is normally used as the secondary gas.
The plasma gas flows into the torch through the positive
lead, around the electrode, and out through the tip orifice.
The secondary gas flows into the torch through the negative lead, down around the outside of the torch liner, and
out between the tip and shield cup around the plasma arc.
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.
_
Power
Supply
+
A
High Frequency
Main Cutting Arc
Interlocks
B
Workpiece
C
A-00002
Figure 1-D Theory of Operation
Because DC current alone is not sufficient to initiate and
maintain the pilot arc, high frequency is superimposed on
the direct current.
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 contactor and resistor.
Two pressure switches (PS1 and PS2) act as an interlock
for the gas supply. If supply pressure falls below minimum requirements the pressure switches will open,
shutting off the power to the contactors, and the GAS
indicator will go out. When adequate supply pressure is
available the pressure switches close, allowing power to be
resumed for cutting.
5
GENERAL INFORMATION
Page 18
1.5 THEORY OF OPERATION (continued)
Thermal Protection
Thermal overload switches are located in the coils of the
main transformers in the power supply. If one of these
components is overheated the appropriate switch will
open, causing the temperature light to go out and shutting
off power to the main contactor. When the overheated
component cools down the switch will close again and
allow operation of the system.
Figure 1-E System Block Diagram
GENERAL INFORMATION
6
Page 19
SECTION 2: UNIT ASSEMBLY
2.1 UNPACKING THE SYSTEM
The power supply is skid-mounted and protected with a
carton and padding material to prevent damage during
shipment. The two front casters are factory-installed on
the unit. The power supply, running gear, work cable,
torch, torch leads, and spare parts kit are packed together.
1. Remove packing material.
2. Locate the packing list. 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 before
proceeding with system installation.
2.2 EQUIPMENT ASSEMBLY
Standard running gear includes rear wheels with mounting hardware, factory-installed front casters, and handle.
The optional cylinder rack running gear (see page 8) is
designed for mounting and transporting two gas cylinders
with the system.
Standard Running Gear
Assembly
Refer to Figure 2-A and:
1. Remove all packing material. Install the running gear
with the unit still on the skid.
2. Locate the two rear wheels, axle, handle, and mounting
accessories.
3. Feed the axle through the large hole on each side of the
base as shown.
4. Slip a flat washer onto the axle, then a wheel, followed
by another flat washer. Locate these parts behind the
groove in the axle.
5. Press the retaining ring into the groove to secure the
wheel assembly.
6. Follow the same procedure for the other wheel.
(continued)
Figure 2-A Standard Running Gear Assembly
7
INSTALLATION
Page 20
2.2 EQUIPMENT ASSEMBLY (continued)
Standard Running Gear
Assembly (continued)
7. Mount the handle on the rear panel of the power supply
(see Figure 2-B).
Cylinder Rack Running
Gear Assembly
INSTALLATION
Figure 2-B Handle Assembly
Refer to Figure 2-C and:
1. Remove all packing material.
2. Remove the unit from the shipping skid and set it
onto a platform to install the cylinder rack.
3. Attach the base extensions to the base of the unit.
4. Attach the cylinder tray to the base extensions.
5. Feed the axle through the large holes in the cylinder
tray and base extensions beneath the rear of the unit.
6. Slip a flat washer onto the axle, then a wheel, followed by another flat washer. Locate these parts
behind the groove in the axle.
8
Page 21
2.2 EQUIPMENT ASSEMBLY (continued)
Cylinder Rack Running
Gear Assembly
(continued)
7. Press the retaining ring into the groove in the axle to
secure the wheel assembly.
8. Follow the same procedure to install the second wheel
assembly.
9. Mount the cylinder support bracket to the back of the
power supply as shown.
10. Attach the handle to the front of the unit as shown.
Figure 2-C Cylinder Rack Assembly
9
INSTALLATION
Page 22
2.3 INSTALLATION
The power supply is shipped with the torch and torch
leads, control cable, and work cable connected. The
following steps are required to complete installation.
Location
CAUTION
Gas Supply Requirements
Air Line Filter and
Regulator Installation
Select a clean, dry location with good ventilation and
adequate working space.
Air flow under the base and out the rear must not be
obstructed. Operation with the base in direct contact with
the floor will inhibit proper cooling air flow and reduce
duty cycle.
Review PRECAUTIONS (General Information Section) to
be sure that the selected location meets all safety requirements.
Plasma Gas:
Compressed Air, Argon/Hydrogen, (recommended
mixture - 65% Argon, 35% Hydrogen), or Nitrogen
Pressure - 40 psi (2.8 bar)
Flow - 22 - 28 SCFH (Standard Cubic Feet/Hour)
(10.4 - 13.2 lpm) For Cutting
22 - 43 SCFH (10.4 - 20.3 lpm) For Gouging
Secondary Gas:
Compressed Air, Nitrogen, or Carbon Dioxide (CO2)
Pressure - 75 psi (5.2 bar)
Flow - 470 SCFH (221 lpm) For Cutting or Gouging
Systems that are set up for shop air operation include the
following parts for air line connections:
(2) Air Line Regulators with Brackets
(1) Air Line Filter Assembly (For Plasma Line)
(2) Hex Nipples
(1) 90° Female Elbow
(1) 90° Street Elbow
(1) Y-Hose Assembly
Refer to Figure 2-D and:
1. Thread the first hex nipple into the 90° female elbow.
2. Thread the other end of the hex nipple into the outlet
of the air filter assembly. Tighten both sides securely.
3. Thread the second hex nipple into the inlet of the
plasma air line regulator.
4. Thread the 90° street elbow into the inlet side of the
air filter assembly.
5. Connect one side of the Y-hose assembly into the
other side of the 90° street elbow.
6. Thread the 90° female elbow onto the other end of the
second hex nipple. Fasten both sides securely.
7. Install the plasma air line regulator and bracket
assembly on the rear panel (plasma side).
8. Connect the other side of the Y-hose assembly to the
secondary air line regulator.
INSTALLATION
10
Page 23
2.3 INSTALLATION (continued)
Air Line Filter and
Regulator Installation
(continued)
High Pressure Regulator
Installation
9. Install the secondary air line regulator and bracket
assembly on the rear panel (secondary side).
10. Connect the Y-hose assembly to the supply air line
from the source. The supply hose from the source to
the Y-hose must be 3/8 in (10 mm) minimum inside
diameter to provide adequate air flow.
Multi-gas systems require high pressure gas regulators on
the gas cylinders.
1. Install regulators on the cylinders (see manufacturer's
specifications for recommended procedures).
2. Connect the input gas hoses from regulator output
fittings to the input fittings on the rear panel of the
power supply.
Figure 2-D Air Line Filter and Regulator Installation
11 INSTALLATION
Page 24
2.3 INSTALLATION (continued)
Input Power Connections
CAUTION
1. Units with 200/220V transformers are factory-wired for
220V input. If actual input power to the unit is less than
210V it is recommended that the unit be rewired to the
low voltage taps on the transformers. 380/415V units
are factory-wired for 415V input and should similarly
be rewired if input voltage falls below 390V.
Figure 2-E Contactor Connections
Disconnect primary power to the system before starting
the low-voltage change-over procedure.
Low Voltage
Change-over
Procedure
WARNING
CAUTION
a. Remove side panels from power supply.
b. Locate the three unused low voltage taps (labeled
105L, 106L and 107L) on the main transformers T1,
T2, and T3. The low voltage leads are color-coded
yellow.
c. Remove the tie wraps securing the insulated sleeving
on the low voltage taps.
d. Remove the high voltage transformer taps (color-
coded red) from contactors W1, W2, and W3.
The unused transformer taps must be properly insulated
to prevent possible shock to the operator or damage to
the equipment.
e. Use tie wraps to securely enclose the unused high
voltage taps in the insulated sleeving from the low
voltage taps. Secure the high voltage taps onto the
transformer where the low voltage taps were originally placed.
f. Install the low voltage taps in the contactors as
shown in Figure 2-E.
g. Reinstall side panels.
To avoid damage to the unit, always make sure all three
contactors are rewired at the same time.
INSTALLATION
12
Page 25
2.3 INSTALLATION (continued)
Input Power Supply
(continued)
Work Cable Connection
2. Connect the power cable to the appropriate three-phase
power source. Input power cable connections to the
contactors are shown in Figure 2-F.
3. Check that power source meets fuse and wiring requirements (see Table 2-A below).
4. Connect the work cable securely to the workpiece. Also
be sure the workpiece is connected to a good electrical
ground.
5. Before operating the system, check the torch for proper
assembly (see page 27).
Voltage Power Input Current* Frequency Phase Recommended
(Volts) (kVA) (Amps) (Hz) Fuse Size Wire Size
200 26 74 50 or 60 3 90 amps AWG 6
220 26 68 50 or 60 3 90 amps AWG 6
380 26 40 50 3 50 amps AWG 8
415 26 37 50 3 45 amps AWG 8
460 26 33 60 3 40 amps AWG 8
500 26 30 50 3 40 amps AWG 8
575 26 26 60 3 35 amps AWG 10
Table 2-A Line Voltages, Circuit Protection and Recommended Wire Size
(Based on Table 310-16, 1981 National Electric Code).
Figure 2-F Input Power Connections
13
INSTALLATION
Page 26
2.4 LIFTING THE POWER SUPPLY
WARNING
CAUTION
Do not lift the power supply by the handle.
Do not lift a power supply equipped with a cylinder rack
running gear.
The recommended method for lifting the power supply is
to use a forklift (see Figure 2-G). Approach from either
side of the unit. Lifting from the front or rear may damage
protruding fittings. Place the forks between the rear wheel
and the front caster. Center the forks under the unit and
carefully check for proper balance.
Figure 2-G Lifting the Power Supply
INSTALLATION
14
Page 27
SECTION 3: OPERATION
3.1 OPERATING CONTROLS
34
1
8
56 7
Figure 3-A PAK 1250 XR Operating Controls
Control Indicator Function
2
A-01461
1. ON/OFF Switch (SW1)
2. RUN/SET Switch (SW2)
3. AC Power Indicator
4. Temperature Indicator
5. Gas Indicator
6. DC Power Indicator
7. High Frequency Indicator
8. Range Control Switch
(SW3)
Move up to ON position to activate the control circuits. All
control circuits are deactivated in OFF position.
Move up to RUN position for torch operation. Move
down to SET position for purging gas lines and setting gas
pressures with external regulator.
Red light indicates AC power is being supplied to the
system when the ON/OFF switch is in ON position.
Red light indicates operating temperature is okay. Light
goes out when an internal thermal overload switch opens,
indicating power supply is overheated. Allow to cool.
In SET position red light indicates gas pressure switch is
satisfied. Light goes out in RUN mode and comes on only
when gas is flowing to the torch.
Red light indicates main contactor closure supplying
current to the main bridge rectifier, and that cutting
current is available. Torch switch must be closed.
Red light indicates high frequency is being supplied to
initiate pilot arc. Light goes out when cutting arc is established and comes back on if cutting arc is interrupted, as
when cutting expanded metal.
Selects current range (see Cutting Speeds, page 24-25 for
applications on various materials and thicknesses).
15
OPERATION
Page 28
3.2 PRE-OPERATION SET-UP
The pre-operation set-up procedure should be followed at
the beginning of each shift:
WARNING
Shield Cup Selection
Tip Selection
(Air or Multi-Gas)
Electrode Selection
CAUTION
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
1. Check the torch for proper assembly (see page 27).
Make sure the proper torch parts are installed:
Standard Shield Cup (Ceramic) .......................... 9-5617
Standard Shield Cup (Phenolic) ......................... 9-5781
Castle (Crown) Shield Cup.................................. 9-5694
Drag Cup ................................................................ 9-5712
Gouging Cup ......................................................... 8-5128
Standoff Attachment (Use with 9-5781) ............ 9-5799
Standoff Attachment, Short (Use with 9-5781) . 9-5780
Heat Shield (For Gouging)................................... 8-5130
Cutting, Range I ................035 Orifice................ 9-5702
Cutting, Range II ...............047 Orifice................ 9-5707
Cutting, Range III..............059 Orifice................ 9-5708
Gouging, All Ranges........ .082 Orifice................ 8-5129
Air Operation (Cutting or Gouging) .................. 9-5619
Multi-Gas (Cutting or Gouging) ......................... 9-5711
Air electrodes are for use with air only. Do not use air
electrodes for multi-gas (nitrogen or argon/hydrogen)
operation. Multi-gas electrodes can be identified by the
ring around the diameter.
OPERATION
2. Connect primary power to the system (close main
disconnect switch or plug unit in).
3. Turn gas supply on.
4. Move the ON/OFF switch to ON position (if the RUN/
SET switch is in SET position, gas will flow).
5. Set the current range (see Cutting Speeds, pages 24-25).
6. Move the RUN/SET switch to SET position. Set plasma
and secondary gas pressures.
7. Purge for approximately three minutes by letting air
run. This will remove any condensation of moisture
that may have accumulated in the torch while the
system was shut down.
8. Return the RUN/SET switch to RUN position.
The system is now ready for operation.
16
Page 29
3.3 CUTTING OPERATION
WARNING
Be sure the operator is equipped with proper gloves,
clothing, eye and ear protection and that all 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 switch is pressed.
CAUTION
Plasma Cutting Operation
(Hand Torch)
WARNING
Cutting with a Hand Torch
The sparks from the cutting process can cause damage to
coated, painted or other surfaces such as glass, plastic, and
metal.
Check torch parts. The torch tip must correspond with
cutting operation and selected current range. The torch
electrode must correspond with cutting mode (air or
multi-gas). See Tip and Electrode Selection, page 16.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
1. The hand torch should be held in both hands for making long cuts. Choose the method that feels the most
comfortable and works the best. Use the thumb to
actuate the control switch on the torch handle.
2. To positively locate the line of the cut, position the torch
over the workpiece, resting the front edge of the shield
cup on the edge where the cut is to start.
3. Lower the welding helmet. Press and hold the torch
control switch. After a two second gas purge, the pilot
arc will start. The pilot arc will stay on as long as the
torch control switch is held.
(continued)
Figure 3-C Hand Cutting Operation
17
OPERATION
Page 30
3.3 CUTTING OPERATION (continued)
Hand Torch Operation
(continued)
NORMAL/DELAYED
RESTART Switch (SW1)
NOTE
4. With the pilot arc on the main cutting arc is established
as soon as the torch tip is brought within 1/8 - 3/8 in
(3 - 10 mm) of the workpiece.
The NORMAL/DELAYED RESTART switch (SW1) is
located on the control logic PC board (refer to Figure 5-5,
page 45). The switch is factory set to NORMAL (open)
position. If the cutting arc is interrupted and the torch
switch is still pressed (as when cutting expanded metal)
the pilot arc will automatically restart. If the switch is set
to DELAYED (closed) position, there is always a two
second pre-flow delay before restarting.
Releasing the torch control switch will shut off either the
pilot or main arc (depending on mode of operation).
5. Cut with the torch tip 1/8 - 3/8 in (3 - 10 mm) from the
work. The torch should be held perpendicular to the
workpiece while cutting.
Rack and
Pinion Mounting
Assembly
Square
OPERATION
A-00175
Workpiece
Figure 3-D Machine Torch Set-up
18
Page 31
3.3 CUTTING OPERATION (continued)
Cutting with a
Machine Torch
(continued)
When using a machine torch, the torch should be aligned
perpendicular to the workpiece to obtain a clean, vertical
cut. Use a square to align the torch (see Figure 3-D).
The torch can be activated by remote control pendant or by
remote interface device. Start cutting slowly and increase
the speed to obtain the desired cut quality. Figures 3-H
and 3-I (page 24-25) contain typical cutting speeds for
various materials and material thicknesses.
To start a cut at the plate edge, line up the center of the
torch along the edge of the plate and press the control
switch. The transferred cutting arc will then be established
at the plate edge. Adjust cutting speed for optimum
cutting performance.
The arc characteristics vary with gases used, cutting speed,
material, and thickness. Air plasma normally produces a 5°
leading arc (on mild steel) or a straight arc (on stainless or
aluminum), while nitrogen plasma generally creates a 5°
trailing arc (see Figure 3-E).
T orch Travel
Five Degree
A-01475
Trailing Arc
Figure 3-E Machine Torch Operation
19
OPERATION
Page 32
3.3 CUTTING OPERATION (continued)
Piercing Technique
Piercing with a Hand Torch
Piercing with a Machine Torch
In some cutting operations, it may be desirable to start the
cut within the plate area rather than at the plate edge.
Piercing the plate is not recommended on plates having a
thickness greater than 1/2 in (13 mm). Blowback from the
piercing operation can shorten the life of torch parts. All
piercing should therefore be done as quickly as possible
and at maximum amperage (105 amps).
When piercing with a hand torch, tip the torch slightly so
that blowback particles blow away from the torch tip (and
operator) rather than directly back into it (see Figure 3-F).
Pierce off the cutting line and then continue the cut as
shown in Figure 3-F. 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.
A method called “running start” is recommended when
piercing with a machine mounted torch. The torch should
be positioned far enough off the cutting line to allow the
pierce to be complete before the cutting line is reached.
This allowance depends on the thickness of the material
and the torch travel speed.
Figure 3-F Piercing with a Hand Torch
OPERATION
20
Page 33
3.4 GOUGING OPERATION
WARNING
Be sure the operator is equipped with proper gloves,
clothing, eye and ear protection and that all 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 switch is pressed.
CAUTION
Plasma Gouging Operation
WARNING
Gouging Parameters
Torch Travel Speed
Current Setting
The sparks from the gouging process can cause damage to
coated, painted or other surfaces such as glass, plastic, and
metal.
Check torch parts. The torch tip must be appropriate for
gouging operation. The torch electrode must correspond
with the plasma gas being used (air or multi-gas). See Tip
and Electrode Selection, page 16.
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Gouging performance depends on the torch travel speed,
the current level, the angle at which the torch is held to the
workpiece (lead angle), and the distance between the torch
tip and the workpiece (standoff). Gouging can be accomplished with either a hand or machine torch.
Optimum torch travel speed for gouging is between 20
and 120 inches per minute (0.5 and 3.0 meters per minute).
Travel speed is dependent on current setting, lead angle,
and mode of operation (hand or machine torch).
Current settings depend on torch travel speed, the mode
of operation (hand or machine torch), and the amount of
material to be removed.
Figure 3-G Gouging with a Hand Torch
21
OPERATION
Page 34
3.4 GOUGING OPERATION (continued)
Lead Angle
Standoff Distance
Slag Build-up
The angle at which the torch is held depends on the
current setting and the torch travel speed. At 35 amps,
(Range I), the recommended lead angle is 35°. At 105
amps (Range III), the recommended lead angle increases to
45°. An angle greater than 45° may result in inconsistent
metal removal. 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.
The tip to work distance affects gouge quality and depth.
A standoff of 1/8 - 1/4 in (3 - 6 mm) allows smooth,
consistent material removal. A smaller standoff may
result in a severance cut rather than a gouge. A standoff
greater than 1/4 in (6 mm) may result in minimal metal
removal or loss of transferred main arc.
Slag generated by gouging on materials such as carbon
and stainless steels, nickels, and alloyed steels, can be
removed easily in most cases. There is little, if any, slag
produced when gouging aluminum, as the material is
vaporized. 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.
Plasma Gas Ar/H2 Ar/H2 Nitrogen Nitrogen Air
Secondary Gas Nitrogen Air Air CO2 Air
Carbon Steel Good Good Good Good Excellent
Stainless Steel Excellent Good Good Good Fair
Aluminum Excellent Good Fair Good Fair
Table 3-A Recommended Gases for Plasma Arc Gouging
OPERATION
22
Page 35
3.5 GENERAL OPERATING NOTES
The suggestions below should be followed in all cutting
and gouging operations:
1. Wait five minutes before opening the main disconnect
switch after shutdown. This allows the cooling fan to
run to dissipate operating heat from the unit.
2. For maximum parts life, do not operate the pilot arc any
longer than necessary.
3. Use care in handling torch leads and protect them from
damage.
4. In continuous cutting applications using CO2, it is often
necessary to manifold four to six cylinders together to
maintain flow at 75 psi (5.2 bar).
NOTE
FREQUENTLY REVIEW THE SAFETY PRECAUTIONS
AT THE FRONT OF THIS MANUAL.
It is not enough to simply move the ON/OFF switch on
WARNING
the unit to OFF p osition when cutting operations have
been completed. Always open the power supply disconnect switch five minutes after the last cut is made.
3.6 COMMON OPERATING PROBLEMS
Listed below are common cutting problems followed by
probable causes of each. If the problems are caused by a
power supply problem, refer to the Troubleshooting
Guide, page 31).
Insufficient Penetration
Main Arc Extinguishes
a. Cutting speed too high
b. Current too low
c. Metal too thick
d. Worn or damaged torch parts
a. Cutting speed too low
b. Standoff too high
Dross Formation
Burned-Out Tips
a. Improper gas pressure
b. Improper cutting speed
(See Figure 3-H and 3-I, pages 24 - 25)
c. Worn or damaged torch parts.
a. High cutting current
b. Damaged or loose cutting tip
c. Tip in contact with work
d. Heavy spatter
e. Low plasma gas pressure
23
OPERATION
Page 36
3.7 CUTTING SPEEDS
(mm) (gage) (in)
25
15
10
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
25
15
10
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
1.00
20
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
(mm) (gage) (in)
1.00
20
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
When hand cutting, cutting speeds primarily depend on
the material being cut, the thickness, and how fast the
operator can comfortably and accurately follow the line.
The following charts show optimum cutting speed ranges
for most materials using a machine torch with air plasma/
air secondary and nitrogen plasma/CO2 secondary. The
data was obtained using 1/8 in (3 mm) standoff.
AIR/AIR ON MILD STEEL
Range III
Range II
Range I
CUTTING SPEED
AIR/AIR ON ALUMINUM
Range III
Range II
Range I
CUTTING SPEED
(mm) (gage) (in)
25
15
10
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
1.00
20
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
Figure 3-H PAK 1250 XR Cutting Speeds - Air Operation
OPERATION
AIR/AIR ON STAINLESS
Range III
Range II
Range I
CUTTING SPEED
24
A-01478
Page 37
3.7 CUTTING SPEEDS (continued)
This information represents realistic expectations using
recommended practices and well maintained systems.
Actual speeds may vary up to 50% from those shown.
Factors such as parts wear, air quality, line voltage fluctuations, operator experience, standoff variation and quality
of ground may impact system performance.
(mm) (gage) (in)
25
20
15
10
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
25
15
10
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
15
MATERIAL THICKNESS
Inches per Minute 50 100 150 200 250 300 350 400
Meters per Minute 1.27 2.54 3.81 5.08 6.35 7.62 8.89 10.16
1.00
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
(mm) (gage) (in)
1.00
20
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
(mm) (gage) (in)
25
20
10
1.00
0.75
0.50
0.25
4
5
8
0.125
12
0.62
16
N2 / CO2 ON MILD STEEL
Range III
Range II
Range I
CUTTING SPEED
N2 / CO2 ON ALUMINUM
Range III
Range II
Range I
CUTTING SPEED
N2 / CO2 ON STAINLESS
Range III
Range II
Range I
CUTTING SPEED
A-01479
Figure 3-I PAK 1250 XR Cutting Speeds - Multi-Gas Operation
25
OPERATION
Page 38
3.8 SEQUENCE OF OPERATION
OPERATION
Figure 3-J Sequence of Operation
26
Page 39
SECTION 4: MAINTENANCE
4.1 TORCH MAINTENANCE
WARNING
Routine Inspection
and Replacement of
Consumable Parts:
NOTE
CAUTION
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Refer to Figure 4-A and:
1. Remove the shield cup (7) from the torch.
2. Unscrew the tip (6) using the tip wrench (8). Check for
tip wear (indicated by elongated or oversize orifice).
Clean the tip and make sure the threads and sealing
face are not damaged. Replace tip if necessary.
3. Remove the electrode (5) using the electrode wrench (9).
Inspect the condition of the face of the electrode
(see CAUTION below).
Check the torch for proper assembly. Tip and electrode
selection must correspond with the type of operation
(cutting or gouging, air or multi-gas). See Torch Parts
Selection, page 16).
If less than 1/8 in (3.2 mm) of the hex area on the front of
the electrode remains, the electrode should be replaced
(see Figure 4-B, page 28).
1
5a
6a
7a
3
1. 180 ° Machine Torch Body
2. 70° Hand Torch Body
3. O-Ring (Handle)
4. O-Ring (Shield Cup)
5a. Multi-Gas Electrode
5b. Air Electrode
Figure 4-A Torch Components
7b
2
4
7c
5b
6b
9
8
A-01480
6a. Gouging Tip
6b. Cutting Tip
7a. Gouging Shield Cup
7b. Standard Shield Cup
7c. Crown Shield Cup
8. Tip Wrench
9. Electrode Wrench
27 SERVICE
Page 40
4.1 TORCH MAINTENANCE (continued)
Routine Inspection
and Replacement of
Consumable Parts:
CAUTION
A-01481
4. Replace the electrode in the torch body. Secure in place
with the electrode wrench.
5. Replace the tip in the front of the torch and secure it
with the tip wrench.
Do not overtighten the electrode or tip.
6. Inspect the shield cup for damage. Wipe it clean, or
replace if it appears to be damaged.
7. Re-install the shield cup. Apply a light coat of O-ring
lubricant to the shield cup O-ring (4). Use a slight
twisting motion to seat the cup properly on the O-ring
and against the torch face.
0.100" (2.5 mm)
0.040" (1.0 mm)
Figure 4-B Electrode Deterioration
4.2 TORCH LEADS REPLACEMENT
WARNING
Hand Torch Leads
Replacement
Negative/Plasma Lead Connection
Positive/Pilot
Lead Connection
Insulating T ab
Negative/Secondary Lead Connection
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Refer to Figure 4-C and:
1. Roll the torch switch sheath up over the handle.
2. Remove the tape from the end of the leads sleeving and
pull the sleeving back approximately 12 in (305 mm).
3. Remove the tape from the two single-pin torch switch
connectors and disconnect the torch switch leads.
Torch Switch Leads Connectors
Torch Handle and Sheath
Electrical T ape
A-01482
Figure 4-C Hand Torch Leads Replacement
SERVICE
28
Page 41
4.2 TORCH LEADS REPLACEMENT (continued)
Hand Torch Leads
Replacement (continued)
CAUTION
4. With a slight twisting motion, pull the handle from
the torch head. Slide it back over the leads to expose
the leads connections.
5. Remove the tape that secures the torch leads connections around the insulating tab. Disconnect the negative/plasma, negative/secondary, and positive/pilot
leads from the torch head.
6. Inside the power supply, disconnect the leads from
the bulkhead fittings (positive lead has left-hand
threads, negative lead has right hand threads).
7. Connect the replacement leads to the bulkhead fittings.
When reassembling the torch, make sure that the
insulating tab separates the positive/pilot lead from the
negative/plasma and negative/secondary leads.
8. Connect the replacement leads to the torch head.
Secure the leads in place around the insulating tab
with electrical tape.
9. Replace the handle on the torch head and reconnect
the torch switch leads connectors. Secure the connectors with electrical tape.
10. Pull the leads sleeving up inside the handle and
secure to the leads with electrical tape.
11. Roll the torch switch sheath back down over the
handle and sleeving.
WARNING
Machine Torch Leads
Replacement
Negative/Plasma Lead Connection
Positive/Pilot Lead Connection
Negative/Secondary Lead Connection
Insulating T ape
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
Refer to Figure 4-D and:
1. Unscrew the torch head from the mounting assembly
and slide the mounting assembly up over the leads to
expose the leads connections.
2. Replace the leads connection as in previous steps 4
through 8.
3. Replace the torch body in the mounting assembly and
replace the leads sleeving.
Electrical T ape
Mounting Assembly
A-01483
Figure 4-D Machine Torch Leads Replacement
29 SERVICE
Page 42
4.3 POWER SUPPLY MAINTENANCE
Fan Motor Lubrication
NOTE
Routine Maintenance
The fan motor in the power supply should be oiled twice
per year or once for each 100 hours of operation. To oil the
motor, remove one side panel and add two or three drops
of 20 SAE oil to the front and rear oil holes on the motor.
Some units may utilize a sealed motor design which does
not require lubrication.
The only other routine maintenance required for the
power supply is a thorough cleaning and inspection, with
the frequency depending on the usage and the operating
environment.
To clean the unit, first make sure that the power is disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air. The unit should
also be wiped clean. If necessary, solvents for cleaning
electrical apparatus may be used.
While the side panels are off, inspect the wiring in the
unit. Look for any frayed wires or loose connections that
should be corrected. When cleaning the unit, inspect the
area around the high frequency spark gap points. Accumulated dirt in the area around the spark gap assembly
can weaken the high frequency starting and cause poor
pilot starting.
Captive Nuts
Press-in ‘captive’ nuts are used to assemble the power
supply enclosure. Occasionally a press-in nut may break
free and turn loosely in the sheet metal.
Should this occur, the nut may be reinstalled using the bolt
that threads into it. Hold the nut securely with vise grips
and thread the bolt into the nut until the nut is drawn up
and compressed against the panel. When the nut is secure,
the bolt may be removed and reinstalled.
SERVICE
Figure 4-E Captive Nuts
30
Page 43
4.4 TROUBLESHOOTING GUIDE
If the power supply malfunctions, the following table will be helpful in correcting the problem.
Since the problem may be due to a faulty connection rather than a faulty component, be sure to
check all connections to a component that appears to be malfunctioning.
The troubleshooting guide is arranged in the normal operating sequence of the system for easy
reference (refer to the Sequence of Operation on page 26). Each problem has listed next to it the
possible causes and the remedy.
When the external disconnect switch is closed and the ON/OFF switch is moved to ON, the red
AC indicator is lit, the fan motor turns on, the TEMP indicator is lit, and the GAS indicator
should be lit (if RUN/SET switch is in SET position with gases flowing). If this does not happen, check as follows:
TROUBLE POSSIBLE CAUSE REMEDY
A. AC indicator not lit.
B. Fan motor does not turn
on.
1. Blown fuse, or open
circuit breaker at disconnect panel
2. Blown fuse (1FU)
3. Rear panel wiring harness
plug not properly connected
4. ON/OFF switch (SW1)
faulty
5. Auxiliary transformer (T4)
faulty
6. Ribbon cable unplugged
7. Faulty status light PC
board
8. Faulty logic PC board
1. Motor not properly connected to rear panel
wiring harness plug.
2. Fan motor faulty (M)
3. Auxiliary transformer (T4)
faulty
1. Replace fuse or breaker at
disconnect, reset breaker.
2. Replace fuse.
3. Check connection.
4. Check switch and replace
if necessary.
5. Check T4 and replace if
necessary.
6. Check connection.
7. Check PC board and
replace if necessary.
8. Check PC board and
replace if necessary.
1. Check wire harness
connection.
2. Check motor and replace
if necessary.
3. Check T4 and replace if
necessary.
C. TEMP indicator is not lit.
1. Rear panel wiring harness
plug not properly connected
2. Unit overheated
3. Faulty thermal overload
switch (TP1, TP2, or TP3)
4. Faulty status light PC
board
31 SERVICE
1. Check wire harness
connection.
2. Allow unit to cool.
3. Check switches and
replace if necessary.
4. Check PC board and
replace if necessary.
Page 44
4.4 TROUBLESHOOTING GUIDE (continued)
TROUBLE POSSIBLE CAUSE REMEDY
D. No gas flow in SET
position
1. Gas supply not turned on,
or empty cylinder
2. Faulty solenoid (SOL)
1. Turn gas supply on, or
replace cylinder.
2. Check and replace solenoid if necessary.
3. Check and replace switch
if necessary.
1. Reset to 40 psi (2.8 bar)
plasma, 75 psi (5.2 bar)
E. GAS indicator not lit in
SET position
3. Faulty RUN/SET switch
(SW2)
1. Gas pressure too low
secondary.
2. Check and replace PC
board if necessary.
1. Repair or replace.
2. Check input pressure.
F. Cannot set desired gas
pressure
2. Faulty status light PC
board
1. Faulty regulator or
plugged filter
2. Supply line too low
When the torch switch is pressed the gas should start to flow and the GAS indicator should
come on. Two seconds later, the main contactor (W) should close (red DC indicator lit), followed by the closing of the high frequency relay (HF indicator lit). At this time the pilot arc
should be established. If this does not happen, check to see if (1) there is any light visible inside
the torch, and (2) the red HF indicator is lit.
TROUBLE POSSIBLE CAUSE REMEDY
G. No gas flow when torch
switch pressed
H. No red DC indicator (gas
flows)
I. Pilot arc comes on imme-
diately (without two
second pre-flow delay)
1. Torch switch not connected
2. Torch switch not closing
3. Faulty control logic PC
board
1. RUN/SET switch in SET
position.
2. Loose control logic PC
board connection
3. Faulty main contactor
(W1, W2, or W3)
4. Diodes failed in main
bridge rectifier
1. No pre-flow delay
2. Unit still in ten second
post flow mode
1. Check wires to plug,
switch, and receptacle.
2. Check switch for continuity when pressed.
3. Check and replace PC
board if necessary.
1. Move to RUN position.
2. Check connections and
correct if necessary.
3. Check main contactors
(see A, page 35).
4. Check diodes (see E, page
35).
1. Replace control logic PC
board.
2. Normal operation.
SERVICE
32
Page 45
4.4 TROUBLESHOOTING GUIDE (continued)
The pilot arc should start two seconds after the torch switch is pressed. If it does not, check the
following:
TROUBLE POSSIBLE CAUSE REMEDY
J. No spark in torch or at
spark gap points
1. Faulty time delay circuit
2. High frequency points
shorted
3. Shorted capacitor C10
4. High frequency transformer failed
5. Failed relay HF
1. Replace PC board
2. Clean and dry area
around high frequency
points, adjust gap (See G,
page 36).
3. Check (See C, page 35).
4. Check (See B, page 35).
5. Check and replace relay if
necessary.
K. Spark in torch but no
pilot
1. Insufficient DC voltage
2. Pilot resistor failed
1. Check open circuit voltage
(See F, page 36).
2. Check resistor R6 (See D,
page 35).
3. R.F. suppression coil
3. Repair or replace.
broken
L. No spark can be seen in
torch, but spark is present
at spark gap points
1. Electrode shorted against
tip
2. Shorted torch head
1. Screw electrode into torch
until properly seated.
2. Check and replace if
necessary.
3. Failed capacitor C8
3. Check and replace if
necessary.
4. Broken conductor in torch
lead
5. Shorted torch lead
4. Check and replace if
necessary.
5. Check and replace if
necessary.
6. Dirty or wet lead
6. Clean and dry lead.
The main cutting arc should start as soon as the torch, with the pilot arc running, is brought to
within 1/8 -3/8 inch (3-10 mm) of the workpiece. If it does not, check:
TROUBLE POSSIBLE CAUSE REMEDY
M. No cutting arc
1. Work cable not connected
2. One leg of power is out
1. Connect.
2. Check T1, T2, and T3
transformer outputs to
main bridge (See H, page
36).
33 SERVICE
Page 46
4.4 TROUBLESHOOTING GUIDE (continued)
Once the cutting arc is established it should remain on until the torch control switch is released
or the torch is moved away from the metal enough to break the arc (pilot arc should re-ignite).
TROUBLE POSSIBLE CAUSE REMEDY
N. Unit shuts down during
cutting operation and:
a. TEMP indicator not lit
b. GAS indicator not lit
c. AC indicator not lit
1. Transformer overheated
2. Gas supply pressure too
low
3. Loss of primary power
4. Blown fuse (1FU)
1. Allow unit to cool.
2. Check and correct .
3. Check primary power
source.
4. Replace fuses.
O. Low output and/or poor
1. Shorted bridge diode on
cut quality in high range,
no or low output in
medium and low range
2. Faulty contactor W1, W2,
3. Faulty range switch SW3
If the torch parts life is short, check:
TROUBLE POSSIBLE CAUSE REMEDY
P. Short torch parts life
1. Incorrect gas pressures
2. Misuse of torch
3. Contaminated (dirty) gas
4. HF relay remains on
5. No pre-flow gas flow (two
6. No post-flow gas flow (ten
Q. Excessive tip deteriora-
1. Replacement contactors
tion occurs
R. Arcing in electrode seat
1. Electrode not tight
area
transformer having low
output
or W3
during cut
seconds)
seconds)
not installed correctly
1. Check diode (See E, page
35).
2. Check contactors and
replace if necessary.
3. Check switch and replace
if necessary.
1. Check and correct.
2. Use torch within ratings.
3. Install filter.
4. Replace control logic PC
board.
5. Check and correct.
6. Replace PC board.
1. Check wire orientation
(see I, page 36).
1. Tighten electrode.
SERVICE
34
Page 47
4.5 TEST PROCEDURES
WARNING
The following tests are suggested for specific problems
listed in the troubleshooting guide. The letter designations
correspond to those listed in the “Remedy” column of the
troubleshooting section.
Several of these tests involve voltage measurements that
must be made with power on. Use extreme care when
making these tests. Tests requiring voltage measurements
are marked with the warning symbol. Disconnect primary
power to the system for all other tests.
A. Main Contactor Check
B. HF Transformer Check
C. HF Capacitor Check
D. Pilot Resistor Check
E. Main Diode Check
To check the main contactor remove the side panels of the
machine. The contactor should close when 24 VAC is
applied to lines 45 and 46 (when the torch switch is
pressed). At this time line power should be present at lines
105 and 107. Power should always be present at lines 1
and 4 when the primary power is turned on.
The high frequency transformer has too much voltage
(6000 volts AC) to check under power. The resistance of
the primary coil should be 5 ohms and the resistance of the
secondary coil should be about 20K ohms.
To check the high frequency capacitor (C10), it is necessary
to try to start the torch. The spark between the spark gap
points should be bright blue. If the spark appears to be
weak or nonexistent, disconnect the wire between the
spark gap and the capacitor and try to start the torch
again. If the spark is stronger with this wire disconnected,
the capacitor must be replaced.
The pilot arc resistor is located on the rear panel beside the
fan. Its resistance should measure 2.5 ohms between wire
10 and wire 38, and should measure 12 ohms between
wire 10 and wire 68.
A ‘quick check’ can be made on the main diodes without
removing them from the circuit. Using an ohmmeter with
the Rx1 or Rx10 scale, measure the resistance of each diode
in both directions. The readings should differ by at least a
factor of 10. If they do not differ (both high or both low)
the diode has failed and must be replaced. There are four
potential causes of diode failures. If a diode fails it is
important to check several things to make sure the replacement diode will not fail:
1. Isolate and check each diode to determine which diode
has failed.
2. High frequency protection for the diodes is provided by
capacitors C4, C5, C6 and C7 which are installed between each side of the bridge rectifier. These capacitors
and their connections should be checked.
(continued)
35 SERVICE
Page 48
4.5 TEST PROCEDURES (continued)
E. Diode Check (continued)
F. Open Circuit Voltage
G. HF Spark Gap Setting
H. Main Transformer Leads
I. Main Contactor Wiring
3. To check capacitor C9 to be sure it is in the circuit, first
disconnect primary power to the system. The resistance
from wire 38 to wire 10 should be 2.5 ohms. The
resistance from wire 12 to the negative heatsink should
be 0 ohms. A quick check can be made on the capacitor
by using an ohmmeter in the Rx1000 position. Disconnect wires from one side of the capacitor and measure
across the capacitor. The reading should sweep up to
near 0 ohms, then gradually drop back if C9 is okay. If
shorted, the reading will remain near 0 ohms and C9
should be replaced.
4. Overheating of the diode can occur if air flow over the
heat sink is inadequate or if the diode is not properly
fastened to the heat sink. Check to see that the diodes
are torqued to 2.5 ft-lbs (3.4 Nm) and that a light film of
electrically conductive heatsink compound (this is a
white grease) is present between the diode and heat
sink. Check to be sure that air passages in and out of
the unit are not obstructed.
5. Diodes that are faulty at the time of manufacture are
difficult to diagnose. These usually fail in the first few
hours of operation. Before deciding that this was the
case, be sure to check out the other possibilities.
Check the open circuit voltage between the two heat sinks
of the main bridge rectifier. This should measure 240-250
vdc on a three-phase unit.
To adjust the spark gap setting, use allen wrench to loosen
the set screw on the top of the brass block until the electrode can be moved. Adjust the electrode until the proper
0.030 in (.76 mm) gap is obtained. Secure the electrode by
tightening the set screw.
Transformer outputs to the main bridge from T1, T2, and
T3 are numbered 132-133, 132-134, and 133-134.
If any one of the main contactors has been removed or
replaced, check input wiring orientation. Make sure that
the wires are as follows:
Figure 4-F Contactor Input Wiring
SERVICE
36
Page 49
SECTION 5: PARTS LISTS
ABOUT THE PARTS LIST
Parts List Contents
Ordering Information
Returns
Figure 5-1 System and Accessories
Figure 5-2 Front Panel Components
Figure 5-3 Rear Panel Components
Figure 5-4 Base Components
Figure 5-5 Upper Equipment Panel Components
Figure 5-6 Bulkhead Components
Figure 5-7 Torch Components
Figure 5-8 Torch Accessories
An item number in parentheses indicates a component
that may differ depending on options such as the voltage
or phase configuration of a particular unit. The description of the item provides identification of the correct
choice for each system configuration.
Parts listed without item numbers are not illustrated, but
may be ordered by the catalog number shown. Order
replacement parts by catalog number and complete description of the part or assembly, as listed in the description column of the Parts List. Also include the model and
serial number of the machine as shown on the plate
attached to the front panel of the unit. Address all inquiries to your authorized distributor.
If a product must be returned for service, contact your
distributor. Materials returned without proper
authorization will not be accepted.
37
PARTS LIST
Page 50
5.1 SYSTEM COMPONENTS & ACCESSORIES
Fig. Item Qty. Catalog Description
No. Number
5-1 1 1 3-6570A PAK 1250 XR Power Supply with Running Gear and Work Cable
5-1 2 1 2-2936 PCH-52 70° Hand Torch with 25 ft (7.6 m) Leads
5-1 1 2-2937 PCH-52 70° Hand Torch with 50 ft (15.2 m) Leads
5-1 1 2-2330 PCH-52 90° Hand Torch with 25 ft (7.6 m) Leads
5-1 1 2-2331 PCH-52 90° Hand Torch with 50 ft (15.2 m) Leads
5-1 1 2-2938 PCM-52 180° Machine Torch with 25 ft (7.6 m) Leads
(Includes Pinion Assembly)
5-1 1 2-2939 PCM-52 180° Machine Torch with 50 ft (15.2 m) Leads
(Includes Pinion Assembly)
5-1 3 1 8-1124 Work Cable with Clamp - 25 ft (7.6 m)
5-1 1 9-5865 Right Side Panel- with Overlay (Not Shown)
5-1 1 8-6184 Upper Side Panel Overlay - Right Side (Not Shown)
5-1 4 1 9-5868 Left Side Panel- with Overlay
5-1 5 1 8-6186 Upper Side Panel Overlay - Left Side
5-1 6 2 8-6185 Lower Side Panel Overlay
5-1 13 1 9-5863 Front Panel
5-1 14 1 9-5864 Front Panel Overlay
5-1 7 1 8-6188 Handle
5-1 8 1 9-4282 Axle
5-1 9 2 9-4283 Wheel
5-1 10 2 9-5539 Retaining Ring
5-1 11 4 Flat Washer- 1/2 in (13 mm) I.D.
5-1 12 2 7-3128 Front Caster
5-1 1 7-3117 Cylinder Rack Running Gear
5-1 1 7-3139 Air Line Filter Assembly - Includes All Fittings
5-1 2 9-1020 Air Line Filter Assembly - Filter Only
5-1 1 9-1021 Replacement Filter Element - First Stage
5-1 1 9-1022 Replacement Filter Element - Second Stage
5-1 2 9-5524 Air Line Regulator Assembly
5-1 1 8-2150 Air Line Regulator Mounting Bracket
5-1 1 8-5527 Plasma Gas Hose - 1.5 ft (457 mm)
5-1 1 8-5528 Secondary Gas Hose - 1.5 ft (457 mm)
5-1 1 9-2184 Street Elbow Fitting (Gas Hose to Regulator)
5-1 1 9-5656 Y-Hose Assembly
5-1 1 7-3144 Male Hose Fitting (Y-Hose Assembly)
5-1 1 9-2034 Female Tee Fitting (Y-Hose Assembly)
5-1 2 8-0263 90° Adaptor Fitting (Y-Hose Assembly)
5-1 2 8-1155 Gas Hose - 12 in (305 mm) (Y-Hose Assembly)
5-1 1 9-3022 High Pressure Regulator - Air
5-1 1 9-3053 High Pressure Regulator - Argon/Hydrogen
5-1 1 9-2722 High Pressure Regulator - Nitrogen
5-1 1 9-2759 High Pressure Regulator - Carbon Dioxide
5-1 1 9-2146 Plasma Gas Hose - 10 ft (3.1 m)
5-1 1 9-2147 Secondary Gas Hose - 10 ft (3.1 m)
5-1 1 5-2935 Service Parts Kit - For 60 Hz System
5-1 1 5-2936 Service Parts Kit - For 50 Hz System
5-1 1 9-5692 Computer Control Cable Kit - 25 ft (7.6 m)
5-1 1 9-5693 Computer Control Cable Kit - 50 ft (15.2 m)
5-1 1 7-3121 SC2/XR Standoff Control
PARTS LIST
38
Page 51
5.1 SYSTEM COMPONENTS & ACCESSORIES (continued)
7
1
10
11
A-01464
5
R
4
R
13
14
6
8
11
9
12
2
3
Figure 5-1 PAK 1250 XR System Components
39
PARTS LIST
Page 52
5.2 FRONT PANEL COMPONENTS
Fig. Item Qty. Catalog Description Reference
No. Number Designator
5-2 1 1 9-4418 Control Panel with Overlay - English
5-2 2 1 9-4419 Control Panel Overlay - English
5-2 (1) 1 9-4420 Control Panel with Overlay - International
5-2 (2) 1 9-4421 Control Panel Overlay - International
5-2 3 1 9-4210 Torch Leads Boot
5-2 4 1 8-1119 Top Panel
5-2 7 1 9-5607 ON/OFF Switch Kit- 3PST SW1
5-2 8 1 9-3405 RUN/SET Switch- DPDT SW2
5-2 9 1 9-4188 LED Control Indicator PC Board
5-2 10 1 9-5608 Range Switch
5-2 11 1 9-5862 Range Switch Knob SW3
5-2 12 2 9-3995 Fastener Receptacle
5-2 13 2 9-4346 Fastener Stud
5-3 14 2 9-4347 Fastener Retaining Ring
8
4
A-01465
7
10
12
9
1
14
13
12
3
11
14
2
13
Figure 5-2 Front Panel Components
PARTS LIST
40
Page 53
5.3 REAR PANEL COMPONENTS
Fig. Item Qty. Catalog Description Reference
No. Number Designator
5-3 1 1 8-1123 Rear Panel
5-3 2 1 8-1154 Pilot Resistor Assembly R6,R10
5-3 3 1 9-5586 Contactor - 24 VAC PCR
5-3 4 1 9-5610 Resistor - 100k ohm, 1/2 W R9
5-3 5 1 9-3568 Resistor - 100 ohm, 100 W R5
5-3 6 2 9-4337 Solenoid Assembly (Includes All Fittings) SOL1,2
5-3 7 2 9-4078 Reducing Bulkhead Fitting
5-3 8 4 8-0354 Close Nipple Fitting
5-3 9 2 8-0312 Female Tee Fitting
5-3 10 2 8-0257 Straight Adaptor Fitting
5-3 11 1 8-6130 Pressure Switch Assembly - Plasma (30 psi) PS1
5-3 12 1 8-6131 Pressure Switch Assembly - Secondary (40 psi) PS2
5-3 13 2 9-5209 Solenoid Receptacle
5-3 14 2 9-3257 Pressure Switch Plug
5-3 15 2 8-0330 Adaptor Fitting
(12)
10
4
3
(11)
13
14
12
10
9
8
14
13
11
9
7
2
8
5
1
15
Figure 5-3 Rear Panel Components
41
A-01466
PARTS LIST
Page 54
5.4 BASE COMPONENTS
Fig. Item Qty. Catalog Description Reference
No. Number Designator
5-4 1 1 8-3241 Base
5-4 2 3 Main Transformers: T1,T2,T3
9-5672 200/220V, 3-phase, 60 Hz
9-5674 200/220V, 3-phase, 50 Hz
9-5676 200/220V, 3-phase, 50/60 Hz
9-5680 380/415V, 3-phase, 50 Hz
9-5682 460V, 3-phase, 60 Hz
9-5684 380/500V, 3-phase, 50 Hz
9-5686 575V, 3-phase, 60 Hz
5-4 3 1 9-2391 Strain Relief - Input Power Cable
5-4 4 3 9-5586 Main Contactor - 24 VAC W1, W2, W3
5-4 5 1 8-1127 Fan Motor Mounting Bracket
5-4 6 1 8-1125 Fan Motor M
5-4 7 1 9-5209 Fan Motor Receptacle
5-4 8 1 8-1126 Fan Blade
5-4 9 1 9-4363 Input Voltage Terminal Board
5-4 10 1 9-4364 Contactor Wire Harness
PARTS LIST
42
Page 55
5.4 BASE COMPONENTS (continued)
A-01467
Figure 5-4 Base Components
43
PARTS LIST
Page 56
5.5 UPPER EQUIPMENT PANEL COMPONENTS
Fig. Item Qty. Catalog Description Reference
No. Number Designator
5-5 1 1 9-4338 Ceramic Disc Capacitor Assembly - .002 mfd C10
5-5 2 1 9-5589 Spark Gap Assembly
5-5 3 2 Set Screw - #6-32UNC X 1/8" lg
5-5 4 2 9-3841 Electrode - HF Spark Gap
5-5 5 2 9-4107 Resistor - 2500 ohm, 50 w R7
5-5 6 1 9-5161 Resistor - 100 ohm, 50 w R8
5-5 7 1 9-5614 Capacitor - 240 mfd, 450 VDC C9
5-5 8 4 9-5333 PC Board Support
5-5 9 1 9-5528 High Frequency Transformer T5
5-5 10 1 9-4330 Auxiliary Transformer (For 60 Hz only) T4
5-5 (10) 1 9-4331 Auxiliary Transformer (For 50 Hz and 50/60 Hz) (T4)
5-5 1 8-4235 Auxiliary Transformer Socket
5-5 1 9-5171 Auxiliary Transformer Receptacle
5-5 11 1 8-0367 Fuse - 5 amp, 250V (For 200/220V units) 1FU
5-5 (11) 1 8-1153 Fuse - 3 amp, 500V (For 380/415 and 460V units) (1FU)
5-5 (11) 1 8-1128 Fuse - 3 amp, 600V (For 500 and 575V units) (1FU)
5-5 12 1 9-5562 Fuse Block
5-5 13 2 9-3293 14-pin Receptacle - Reverse Sex
5-5 14 2 9-3297 14-pin Socket
5-5 15 4 9-5544 Grommet
5-5 16 1 8-2156 Upper Equipment Chassis
5-5 17 1 9-5616 Capacitor Holder
5-5 18 1 9-4189 Control Logic PC Board PC1
PARTS LIST
44
Page 57
5.5 UPPER EQUIPMENT PANEL COMPONENTS (continued)
8
11
12
18
9
11
10
13,14
16
15
15
7
4
2
5
6
3
1
17
A-01468
Figure 5-5 Upper Equipment Panel Components
45
PARTS LIST
Page 58
5.6 BULKHEAD COMPONENTS
Fig. Item Qty. Catalog Description Reference
No. Number Designator
5-6 1 1 9-4045 Bulkhead Fitting - 1/8 NPT, Standard Thread
5-6 2 1 9-4046 Bulkhead Fitting - 1/8 NPT, Left-Hand Thread
5-6 3 1 8-2141 Insulator - Bulkhead & Bridge
5-6 4 1 9-4333 Filter PC Board - Main Bridge
5-6 5 1 8-1129 Negative Heatsink
5-6 6 1 8-1130 Positive Heatsink
5-6 7 1 8-1131 Suppression Coil L1
5-6 8 2 8-1163 Internal Gas Hose
5-6 9 9 9-5466 Diode - Reverse Polarity , 40A, 1000v D1,3,5,11,13,15,21,23,25
5-6 10 9 9-5260 Diode - Straight Polarity, 40A, 1000v D2,4,6,12,14,16,22,24,26
5-6 11 4 8-2149 Jam Nut
Figure 5-6 Bulkhead Components
PARTS LIST
A-01469
46
Page 59
5.7 TORCH COMPONENTS
Fig. Item Qty. Catalog Description
No. Number
5-7 1 2-2940 PCH-52 70° Hand Torch with Parts
5-7 1 2-2398 PCH-52 90° Hand Torch with Parts
5-7 1 2-2941 PCM-52 180° Machine Torch with Parts
5-7219-5642PCH-52 Basic 70° Hand Torch Body
5-7 1 9-5854 PCH-52 Basic 90° Hand Torch Body
5-7119-5643PCM-52 Basic 180° Machine Torch Body
5-7 3 2 8-0536 O-Ring (Handle)
5-7 4 1 8-5525 O-Ring (Shield Cup)
5-7 5a 1 9-5711 Multi-Gas Electrode
5-7 5b 1 9-5619 Air Electrode
5-7 6a 1 8-5129 Gouging Tip
5-7 6b 1 9-5702 Cutting Tip - .031 in Orifice (For Range I - 35 amps)
5-7 1 9-5707 Cutting Tip - .047 in Orifice (For Range II - 70 amps)
5-7 1 9-5708 Cutting Tip - .059 in Orifice (For Range III - 105 amps)
5-7 7a 1 8-5128 Gouging Cup
5-7 7b 1 9-5617 Standard Shield Cup - Ceramic
5-7 1 9-5781 Standard Shield Cup - Phenolic (Not Shown)
5-7 7c 1 9-5694 Crown Cup
5-7 1 9-5712 Drag Cup (Not Shown)
5-7 1 9-5799 Standoff Attachment - Use with 9-5781 (Not Shown)
5-7 1 9-5780 Standoff Attachment (Short) - Use with 9-5781 (Not Shown)
5-7 1 8-5130 Heat Shield - For Gouging (Not Shown)
5-7 8 1 8-4007 Tip Wrench (for Spare Parts Kit)
5-7 9 1 9-5620 Electrode Wrench (for Spare Parts Kit)
5-7 1 8-4025 O-Ring Lubricant (for Spare Parts Kit - not shown)
5-7 1 8-3141 Tool Box (for Spare Parts Kit)
1
5a
2
3
4
5b
6a
6b
9
8
7a
7b
7c
A-01480
Figure 5-7 Torch Components
47
PARTS LIST
Page 60
5.8 TORCH ACCESSORIES
Fig. Item Qty. Catalog Description
No. Number
5-8 1 1 9-5644 Handle
5-8 2 1 9-5522 Switch Assembly
5-8 3 1 8-4216 Switch Retaining Sheath
5-8 4 1 8-4018 Retaining Nut
5-8 5 1 9-1901 Adaptor
5-8 6 1 8-5005 Positioning Tube
5-8 7 1 7-2827 Pinion Assembly
5-8 8 1 8-4204 Bushing (End Cap)
5-8 9 1 7-3124 Circle Cutting Attachment
5-8 1 4-5034 PCH-52 Replacement Hand Torch Leads - 25 ft (7.6 m)
5-8 1 4-5035 PCH-52 Replacement Hand Torch Leads - 50 ft (15.2 m)
5-8 1 4-5036 PCM-52 Replacement Machine Torch Leads - 25 ft (7.6 m)
5-8 1 4-5037 PCM-52 Replacement Machine Torch Leads - 50 ft (15.2 m)
5-8 1 4-2848 PCH-52 Hand Torch Leads Extension Kit - 25 ft (7.6 m)
5-8 1 4-2849 PCH-52 Hand Torch Leads Extension Kit - 50 ft (15.2 m)
5-8 1 4-2850 PCM-52 Machine Torch Leads Extension Kit - 25 ft (7.6 m)
5-8 1 4-2851 PCM-52 Machine Torch Leads Extension Kit - 50 ft (15.2 m)
5-8 1 8-1498 Torch Leads Sleeving - 25 ft (7.6 m)
5-8 1 9-3035 Torch Leads Sleeving - 50 ft (15.2 m)
5-8 1 9-5662 Negative Torch Lead - 25 ft (7.6 m)
5-8 1 9-5663 Negative Torch Lead - 50 ft (15.2 m)
5-8 1 9-5664 Plasma Gas Hose - 25 ft (7.6 m)
5-8 1 9-5665 Plasma Gas Hose - 50 ft (15.2 m)
5-8 1 9-4279 Positive Pilot Wire - 25 ft (7.6 m)
5-8 1 9-4280 Positive Pilot Wire - 50 ft (15.2 m)
5-8 1 9-4276 Control Cable Assembly - 25 ft (7.6 m)
5-8 1 9-4277 Control Cable Assembly - 50 ft (15.2 m)
5-8 1 9-3294 14-pin Plug- for Control Cable (Console End)
5-8 1 9-3295 Cable Clamp - for Control Cable Plug
5-8 1 9-5170 Pin - for Control Cable Plug
5-8 2 8-5085 Ferrule - Negative Lead
5-8 1 8-7033 Fitting - Negative Lead, Console End
5-8 1 8-4190 Fitting - Negative Lead, Torch End
5-8 2 8-5013 Ferrule - Plasma Gas Hose
5-8 1 8-5518 Nut - Plasma Gas Hose, Console End
5-8 1 8-0328 Fitting - Plasma Gas Hose, Console End
5-8 1 8-0338 Fitting - Plasma Gas Hose, Torch End
5-8 1 8-0339 Nut - Plasma Gas Hose, Torch End
5-8 10 1 7-3114 Remote Pendant Control Assembly
5-8 11 1 9-4229 Switch - for Remote Pendant
5-8 12 1 9-4228 Cord Grip - for Remote Pendant
5-8 13 1 8-1662 Handle Only - for Remote Pendant
5-8 14 1 9-3294 14-pin Plug - for Remote Pendant
5-8 15 3 9-3296 Pin - for Remote Pendant Plug
5-8 16 1 9-3295 Cable Clamp - for Remote Pendant
PARTS LIST
48
Page 61
5.8 TORCH ACCESSORIES (continued)
1
4
2
5
9
6
7
11
3
8
A-01484
10
Figure 5-8 Torch Accessories
15
13
12
14
16
49
PARTS LIST
Page 62
5.9 TROUBLESHOO TING DIA GRAM
PARTS LIST
50
Page 63
5.10 CNC INTERFACE SCHEMATIC
CNC SIGNAL INTERFACE CABLE POWER SUPPLY
J5
24 VAC
CONTACTOR
Start/Stop
CSR
Ready to Move
Ground
49
50
54
55
GND
45
RED
BLACK
WHITE
BROWN
GREEN
BLUE
4
3
12
14
13
10
24 VAC
W
CSR
GND
45
I
58
II
W1
W2
CSD
Corner
Slowdown
(Customer-
Supplied)
CSD
59
ORANGE
51
11
III
III
I
II
59
W3
PARTS LIST
Page 64
5.11 SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 1)
A-01583
PARTS LIST
52
Page 65
A-01583
53
PARTS LIST
Page 66
SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 2)
A-01584
PARTS LIST
54
Page 67
A-01584
55
PARTS LIST
Page 68
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