Thermal Dynamics SureLok PCM-102 Instruction Manual

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PLASMA

CUTTING TORCH

PCM-102 For Automated Systems

For Use With:

• Automated Pak Master 75XL Plus

• Automated Pak Master 100XL Plus

• CE Automated Pak Master 75XL Plus

• CE Automated Pak Master 100XL Plus

March 9, 2001 Manual No. 0-2815

Instruction Manual

WARNINGS

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

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

Plasma Cutting Torch PCM-102 For Automated Systems Instruction Manual Number 0-2815

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

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

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

Printed in the United States of America

Publication Date: March 9, 2001

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

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

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

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

1.03 Publications..................................................................................................1-2

1.04 Note, Attention et Av ertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference............................................................................ 1-5

1.07 Declaration of Conformity............................................................................. 1-7

1.08 Statement of W arranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION & DESCRIPTION.................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description ..................................................................................... 2-1

2.03 Specifications & Design Features................................................................. 2-1

2.04 Options And Accessories ............................................................................. 2-2

2.05 Introduction to Plasma.................................................................................. 2-2

SECTION 3:

INSTALLATION PROCEDURES ....................................................................................... 3-1

3.01 Introduction .................................................................................................. 3-1

3.02 Site Location ................................................................................................ 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Setting Up Machine Torch ............................................................................ 3-1

3.05 Connecting T orch ......................................................................................... 3-1

3.06 Gas Connection ........................................................................................... 3-2

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 Functional Overview..................................................................................... 4-1

4.03 Getting Started ............................................................................................. 4-1

4.04 Torch Parts Selection ................................................................................... 4-2

4.05 Cut Quality ................................................................................................... 4-2

4.06 Operating the System .................................................................................. 4-3

4.07 Machine T orch Operation ............................................................................. 4-4

4.08 Recommended Cutting Speeds.................................................................... 4-5

4.09 Gouging ....................................................................................................... 4-5

SECTION 5:

CUSTOMER/OPERAT OR SERVICE................................................................................. 5-1

5.01 Introduction .................................................................................................. 5-1

5.02 General T orch Maintenance.......................................................................... 5-1

5.03 Common Operating Faults ........................................................................... 5-2

5.04 Inspection and Replacement Consumable Torch P arts ................................ 5-2

5.05 T roub leshooting Guide.................................................................................. 5-3

5.06 Torch & Leads Troubleshooting..................................................................... 5-4

5.07 Servicing Machine Torch (PCM) Components .............................................. 5-6

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction .................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Replacement Machine Torch With Pinch Bloc k Mounting Parts .................... 6-2

6.04 Replacement Torch Lead Parts .................................................................... 6-4

6.05 Complete Assembly Replacement ............................................................... 6-5

6.06 Options & Accessories ................................................................................. 6-5

6.07 Torch Spare Parts Kits.................................................................................. 6-6

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERA TION BLOCK DIA GRAM.............. A-1

APPENDIX 2: TORCH CONTROL CABLE WIRING DIA GRAM FOR

MECHANIZED SYSTEMS ................................................................................................A-2

APPENDIX 3: GENERAL APPLICATION NO TES.....................................................................A-3

APPENDIX 4: PAK MASTER 75XL PLUS A UTOMATED SYSTEM DATA..................................A-4

APPENDIX 5: CE AUTOMATED PAK MASTER 75XL PLUS SYSTEM DATA............................A-8

APPENDIX 6: AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA..............................A-12

APPENDIX 7: CE AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA........................ A-16

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

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

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

GASES AND FUMES

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

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

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

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

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

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

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

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

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

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

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

ELECTRIC SHOCK

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

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

Date: May 1, 2000 1-1 GENERAL INFORMATION

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any service or repairs.

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

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from the workplace.

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

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

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

NOISE

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

• T o protect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

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

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

PLASMA ARC RAYS

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

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

• Wear welding gloves and suitable clothing to 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.

1.03 Publications

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

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

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

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

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

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

GENERAL INFORMATION 1-2 Date: Ma y 1, 2000

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

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

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

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

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

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

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

ATTENTION

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

AVERTISSEMENT

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

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

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

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

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

1.04 Note, Attention et

Avertissement

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

NOTE

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

Date: May 1, 2000 1-3 GENERAL INFORMATION

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

FUMÉE et GAZ

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

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

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

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

• Réparez ou remplacez toute pièce usée ou endommagée.

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

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

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

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

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

INCENDIE ET EXPLOSION

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

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

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

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

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

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

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

GENERAL INFORMATION 1-4 Date: Ma y 1, 2000

RAYONS D’ARC DE PLASMA

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

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

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

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

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

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

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

1.06 Documents De Reference

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

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

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

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

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

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

BRUIT

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

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

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

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

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

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

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

Date: May 1, 2000 1-5 GENERAL INFORMATION

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

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

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

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

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

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

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

GENERAL INFORMATION 1-6 Date: Ma y 1, 2000

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2

W est Lebanon, New Hampshir e 03784 USA

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

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

National Standard and Technical Specifications

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

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

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

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

ated accessories.

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

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

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

Manufacturers responsible repr esentative: Giorgio Bassi

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

Date: May 1, 2000 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

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

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

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

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

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

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

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years 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 fr om date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

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

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

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

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

Torch And Leads

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

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

Effective May 1, 2000

GENERAL INFORMATION 1-8 Date: Ma y 1, 2000

SECTION 2:

INTRODUCTION &

A. Torch Configuration

The standard machine torch has a fiberglass positioning tube with rack & pinch block assembly.

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the PCM-102 Torch using the SureLok electrode design for Automated Systems. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the W arranty.

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

2.02 General Description

NOTE

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

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

Available options include a kit with metal mounting tube with rack & pinion assembly or a kit with the pinion assembly only.

A-02805

Figure 2-1 Machine Torch

B. Torch Leads Lengths

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

C. Torch Pa rts

Gas Distributor , Electrode, T ip, Shield Cup

D. Parts-In-Place (PIP)

Torch Head has built-in contacts 12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch

F. Torch Ratings

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

2.03 Specifications & Design

Ambient

Temperature

Duty Cy cle

Maxi mu m C u r r e n t

Voltage (V

Arc Stri kin g Voltag e

Torch Ratings

100% @ 100 Amps @ 400 scfh

)

peak

104° F

(40° C)

100 Amps

500V

12 kV

Features

NOTE

Refer to Appendix Pages for additional specifications as related to the Power Supply used.

Manual 0-2815 2- 1 INTRODUCTION & DESCRIPTION

G. Product Used With

• Automated Pak Master 75XL Plus

• Automated Pak Master 100XL Plus

• CE Automated Pak Master 75XL Plus

• CE Automated Pak Master 100XL Plus

H. Torch Dimensions

()

A-00002

Workpiece

Power

Supply

14.1 in

(358 mm)

13.5 in (343 mm) Max

3.7 in (94 mm) Min

1.1 in

(28 mm)

1.4 in

(35.6 mm)

0.62 in

(15.2 mm)

0.75 in

(19 mm)

5.1 in

(129.5 mm)

A-02804

Figure 2-2 Torch Dimensions

2.04 Options And Accessories

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

• Spare Parts Kits - Various kits containing replacement front-end torch parts for various applications.

• 1-3/8" Metal Mounting Tube w/Rack & Pinion Assembly

• Pinion Assembly

• Computer Control (CNC) Cable 25 Ft (7.6 m) or 50 Ft

(15.2 m)

2.05 Introduction to Plasma

A. Plasma Gas Flow

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

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

In a Thermal Arc Plasma Cutting Torch a cool gas such as air or nitrogen (N2) enters Zone B (refer to Figure 2-3), 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.

Figure 2-3 Typical Torch Head Detail

By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C (Figure 2-3). Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.

Zone A (Figure 2-3) is used as a secondary gas that cools the torch. This gas assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast, slag-free cut.

B. Gas Distribution

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

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

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

C. Pilot Arc

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.

D. Capacitive Discharge

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

INTRODUCTION & DESCRIPTION 2- 2 Manual 0-2815

E. Main Cutting Arc

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

F . Interlocks

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

G. Parts-In-Place (PIP)

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

Manual 0-2815 2- 3 INTRODUCTION & DESCRIPTION

INTRODUCTION & DESCRIPTION 2- 4 Manual 0-2815

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

This section describes installation of the Torch. These instructions apply to the Torch and Leads Assemblies only; installation procedures for the Power Supply, Options and Accessories are given in Manuals specifically provided for those parts.

The complete installation consists of:

• Site Selection

• Unpacking

• Setting Up Torch

• Connecting Torch

• Gas Connection

The standard machine torch includes a fiberglass positioning tube with rack and pinch block assembly. A metal mounting tube with rack & pinion assembly or the pinion assembly only are available as options.

1. Mount the torch assembly on the cutting table.

2. T o obtain a clean vertical cut, use a squar e to align the torch perpendicular to the surface of the workpiece.

Pinch Block Assembly

Square

3.02 Site Location

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

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

3.03 Unpacking

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

1. Unpack each item and remove all packing material.

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

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

3.04 Setting Up Machine Torch

Workpiece

A-02585

Figure 3-1 Machine Torch Set-Up

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

3.05 Connecting T orch

The instructions for connecting the Torch Leads to the Automated Power Supply.

The T or ch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the Torch Bulkhead Panel.

WARNING

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

Manual 0-2815 3-1 INSTALLATION PROCEDURES

NOTE

Equipment ordered as a system will have the Torch factory connected to the Power Supply.

1. Remove the retaining nut from the Strain Relief.

Strain Relief

Torch Leads Assembly

7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed in the above Step.

8. Tighten the Strain Relief onto the Torch Leads.

9. Check the torch for proper parts assembly.

A-02826

Strain Relief Nut

Figure 3-2 Strain Relief Nut Removal

2. Feed the torch lead ends and the Strain Relief into the hole in the unit.

3. Secure the Strain Relief with the retaining nut removed earlier.

Adapter Connector

Adapter (Supplied With Power Supply)

Control (PIP) Circuit

Connectors

Shield Connectors

Negative/Plasma

Torch Lead

Assembly

Negative/Plasma Lead Connection

Lead

Pilot Lead

Stud

Pilot Lead

A-02831

CAUTION

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

3.06 Gas Connection

A. Connection

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

CAUTION

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

B. Checking Air Quality

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

C. Filtering

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

Figure 3-3 Torch Lead Connections

4. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.

5. Connect the PIP and Shield Cables to the mating connectors on the Adapter supplied on the Power Supply.

6. Remove the top nut and washer from the Pilot Stud.

INSTALLA TION PROCEDURES 3-2 Manual 0-2815

SECTION 4:

OPERATION

4.01 Introduction

This section provides a description of the PCM-102 T o rch Assembly for Automated Systems followed by operating procedures.

4.02 Functional Overview

The T orch is designed to operate with various Power Supplies to provide a plasma cutting system which can cut most metals from gauge thickness up to 1 inch (25.4 mm). Using gouging torch parts the torch can be used for plasma arc gouging up to 1/4 inch (3.2 mm) wide and 3/ 16 inch (4.8 mm) deep in a single pass on carbon steel.

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

4.03 Getting Started

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

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

E. Power On

Place the ON/OFF Switch on the Power Supply to the ON position. If the RUN/SET/LATCH switch is in SET position, gas will flow. If the switch is in RUN position there will be no gas flow.

F. RUN/SET or RUN/SET/LATCH Switch

If the RUN/SET or RUN/SET/LATCH switch is in SET position, gas will flow. If the switch is in RUN position there will be no gas flow.

G. Current Output Level

At the Power Supply, set the desired current output level to a maximum of 100 amperes. For drag cutting set the control at 35 amps or less only.

H. Pressure Settings

Place the RUN/SET or RUN/SET/LA TCH switch to the SET position. Adjust the gas pr essure contr ol on the Power Supply for the proper gas pressure (see Note) between 60 psi (4.1 bar) to 70 psi (4.8).

NOTE

WARNING

Disconnect primary power at the source before assembling or disassemblingpower supply, torch parts, or torch and leads assemblies.

A. Torch Parts

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

B. Input Power

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

C. Work Cable

Check for a solid work cable connection to the workpiece.

D. Gas Supply

Select desired single gas supply. Make sure gas sources meet requirements (see Note). Check connections and turn gas supply on.

For the proper gas pressure to be used refer to the Operating Manual supplied with the Power Supply or the Torch Label installed on the Power Supply.

I. Ready for Operation

Return the RUN/SET or RUN/SET/LATCH switch to RUN position.

NOTES

For general cutting, use the RUN position which provides normal torch operation where the torch switch must be held throughout the main arc transfer.

For specific applications, use the LA TCH position where the torch switch can be r eleased after the main arc transfer. The torch remains activated until the main arc breaks from the workpiece.

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

The system is now ready for operation. Supply a Start Signal from the CNC control to initiate the

pilot arc. There is a 2 second pr e-flow before the arc starts.

Manual 0-2815 4-1 OPERATION

4.04 Torch Par ts Selection

4.05 Cut Quality

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

Type of operation:

Standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Gas Distributor

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

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

NOTE

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

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

NOTES

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

Refer to Appendix Pages for additional information as related to the Power Supply used.

Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics are illustrated in Figure 4-2:

Kerf Width

Cut Surface Bevel Angle

Top

Spatter

Top Edge Rounding

Torch Head Assembly

Electrode

A-02832

Gas

Distributor

Tip

Shield Cup

Figure 4-1 Torch Parts

2. Tilt the torch head to remove the tip and gas distributor.

3. Remove the SureLok Electrode by pulling it straight out of the Torch Head.

4. Install the desired SureLok Eelectrode by pushing it

straight into the torch head until it clicks.

5. Install the desired gas distributor and tip for the op-

eration into the torch head.

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

Dross

Build-Up

Cut Surface

Drag Lines

Figure 4-2 Cut Quality Characteristics

A. Cut Surface

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

B. Nitride Build-Up

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

C. Bevel Angle

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

D. Top-Edge Rounding

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

A-00007

OPERATION 4-2 Manual 0-2815

E. Bottom Dross Build-up

C. Edge Starting

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

F . Kerf Width

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

G. Top Spatter (Dross)

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

4.06 Operating the System

WARNINGS

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

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

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

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left (Refer to Figure 4-3). To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Left Side

Cut Angle

Right Side

Cut Angle

Figure 4-3 Side Characteristics Of Cut

A-00512

CAUTION

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

NOTE

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

A. Piloting

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

B. Torch Standoff

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

E. Dross

When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance. "Top dross" is normally very easy to remove and can often be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. It can vary from a light to heavy bead, but does not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.

Manual 0-2815 4-3 OPERATION

4.07 Machine T orc h Operation

A. Cutting With Machine T or ch

The machine torch can be activated by remote control pendant or by a remote interface device such as CNC.

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

Pinch Block Assembly

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel. Generally recommended for Nitrogen plasma.

Direction of Torch Travel

Standoff Distance

Straight Arc

Square

Workpiece

A-02585

Figure 4-4 Checking Alignment

2. To start a cut at the plate edge, position the center of the torch along the edge of the plate (refer to Figure 4-5.

B. Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate ( Figure 4-5). The arc can be one of the following:

1. Straight Arc

Trailing Arc

Leading Arc

Figure 4-5 Machine Torch Operation

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

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

C. Piercing With Machine T orch

A-02586

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

2. Leading Arc

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

OPERATION 4-4 Manual 0-2815

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

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

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

4.08 Recommended Cutting Speeds

WARNING

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

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

• Torch parts wear

• Air quality

• Line voltage fluctuations

• Torch standoff height

• Proper work cable connection

NOTES

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

Refer to Appendix Pages for cutting speed chart information as related to the Power Supply used.

4.09 Gouging

A. Gouging Parameters

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

B. Tor ch T ravel Speed

NOTE

Refer to Appendix Pages for additional information as related to the Power Supply used.

Optimum torch travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

C. Current Setting

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

D. Lead Angle

WARNING

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

CAUTIONS

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

Check torch parts. The torch parts must correspond with the type of operation. Refer to Section

4.04, Torch Parts Selection.

The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 80 amps, the recommended lead angle is 35° (refer to Figure 4-6). At a lead angle greater than 45° the molten metal will not be blown out of the gouge and may be blown back onto the torch. If the lead angle is too small (less than 35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

Torch Head

35˚

Standoff Height

1/8 - 1/4"

Workpiece

A-00941

Figure 4-6 Gouging Angle and Standoff Distance

Manual 0-2815 4-5 OPERATION

E. Standoff Distance

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

F. Slag Build-up

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

OPERATION 4-6 Manual 0-2815

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

5.01 Introduction

This section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.

WARNINGS

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

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

CAUTION

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

NOTE

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

5.02 General T orch Maintenance

A. Cleaning Tor ch

Refer to Section 5.07, Servicing Machine Torch Components (PCM) for disassembling the T orch and Leads Assembly.

CAUTION

Dry the torch thoroughly before r einstalling.

B. Checking Center Insulator

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

WARNINGS

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

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

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

2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch fittings. Infinite resistance (no continuity) should be found. If continuity is found, refer to Section 5.06, Torch and Leads T roubleshooting.

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

WARNINGS

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

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

Manual 0-2815 5-1 SER VICE

C. O-Ring Lubrication

The external o-ring on the Torch Head Assembly (shield cup) requires lubrication on a scheduled basis. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, becoming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential leaks of the secondary gas around the end of the shield cup.

It is recommended to apply a very light film of oring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.

NOTE

DO NOT use other lubricants or grease, they may

not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.

5.03 Common Operating Faults

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

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts

5.04 Inspection and Replacement Consumable T or ch Parts

WARNINGS

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

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

Remove the consumable torch parts per the following procedure:

NOTE

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

e. Cutting current too low f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

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

3. Excessive Dross Formation

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

4. Short T orch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick) c. Excessive pilot arc time

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

NOTE

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

2. Inspect the cup for damage. Wipe it clean or replace

if damaged.

Torch Head Assembly

Electrode

A-02832

Gas

Distributor

Tip

Shield Cup

Figure 5-1 Consumable Parts

3. Remove the tip. Check for excessive wear (indicated

by an elongated or oversized orifice). Clean or replace the tip if necessary.

d. Air flow too low (incorrect pressure) e. Improperly assembled torch f. Non-Genuine Thermal Dynamics Parts

)SERVICE 5-2 Manual 0-2815

Good Tip

Worn Tip

5.05 Troubleshooting Guide

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

A-00942

Figure 5-2 Tip Wear

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

5. Remove the SureLok Electrode by pulling it straight out of the Torch Head. Refer to the following figure and check the face of the electrode for excessive wear .

New Electrode

A-02794

Worn Electrode

Figure 5-3 Electrode Wear

. Reinstall the SureLok Eelectrode by pushing it straight

into the torch head until it clicks.

7. Reinstall the desired gas distributor and tip into the

torch head.

How to Use This Guide

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

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

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

A. Torch will not pilot when torch activated (Remote

Hand Pendant or CNC Start Signal)

1. Power Supply RUN/SET/LATCH switch in SET position

a. Place RUN/SET/LATCH switch to RUN po-

sition.

2. Parts-In-Place (PIP) not satisfied. a. Check canted coiled spring inside shield cup

3. Faulty Remote Hand Pendant Switch

a. Check for continuity

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

Manual 0-2815 5-3 SER VICE

4. Faulty CNC Start or OK-T o-Move Signal

a. Check that proper signal(s) are applied

5. Faulty torch parts

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

fer to Section 5.04, Inspection and Replacement Consumable Torch Parts

6. Gas pressure too high

a. Set proper operating gas pressure.

7. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads Troubleshooting.

8. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

B. No cutting output

E. No gas flow

1. T orch not properly connected to power supply

a. Check that torch leads are properly attached

to power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against

torch head (do not overtighten)

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

a. Check canted coiled spring inside shield cup

4. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads Troubleshooting.

5. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Faulty components in torch and leads assembly

1. Gas not connected or pressure too low

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

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

F. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

2. T orch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

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

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

D. Erractic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. T orch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

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

5.06 Torch & Leads Troubleshooting

A. General Information

Failures in the T or ch and Leads can be isolated to the T or ch Head or Torch Lead components. T o properly isolate the failed part requires the use of an ohmmeter and a Hi-Pot Tester.

WARNING

The use of a Hi-Pot T ester should be performed only by a qualified electronic technician.

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

In the Torch Leads the negative and positive leads are isolated from each other. If there is not adequate resistance between the leads then torch failure may occur.

5. T orch tip contacts workpiece

a. When the tip is contacts the workpiece, the

amperage automatically cuts back to 35 amps .

)SERVICE 5-4 Manual 0-2815

B. Quick Check Procedure

This quick check will identify major isolation failures in the T or ch Head or T orch Lead components using an ohmmeter.

The actual assembly and consumables may vary for different torches but the basic procedure is the same for all torches. Make the quick check on the Torch Head and Leads per the following procedure:

NOTE

It is possible that the Torch Head and Torch Leads will test properly with an ohmmeter. The Torch Head and Torch Leads should be tested further for insulation breakdown if no other fault can be found.

C. Checking Proper Isolation Resistance

Procedure

WARNINGS

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

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

1. Remove the consumables from the torch.

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

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

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

• If no continuity (infinite resistance) is found between the two torch fittings proceed to paragraph C.

4. Remove the torch head from the leads (refer to the proper Section on servicing the Torch Components).

5. With the torch head disconnected from the leads, measure the resistance between negative fitting or cathode body of the torch head and the positive fitting or anode body of the torch head.

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

• If there is continuity, torch head must be replaced.

• If no continuity (infinite resistance) is found proceed to Step 6.

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

The Torch Head and Torch Leads should be tested further for insulation breakdown if no other fault has been found. This procedure requir es the use of a Hi-Pot Tester.

WARNING

This procedure should be performed only by a qualified electronic technician.

1. To test the Torch Head center insulator for insulation breakdown use the following procedur e:

a. Remove the Torch Head Assembly from the

Torch Leads if not already done.

b. Remove the consumables from the T orch Head

Assembly if not already done.

c. Connect a Hi-Pot T ester capable of producing

2500VAC between the positive pilot lead and the negative lead fittings.

d. Increase the output of the Hi-Pot Tester to a

maximum of 2500VAC.

• If the voltage drops to 0VAC or leakage cur-

rent is detected, then the Torch Head center insulator is breaking down and the T orch Head must be replaced.

• If the Torch Head center insulator passes the

test, then proceed to Step 2.

2. To test the Torch Leads for insulation breakdown use the following procedure:

a. Connect the Hi-Pot Tester between the posi-

tive pilot lead and the negative lead fittings. The fitting on the other end of the T or ch Leads must be separated (isolated) from each other.

b. Increase the output of the Hi-Pot Tester to a

maximum of 2500VAC.

• If there is continuity, torch leads must be replaced.

• If no continuity (infinite resistance) is found proceed to paragraph ‘C’ (see NOTE).

Manual 0-2815 5-5 SER VICE

• If the voltage drops to 0VAC or leakage current is detected, then the insulation between the Torch Leads is breaking down and the Torch Leads must be replaced.

• If the T orch Leads passes the test, then pr oceed to Step 3.

3. Visually check that the PIP wires, pilot lead connection, and negative lead connections are properly connected and in good condition (no shorts or arcing).

• If problems are evident, repair or r eplace as required.

• If there are no visual problems, then proceed to Step 4.

4. Check the pilot lead, negative lead and PIP wires for opens from one end of the torch leads to the other.

• If open, replace leads or open component of the Torch Leads Assembly.

• If not open, then proceed to Step 5.

5. Check the pilot and PIP wires for shorts to other components in the Torch Leads.

• If shorted, then replace Torch Leads.

• If not shorted, then proceed to Step 6.

6. Carefully reassemble the components and r echeck the completed assembly per paragraph ‘B’, Step 3 to confirm that the components have been properly assembled.

Pinch Block Assembly

Positioning Tube

A-02587

Machine T orch Head

Figure 5-4 Torch Mounting Assembly

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

Negative/Plasma Lead Connection

Parts-in-Place Wires

This completes the checks for the proper operation of the Torch Head and Torch Leads.

5.07 Servicing Machine Torch (PCM) Components

WARNINGS

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

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

A. Removing Machine Torch Head

1. Unscrew the positioning tube from the tor ch head.

2. Slide the positioning tube back over the leads to expose the negative/plasma lead connection, pilot lead connection, and two PIP (parts-in-place circuit) connectors.

Pilot Lead Connection

A-02581

Figure 5-5 Torch Head Removal

B. Reassembling Machine Torch Assembly

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

NOTE

Tape the PIP lead connectors to the leads covering.

2. Screw the positioning tube tightly onto the torch head.

)SERVICE 5-6 Manual 0-2815

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

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

Section 6.03: Replacement Machine Torch Parts Section 6.04: Replacement Torch Leads Section 6.05: Complete Assembly Replacements Section 6.06: Options & Accessories Section 6.07: Spare Parts Kits

NOTE

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

B. Returns

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

6.02 Ordering Information

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

Manual 0-2815 6-1 PARTS LISTS

6.03 Replacement Machine Torch With Pinch Block Mounting Parts

Item # Qty Description Catalog #

1 Shield Cup Assemblies (All include item #3)

1 1 Standard Shield Cup 8-7500

1a 1 Copper Shield Cup Assembly 8-7496

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

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

2 1 Spring, Canted Coil 9-7501 3 1 Tip (Refer to Appendix Page for the proper application) 4 1 Distributor, Gas (Refer to Appendix Page for the proper application) 5 1 Electrode (Refer to Appendix Page for the proper application) 6 1 Assembly, Torch Head, PCM-102 RPT (Includes items #7 - 9) 9-8403 7 1 O-Ring 8-0532 8 1 #6-32 x 3/16 Phillips Pan Head Screw See Note 9 1 #6 Internal Star Washer See Note

10 Shielded Lead Assembly, Cable Complete

25 ft (7.6 m) Length 4-7531

50 ft (15.2 m) Length 4-7532 11 1 Positioning Tube With Rack, Fiberglass 9-7835 12 2 Body, Mounting, Pinch Block Phenolic (Plastic) 9-4513 13 1 Pin, Mounting, Pinch Block 9-4521 14 1 Torch Holder Sleeve 7-2896 15 3 #10-32 x 5/8" Phillips Pan Head Screw See Note 16 2 #10-32 x 32 x 1 1/4 Lg Phillips Pan Head Screw See Note 17 2 #10-32 Regular Nylon Lock Nut See Note 18 1 Strain Relief, Notched (Supplied with Nut) 9-7016 19 1 Adapter, Torch Control (Automated Systems) 8-6469

NOTE: Item can be purchased locally.

PARTS LISTS 6-2 Manual 0-2815

Shield Cup

Body

Heat Shield

(Copper)

9 8

Hi-Vis Shield

Cup (Black)

Copper Shield

Cup Assembly

Manual 0-2815 6-3 PARTS LISTS

A-02833

6.04 Replacement Torch Lead Parts

Item # Qty Description Catalog #

1 Nylon Sleeving

1 25 ft (7.6 m) Length 8-1498

1 50 ft (15.2 m) Length 9-3035 2 1 Strain Relief, Knotched 9-7016 3 1 Boot 9-7017 4 Lead, Pilot Return, 14 A WG

1 25 ft (7.6 m) Length 8-6460

1 50 ft (15.2 m) Length 8-6461 5 Lead, Gas Cooled, Negative, #5

1 25 ft (7.6 m) Length 9-7665

1 50 ft (15.2 m) Length 9-7796 6 Assembly, Control Cable (Shielded Leads)

1 25 ft (7.6 m) Length 8-6456

1 50 ft (15.2 m) Length 8-6457 7 PVC Sleeving

1 25 ft (7.6 m) Length 8-6478

1 50 ft (15.2 m) Length 8-6479 8 Shield Braid

1 25 ft (7.6 m) Length 8-6458

1 50 ft (15.2 m) Length 8-6459

A-02803

PARTS LISTS 6-4 Manual 0-2815

6.05 Complete Assembly Replacement

Description Catalog #

Machine Torches with Shielded Leads (Fiberglass Mounting Tube w/Rack & Phenolic Pinch Block Assembly):

PCM-102 RPT Machine Torch, 25 ft (7.6 m) Leads 7-7538-SL PCM-102 RPT Machine Torch, 50 ft (15.2 m) Leads 7-7539-SL

6.06 Options & Accessories

Item # Qty Description Catalog #

1 Computer Control (CNC) Cable

25 Ft (7.6 m) 8-5557 50 Ft (15.2 m) 8-5558

Kevlar Sleeving: 1 25 ft. (7.6 m) 9-7905 1 50 ft. (15.2 m) 9-7906

1 1-3/8" Metal Positioning Tube w/Rack & Pinion Assembly Kit 7-7745 1 Pinion Assembly Only 7-2827

1 1 Torch Holder Sleeve 7-2896 2 1 Pinion Gear -Short 8-6074 3 1 Handwheel (Torch Holder) 9-4514 4 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515 5 1 Calibrated Torch Holder Bushing 9-4366 6 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 7 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 8 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 9 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note

NOTE: Item can be purchased locally.

A-02737

Manual 0-2815 6-5 PARTS LISTS

6.07 Torch Spare Par ts Kits

A. For Automated Pak Master 75XL Plus Applications

Qty Description Catalog #

VIP Spare Parts Kit Includes: 5-3511

20 Electrode (SureLok), MaximumLife™ 9-8407 40 Tip, Cutting, Air/N2, 60 Amp (0.049" Orifice) 9-7726

2 Gas Distributor 8-7501 1 Standard Shield Cup 8-7500 1 Shield Cup, Copper 8-7496 5 O-Ring 8-0532 3 Canted Coil Spring 9-7501

B. For CE Automated Pak Master 75XL Plus Applications

Qty Description Catalog #

VIP Spare Parts Kit Includes: 5-7615

20 Electrode (SureLok), General Purpose 9-8402 40 Tip, Cutting, Air/N2, 60 Amp (0.049" Orifice) 9-7726

2 Gas Distributor 8-7501 1 Standard Shield Cup 8-7500 1 Shield Cup, Copper 8-7496 5 O-Ring 8-0532 3 Canted Coil Spring 9-7501

C. For Automated Pak Master 100XL Plus Applications

Qty Description Catalog #

VIP Spare Parts Kit Includes: 5-3513

20 Electrode (SureLok), MaximumLife™ 9-8407 40 Tip, Cutting, Air/N2, 80 Amp (0.055" Orifice) 9-7728

2 Gas Distributor 8-7501 1 Standard Shield Cup 8-7500 1 Shield Cup, Copper 8-7496 3 Canted Coil Spring 9-7501 5 O-Ring 8-0532

D. For CE Automated Pak Master 100XL Plus Applications

Qty Description Catalog #

VIP Spare Parts Kit Includes: 5-7614

20 Electrode (SureLok), General Purpose 9-8402 40 Tip, Cutting, Air/N2, 80 Amp (0.055" Orifice) 9-7728

2 Gas Distributor 8-7501 1 Standard Shield Cup 8-7500 1 Shield Cup, Copper 8-7496 3 Canted Coil Spring 9-7501 5 O-Ring 8-0532

PARTS LISTS 6-6 Manual 0-2815

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF

OPERATION BLOCK DIAGRAM

LATCH

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8

seconds then steady on.

Fans on.

Power circuit ready.

RUN/SET/LATCH switch

gas flows to set pressure.

PILOT ARC

ACTION

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET/LATCH

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch moved within

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed.)

post-flow, pilot arc will immediately restart. If torch is within transfer distance (3/8 in) of

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (15 seconds)

NOTE - If torch is activated during

workpiece, main arc will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

ACTION

Torch Switch

can be released.

RESULT Transfer will continue until torch is removed

from workpiece.

A-02461

Manual 0-2815 A-1 APPENDIX

T o Torch

Control Device

APPENDIX 2: TORCH CONTROL CABLE WIRING

DIAGRAM FOR MECHANIZED SYSTEMS

Torch Control

Cable

Torch Control

Connectors

Control Shield

Connector

Control Connector

Plug with Connectors

To Power Supply

Control Connector

Shield

Return

Power Supply

Control

OK-To-Move

Relay

A-02821

12 14

Torch Lead

Assembly

Mate & Lock

2 1 3 4

Connectors

Lead Shield

Connector

Torch Leads

Connectors only on

Shielded Leads

Mate & Lock

Connectors

Torch Head

PIP Pin

Shield Cup

PIP Pin

3 4

OK-To-Move

A-02801

Control

Torch Control

Cable Connector

APPENDIX A-2 Manual 0-2815

Pendant Ground

Remote Pendant/CNC

Cable Connector

APPENDIX 3: GENERAL APPLICATION NOTES

A. Electrode Selection

The SureLok this section is to help determine which electrode to use for best performance.

Torches offer two Electrodes, General Purpose and MaximumLifeTM. The information supplied in

General Purpose SureLok

Electrode (Cat.No. 9-8402)

• General Purpose- Good performance with all systems.

• Design of electrode is similar to previous designed electrodes used in the PCH/M-60, 75, 76, 80, and 100XL

Torches.

• New patented locking design offers improved parts life, excellent piloting, improved arc transfer distance and excellent arc characteristics as compared to older electrode designs.

• The General Purpose electrode is the standard electrode offered with SureLok RPT Replacement Torches providing good all around characteristics and performance.

MaximumLifeTM SureLokTM Electrode (Cat.No. 9-8407)

• New innovative patented “fluted” design.

• Fluted design optimizes electrode cooling and in most applications resulting in a significant improvement in

consumable parts life.

Suggested Applications

Electrode

System

Pak M ast er 75XL Pl us Opti onal Sugges t ed Pak M ast er 100XL Pl us Opti onal Sugges t ed CE PakMast er 75XL Pl us Sugges t ed Opti onal CE PakMast er 100XL Pl us S uggest ed Optional

Gene ral Purpose

Cat # 9-8402

MaximumLife™

Cat # 9-8407

B. Frequenly Asked Questions

Q. What Electrode can be used?

A. Only SureLok Electrodes, 9-8402 and 9-8407 may be used. Depending on the application and power supply

the General Purpose Electrode (9-8402) provides good all around characteristics and performance. The MaximumLike™ Electrode (9-8407) design offers improved electrode cooling resulting in a significant improvement in parts life.

Q. Which Tip can be used?

A. All the Tips listed on the Appendix Page for the selected Power Supply application can be used. Select the

proper Tip for the desired application. It is recommended to use the Cutting/Drag Tip for general purpose drag and light cutting applications. The Gouging Tip is recommended for gouging applications only. The Standoff Tip can be used for standoff cutting applications for improved cut quality and speed.

Q. What if Electrode parts life is low?

A. Try using the MaximumLife™ Electrode.

Manual 0-2815 A-3 APPENDIX

APPENDIX 4: PAK MASTER 75XL PLUS AUTOMATED

SYSTEM DATA

Torch Specifications

Torch Specifica tions For

Pa k Ma ste r 75XL Pl us Powe r S upply

Cutting Range

Mat erial Mild St eel

Up to 3/4 inch (19 mm )

Speed 10 ipm (0.25 m pm )

Pierce Rating

Mat erial Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance

3/8 inch (9.5 m m )

Gouging

Width 1/8 inch (3.2 mm) Depth 1/8 inch (3.2 mm)

Number Passes Single

Speed 20 ipm (0.5 m pm )

Bevel Cut Capability

Degrees 0° to 45°

Material Thickness 1/4 inch (6.3 mm)

Gas Re quirem ent

Type Gas Air or Nitrogen (N2)

Operating P res sure See Speed Charts

Max Input P res sure 125 psi (8.6 bar)

Cutt ing & Gouging

Total Flow

See S peed Charts

Cut Quality on Various Materials and Thicknesses

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

Table 4-A Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Carbon Steel Air Good - Excellent

Gage

3/4 inch

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

Nitrogen Good

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

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

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

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

Torch Consumables

Standard Shield Cup

Catalog No. 8-7500

40 Amp Shield Cup (Gray)

Catalog No. 9-8400

Cutting Tip, Air/N2 60 Amp (0.049 in)

Catalog No. 9-7726

Gouging Tip, Air

(0.073 in Orifice)

Catalog No. 8-7506

Electrode (SureLok)

MaximumLife™

Catalog No. 9-8407

Gas Distributor

Catalog No. 8-7501

Copper Shield Cup

Catalog No. 8-7496

Hi-Vis Shield Cup (Black)

Catalog No. 8-7525

Cutting/Drag Tip, Air/N2

40 Amp (0.031 in)

Catalog No. 9-8411

Gas Distributor

40 Amp

Catalog No. 9-8401

Gouging Gas Distributor

Catalog No. 8-7508

A-02834

APPENDIX A-4 Manual 0-2815

Cutting Speed Charts

Torch Head

9-8403

A-02889

Electrode

9-8407

Gas Distributor

(See Chart)

Tip

(See Chart)

Shield Cup

(See Chart)

US M easu r em en t s

Ai r Plasma C utti ng D at a C hart

PC M- 102 A u t omated T orch Wit h A u t omated Pak Mast er 75X L Pl u s

Aluminum

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

inches Cat. No. Cat. No. Cat . No. amps vdc inches/min i nches psi Plasma Tot al seconds

20 ga 9-8401 9-8411 9-8400 40 93 350 0. 187 65 50 180 0.00 0.18 7 16 ga 9-8401 9-8411 9-8400 40 95 275 0. 187 65 50 180 0.00 0.18 7 10 ga 9-8401 9-8411 9-8400 40 95 100 0. 187 65 50 180 0.00 0.18 7

7 ga 9-84 01 9-8411 9-8400 40 100 70 0.187 65 50 180 0.00 0.187

1/4 9-8401 9-8411 9- 8400 40 107 30 0.187 65 50 180 0.50 0.187 3/8 9-8401 9-8411 9- 8400 40 110 18 0.187 65 50 180 0.50 0.187

1/2 9-8401 9-8411 9- 8400 40 115 10 0.187 65 50 180 1.00 0.187 16 ga 8-7501 9-7726 8-7500 60 100 375 0. 188 60 50 275 0.10 0.25 10 ga 8-7501 9-7726 8-7500 60 100 225 0. 188 60 50 275 0.10 0.25

1/4 8-7501 9-7726 8- 7500 60 100 90 0.188 60 50 275 0.15 0.25

1/2 8-7501 9-7726 8- 7500 60 100 30 0.188 60 50 275 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (SCFH)

Pierce

Delay

Pierce Height

inches

Metri c M easuremen t s

Ai r Plasma C utti ng D at a C hart

PC M- 102 A u t omated T orch Wit h A u t omated Pak Mast er 75X L Pl u s

Aluminum

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

mm Cat. No. Cat. No. Cat . No. amps vdc m / min mm bar Plasma Tot al seconds

0.8 9-8401 9-8411 9-8400 40 93 8.89 4.7 4.5 24 85 0.00 4.7

1.3 9-8401 9-8411 9-8400 40 95 6.99 4.7 4.5 24 85 0.00 4.7

2.6 9-8401 9-8411 9-8400 40 95 2.54 4.7 4.5 24 85 0.00 4.7

3.7 9-8401 9-8411 9- 8400 40 100 1.78 4.7 4.5 24 85 0.00 4.7 6 9-8401 9-8411 9-8400 40 107 0.76 4.7 4.5 24 85 0.50 4.7

10 9-8401 9-8411 9-8400 40 110 0.46 4.7 4.5 24 85 0.50 4.7 13 9-8401 9-8411 9-8400 40 115 0.25 4.7 4.5 24 85 1.00 4.7

1.3 8-7501 9-7726 8- 7500 60 100 9.53 4.8 4.1 24 130 0.10 6.4

2.6 8-7501 9-7726 8- 7500 60 100 5.72 4.8 4.1 24 130 0.10 6.4 6 8-7501 9-7726 8-7500 60 100 2.29 4.8 4.1 24 130 0.15 6.4

13 8-7501 9-7726 8-7500 60 100 0.76 4.8 4.1 24 130 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (lpm)

Pierce

Delay

Pierce Height

Manual 0-2815 A-5 APPENDIX

Cutting Speed Charts (continued)

Torch Head

9-8403

A-02889

Electrode

9-8407

Gas Distributor

(See Chart)

Tip

(See Chart)

Shield Cup

(See Chart)

US M e asuremen t s

Air Plasma Cutting Dat a Chart

PC M -102 A uto mated Torch Wi t h Au t o m ated Pak Mast er 75X L Plus

Mild Steel

Single Gas T orch - A ir Plasma / A i r Secon dary

Materia l

Thickness

inches Cat. No. Cat. No. Cat. No. amps vdc i nches/min i nches psi Plasma Total seconds

20 ga 9-8401 9-8411 9-8400 40 90 300 0.125 65 50 180 0.00 0.188 16 ga 9-8401 9-8411 9-8400 40 90 275 0.125 65 50 180 0.00 0.188 10 ga 9-8401 9-8411 9-8400 40 90 75 0.125 65 50 180 0.00 0.188

7 ga 9-8401 9-8411 9-8400 40 95 40 0.125 65 50 180 0.50 0.188

1/4 9-8401 9-8411 9-8400 40 95 28 0.125 65 50 180 0.50 0.188 3/8 9-8401 9-8411 9-8400 40 100 15 0.187 65 50 180 1.00 0.250

1/2 9-8401 9-8411 9-8400 40 105 10 0.187 65 50 180 1.50 0.250 16 ga 8-7501 9-7726 8-7500 60 100 300 0. 1 88 60 50 275 0.1 0 0.250 10 ga 8-7501 9-7726 8-7500 60 95 145 0.188 60 50 275 0.25 0.250

1/4 8-7501 9-7726 8-7500 60 105 65 0.188 60 50 275 0.25 0.250

3/8 8-7501 9-7726 8-7500 60 105 45 0.188 60 50 275 0.25 0.250

1/2 8-7501 9-7726 8-7500 60 105 22 0.188 60 50 275 0.50 0.250

3/4 8-7501 9-7726 8-7500 60 115 10 0.188 60 50 275 NR NR

1 8-7501 9-7726 8-7500 60 115 5 0.188 60 50 275 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (SCFH)

Pierce

Delay

Pierce

Height

inches

Metri c Measuremen ts

Air Plasma Cutting Dat a Chart

PC M -102 A uto mated Torch Wi t h Au t o m ated Pak Mast er 75X L Plus

Mild Steel

Single Gas T orch - A ir Plasma / A i r Secon dary

Materia l

Thickness

mm Cat. No. Cat. No. Cat. No. amps vdc m / min mm bar Plasma Total seconds

0.9 9-8401 9-8411 9-8400 40 90 7.62 3.2 4.5 24 85 0.00 4.8

1.5 9-8401 9-8411 9-8400 40 90 6.99 3.2 4.5 24 85 0.00 4.8

3.4 9-8401 9-8411 9-8400 40 90 1.91 3.2 4.5 24 85 0.00 4.8

4.6 9-8401 9-8411 9-8400 40 95 1.02 3.2 4.5 24 85 0.50 4.8 6 9-8401 9-8411 9-8400 40 95 0.71 3.2 4.5 24 85 0.50 4.8

10 9-8401 9-8411 9-8400 40 100 0.38 4.7 4.5 24 85 1.00 6.4 13 9-8401 9-8411 9-8400 40 105 0.25 4.7 4.5 24 85 1.50 6.4

1.5 8-7501 9-7726 8-7500 60 100 7.62 4.8 4.1 24 130 0.10 6.4

3.4 8-7501 9-7726 8-7500 60 95 3.68 4.8 4.1 24 130 0.25 6.4 6 8-7501 9-7726 8-7500 60 105 1.65 4.8 4.1 24 130 0.25 6.4

10 8-7501 9-7726 8-7500 60 105 1.14 4.8 4.1 24 130 0.25 6.4 13 8-7501 9-7726 8-7500 60 105 0.56 4.8 4.1 24 130 0.50 6.4 19 8-7501 9-7726 8-7500 60 115 0.25 4.8 4.1 24 130 NR NR 25 8-7501 9-7726 8-7500 60 115 0.13 4.8 4.1 24 130 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (lpm)

Pierce

Delay

Pierce Height

APPENDIX A-6 Manual 0-2815

Cutting Speed Charts (continued)

Torch Head

9-8403

A-02889

Electrode

9-8407

Gas Distributor

(See Chart)

Tip

(See Chart)

Shield Cup

(See Chart)

US M easu r em en t s

Ai r Plasma C utti ng D at a C hart

PC M- 102 A u t omated T orch Wit h A u t omated Pak Mast er 75X L Pl u s

St ai n less Steel

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

inches Cat. No. Cat. No. Cat . No. amps vdc inches/min i nches psi Plasma Tot al seconds

20 ga 9-8401 9-8411 9-8400 40 80 250 0. 187 65 50 180 0. 00 0.187 16 ga 9-8401 9-8411 9-8400 40 90 150 0. 187 65 50 180 0. 00 0.187 10 ga 9-8401 9-8411 9-8400 40 92 60 0.187 65 50 180 0.00 0. 18 7

7 ga 9-84 01 9-8411 9-8400 40 95 45 0. 18 7 65 50 180 0.00 0.187

1/4 9-8401 9-8411 9- 8400 40 95 21 0.187 65 50 180 0.50 0.187 3/8 9-8401 9-8411 9- 8400 40 105 12 0.187 65 50 180 1.00 0.187 1/2 9-8401 9-8411 9- 8400 40 110 6 0.187 65 50 180 1.50 0.187

16 ga 8-7501 9-7726 8-7500 60 95 130 0. 188 60 50 275 0. 25 0.200

1/4 8-7501 9-7726 8- 7500 60 100 45 0.188 60 50 275 0.50 0.200 3/8 8-7501 9-7726 8- 7500 60 100 25 0.188 60 50 275 0.50 0.200 1/2 8-7501 9-7726 8- 7500 60 105 16 0.188 60 50 275 NR NR 5/8 8-7501 9-7726 8- 7500 60 115 12 0.188 60 50 275 NR NR 3/4 8-7501 9-7726 8- 7500 60 115 8 0.188 60 50 275 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (SCFH)

Pierce

Delay

Pierce

Height

inches

Metri c M easuremen t s

Ai r Plasma C utti ng D at a C hart

PC M- 102 A u t omated T orch Wit h A u t omated Pak Mast er 75X L Pl u s

St ai n less Steel

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

mm Cat. No. Cat. No. Cat . No. amps vdc m / min mm bar Plasma Tot al seconds

0.9 9-8401 9-8411 9-8400 40 80 6.35 4.7 4.5 24 85 0.00 4.7

1.5 9-8401 9-8411 9-8400 40 90 3.81 4.7 4.5 24 85 0.00 4.7

3.4 9-8401 9-8411 9-8400 40 92 1.52 4.7 4.5 24 85 0.00 4.7

4.6 9-8401 9-8411 9-8400 40 95 1.14 4.7 4.5 24 85 0.00 4.7 6 9-8401 9-8411 9-8400 40 95 0.53 4.7 4.5 24 85 0.50 4.7

10 9-8401 9-8411 9-8400 40 105 0.30 4.7 4.5 24 85 1.00 4.7 13 9-8401 9-8411 9-8400 40 110 0.15 4.7 4.5 24 85 1.50 4.7

1.5 8-7501 9-7726 8- 7500 60 95 3.30 4.8 4.1 24 130 0.25 5.1 6 8-7501 9-7726 8-7500 60 100 1.14 4.8 4.1 24 130 0.50 5.1

10 8-7501 9-7726 8-7500 60 100 0.64 4.8 4.1 24 130 0.50 5.1 13 8-7501 9-7726 8-7500 60 105 0.41 4.8 4.1 24 130 NR NR 16 8-7501 9-7726 8-7500 60 115 0.30 4.8 4.1 24 130 NR NR 19 8-7501 9-7726 8-7500 60 115 0.20 4.8 4.1 24 130 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (lpm)

Pierce

Delay

Pierce

Height

Manual 0-2815 A-7 APPENDIX

APPENDIX 5: CE AUTOMATED PAK MASTER 75XL PLUS

SYSTEM DATA

Torch Specifications

Torch Specifica tions For

Pa k Ma ste r 75XL Pl us Powe r S upply

Cutting Range

Mat erial Mild St eel

Up to 3/4 inch (19 mm )

Speed 10 ipm (0.25 m pm )

Pierce Rating

Mat erial Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance

3/8 inch (9.5 m m )

Gouging

Width 1/8 inch (3.2 mm) Depth 1/8 inch (3.2 mm)

Number Passes Single

Speed 20 ipm (0.5 m pm )

Bevel Cut Capability

Degrees 0° to 45°

Material Thickness 1/4 inch (6.3 mm)

Gas Re quirem ent

Type Gas Ai r or Nit rogen (N2)

Operating P res sure See Speed Charts

Max Input P res sure 125 psi (8.6 bar)

Cutt ing & Gouging

Total Flow

See S peed Charts

Cut Quality on Various Materials and Thicknesses

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

Table 4-A Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Char acteristics

Carbon Steel Air Good - Excellent

Gage

3/4 inch

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

Nitrogen Good

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

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

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

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

Torch Consumables

Standard Shield Cup

Catalog No. 8-7500

40 Amp Shield Cup (Gray)

Catalog No. 9-8400

Cutting Tip, Air/N2

60 Amp (0.049 in)

Catalog No. 9-7726

Gouging Tip, Air (0.073 in Orifice)

Catalog No. 8-7506

Electrode (SureLok)

General Purpose

Catalog No. 9-8402

Gas Distributor

Catalog No. 8-7501

Copper Shield Cup

Catalog No. 8-7496

Hi-Vis Shield Cup (Black)

Catalog No. 8-7525

Cutting/Drag Tip, Air/N2

40 Amp (0.031 in)

Catalog No. 9-8411

Gas Distributor

40 Amp

Catalog No. 9-8401

Gouging Gas Distributor

Catalog No. 8-7508

A-02945

APPENDIX A-8 Manual 0-2815

Cutting Speed Charts

Torch Head

9-8403

A-02946

Electrode

9-8402

Gas Distributor

(See Chart)

Tip

(See Chart)

Shield Cup

(See Chart)

US M easu r em en t s

Ai r Plasma C utti ng D at a C hart

PCM-102 Auto mated Torch With CE Au to mated Pak Master 75XL Plus

Aluminum

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

inches Cat. No. Cat. No. Cat . No. amps vdc inches/min i nches psi Plasma Tot al seconds

20 ga 9-8401 9-8411 9-8400 40 93 350 0. 187 65 50 180 0. 00 0.187 16 ga 9-8401 9-8411 9-8400 40 95 275 0. 187 65 50 180 0. 00 0.187 10 ga 9-8401 9-8411 9-8400 40 95 100 0. 187 65 50 180 0. 00 0.187

7 ga 9-84 01 9-8411 9-8400 40 100 70 0.187 65 50 180 0.00 0.187

1/4 9-8401 9-8411 9- 8400 40 107 30 0.187 65 50 180 0.50 0.187 3/8 9-8401 9-8411 9- 8400 40 110 18 0.187 65 50 180 0.50 0.187

1/2 9-8401 9-8411 9- 8400 40 115 10 0.187 65 50 180 1.00 0.187 16 ga 8-7501 9-7726 8-7500 60 100 375 0.188 60 50 275 0.10 0.25 10 ga 8-7501 9-7726 8-7500 60 100 225 0.188 60 50 275 0.10 0.25

1/4 8-7501 9-7726 8- 7500 60 100 90 0.188 60 50 275 0.15 0.25

1/2 8-7501 9-7726 8- 7500 60 100 30 0.188 60 50 275 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (SCFH)

Pierce

Delay

Pierce

Height

inches

Metri c M easuremen t s

Ai r Plasma C utti ng D at a C hart

PCM-102 Auto mated Torch With CE Au to mated Pak Master 75XL Plus

Aluminum

Single Gas Torch - Air Plasma / Air Secondary

Material

Thicknes s

mm Cat. No. Cat. No. Cat . No. amps vdc m / min mm bar Plasma Tot al seconds

0.8 9-8401 9-8411 9-8400 40 93 8.89 4.7 4.5 24 85 0.00 4.7

1.3 9-8401 9-8411 9-8400 40 95 6.99 4.7 4.5 24 85 0.00 4.7

2.6 9-8401 9-8411 9-8400 40 95 2.54 4.7 4.5 24 85 0.00 4.7

3.7 9-8401 9-8411 9- 8400 40 100 1.78 4.7 4.5 24 85 0.00 4.7 6 9-8401 9-8411 9-8400 40 107 0.76 4.7 4.5 24 85 0.50 4.7

10 9-8401 9-8411 9-8400 40 110 0.46 4.7 4.5 24 85 0.50 4.7 13 9-8401 9-8411 9-8400 40 115 0.25 4.7 4.5 24 85 1.00 4.7

1.3 8-7501 9-7726 8- 7500 60 100 9.53 4.8 4.1 24 130 0.10 6.4

2.6 8-7501 9-7726 8- 7500 60 100 5.72 4.8 4.1 24 130 0.10 6.4 6 8-7501 9-7726 8-7500 60 100 2.29 4.8 4.1 24 130 0.15 6.4

13 8-7501 9-7726 8-7500 60 100 0.76 4.8 4.1 24 130 NR NR

Gas

Distributor

Tip

Shield

Cup

Amperage

Output

Volts

Speed Standoff

Plasma

Pressure

Flow (lpm)

Pierce

Delay

Pierce

Height

Manual 0-2815 A-9 APPENDIX

Cutting Speed Charts (continued)

Torch Head

9-8403

A-02946

Electrode

9-8402

Gas Distributor

(See Chart)

Tip

(See Chart)

Shield Cup

(See Chart)

US M e asuremen t s

Air Plasma Cutting Dat a Chart

PC M -102 A uto mated Torch Wi t h CE A u t omated Pak Master 75XL Plus