Tweco 15XC User Manual

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MERLIN

™

PAK® 15XC

Plasma Cutting System

October 6, 1999

Instruction Manual

Manual No. 0-2251

WARNING

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

WARNING

While the information contained in this Instruction Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use.

Merlin PAK 15XC Plasma Cutting System With PCH/M-150 Torch Instruction Manual Number 0-2251

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

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 the Merlin PAK 15XC Plasma Cutting System With PCH/M-150 Torch Instruction Manual, whether such error results from negligence, accident, or any other cause.

Printed in the United States of America

October 6, 1999

TABLE OF CONTENTS

SECTION 1:

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

1.01 Notes, Cautions and Warnings ...................................................................... 1

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

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

1.04 Note, Attention et A v ertissement ................................................................... 3

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

1.06 Documents De Reference ............................................................................. 5

1.07 Declaration of Conformity .............................................................................. 7

1.08 Statement of W arr anty................................................................................... 8

SECTION 2: INTR ODUCTION & DESCRIPTION........................................................................ 9

2.1 SYSTEM DESCRIPTION ................................................................................ 9

2.2 POWER SUPPLY SPECIFICATIONS ............................................................ 10

2.3 TORCH SPECIFICATIONS............................................................................ 11

2.4 OPTIONS AND ACCESSORIES ................................................................... 13

2.5 THEORY OF OPERATION ............................................................................ 14

SECTION 3: INSTALLATION PROCEDURES ........................................................................... 17

3.1 UNPACKING THE SYSTEM .......................................................................... 17

3.2 LOCATION .................................................................................................... 18

3.3 PLASMA AND SECONDARY CONNECTIONS............................................. 18

3.4 ELECTRICAL CONNECTIONS ..................................................................... 22

3.5 W ORK AND GR OUND CONNECTIONS....................................................... 24

3.6 COOLANT INSTALLATION............................................................................ 25

3.7 AUXILIARY CONNECTIONS......................................................................... 26

3.8 LIFTING THE PO WER SUPPLY.................................................................... 28

SECTION 4: OPERATION ......................................................................................................... 29

4.1 OPERATING CONTROLS ............................................................................. 29

4.2 PRE-OPERATION SET -UP............................................................................ 32

4.3 TORCH PARTS SELECTION ........................................................................ 33

4.4 GAS SELECTION FOR PLASMA CUTTING................................................. 36

4.5 PLASMA CUTTING OPERATION ................................................................. 40

4.6 HAND TORCH OPERATION ......................................................................... 44

4.7 MACHINE TORCH OPERATION ................................................................... 46

4.8 PIERCING ..................................................................................................... 49

4.9 GOUGING OPERATION ............................................................................... 50

4.10 COMMON OPERATING ERRORS .............................................................. 53

4.11 CUTTING SPEEDS ..................................................................................... 54

4.12 SEQUENCE OF OPERATION ..................................................................... 61

TABLE OF CONTENTS (continued)

SECTION 5: CUST OMER/OPERATOR SERVICE..................................................................... 63

5.1 TORCH MAINTENANCE ............................................................................... 63

5.2 HAND TORCH HEAD REPLACEMENT ........................................................ 64

5.3 MACHINE TORCH HEAD REPLACEMENT .................................................. 66

5.4 HAND TORCH SWITCH REPLACEMENT .................................................... 68

5.5 HAND TORCH LEADS REPLACEMENT....................................................... 69

5.6 MACHINE TORCH LEADS REPLACEMENT ................................................ 71

5.7 LEADS EXTENSION KITS - HAND TORCH.................................................. 73

5.8 LEADS EXTENSION KITS - MACHINE TORCH ........................................... 75

5.9 POWER SUPPLY MAINTENANCE................................................................ 78

5.10 TROUBLESHOOTING THEORY ................................................................. 79

5.11 TROUBLESHOOTING GUIDE ..................................................................... 83

5.12 SERVICE AND TEST PROCEDURES ........................................................ 89

SECTION 6: PARTS LISTS........................................................................................................ 99

6.1 ABOUT THE PARTS LIST ............................................................................. 99

6.2 SYSTEM COMPONENTS AND ACCESSORIES ........................................ 100

6.3 ACCESS PANEL COMPONENTS ............................................................... 102

6.4 FRONT PANEL/CHASSIS COMPONENTS................................................. 103

6.5 REAR PANEL COMPONENTS.................................................................... 104

6.6 BASE COMPONENTS ................................................................................ 106

6.7 UPPER CHASSIS COMPONENTS............................................................. 108

6.8 MAIN HEATSINK COMPONENTS .............................................................. 110

6.9 TORCH COMPONENTS ............................................................................. 112

6.10 TORCH ACCESSORIES ........................................................................... 114

APPENDIX I: LADDER DIAGRAM - 120 VAC.......................................................................... 115

APPENDIX II: LADDER DIA GRAM - 15 VDC .......................................................................... 116

APPENDIX III: DIGITAL CURRENT CONTROL INTERF ACE.................................................. 117

APPENDIX IV: CNC INTERFACE ............................................................................................ 118

APPENDIX V: POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE .................... 119

APPENDIC VI: REMOTE CONTROL CHASSIS SCHEMATIC................................................. 120

APPENDIX VII: RECOMMENDED ROUTINE MAINTENANCE SCHEDULE

FOR WATER COOLED PLASMA CUTTING SYSTEMS .................................................. 121

APPENDIX VIII: SYSTEM SCHEMATIC .................................................................................. 122

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 procedure which, if not properly followed, may cause damage to the equipment.

W ARNING

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

1.02 Important Safety Precautions

WARNINGS

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

GASES AND FUMES

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

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

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

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

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

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

• For information on how to test for fumes and gases in your workplace, refer to item 1 in 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.

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

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

Date: 6/22/99 1 GENERAL INFORMA TION

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.

ELECTRIC SHOCK

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

• W ear 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 wher e fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen 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 pr otect 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 injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly pr otected.

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

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

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

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

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

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

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, W ashington, 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, W ashington, D.C. 20402

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

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

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

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

GENERAL INFORMATION 2 Date 6/22/99

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. NFP A Standar d 70, NA TIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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

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

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

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

14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

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

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 :

A VERTISSEMENT

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

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.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votr e distributeur local si vous avez des questions.

FUMÉE et GAZ

NOTE

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

ATTENTION

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

Date: 6/22/99 3 GENERAL INFORMA TION

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.

• 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.

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 P AS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

CHOC ELECTRIQUE

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

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

• Réparez ou remplacez toute pièce usée ou endommagée.

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

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir 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.

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 oculaire.

• 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.

GENERAL INFORMATION 4 Date 6/22/99

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

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

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

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. 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.

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 TRAVAIL 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 aupr ès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRA TIQUES 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 York, NY 10018

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

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

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

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), 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

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, Batterymarch 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 W1 17.2, 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. ivret 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

Date: 6/22/99 5 GENERAL INFORMA TION

14. Norme A WSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

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

GENERAL INFORMATION 6 Date 6/22/99

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2

W est Lebanon, New Hampshire 03784 USA

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

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements among them are:

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

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

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

ated accessories.

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

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

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

Manufacturers responsible repr esentative: Steve W ard

Director of Operations Thermadyne UK Chorley England

Date: 6/22/99 7 GENERAL INFORMA TION

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 thereof and substantiation that the product has been stor ed, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry prac tice, and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

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

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

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

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

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

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , 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 80XL shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).

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

Parts

XL Plus Series & Parts Parts

PAK Units, Power Supplies CutMaster 80XL 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 Year 1 Year 1 Year Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 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. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective May 6, 1999

GENERAL INFORMATION 8 Date 6/22/99

SECTION 2: INTRODUCTION & DESCRIPTION

2.1 SYSTEM DESCRIPTION

PAK 15XC Power Supply

Work Cable

Figure 2-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging System

The Merlin PAK 15XC

System Includes:

PCM-150 Machine Torch

• PAK 15XC 150 Amp Power Supply

• PCH-150 90° or 70° Hand Torch

• 25 ft (7.6 m) or 50 ft (15.2 m) Torch Leads

• PCH/M-150 Spare Parts Kit

• 25 ft (7.6 m) Work Cable and Clamp

• Running Gear and Handle

• Air Line Filter Assembly (or) High Pressure Regulators

NOTE

System options and accessories are listed in Section 2.4.

Torch Leads

Remote Control Panel

A-00875

Spare Parts Kit

with Running Gear and Handle

(or) PCM-150 Machine Torch with Mounting Assembly

Manual 0-2251 9 INTRODUCTION & DESCRIPTION

2.2 POWER SUPPLY SPECIFICATIONS

Shipping Weight

Enclosure Only:

Input Power

Output Power

Duty Cycle

A-00876

Voltage Frequency Phase Amperage

200/220/230 50 or 60 Hz 3 84/76/73 380/415/460 50 or 60 Hz 3 44/40/36

500/575 50 or 60 Hz 3 34/29

Table 3-A (page 23) contains information on power input, current ratings, circuit protection, and wire sizes.

Continuously adjustable from 50 to 150 amps 100% duty cycle. Approximate Shipping Weight - 678 lbs (308 kg)

34.25 in

24.12 in

(0.61 m)

(0.87 m)

Figure 2-B Power Supply Dimensions

38.38 in

(0.98 m)

Fully Assembled: Width: 28.50 in (0.72 m) Height: 43.38 in (1.10 m) Depth: 43.75 in (1.11 m)

INTRODUCTION & DESCRIPTION 10 Manual 0-2251

2.3 TORCH SPECIFICATIONS

Torch Configurations

Torch Leads Lengths

Current Rating

Cutting Range

Gas Requirements

• PCH-150 90° Hand Torch

• PCH-150 70° Hand Torch

• PCM-150 Machine Torch Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m).

Extendable in increments of 25 ft or 50 ft up to a maximum of 150 ft (45.7 m) with available leads extension packages (see Section 2.4, Options and Accessories)

150 Amps Maximum, Direct Current Straight Polarity Hand and Machine Torch rated at 100% Duty Cycle

Most materials up to 2.0 in (50.8 mm)

Plasma

Gases

• Compressed Air

• Oxygen (O

• Argon/Hydrogen (Ar/H

• Nitrogen (N

Pressure

50 psi

(3.4 BAR,

340 kPa)

Hot Flow *

For Cutting:

22-28 scfh

(10.4-13.2 lpm)

For Gouging:

22-43 scfh

(10.4-20.3 lpm)

Secon-

dary

• Compressed Air

• Nitrogen (N

• Carbon Dioxide (CO

• Water

50 psi

(3.4 BAR,

340 kPa)

Min.50 psi

(3.4 BAR,

340 kPa)

For Cutting or

Gouging:

220 scfh

(103 lpm)

8 gph

(30.3 lph)

NOTE

* Hot flow is measured with the main arc activated. When

pressure is set correctly the plasma gas flow rate is significantly higher until the arc is initiated.

PCH-150 90° Hand Torch (without Leads) - 1.0 lb (.45 kg)Weight

(continued)

Manual 0-2251 11 INTRODUCTION & DESCRIPTION

2.3 TORCH SPECIFICATIONS (continued)

PCH-150 90o Hand Torch

13.31 in

(338 mm)

1.62 in

(41 mm)

PCH-150 70

Hand Torch

13.87 in

(352 mm)

1.62 in

(41 mm)

3.81 in

(97 mm)

3.96 in

(101 mm)

1.38 in

(35 mm)

PCM-150 Machine Torch With Rack

And Pinion Mounting Assembly

6.75 in (171 mm) Min.

16.75 in (425 mm) Max.

17.65 in (448 mm)

Figure 2-C PCH/M-150 Torch Dimensions

1.62 in

(41 mm)

A-02685

INTRODUCTION & DESCRIPTION 12 Manual 0-2251

2.4 OPTIONS AND ACCESSORIES

Power Supply Options

and Accessories

NOTE

Torch Options

and Accessories

• Remote Control Panel - For machine torch systems, the low profile operator control panel allows system control from a remote location with 25 or 50 ft (7.6 or 15.2 m) cable included.

• Remote Pendant Control - Hand-held remote contactor control device for machine torch systems.

• Computer Control Cable Kits - For interfacing the power supply with a computer or auxiliary control device. Available in 5 or 10 ft (1.5 or 3.0 m) lengths.

• SC-5 Standoff Control - For machine torch systems, the SC-5 automatically finds height and maintains torch standoff with a high speed torch lifter motor.

• High Pressure Regulators - Available for air, oxygen, argon/hydrogen, nitrogen, CO

2, and water.

See Section 6.2, System Components and Accessories for ordering information.

• Spare Parts Kits - Kits contain replacement front-end torch parts and tools. Spare parts kits are available for air cutting with hand or machine torch, multi-gas cutting with hand or machine torch, or for gouging.

NOTE

• Leads Extension Packages - Available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. For extending leads up to a maximum of 150 ft (45.7 m).

• Metal Shield Cup - For durability in hand cutting.

See Section 6.9, Torch Components and Section 6.10, Torch Accessories for ordering information.

Manual 0-2251 13 INTRODUCTION & DESCRIPTION

2.5 THEORY OF OPERATION

,



Plasma Arc Cutting and

Gouging

Plasma Gas Flow

Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away. The Merlin PAK 15XC is a high performance plasma cutting system designed to cut most metals up to two inches thick.

With a simple change of torch parts, the system can also be used for plasma arc gouging. Plasma arc gouging is used to remove material to a controlled depth and width.

The torch uses a cool plasma gas such as compressed air, nitrogen, argon/hydrogen, or oxygen. The plasma gas flows into the torch through the plasma torch lead and is channelled into Zone A (Figure 2-D), where a pilot arc between the torch electrode and tip heats and ionizes the gas. The main cutting arc transfers to the workpiece through the column of plasma gas as it flows out through the torch tip orifice.

Power Supply

(-)

Zone D

Zone C

(+)

Figure 2-D Theory of Operation

Zone A Zone B

Workpiece

Coolant

Plasma Gas

Secondary Gas

A-00900

INTRODUCTION & DESCRIPTION 14 Manual 0-2251

2.5 THEORY OF OPERATION (continued)

Plasma Gas Flow

(continued)

Secondary Flow

Coolant Flow

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

The torch also uses a secondary gas (or water) which assists the high velocity plasma gas in blowing molten metal from the area of the cut to create a fast, slag-free cut. The secondary flow (Zone C, Figure 2-D) also cools the torch and minimizes heat input to the workpiece. The secondary flows into the torch through the secondary lead, down around the outside of the torch liner, and out between the tip and shield cup around the plasma arc. Compressed air, supplied by either a cylinder or plant air system, nitrogen, CO

2, or water can be used as the secon-

dary. An exception to this is oxygen plasma operation, which requires no secondary.

The torch is liquid-cooled by an internal closed cooling system. De-ionized coolant is distributed from a reservoir in the power supply through the coolant supply lead. At the torch, the coolant is circulated around the torch tip and electrode (Zone D, Figure 2-D), where the extra cooling effect helps to increase parts life. The coolant then flows back to the power supply through the return lead.

Pilot Arc

Main Cutting Arc

RF Shielding

When the torch is started, a DC pilot arc is established between the electrode and cutting tip after a two-second pre-flow delay. The pilot arc is initiated by a momentary high frequency pulse. The pilot arc creates a path for the main cutting arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated.

The PAK 15XC accepts 50 or 60 Hz three-phase line input. An internal changeover switches input line voltages in three ranges, for 200/220/230V, 380/415/460V, or 500/ 575V operation. The power supply converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead. The positive output is connected to the workpiece via the work cable and clamp connection.

All machine torch systems are shielded to minimize radio frequency (RF) interference which results from the high frequency arc initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads.

Manual 0-2251 15 INTRODUCTION & DESCRIPTION

2.5 THEORY OF OPERATION (continued)

Interlocks

Parts-In-Place Interlock

Gas Pressure Interlock

Thermal Interlock

The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the torch switch (or control device) must be used to restart the system.

The torch has a built-in parts-in-place interlock that prevents accidental torch starting when torch parts are not properly installed. A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly. If not satisfied, the switch interrupts power to the tip and electrode.

Pressure switches act as an interlock for the gas supplies. If supply pressure falls below minimum requirements the pressure switches will open, shutting off the power to the contactors, and the GAS indicator will go out. When adequate supply pressure is available the pressure switches close, allowing power to be resumed for cutting.

Thermal overload sensors are located in the transformer and main heatsink in the power supply. If one of these components is overheated the appropriate switch will open up, causing the temperature light to turn from green to red and shutting off power to the main contactor. When the overheated component cools down the switch will close again and allow operation of the system.

INTRODUCTION & DESCRIPTION 16 Manual 0-2251

SECTION 3: INSTALLATION PROCEDURES

3.1 UNPACKING THE SYSTEM

The power supply is skid-mounted and protected with a carton and padding material to prevent damage during shipment. The power supply, work cable, torch, and torch leads are factory-assembled and packaged together. Also packed with the system are:

1. Remove all packing material.

2. Locate the packing list. Use the list to identify and

3. Inspect each item for possible shipping damage. If

The unit is mounted on the skid with two brackets. To remove the unit from the skid, refer to Figure 3-A and:

• Spare parts kit for the torch

• Coolant de-ionizing cartridge

• Air filter assembly (for air systems)

account for each item.

damage is evident, contact your distributor before proceeding with system installation.

4. Remove the six bolts connecting the brackets to the

base of the unit.

5. Roll the unit off the skid backwards (rear wheels first).

Shipping Brackets

A-00953

Shipping Pallet

Three Bolts (Each Side)

Figure 3-A Unpacking the System

Manual 0-2251 17 INST ALLATION PROCEDURES

3.2 LOCATION

Choosing the Location

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

The power supply is air cooled and air flow through the front, rear, and side panels must not be obstructed. At least two feet (0.61 m) of clearance should be provided on all sides.

CAUTION

Operation without proper air flow will inhibit proper cooling and reduce duty cycle.

Review Operating Precautions (page iv) to be sure that the selected location meets all safety requirements.

3.3 PLASMA AND SECONDARY CONNECTIONS

Plasma Gas Requirements

Compressed air, oxygen (O2), nitrogen (N2), or argon/ hydrogen (Ar/H

2).

Pressure 50 psi (3.5 BAR)

Secondary Gas

Requirements

Secondary Water

Requirements

NOTE

CAUTION

Flow 22 - 28 scfh (10.4 - 13.2 lpm) For Cutting

22 - 43 scfh (10.4 - 20.3 lpm) For Gouging

Compressed Air, nitrogen (N

2), or carbon dioxide (CO2).

Pressure 50 psi (3.5 BAR)

Flow 220 scfh (103 lpm) For Cutting or Gouging

Tap Water

Pressure Min. 50 psi (3.5 BAR)

Flow 8 gph (30.3 lph) For Cutting

See Section 4.4, Gas Selection for Plasma Cutting, for detailed information on operation with various plasma and secondary options.

Maximum input gas pressure to the power supply's internal regulator must not exceed 125 psi (8.6 BAR).

INST ALLATION PROCEDURES 18 Manual 0-2251

3.3 PLASMA AND SECONDARY CONNECTIONS (continued)

Input Gas Connections

(Air Operation)

Air Line Filter Installation

Systems that are set up for operation with shop air require installation of the air line filter on the plasma input fitting on the rear panel. These systems are shipped with the following components:

(1) Air Line Filter Assembly (For Plasma Line) (2) Hex Nipples (1) 90° Female Elbow (1) 90° Street Elbow (1) Y-Hose Assembly

Refer to Figure 2-B and:

1. Thread the first hex nipple into the 90° female elbow.

2. Thread the other end of the hex nipple into the outlet

of the air filter assembly. Tighten both sides securely.

3. Thread the second hex nipple into the fitting on the

rear panel marked PLASMA.

4. Thread the 90° street elbow into the inlet side of the air

filter assembly.

(continued)

Secondary Gas

Plasma Gas

Fitting

Hex Nipple

Female Elbow

Hex Nipple

Air Filter Assembly

(Plasma Line Only)

Fitting

Y-Hose

Assembly

Street Elbow

From Supply

Figure 3-B Air Line Filter Installation

A-00902

Manual 0-2251 19 INST ALLATION PROCEDURES

3.3 PLASMA AND SECONDARY CONNECTIONS (continued)

Air Line Filter Installation

(continued)

Input Gas Connections

(Multi-Gas Operation)

WARNING

5. Connect one side of the Y-hose assembly into the other

side of the 90° street elbow.

6. Thread the 90° female elbow onto the other end of the

second hex nipple. Fasten both sides securely.

7. Connect the other side of the Y-hose assembly to the fitting on the rear panel marked SECONDARY.

8. Connect the supply line from the source to the Y-hose assembly. The supply hose must be 3/8 in (10 mm) min. inside diameter to provide adequate air flow.

1. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foriegn material. Momentarily open each cylinder valve to blow out any dust which may be present.

Do not stand in front of the valve outlet when opening.

2. Each cylinder must be equipped with an adjustable high-pressure regulator capable of pressures up to 125 psi (8.6 BAR) maximum and flows of up to 220 scfh (103 lpm) for cutting or 470 scfh (222 lpm) for gouging.

CAUTION

Maximum input pressure to the power supply's internal regulator must not exceed 125 psi (8.6 BAR).

Refer to the regulator manufacturer's specifications for installation and maintenance procedures. Refer to Section 6.2, System Components and Accessories, for a listing of available high-pressure regulators.

3. Connect the plasma supply hose (black) to the plasma gas cylinder and to the input fitting on the rear panel marked PLASMA.

4. Connect the secondary supply hose (yellow) to the secondary gas cylinder and to the input fitting on the rear panel marked SECONDARY.

NOTE

A typical 50 lb. CO

2 cylinder can deliver a continuous flow

rate of 35 scfh (16.5 lpm). To obtain the required flow rate for the torch, it may be necessary to manifold several CO

cylinders. Continuous flow requirements will depend on the specific application and duty cycle.

INST ALLATION PROCEDURES 20 Manual 0-2251

3.3 PLASMA AND SECONDARY CONNECTIONS (continued)

Secondary Water

Connections

NOTE

Secondary Water

1. The water source must be capable of delivering a minimum water pressure of 50 psi (3.5 BAR) and flow of 8 gph (30.3 lph).

2. Connect the secondary water supply hose to the rear panel fitting marked SEC. WATER.

The water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.

Secondary Gas

High Flow

Water Shield

Remote Interface

Connection

Plasma Gas

A-00874

Figure 3-C Rear Panel Connections

Manual 0-2251 21 INST ALLATION PROCEDURES

3.4 ELECTRICAL CONNECTIONS

Electrical Requirements

Electrical Connections

WARNING

The PAK 15XC power supply is designed to accept a variety of input voltages:

• 200/220/230 VAC

• 380/415/460 VAC

• 500/575 VAC

The electrical power source must conform to local electric code and the following recommended circuit protection and wiring requirements (see Table 3-A).

1. Check the three-phase electrical power source for line voltage and proper circuit protection and wiring (see Table 3-A).

Disconnect primary power at the source before connecting the primary power cable to the power supply.

Refer to Figure 3-D and:

2. Remove the left side panel of the power supply (as viewed from the front).

3. Check the bus bar configuration on the input voltage terminal board . The bus bar configuration must correspond with the available line voltage.

4. If necessary, re-position the bus bars to correspond to the available line voltage.

5. Insert the primary power cable through the strain relief in the rear panel of the power supply.

6. Connect the electrical ground wire to the ground lug on the base of the unit.

7. The other three leads attach to terminals L1, L2, and L3 on the input terminal board.

INST ALLATION PROCEDURES 22 Manual 0-2251

3.4 ELECTRICAL CONNECTIONS (continued)

200, 208,

220, or 230

380, 415,

or 460

500, or 575

Busbar Connections For Input Voltages

A-00904

Voltage Power Input Current Frequency Phase Recommended

(Volts) (kVA) (Amps) (Hz) Fuse Size Wire Size

200 29 84 50 3 90 amps AWG 4 208 29 81 60 3 90 amps AWG 4 220 29 76 50 3 90 amps AWG 4 230 29 73 60 3 90 amps AWG 6 380 29 44 50 3 50 amps AWG 8 415 29 40 50 3 45 amps AWG 8 460 29 36 60 3 40 amps AWG 10 500 29 34 50 3 40 amps AWG 10 575 29 29 60 3 35 amps AWG 10

Table 3-A Line Voltages, Circuit Protection and Recommended Wire Size

(Based on Table 310-16, 1987 National Electric Code).

Primary Power

Cable

Input Voltage

Terminal Board

Busbars

Strain Relief

Fitting

Figure 3-D Input Voltage Connections and Bus Bar Configuration

Ground

Connection

A-00893

Manual 0-2251 23 INST ALLATION PROCEDURES

3.5 WORK AND GROUND CONNECTIONS

Machine torch systems are equipped with shielded torch leads to minimize RF interference from high frequency pilot arc initiation. Follow these grounding procedures when installing machine torch systems:

1. Connect the ground wire (from the front panel) to a solid earth ground, which is created by driving a copper rod approximately 7 ft (2 m) into the earth. Locate the rod as close as possible to the power supply. Cut the ground wire to the appropriate length.

2. The power supply and work table should be grounded to the same earth ground. The control device should be grounded separately to a similar earth ground.

3. To minimize RF interference, torch leads should be run as far as possible from any CNC components, control lines, or primary power lines.

4. Connect work ground cables as shown (Figure 3-E).

3-Phase

Input

Earth

Ground

Power

Supply

Power Supply Remote Panel

CNC Control

Earth

Ground

Work Cable

Standoff Control

Console

Green Cable

(Work Ground)

Standoff Control

Remote Panel

Workpiece

Work Ground

A-00880

Figure 3-E Proper Work and Ground Cable Connections

INST ALLATION PROCEDURES 24 Manual 0-2251

3.6 COOLANT INSTALLATION

Coolant Installation

CAUTION

Refer to Figure 3-F and:

1. Locate the coolant de-ionizing cartridge and remove from the plastic shipping bag.

2. Remove the plastic cover from the coolant reservoir filler.

3. Place the de-ionizing cartridge into the basket in the coolant reservoir.

4. Fill the reservoir to the line marked FULL on the rear panel.

Use only Thermal Arc torch coolant. Use of any other coolant can result in torch damage, insufficient thermal protection, and/or pilot arc interference.

The deionizer cartridge should be checked periodically. The contents of the cartridge take on a light straw-colored appearance when spent. Replace the cartridge when the material has completely changed color.

Coolant Reservoir

Filler Cap

Deionizer

Bag

Basket

A-00872

Coolant Level Indicator

Figure 3-F Coolant Reservior and De-ionizing Cartridge

Manual 0-2251 25 INST ALLATION PROCEDURES

3.7 AUXILIARY CONNECTIONS

Remote Operator Control

Panel Installation

Computer Control Interface

Installation

SC-5 Standoff Control

Installation

High-Flow Water Shield

Installation

The Remote Operator Control Panel consists of the control panel enclosure and cables required for connection.

1. Connect the control cable to the receptacle marked REMOTE (J15) on the rear panel.

2. Connect the other end of the control cable to the receptacle marked PS (J37) on the remote operator control panel enclosure.

1. Connect the interface cable to the receptacle marked CNC (J29) on the remote operator control panel.

2. Connect the other end to the customer-supplied motion control device (refer to Appendix IV, CNC Interface).

The SC-5 Standoff Control consists of a control panel, an electronic unit, a voltage divider board, a torch lifter motor, and cables required for installation (refer to Figure 3-G). It is ordered and shipped separately and must be installed according to the SC-5 Standoff Control Instruction Manual, which is included with the SC-5 unit.

Refer to the High-Flow Water Shield Instruction Manual and:

1. Connect the high-flow starter control cable to the receptacle marked HI-FLOW WATER SHIELD on the power supply rear panel. The receptacle is 115VAC to activate the high-flow water shield.

2. To shut off the high-flow water shield remove the control cable or disconnect power to the high-flow water shield unit.

INST ALLATION PROCEDURES 26 Manual 0-2251

3.7 AUXILIARY CONNECTIONS (continued)

POWER SUPPLY

CNC

CONTROL

SC-5

CONTROL

CONSOLE

SC-5 REMOTE

CONTROL

POWER SUPPLY

REMOTE CONTROL

Cable Description Letter Designation

SC-5 Remote to Console A SC-5 Torch Lifter (Positioner) to Console B

WORK

GROUND

TORCH

POSITIONER

(LIFTER)

A-00879

SC-5 Console to Power Supply Remote C/F SC-5 Console to Power Supply D SC-5 Console to Work (Ground) E

NOTE - See Catalog Pages for ordering information.

Figure 3-G Typical Mechanized System Installation and Cable Interconnection Diagram

Manual 0-2251 27 INST ALLATION PROCEDURES

3.8 LIFTING THE POWER SUPPLY

WARNING Do not lift the power supply by the handles.

CAUTION

Do not lift a power supply equipped with a cylinder rack running gear.

The recommended method for lifting the power supply is to use a forklift (see Figure 3-H). Approach from the front or rear of the unit. Place the forks between the rear wheels or the front casters. Center the forks under the unit and carefully check for proper balance before lifting.

Approach From Front Or Rear

Do Not Lift From Sides

A-00873

Figure 3-H Lifting the Power Supply

INST ALLATION PROCEDURES 28 Manual 0-2251

SECTION 4: OPERATION

4.1 OPERATING CONTROLS

1 2

5 6

OFF

RUN

PURGE

Figure 4-A PAK 15XC Operating Control Panel

Control Indicator

1. ON/OFF Switch

2. RUN/SET/PURGE Switch

3. Current Control

SET

GAS

COOLANT

PRES.

COND.

PILOT

A-00887

100

125

AC TEMP

150

AMPS

Function

ON position activates all system control circuits. OFF position deactivates control circuits.

RUN position is used for torch operation. SET position is used for setting gas pressures. PURGE position is for purging the plasma gas line.

Selects output current from 50 to 150 amps (see Section

4.11, Cutting Speeds, for applications on various materials and thicknesses). Current control is disabled when Remote Operator Control Panel is used.

4. AC Power Indicator

Green light indicates AC power is being supplied to the system when the ON/OFF switch is in ON position.

5. TEMP Indicator

Green light indicates proper operating temperature. Red light indicates overheating. Unit must be allowed to cool.

6. GAS Indicator

In SET position, yellow light in SET mode indicates gas pressure switches are satisfied when gas is flowing to the torch. Light goes out in PURGE or RUN mode.

7. Coolant Pressure Indicator

8. Coolant Conductivity Indicator

Yellow light indicates adequate coolant pressure. Yellow light indicates proper coolant conductivity. Light

out indicates excessive coolant conductivity (resistivity less than 0.1 MΩ). Replace coolant and de-ionizer cartridge.

9. DC Indicator

Yellow light indicates main contactor closure supplying voltage to the power supply output and cutting current is available. Torch switch must be closed.

10. PILOT Indicator

Yellow light indicates pilot arc contactor closure. Light goes out when cutting arc is established and comes back on if cutting arc is interrupted.

Manual 0-2251 29 OPERA TION

4.1 OPERATING CONTROLS (continued)

Figure 4-B PAK 15XC Upper Gauge Panel

Control Indicator

1. Secondary Pressure Control

2. Secondary Pressure Gauge

3. Secondary Mode Selector

4. Coolant Pressure Gauge

5. Plasma Pressure Gauge

6. Plasma Pressure Control

Function

Adjusts secondary gas pressure. Pull knob out and turn clockwise to increase secondary pressure to desired level.

Displays secondary pressure from 0 - 100 psi (0 - 6.9 BAR). Selects secondary mode to gas, oxygen (no secondary), or

water. See Section 4.4, Gas Selection For Plasma Cutting, for applications on various materials and thicknesses.

Displays coolant pressure from 0 - 160 psi (0 - 11.0 BAR). Displays plasma gas pressure from 0 - 100 psi (0 - 6.9

BAR). Adjusts plasma gas pressure. Pull knob out and turn

clockwise to increase plasma pressure to desired level.

OPERA TION 30 Manual 0-2251

4.1 OPERATING CONTROLS (continued)

E-STOP

A-00575

Figure 4-C PAK 15XC Remote Operator Control Panel (RC6045)

Control Indicator

1. E-STOP (Emergency Stop)

2. RUN/PURGE Switch

3. START Switch

4. Start Enable Indicator

5. STOP Switch

6. CURRENT Control Adjustment

RUN

PURGE

START STOP

AMPS

CURRENT

PIERCE DELAY

CSD

4567

SPEED

LOW HIGH

Function

Immediately de-activates pump, motor, and all control circuits (logic circuit and control panel LED display remain on).

None functional. Activates gas flow, pilot arc, and main cutting arc. Green light indicates remote control logic has received start

signal from control device (CNC or START switch). Deactivates gas flow, pilot arc, and main cutting arc. Sets output current level from 50 to 150 amps.

7. AMPS Meter

8. CSD (Corner Slowdown) Control Adjustment

9. PIERCE DELAY Control Adjustment

10. LOW/HIGH SPEED Switch

Displays actual output during cutting operation. Preview mode displays expected output before starting a cut according to the current setting. A decimal point to the right of the display is lit whenever the meter is in preview mode. All three decimal points remain lit when displaying corner slowdown output or operating in corner slowdown mode. Left and center decimal points blinking indicates PIP (parts-in-place) circuit not satisfied.

Sets corner slowdown (CSD) output from 50 to 150 amps. Push STOP button to display corner slowdown output setting on AMP meter. Refer to Section 4.7, Machine Torch Operation for operating instructions.

Provides an adjustable time delay (approximately 0-11 seconds) which delays the CNC and 'OK-to-Move' signal, allowing time to pierce before the starting the cutting machine. Set PIERCE DELAY to zero for immediate 'OKto-Move' signal.

None functional.

Manual 0-2251 31 OPERA TION

4.2 PRE-OPERATION SET-UP

The pre-operation set-up procedure should be followed at the beginning of each shift:

WARNING

Coolant Check

Torch Check

Optional Auto-Restart

Settings

Input Power Check

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

1. Check the coolant level indicator and add coolant if necessary (see Section 3.6, Coolant Installation).

2. Check the torch for proper assembly (see Section 5.1, Torch Maintenance). Install proper torch parts for the application (see Section 4.3, Torch Parts Selection).

3. Select the desired pre-flow, post-flow, and auto-restart settings (see Section 4.5, Plasma Cutting Operation). The system is factory-set for normal auto-restart, which allows the pilot arc to restart instantly when the cutting arc is interrupted with the torch still activated. The system is factory-set for two-second pre-flow and tensecond post-flow.

4. Check the power source for proper three-phase input voltage. Make sure the input power terminal board in the power supply is set up for the available voltage (see Section 3.4, Electrical Connections). Connect primary power to the system (close main disconnect switch or plug unit in).

Plasma and Secondary

Supply Check

Line Purge

Output Selection

Plasma and Secondary

Pressure Settings

OPERA TION 32 Manual 0-2251

5. Select desired plasma and secondary (see Section 4.4, Gas Selection For Plasma Cutting). Make sure gas sources meet requirements (see Section 3.3, Plasma and Secondary Connections). Check connections and turn plasma and secondary supplies on.

6. Move the ON/OFF switch to ON position. An automatic forty second gas purge will let gas run to remove any condensation that may have accumulated in the torch and leads while the system was shut down. After the purge is complete, if the RUN/SET/PURGE switch is in SET position, gases will flow. If the switch is in PURGE position plasma gas only will flow. If the switch is in RUN position there will be no gas flow.

7. Select the desired current output level. Refer to Section

4.11, Cutting Speeds.

8. Move the RUN/SET/PURGE switch to SET position. Set plasma and secondary pressures (see Section 3.3, Plasma and Secondary Connections).

4.2 PRE-OPERATION SET-UP (continued)

Additional Line Purge 9. If additional purging of the plasma gas line is desired,

move the RUN/SET/PURGE switch to PURGE position. In PURGE mode, with secondary mode selector set to GAS, the GAS indicator will only plasma gas runs and the secondary gas flow switch is not satisfied.

10. Return the RUN/SET/PURGE switch to RUN. The system is now ready for operation.

not come on because

NOTE

Refer to Section 3.12 for detailed block diagram of the Sequence Of Operation.

4.3 TORCH PARTS SELECTION

WARNING

Shield Cup Selection

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

Shield Cups (See Figure 4-D) Cat. No.

• Ceramic Shield Cup (For Cutting) ........................ 9-5750

• Metal Shield Cup (For Cutting)............................. 9-5790

• Touch Cup (For Height Sensing with SC-5) ........ 9-5758

• Gouging Cup............................................................ 9-5774

Ceramic Shield Cup

(For Cutting)

Cat. No. 9-5750

Metal Shield Cup

(For Cutting)

Cat. No. 9-5790

Touch Cup

(For Height Sensing

with SC-5)

Cat. No. 9-5758

Gouging Cup

Cat. No. 9-5774

Figure 4-D Shield Cup Selection

Manual 0-2251 33 OPERA TION

4.3 TORCH PARTS SELECTION (continued)

WARNING

CAUTION

Tip Selection

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

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used.

Cutting tips and electrodes can be identified by the ring(s) around the diameter (see Figure 4-E). Air tips and electrodes have no rings, oxygen tips and electrodes have one ring, nitrogen tips and multi-gas (N

2 or Ar/H2) elec-

trodes have two rings, and argon/hydrogen tips have three rings.

Cutting Tips - Air Plasma Cat. No.

50 Amps (.043 in) ..................................................... 9-5748

100 Amps (.055 in) ................................................... 9-5747

150 Amps (.070 in) ................................................... 9-5746

Cutting Tips - O

2 Plasma

50 Amps (.043 in) ..................................................... 9-5753

Electrode Selection

100 Amps (.057 in) ................................................... 9-5752

150 Amps (.070 in) ................................................... 9-5751

Cutting Tips - N

2 Plasma

50 Amps (.043 in) ..................................................... 9-5765

100 Amps (.052 in) ................................................... 9-5766

150 Amps (.067 in) ................................................... 9-5767

Cutting Tips - ArH2 Plasma

150 Amps (.073 in) ................................................... 9-5775

Gouging Tips - Air or Multi-Gas

85 Amps (.078 in) ..................................................... 9-5756

150 Amps (.120 in) ................................................... 9-5755

Electrodes Cat. No.

Air Plasma - Cutting ............................................... 9-5749

Oxygen Plasma - Cutting ....................................... 9-5760

Multi-Gas (N

2 or Ar/H2)- Cutting ........................ 9-5754

OPERA TION 34 Manual 0-2251

4.3 TORCH PARTS SELECTION (continued)

Cutting Gouging

Air Plasma Oxygen Plasma Nitrogen Plasma Argon/Hydrogen Air or Multi-Gas

Air Plasma

50 Amp (.043) Tip

Cat. No. 9-5748

Air Plasma

100 Amp (.055) Tip

Cat. No. 9-5747

Air Plasma

150 Amp (.070) Tip

Cat. No. 9-5746

Air Plasma Electrode

Cutting or Gouging

Cat. No. 9-5749

O2 Plasma

50 Amp (.043) Tip

Cat. No. 9-5753

2 Plasma

100 Amp (.057) Tip

Cat. No. 9-5752

2 Plasma

150 Amp (.070) Tip

Cat. No. 9-5751

2 Plasma Electrode

Cutting or Gouging

Cat. No. 9-5760

N2 Plasma

50 Amp (.043) Tip

Cat. No. 9-5765

2 Plasma

100 Amp (.052) Tip

Cat. No. 9-5766

2 Plasma

150 Amp (.067) Tip

Cat. No. 9-5767

N2 or Ar/H2 Plasma Electrode

Cutting or Gouging

Cat. No. 9-5754

ArH

2 Plasma

150 Amp (.073) Tip

Cat. No. 9-5775

Gouging Tip

Air or Multi-Gas

85 Amp (.078)

Cat. No. 9-5756

Gouging Tip

Air or Multi-Gas

150 Amp (.120) Cat. No. 9-5755

For gouging, select proper electrode to

correspond to the

type of plasma gas

being used (same as

cutting).

Figure 4-E Tip and Electrode Selection

Manual 0-2251 35 OPERA TION

4.4 GAS SELECTION FOR PLASMA CUTTING

• Air plasma is normally used with air secondary.

• Only clean, dry air is recommended for use as plasma

gas. Any oil or moisture in the air supply can substan-

AIR PLASMA

tially reduce torch parts life.

• Most often used on ferrous or carbon base materials to

obtain good cutting quality at faster cutting speeds.

• Provides satisfactory results on non-ferrous materials.

• Can be used in place of air plasma with air secondary or

NITROGEN PLASMA

ARGON/HYDROGEN

PLASMA

OXYGEN PLASMA

• Provides much better parts life than air.

• Provides better cut quality on non-ferrous materials such

as stainless steel and aluminum.

• A good clean welding grade nitrogen should be used.

• A 65% argon/35% hydrogen mixture should be used.

• Recommended for use on thicker (1/2 inch and up) non-

ferrous materials. Ar/H

2 is not normally used for thin-

ner non-ferrous materials because less expensive gases can achieve similar cut quality.

• Provides faster cutting speeds and high cut quality on

thicker materials to offset a higher cost.

• Poor cut quality on ferrous materials.

• Oxygen is recommended for cutting ferrous materials.

• Provides faster cutting speeds.

• Provides very smooth finishes and minimizes nitride build-up on cut surface (nitride build-up can cause difficulties in producing high quality welds if not removed).

Table 4-A Plasma Gas Selection for Plasma Cutting

OPERA TION 36 Manual 0-2251

4.4 GAS SELECTION FOR PLASMA CUTTING (continued)

• Air secondary is normally used when operating with air plasma and occasionally with nitrogen plasma.

AIR SECONDARY

• Inexpensive - reduces operating costs.

• Improves cut quality on some ferrous materials.

•CO2 secondary is used with nitrogen or Ar/H2 plasma.

2 SECONDARY

NITROGEN

SECONDARY

WATER SECONDARY

• Provides good cut quality on ferrous or non-ferrous materials.

• May reduce smoke when used with Ar/H

2 plasma.

• Nitrogen secondary is used with Ar/H2 plasma.

• Provides smooth finishes on non-ferrous materials.

• May be used with nitrogen plasma in order to operate from one compressed gas cylinder.

• May reduce smoke when used with Ar/H

2 plasma.

• Water secondary should be used only in mechanized applications - never in hand cutting!

• Normally used with nitrogen, Ar/H

2, or air plasma.

• Provides very smooth cut surface.

• Reduces smoke and heat input to the workpiece.

• Effective up to 1 inch maximum material thickness.

• Tap water provides low operating expense.

Table 4-B Secondary Selection for Plasma Cutting

Manual 0-2251 37 OPERA TION

4.4 GAS SELECTION FOR PLASMA CUTTING (continued)

Cut Quality Cut quality requirements differ depending on application.

For instance, nitride build-up and bevel angle may be major factors when the surface that is cut will be welded after the cutting operation. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation.

Cut Surface

Nitride Deposits

Bevel Angle

Top-Edge Rounding

Dross Build-up

Kerf Width

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

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

• 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.

• The amount of rounding on the top edge of the cut.

• Molten material which is not blown away from the cut area and re-solidify on the base of the plate. Excessive dross build-up may require a secondary clean-up operation after the cutting process.

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

Table 4-C contains cut quality information for each plasma and secondary combination on a variety of materials and thicknesses.

Kerf Width

Cut Surface Bevel Angle

Top

Spatter

Top Edge Rounding

Dross

Build-Up

Cut Surface

Drag Lines

A-00007

Figure 4-F Cut Characteristics

OPERA TION 38 Manual 0-2251

4.4 GAS SELECTION FOR PLASMA CUTTING (continued)

GAS

Description

Excellent

Good

Fair

NOTE

MATERIAL

THICKNESS

Cut Characteristics: Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice),

little or no dross, smooth cut surface. Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip ori-

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

Excessive bevel (over 10°), wide kerf (over 2-1/2 x tip orifice), medium to heavy dross, rough cut surface, top edge rounding.

Not Recommended.

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

TYPE OF MATERIAL

Carbon Steel

Stainless Steel

Aluminum

Air Plasma

Air Secondary

Nitrogen Plasma

Air Secondary

or CO

2 Secondary

Nitrogen Plasma

Water Secondary

Ar/H

2 Plasma

2 or CO2

Secondary

Oxygen Plasma

Gage

Gage to 1 in.

1 to 2 in.

Gage

Gage to 1/2 in.

1/2 to 2 in.

Gage to 1/4 in.

1/4 to 1 in.

1 to 2 in.

Gage to 1/4 in.

1/4 to 1-1/4 in.

1/2 to 2 in.

Gage to 2 in.

Good/Excellent

Excellent Excellent

Good/Excellent Good/Excellent Good/Excellent

Excellent

Good

NR NR NR

Excellent

Good/Excellent

Good Good

Good/Excellent Good/Excellent Good/Excellent

Good

Excellent

Good

Excellent

Good

Table 4-C Cut Quality: Plasma and Secondary Gas Selection

for Various Materials and Material Thicknesses

Good/Excellent

Good Good

Good/Excellent Good/Excellent Good/Excellent

Good

Good/Excellent

NR Excellent Excellent

Manual 0-2251 39 OPERA TION

4.5 PLASMA CUTTING OPERATION

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at

WARNING

the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch switch is pressed.

CAUTION

WARNING

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

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Section 4.3, Torch Parts Selection).

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

The suggestions below should be followed in all cutting and gouging operations:

1. Wait five minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run to dissipate operating heat from the power supply.

2. For maximum parts life, do not operate the pilot arc any longer than necessary.

3. Use care in handling torch leads and protect them from damage.

4. In continuous cutting applications using CO

2, it is often

necessary to manifold four to six cylinders together to maintain adequate flow at operating pressures.

NOTE

FREQUENTLY REVIEW THE SAFETY PRECAUTIONS AT THE FRONT OF THIS MANUAL.

It is not enough to simply move the ON/OFF switch on

WARNING

the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.

OPERA TION 40 Manual 0-2251

4.5 PLASMA CUTTING OPERATION (continued)

Auto-Restart Options

On/Off

Normal/Delayed

Pre-Flow Delay

Post-Flow Delay

The auto-restart function provides an immediate pilot arc restart during post-flow if the torch is brought within range of the workpiece. The power supply can be set up to provide a variety of optional auto-restart settings.

• Auto-Restart On/Off - The auto-restart function can be switched off completely so that the torch must be reactivated (via torch switch or control device) to restart the pilot arc when the main arc is interrupted.

• Auto-Restart Normal/Delayed - Normal mode provides an immediate pilot arc restart when the main arc is interrupted. Delayed mode provides a gas pre-flow each time before the pilot arc restarts.

• Pre-Flow Delay - Pre-flow is the time interval from when the torch is activated (start of gas flow) to pilot arc initiation. Pre-flow duration is factory-set to two seconds, but can be re-set to four, seven, or ten seconds as desired.

• Post-Flow Delay - Gases continue to flow for a period of time after the main cutting arc is interrupted and the torch remains activated. Post-flow is factory-set to ten seconds, but can be re-set to five, twenty, or forty seconds as desired.

Applications

In machine torch operation, optional auto-restart settings may be useful where:

1. The system is used for direct replacement of units not having auto-restart for use with motion control devices.

2. Torch parts life may improve without auto-restart in some applications by reducing excessive pilot arc time.

3. In some shape-cutting applications, immediately restarting the main arc after the torch passes beyond the desired cutting line (or between cuts) may not be desirable.

4. Extended leads may require longer pre-flow duration.

5. Other special applications require various arrangements.

(continued)

Manual 0-2251 41 OPERA TION

4.5 PLASMA CUTTING OPERATION (continued)

Auto-Restart

(continued)

On/Off (SW1)

Note: Either pole set to 1(on)

disables auto-restart function

Normal/Delayed (SW2)

Note: Either pole set to 1(on)

sets auto-restart function

Pre-Flow Delay (SW3)

Four two-pole DIP switches located on the control logic PC board control the auto-restart functions.

Auto-Restart SW1-1 SW1-2

Mode Position Position

Normal 0 (Off) 0 (Off)

Disabled 0 (Off) 1 (On)

1 (On) 0 (Off) 1 (On) 1 (On)

Auto-Restart SW2-1 SW2-2

Mode Position Position

Normal 0 (Off) 0 (Off)

Delayed 0 (Off) 1 (On)

1 (On) 0 (Off) 1 (On) 1 (On)

Pre-Flow Time SW3-1 SW3-2

(Seconds) Position Position

Post-Flow Delay (SW4)

For Hand Cutting

Systems (A1845-01)

with 19x704 Logic PCB

Post-Flow Delay (SW4)

For Machine Cutting

Systems (A1845-15)

with 19x910 Logic PCB

2 0 (Off) 0 (Off) 4 0 (Off) 1 (On)

7 1 (On) 0 (Off)

10 1 (On) 1 (On)

Post-Flow Time SW4-1 SW4-2

(Seconds) Position Position

5 0 (Off) 1 (On)

10 0 (Off) 0 (Off) 20 1 (On) 0 (Off) 40 1 (On) 1 (Off)

Post-Flow Time SW4-1 SW4-2

(Seconds) Position Position

2.5 0 (Off) 1 (On) 5 0 (Off) 0 (Off)

10 1 (On) 0 (Off) 20 1 (On) 1 (Off)

OPERA TION 42 Manual 0-2251

4.5 PLASMA CUTTING OPERATION (continued)

Figure 4-G Control Logic PC Board - Setting Auto-Restart Options

Manual 0-2251 43 OPERA TION

4.6 HAND TORCH OPERATION

Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at

WARNING

the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch switch is pressed.

CAUTION

Plasma Cutting Operation

(Hand Torch)

WARNING

Cutting with a Hand Torch

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

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Section 4.3, Torch Parts Selection).

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

1. The hand torch should be held in both hands for making long cuts. Choose the method that feels the most comfortable and works the best. Use the thumb to actuate the control switch on the torch handle.

Figure 4-H Cutting with a Hand Torch

OPERA TION 44 Manual 0-2251

4.6 HAND TORCH OPERATION (continued)

Hand Torch Operation

(continued)

NOTE

CAUTION

2. To positively locate the line of the cut, position the torch over the workpiece, resting the front edge of the shield cup on the edge where the cut is to start.

3. Lower the welding helmet. Press and hold the torch control switch. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch control switch is held.

4. With the pilot arc on the main cutting arc is established as soon as the torch is brought within 1/8 - 3/8 in (3 - 10 mm) of the workpiece. If the cutting arc is interrupted and the switch is still pressed, as when cutting expanded metal, the pilot arc will automatically restart.

Releasing the torch control switch will shut off either the pilot or main arc (depending on the mode of operation).

5. Cut with the torch held 1/8 - 3/8 in (3 - 10 mm) from the work. The torch should be held perpendicular to the workpiece while cutting.

Use a standard ceramic or metal shield cup for hand cutting. The touch cup (short shield cup) and gouging cup

Manual 0-2251 45 OPERA TION

4.7 MACHINE TORCH OPERATION

Cutting with a

Machine Torch

1. A machine torch should be aligned perpendicular to the surface of the workpiece to obtain a clean, vertical cut. Use a square to align the torch (see Figure 4-I).

2. Position the center of the torch over the edge of the workpiece where the cut is to start. The transferred cutting arc will then be established at the plate edge when the torch is activated.

3. The machine torch can be activated by the remote operator control panel, remote control pendant, or by remote interface device such as CNC. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch is activated.

4. With the pilot arc on the main cutting arc is established as soon as the torch is brought within 1/8 - 3/8 in (3 10 mm) of the workpiece. If the cutting arc is interrupted and the torch is still activated, as when cutting expanded metal, the pilot arc will automatically restart (see Section 4.5, Plasma Cutting Operation, AutoRestart Options). De-activating the torch will shut off either the pilot or main arc (depending on the mode of operation).

Figure 4-I Machine Torch Set-up

OPERA TION 46 Manual 0-2251

4.7 MACHINE TORCH OPERATION (continued)

Cutting with a

Machine Torch

(continued)

5. Cut with a standoff of 1/8 - 3/8 in (3 - 10 mm) from the work. The torch should be held perpendicular to the workpiece while cutting. Start cutting slowly and adjust cutting speed for optimum cutting performance. Section 3.11, Cutting Speeds, contains typical cutting speeds for various materials and material thicknesses.

A standard shield cup is recommended for most machine cutting applications. The touch cup (short shield cup) is designed for light gage cutting where arc voltage measurement is needed for a standoff control. Do not allow an exposed torch tip to contact the workpiece.

The arc characteristics vary with gases used, cutting speed, material, and thickness. Air plasma normally produces a straight arc (on stainless or aluminum), while nitrogen plasma generally creates a 5° trailing arc (see Figure 4-J).

Figure 4-J Machine Torch Operation

Manual 0-2251 47 OPERA TION

4.7 MACHINE TORCH OPERATION (continued)

Corner Slowdown (CSD)

NOTE

Corner Slowdown Settings

The corner slowdown feature provides an output current reduction in to correspond with the reduction in torch travel speed as a mechanized torch moves through a corner. When activated by CNC or other control device, the corner slowdown eliminates excessive metal removal in corners.

Normally open (NO) contacts (supplied by the control device) close when the torch travel speed decreases through a corner. When the contacts close, power supply output drops to a pre-set current level.

A two-pole DIP switch in the remote operator control panel PC board allows the corner slowdown to operate with normally closed (NC) contacts in the control device if desired.

Corner slowdown adjustment is located on the remote operator control panel (see Section 4.1, Operating Controls).

The control is factory set fully counter-clockwise for minimum 50 amps output during corner slowdown. Turn the control clockwise to increase corner slowdown output. When the control is turned fully clockwise, corner slowdown output is increased to a maximum 150 amps.

NOTE

To view the corner slowdown setting, press and hold the stop control. The expected CSD output level will be displayed on the ammeter.

In the PAK 15XC, the corner slowdown setting is independent ( example, if CSD current is set to 100 amps, and main cutting current is set to the minimum 50 amps, the actual current level would actually cycle.

For electrical connections, refer to Appendix IV, CNC Interface.

not a percentage) of the main current setting. For

increase through the CSD

OPERA TION 48 Manual 0-2251

4.8 PIERCING

In some cutting operations, it may be desirable to start the cut within the plate area rather than at the plate edge. Piercing the plate is not recommended on plates having a thickness greater than 3/4 in (19 mm). Blowback from the piercing operation can shorten the life of torch parts. All piercing should therefore be done as quickly as possible and at maximum amperage (150 amps) and maximum standoff.

Piercing with a Hand Torch

When piercing with a hand torch, tip the torch slightly so that blowback particles blow away from the torch tip (and operator) rather than directly back into it (see Figure 4-K).

Pierce off the cutting line and then continue the cut as shown in Figure 4-K. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it.

A method called “running start” is recommended when piercing with a machine mounted torch. The torch should be positioned far enough off the cutting line to allow the pierce to be complete before the cutting line is reached. This allowance depends on the thickness of the material and the torch travel speed.

Figure 4-K Piercing with a Hand Torch

Manual 0-2251 49 OPERA TION

4.9 GOUGING OPERATION

WARNING

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

CAUTION

WARNING

The sparks from the gouging process can cause damage to coated, painted or other surfaces such as glass, plastic, and metal.

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Section 4.3, Torch Parts Selection).

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

Figure 4-L Gouging with a Hand Torch

OPERA TION 50 Manual 0-2251

4.9 GOUGING OPERATION (continued)

Gouging Parameters

Torch Travel Speed

Current Setting

Lead Angle

(Travel Angle)

Gouging performance depends on the torch travel speed, the current level, the angle at which the torch is held to the workpiece (lead angle), and the distance between the torch tip and the workpiece (standoff). Gouging can be accomplished with either a hand or machine torch.

Optimum torch travel speed for gouging is between 20 and 120 inches per minute (0.5 and 3.0 meters per minute). Travel speed is dependent on current setting, lead angle, mode of operation (hand or machine torch), and desired results.

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

The angle at which the torch is held depends on the current setting and the torch travel speed. The recommended lead angle is 20-25°. An angle greater than 25° may result in inconsistent metal removal, blowback of slag, and contaminated gouges. If the lead angle is too small (less than 20°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.

(continued)

Figure 4-M Gouging Parameters

Manual 0-2251 51 OPERA TION

4.9 GOUGING OPERATION (continued)

Standoff Distance

Slag Build-up

GAS

Air Plasma

Air Secondary

The tip to work distance affects gouge quality and depth. A standoff of 1/8 - 1/4 in (3 - 6 mm) allows smooth, consistent material removal. A smaller standoff may result double arcing from tip to work. A standoff greater than 1/4 in (6 mm) may result in minimal metal removal or loss of transferred main arc.

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

MATERIAL

Carbon Steel

Excellent

Stainless Steel

Good

Aluminum

Fair

Nitrogen Plasma

Good

Fair

Air Secondary

Nitrogen Plasma

2 Secondary

2 Plasma

Ar/H

Good

Excellent

Good

Excellent

Nitrogen Secondary

Ar/H

2 Plasma

Good

Excellent

Argon Secondary

Table 4-D Recommended Gases for Plasma Arc Gouging

OPERA TION 52 Manual 0-2251

4.10 COMMON OPERATING ERRORS

Listed below are common cutting problems followed by probable causes of each. If the problems are caused by a power supply problem, refer to Section 5.11, Troubleshooting Guide).

Insufficient Penetration

Main Arc Extinguishes

Dross Formation

Burned-Out Tips

a. Cutting speed too high b. Current too low c. Metal too thick d. Worn or damaged torch parts

a. Cutting speed too low b. Standoff too high

a. Improper gas pressure b. Improper cutting speed

(See Section 3.11, Cutting Speeds)

c. Worn or damaged torch parts.

a. Cutting current too high b. Damaged or loose cutting tip c. Tip in contact with work d. Heavy spatter e. Low plasma gas pressure

Poor Pilot Starting

Manual 0-2251 53 OPERA TION

a. High coolant conductivity

4.11 CUTTING SPEEDS

When hand cutting, cutting speeds primarily depend on the material being cut, the thickness, and how fast the operator can comfortably and accurately follow the line. The following charts show optimum cutting speed ranges for most materials using a machine torch with various plasma and secondary combinations. The data was obtained using the recommended 1/8 in (3 mm) standoff.

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

Factors such as parts wear, air quality, line voltage fluctuations, operator experience, standoff variation and quality of work connection may impact system performance.

OPERA TION 54 Manual 0-2251

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 150 (3.81)

3/16 110 (2.79)

1/4 65 (1.65) 90 (2.29) 150 (3.81) 1/2 48 (1.22) 80 (2.30) 3/4 30 (0.76) 40 (1.02)

1 17 (0.43) 25 (0.64) 1-1/4 10 (0.25) 18 (0.46) 1-1/2 14 (0.36)

2 6 (0.15)

Table 4-E Cutting Speeds - Air Plasma on Mild Steel

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute Meters per Minute

10 16 24

.50

.25

050

1.0 2.0

Optimum Cutting Speeds

Air Plasma - Air Secondary

on Mild Steel

150 Amps 100 Amps

50 Amps

100 150 200

3.0 4.0 5.0 6.00

A-00881

250

CUTTING SPEED

Figure 4-N Cutting Speeds - Air Plasma on Mild Steel

Manual 0-2251 55 OPERA TION

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 130 (3.30) 225 (5.7)

3/16

1/4 65 (1.65) 100 (2.54) 160 (4.06) 3/8 28 (.71) 100 (2.54) 1/2 16 (.41) 58 (1.47) 80 (2.03) 3/4 32 (0.81) 35 (0.89)

1 22 (0.56) 28 (0.71)

1-1/2 12 (0.30)

2 5 (0.13)

Table 4-F Cutting Speeds - Oxygen Plasma on Mild Steel, CO

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute

10 16 24

.50

.25

050

Optimum Cutting Speeds

Oxygen Plasma

on Mild Steel

150 Amps 100 Amps

50 Amps

100 150 200

Secondary

A-00883

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 4-O Cutting Speeds - Oxygen Plasma on Mild Steel

OPERA TION 56 Manual 0-2251

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 100 (2.54) 1/4 40 (1.02) 140 (3.56) 175 (4.45)

5/16 30 (0.76)

3/8 9 (0.23) 75 (1.90) 110 (2.79) 1/2 60 (1.52) 85 (2.16) 3/4 40 (1.02)

1 25 (0.64)

1-1/2 12 (0.30)

Table 4-G Cutting Speeds - Nitrogen Plasma on Stainless Steel

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute

10 16 24

.50

.25

050

Optimum Cutting Speeds

Nitrogen Plasma - CO2 Secondary

on Stainless Steel

150 Amps 100 Amps

50 Amps

100 150 200

A-00882

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 4-P Cutting Speeds - Nitrogen Plasma on Stainless Steel

Manual 0-2251 57 OPERA TION

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 1/4

5/16

3/8 1/2 35 (0.89) 3/4 27 (0.69)

1 20 (0.51)

1-1/2 10 (0.25)

Table 4-H Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute

10 16 24

.50

.25

050

Optimum Cutting Speeds

Ar/H2 Plasma - N2 Secondary

on Stainless Steel

150 Amps

100 150 200

A-00886

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 4-Q Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

OPERA TION 58 Manual 0-2251

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 150 (3.81) 225 (5.72) 275 (6.99) 1/4 40 (1.02) 135 (3.43) 150 (3.81)

5/16

3/8 1/2 60 (1.52) 95 (2.41) 3/4 18 (0.46) 52 (1.32)

1 15 (0.38) 36 (0.91)

1-1/2 18 (.46)

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute

10 16 24

.50

.25

Table 4-I Cutting Speeds - Air Plasma on Aluminum

Optimum Cutting Speeds

Air Plasma - Air Secondary

on Aluminum

150 Amps 100 Amps

50 Amps

050

100 150 200

A-00884

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 4-R Cutting Speeds - Air Plasma on Aluminum

Manual 0-2251 59 OPERA TION

4.11 CUTTING SPEEDS (continued)

Material Thickness Inches per Minute (Meters per Minute)

50 Amps 100 Amps 150 Amps

1/8 1/4 100 (2.54)

5/16

3/8 1/2 75 (1.90) 3/4 60 (1.52)

1 35 (0.89)

1-1/2 21 (0.53)

Table 4-J Cutting Speeds - ArH

Gage MM Inches

2.00

1.75

1.50

1.25

1.00

.75

MATERIAL THICKNESS

Inches per Minute

10 16 24

.50

.25

050

2 Plasma/Nitrogen Secondary on Aluminum

Optimum Cutting Speeds

ArH2 Plasma - N2 Secondary

on Aluminum

150 Amps 100 Amps

50 Amps

100 150 200

A-00885

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 4-S Cutting Speeds - ArH2 Plasma/Nitrogen Secondary on Aluminum

OPERA TION 60 Manual 0-2251

4.12 SEQUENCE OF OPERATION

ACTION

Close external

disconnect switch

RESULT

• Power to system

ACTION

Protect eyes and

activate torch

RESULT

• Gas indicator ON

• Gas pre-flow

• Main contactor closes

• DC indicator ON

• Pilot contactor closes

• PILOT indicator ON

• Pilot arc established

ACTION

Enable ON at Remote

or TB2

ON/OFF switch to ON

RESULT

• AC indicator ON

• TEMP Indicator ON

• GAS indicator ON

• Fan and pump ON

• 40 second auto-purge

PILOT ARC

ACTION

RUN/SET/PURGE

switch to SET

RESULT

• Gas solenoids open, gases flow to set

pressures

• GAS indicator ON

ACTION

RUN/SET/PURGE

switch to RUN

RESULT

• Gas flow stops

• Power circuit ready

• GAS indicator OFF

ACTION

Torch removed from

work

RESULT

• Main arc stops

• Pilot arc auto-restart

• PILOT indicator ON

ACTION

Torch moved to

within

1/8 - 3/8 inch of

work

ACTION

Torch de-activated by torch switch

released or remote device

RESULT

• Main arc stops

• Main contactor opens

• DC indicator OFF

• Pilot and PILOT indicator OFF

NOTE- If torch is activated during post-flow

the pilot arc will immediately restart. If

within range of work, main arc will transfer.

After post-flow:

• Gas solenoids close, gas flow stops

• GAS indicator OFF

ACTION

ON/OFF switch to

OFF

RESULT

• AC indicator OFF

• TEMP Indicator OFF

• Fan and pump OFF

RESULT

• Main arc transfer

• PILOT indicator OFF

• Pilot arc OFF

ACTION

Open external

disconnect

RESULT

• No power to system

A-01016

Figure 4-T Sequence of Operation

Manual 0-2251 61 OPERA TION

OPERA TION 62 Manual 0-2251

SECTION 5: CUSTOMER/OPERATOR SERVICE

5.1 TORCH MAINTENANCE

WARNING

Routine Inspection

and Replacement of

Consumable Parts:

NOTE

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

Refer to Figure 5-A and:

1. Remove the shield cup (1) from the torch body (6 or 7).

2. Unscrew the tip (2) using the tip wrench (9). Check for tip wear (indicated by elongated or oversize orifice). Clean the tip and make sure the threads and sealing face are not damaged. Replace tip if necessary.

3. Remove the electrode (3) using the electrode wrench (10). Inspect the condition of the face of the electrode (see CAUTION below).

Check the torch for proper assembly. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Section 4.3, Torch Parts Selection).

1. Machine Torch Body

2. 70° Hand Torch Body

3. O-Ring (Handle)

4. O-Ring (Cup - Lg.)

5. O-ring (Cup - Sm.)

6. Air Electrode

7. Oxygen Electrode

8. Multi-Gas Electrode

9. Air Tip

10. Oxygen Tip

11. Nitrogen Tip

12. Ar/H

13. Gouging Tip

14. Standard Shield Cup

15. Copper Shield Cup

16. Touch Cup

17. Gouging Cup

18. Tip Wrench

19. Electrode Wrench

2 Tip

Figure 5-A PCH/M-150 Torch Components

Manual 0-2251 63 CUSTOMER/OPERATOR SER VICE

5.1 TORCH MAINTENANCE (continued)

NOTE

CAUTION

If face of electrode is pitted or gouged more than 3/32 in (2.4 mm) deep, the electrode should be replaced (see Figure 5-B).

4. Replace the electrode in the torch body. Secure in place using the electrode wrench.

5. Replace the tip in the front of the torch and secure it with the tip wrench.

Do not overtighten the electrode or tip.

6. Inspect the shield cup for damage. Wipe it clean, or replace if it appears to be damaged.

7. Re-install the shield cup. Apply a light coat of O-ring lubricant to the shield cup O-rings (4,5). Use a slight twisting motion to seat the cup properly on the O-rings and against the torch face.

Look for extreme

pitted or blown out

appearance

3/32 in

Figure 5-B Electrode Deterioration

5.2 HAND TORCH HEAD REPLACEMENT

WARNING

Hand Torch Head

Replacement

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

Refer to Figure 5-C and:

1. Roll the torch switch sheath up over the handle to expose the two torch switch connectors.

2. Remove the tape from the end of the leads sleeving and pull the sleeving back approximately one foot (0.3 m).

3. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads.

Worn ElectrodeNew Electrode

CUSTOMER/OPERATOR SERVICE 64 Manual 0-2251

5.2 HAND TORCH HEAD REPLACEMENT (continued)

Hand Torch Head

Replacement (continued)

NOTE

CAUTION

4. With a twisting motion, pull the handle from the torch head. Slide the handle back over the leads to expose the leads connections.

5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.

To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir.

6. Connect the plasma, secondary, coolant supply, and coolant return leads onto the replacement torch head fittings.

7. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.

Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads.

8. Replace the handle onto the torch head.

9. Connect the two torch switch leads connectors and

secure the torch switch leads in place with electrical tape.

10. Secure the leads sleeving to the leads with electrical

tape. Position the tape close to the back of the handle.

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

Figure 5-C Hand Torch Head Replacement

Manual 0-2251 65 CUSTOMER/OPERATOR SER VICE

5.3 MACHINE TORCH HEAD REPLACEMENT

WARNING

Machine Torch Leads

Replacement

NOTE

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

Refer to Figure 5-D and:

1. Remove the electrical tape from the end of the nylon outer leads sleeving next to the mounting assembly and push the sleeving back onto the leads approximately one foot (0.3 m) to expose the shielded inner leads sleeving.

2. Remove the electrical tape from the shielded inner sleeving and push back over the leads approximately one foot (0.3 m).

3. Unscrew the mounting assembly from the torch head. Slide the mounting assembly back over the leads to expose the leads connections.

4. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.

To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir.

5. Connect the plasma, secondary, coolant supply, and coolant return leads onto the replacement torch head fittings.

6. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.

CUSTOMER/OPERATOR SERVICE 66 Manual 0-2251

5.3 MACHINE TORCH HEAD REPLACEMENT (continued)

Torch Head

CAUTION

Electrical

Tape

Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads.

7. Replace the mounting assembly onto the torch head.

8. Secure the shielded inner sleeving to the leads with electrical tape. Position the end of the sleeving a few inches back from the mounting assembly.

9. Position the nylon outer sleeving over the shielded inner sleeving. The shielded inner sleeving must be completely covered by the outer sleeving to avoid any possible contact with the mounting assembly.

10. Secure the nylon outer leads sleeving to the leads with electrical tape. Position the tape close to the back of the mounting assembly.

Coolant Return

Lead

Plasma

Lead

Mounting

Assembly

Shielded Inner

Leads Sleeving

Electrical

Tape

A-00961

Insulating T ape

Secondary

Lead

Coolant Supply

Lead

Nylon Outer

Leads Sleeving

Figure 5-D Machine Torch Head Replacement

Manual 0-2251 67 CUSTOMER/OPERATOR SER VICE

5.4 HAND TORCH SWITCH REPLACEMENT

WARNING

Hand Torch Head

Replacement

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

Refer to Figure 5-C and:

1. Roll the sheath up over the torch handle to expose the torch switch connectors and the torch switch.

2. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads.

3. Replace the torch switch and connect the two torch switch leads connectors.

4. Secure the torch switch leads in place with electrical tape. Locate the tape over the two connectors.

5. Roll the torch switch sheath back over the handle to cover the torch switch and connectors.

CUSTOMER/OPERATOR SERVICE 68 Manual 0-2251

5.5 HAND TORCH LEADS REPLACEMENT

WARNING

Hand Torch Leads

Replacement

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

Refer to Figure 5-C and:

1. Roll the torch switch sheath up over the handle to expose the two torch switch connectors.

2. Remove the tape from the end of the leads sleeving and pull the sleeving back approximately one foot (0.3 m).

3. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads.

4. With a twisting motion, pull the handle from the torch head. Slide the handle back over the leads to expose the leads connections.

5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.

(continued)

Control Cable

(Hand T orch Only)

Plasma Lead

Secondary Lead

Shielded Inner Leads Sleeving

(Machine T orch Only)

Torch Leads Shield Assembly

Nylon Outer Leads Sleeving

Coolant Supply Lead

Hose Clamp

Torch Leads Boot

Coolant Return Lead

A-00903

Figure 5-E Leads Connections at the Power Supply

Manual 0-2251 69 CUSTOMER/OPERATOR SER VICE

5.5 HAND TORCH LEADS REPLACEMENT (continued)

NOTE

CAUTION

To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir.

6. Position the replacement leads and connect the plasma, secondary, coolant supply, and coolant return leads onto the torch head fittings.

7. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.

Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads.

8. Replace the handle onto the torch head.

9. Connect the two torch switch leads connectors. Secure the torch switch leads in place with electrical tape.

10. Secure the leads sleeving to the leads with electrical tape. Position the tape close to the back of the handle.

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

Refer to Figure 5-E and:

12. Open the leads connection access door on the power supply. Disconnect the plasma, secondary, coolant supply and coolant return leads and the control cable plug from the bulkhead.

13. Position the replacement leads. Feed the control cable plug through the torch leads boot first and connect to the bulkhead. Then feed the other leads through the torch leads boot and connect the plasma, secondary, coolant supply and coolant return leads to the bulkhead.

CUSTOMER/OPERATOR SERVICE 70 Manual 0-2251

5.6 MACHINE TORCH LEADS REPLACEMENT

WARNING

Machine Torch Leads

Replacement

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

Refer to Figure 5-D and:

1. Remove the electrical tape from the end of the nylon outer leads sleeving next to the mounting assembly.

2. Push the nylon outer sleeving back up the leads approximately one foot (0.3 m) to expose the shielded inner leads sleeving.

3. Remove the electrical tape from the shielded inner sleeving and push back up the leads approximately one foot (0.3 m).

4. Unscrew the mounting assembly from the torch head. Slide the mounting assembly back over the leads to expose the leads connections.

5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.

NOTE

CAUTION

To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir.

6. Connect the plasma, secondary, coolant supply, and coolant return leads onto the replacement torch head fittings.

7. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.

Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads.

8. Replace the mounting assembly onto the torch head.

9. Secure the shielded inner sleeving to the leads with electrical tape. Position the end of the sleeving a few inches back from the mounting assembly.

Manual 0-2251 71 CUSTOMER/OPERATOR SER VICE

5.6 MACHINE TORCH LEADS REPLACEMENT (continued)

Machine Torch Leads

Replacement (continued)

Power Supply Connections

10. Position the nylon outer sleeving over the shielded inner sleeving. The shielded inner sleeving must be completely covered by the outer sleeving to avoid any possible contact with the mounting assembly.

11. Secure the nylon outer leads sleeving to the leads with electrical tape. Position the tape close to the back of the mounting assembly.

Refer to Figure 5-E and:

12. Open the leads connection access door on the power supply. Remove the hose clamp that secures the shielded inner leads sleeving to the brass grounding tube.

13. Disconnect the plasma, secondary, coolant supply and coolant return leads from the bulkhead.

14. Position the replacement leads and connect the plasma, secondary, coolant supply and coolant return leads to the bulkhead.

15. Attach the shielded inner leads sleeving to the brass grounding tube and secure with hose clamp. The shielded inner sleeving must not contact any torch fittings, ferrules, or connections.

CUSTOMER/OPERATOR SERVICE 72 Manual 0-2251

5.7 LEADS EXTENSION KITS - HAND TORCH

Leads extension packages are available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. Leads can be extended up to a maximum of 150 ft (45.8 m).

Leads extension kits for hand torch systems include:

• Plasma, Secondary, Coolant Supply and Coolant Return Leads Extensions in 25 or 50 ft (7.6 or 15.2 m) lengths

• Control Cable Extension - 25 or 50 ft (7.6 or 15.2 m)

• Nylon Outer Sleeving - 25 or 50 ft (7.6 or 15.2 m)

• Coolant Supply Lead Insulator

• Plasma Lead Insulator

• (2) Union Fittings

WARNING

Disconnect Existing Leads

NOTE

Connect Leads Extension

to Power Supply

Connect Coolant Supply

Lead to Extension Package

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

Refer to Figure 5-E and:

1. Disconnect the plasma lead, secondary lead, coolant

supply lead, coolant return lead, and the control cable plug from the bulkhead.

To minimize coolant leaking from the leads during installation, keep the leads connections above the level of the torch head and existing leads.

2. Position the extension kit and connect the plasma,

secondary, coolant supply, coolant return leads extensions and the control cable extension to the bulkhead.

Refer to Figure 5-F and:

3. Slide the coolant supply insulator over the coolant

supply lead on the existing torch leads.

4. Push the coolant supply lead on the existing leads into

the union fitting as far as possible.

5. Connect the coolant supply lead from the torch leads

through the union fitting to the coolant supply lead from the extension kit and tighten securely.

6. Thread the coolant supply insulator on the existing

torch leads onto the union fitting and tighten securely.

(continued)

Manual 0-2251 73 CUSTOMER/OPERATOR SER VICE

5.7 LEADS EXTENSION KITS - HAND TORCH (continued)

7. Thread the coolant supply insulator on the leads extension into the union fitting and tighten securely.

8. Slide the plasma insulator over the plasma lead on the existing torch leads.

9. Push the plasma lead on the existing leads into the union fitting as far as possible.

Connect Plasma Lead to

Extension Package

Connect Coolant Return,

Secondary, and Control

Cable to Extension Package

Electrical

Tape

From

Power Supply

(Extension Kit)

Plasma

Lead

10. Connect the plasma lead from the torch leads, through

11. Thread the plasma insulator on the existing torch leads

12. Thread the plasma insulator on the leads extension into

13. Connect the secondary and coolant return leads to the

14. Connect the control cable plug to the receptacle on the

Coolant Supply

Lead

the union, to the plasma lead from the extension kit and tighten securely.

onto the union fitting and tighten securely.

the union fitting and tighten securely.

extension kit fittings.

leads extension package.

Coolant Supply

Union

Fitting

Insulator

Plasma

Insulator

Electrical

Tape

T o Torch

(Existing Leads)

Secondary

Lead

Coolant Return

Lead

Control Cable

(Hand T orch Only)

A-00962

Figure 5-F Hand Torch Leads Extension Package

CUSTOMER/OPERATOR SERVICE 74 Manual 0-2251

5.8 LEADS EXTENSION KITS - MACHINE TORCH

Leads extension packages are available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. Leads can be extended up to a maximum of 150 ft (45.8 m).

Leads extension kits for machine torch systems include:

• Plasma, Secondary, Coolant Supply and Coolant Return Leads Extensions in 25 or 50 ft (7.6 or 15.2 m) lengths

• Shielded Inner Sleeving - 25 or 50 ft (7.6 or 15.2 m)

• Nylon Outer Sleeving - 25 or 50 ft (7.6 or 15.2 m)

• Shielded Inner Sleeving Connector - 12 in (0.30 m)

• Nylon Outer Sleeving Connector - 24 in (0.61 m)

• (2) Hose Clamps

• Coolant Supply Lead Insulator

• Plasma Lead Insulator

• (2) Union Fittings

WARNING

Disconnect Existing Leads

NOTE

Connect Leads Extension

to Power Supply

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

Refer to Figure 5-E and:

1. Remove the hose clamp from the torch leads shield

assembly inside the leads access area to release the shielded inner sleeving.

2. Disconnect the plasma and secondary leads and

coolant supply and return leads from the bulkhead.

To minimize coolant leaks from the leads during installation, keep the leads connections above the level of the torch head and existing leads.

3. Position the extension kit and connect the plasma,

secondary, coolant supply, and coolant return leads extensions to the bulkhead.

4. Connect the shielded inner sleeving to the torch leads

shield assembly and secure with the hose clamp.

(continued)

Manual 0-2251 75 CUSTOMER/OPERATOR SER VICE

5.8 LEADS EXTENSION KITS - MACHINE TORCH (continued)

Connect Existing Leads to

Leads Extension

Connect Coolant Supply

Lead to Extension Package

Refer to Figure 5-G and:

5. Slide the 24-inch nylon outer sleeving connector over the existing leads before making connections. The connector will later be pulled down to cover all connections.

6. Remove the shrink-on tubing and tape that secures the end of the nylon outer sleeving to the existing leads.

7. At the end of the existing leads, all four individual leads are enclosed by the shielded inner sleeving. Pull the nylon outer sleeving back approximately 12 in (0.3 m) to expose the area where the coolant return and secondary leads are run through from the outside to the inside of the shielded inner sleeving.

8. Pull the secondary and coolant return leads out through the shielded inner sleeving (only the coolant supply and plasma leads remain inside the sleeving).

9. Slide the 12-inch shielded inner sleeving connector over the coolant supply and plasma leads of the extension kit.

Refer to Figure 5-F and:

10. Slide the coolant supply insulator over the coolant supply lead on the existing torch leads.

Connect Plasma Lead to

Extension Package

11. Push the coolant supply lead on the existing leads into the union fitting as far as possible.

12. Connect the coolant supply lead from the torch leads through the union fitting to the coolant supply lead from the extension kit and tighten securely.

13. Thread the coolant supply insulator on the existing torch leads onto the union fitting and tighten securely.

14. Thread the coolant supply insulator on the leads extension into the union fitting and tighten securely.

15. Slide the plasma insulator over the plasma lead on the existing torch leads.

16. Push the plasma lead on the existing leads into the union fitting as far as possible.

17. Connect the plasma lead from the existing torch leads through the union fitting to the plasma lead from the extension kit and tighten securely.

18. Thread the plasma insulator on the existing torch leads onto the union fitting and tighten securely.

CUSTOMER/OPERATOR SERVICE 76 Manual 0-2251

5.8 LEADS EXTENSION KITS - MACHINE TORCH (continued)

19. Thread the plasma insulator on the leads extension into the union fitting and tighten securely.

Refer to Figure 5-G and:

20. Pull each end of the shielded inner sleeving (from the existing leads and from the leads extension) up and over the plasma and coolant supply insulators. Position the 12-inch shielded inner sleeving connector down over the completed coolant supply and plasma connections. Secure the connector in place with a hose clamp on each end.

NOTE

Connect Coolant Return and

Secondary to

Extension Package

Electrical

Tape

From

Power Supply

(Extension Kit)

Locate Clamp

Over Insulators

Locate the hose clamps over the plasma and coolant supply insulators to provide a solid connection. The shielding must be continuous throughout the connection (from the extension kit, through the connector, to the original leads) to ensure proper shielding protection.

21. Connect the secondary and coolant return leads to the

extension kit fittings.

22. Slide the 24-inch nylon sleeving connector down to

cover all connections. Secure with electrical tape.

Coolant Supply

Plasma

Lead

12" Shielded

Inner Sleeving

Electrical

Tape

T o Torch

(Existing Leads)

Secondary

Lead

From

Power Supply

(Extension Kit)

24" Nylon Outer Sleeving

Coolant Return

Lead

Locate Clamp

Over Insulators

T o Torch

(Existing Leads)

A-00963

Figure 5-G Machine Torch Leads Extension

Manual 0-2251 77 CUSTOMER/OPERATOR SER VICE

5.9 POWER SUPPLY MAINTENANCE

Fan Motor and Pump

Lubrication

NOTE

Routine Maintenance

The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation. To oil the motor, remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor.

Some units may utilize a sealed motor design which does not require lubrication.

The only other routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

To clean the unit, first make sure that the power is disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used.

While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected. When cleaning the unit, inspect the area around the high frequency spark gap points. Accumulated dirt in the area around the spark gap assembly can weaken the high frequency starting and cause poor pilot starting.

CUSTOMER/OPERATOR SERVICE 78 Manual 0-2251

5.10 TROUBLESHOOTING THEORY

Input Voltage Selection

Switch-Mode Power

Supply Operation

The main transformer (T1) has buss bar connections to select one of three input voltage ranges (see page 2-6). Each main transformer secondary has two taps. One secondary tap is automatically selected by the voltage selection PC board when primary power is applied. If input voltage is within the lower half of the selected voltage range (for example, 380V or 415V in the 380/415/ 460V range), the higher voltage taps are selected. If input voltage is within the upper half of the selected voltage range (460 V in the 380/415/460V range), the lower voltage taps are selected. This arrangement provides secondary voltages close to the optimum levels. When the lower voltage taps are selected a red LED indicator (D18) on the voltage selection PC board will be lit.

The 115 VAC and lower voltage taps are selected directly by relays on the voltage selection PC board. The fan and pump motors are supplied by the motor control contactors (MC1 and MC2). MC1 is for the high voltage tap and MC2 is for the low voltage tap. Three-phase primary power is controlled by one of the main contactors (W1 for the high voltage tap or W2 for the low voltage tap).

Primary three-phase power is rectified by diodes D1-D6. The resulting negative DC voltage (approximately -320 VDC) is applied to the switching transistor (Q1). The switching transistor controls the output current by pulse width modulation (PWM). PWM varies the duty cycle (or on-time versus off-time) of the switch. The greater the ontime, the higher the output current will be. The switching transistor output is a series of pulses which are filtered back into pure DC voltage by the output network. The output network consists primarily of the main inductor (L2A and L2B), resistor R13, and capacitor C23.

The switching control PC board compares the shunt amp output with the current control pot setting and generates logic level PWM signals. The shunt and shunt amp PC board are located between the positive bridge and work lead to measure the output cutting current. The signals are sent to the driver PC board, where they are converted into the current and voltage levels needed to drive the switching transistor.

Switching Control Board

Manual 0-2251 79 CUSTOMER/OPERATOR SER VICE

The switching control PC board senses if the remote control panel is connected by a jumper in the remote cable. If the remote cable is not used, a relay on the switching control PC board shorts J15-35 to J15-36. The short by-

(continued)

5.10 TROUBLESHOOTING THEORY (continued)

Switching Control Board

(continued)

Logic Board Functions

passes the E-Stop function of the remote. The switching control PC board also routes the shunt amp output to the digital ammeter in the remote. CSR (current greater than 25A) and over-current shutdown (greater than 175A) signals are sent to the logic PC board.

The logic PC board controls the timing and sequencing of the system. It monitors the pressure, temperature, and flow interlocks and controls the gas flow in run, set, and purge modes by turning on the plasma and secondary solenoids. The logic PC board also controls pre-flow and post-flow durations, which are selectable by DIP switches on the board (see Figure 4-G). The logic board drives the sequence status LED indicators and contains the circuit for measuring coolant conductivity.

The logic board receives either a latched start signal from the remote control panel or a non-latching start signal from the hand torch switch or remote pendant. Both latching and non-latching signals are available from CNC devices. The logic PC board then initiates gas pre-flow and energizes the main contactor W1 or W2 (as directed by the voltage selection PC board). The logic board then enables the PWM switching control circuit. The logic board immediately activates the pilot contactor to initiate the pilot arc. As soon as the pilot arc (constant DC current) is established, the PSR relay shuts off the high frequency. The logic board supplies ‘OK-to-move’ contacts, which close when main arc transfer has occurred and pilot has shut off. A second ‘OK-to-move’ contact is wired to control an optional high-flow water shield.

LED/Current Control Board

Remote Control

CUSTOMER/OPERATOR SERVICE 80 Manual 0-2251

The LED and current control PC board contains the sequence status LED indicators and the front panel current control pot.

The remote control unit contains the several system control functions. Momentary start and stop switches control system operation and the main current control pot controls cutting current output. A digital ammeter displays a preview of the main current setting (or corner slowdown setting) before starting the cut and displays actual cutting current after arc transfer. A behind-the-panel control sets corner slowdown current reduction and an emergency stop switch shuts off the power supply's main contactors, gases, and coolant system. CNC interface connectors and the power supply remote cable connection are located on the rear panel of the remote.

5.10 TROUBLESHOOTING THEORY (continued)

Figure 5-H Major System Components - Front View

Manual 0-2251 81 CUSTOMER/OPERATOR SER VICE

5.10 TROUBLESHOOTING THEORY (continued)

Figure 5-I Major System Components - Rear View

CUSTOMER/OPERATOR SERVICE 82 Manual 0-2251

5.11 TROUBLESHOO TING GUIDE

SYMPTOM POSSIBLE CAUSE REMEDY

A. No front panel LED

indicators lit. Fan and pump off.

B. AC indicator on. Fan and

pump off.

1. No primary power. See also Symptoms C and D

2. Blown fuse (F2)

3. Faulty ON/OFF switch (SW1)

4. Faulty voltage selection board

1. No primary power See also Symptoms C and D

2. Blown fuse (F1 or F2)

3. Faulty ON/OFF switch (SW1)

4. Faulty voltage selection board

1. Check for proper threephase power at input terminal board

2. Check and replace fuse if necessary

3. Disconnect primary power. Check each section for continuity. Replace switch if necessary

4. See Sction 5.12-Test A and replace board if necessary

1. Check for proper threephase power at input terminal board

2. Check and replace fuse if necessary. See Section

5.12-Test B

3. Disconnect primary power. Check each section for continuity. Replace switch if necessary

4. See Section 5.12-Test A and replace board if necessary

5. Faulty motor contactor (MC1 or MC2)

(Causes 6 and 7 are only for systems having remote control panel)

Manual 0-2251 83 CUSTOMER/OPERATOR SER VICE

6. Faulty switching control board (relay K1 not energized to bypass remote E-stop function)

7. Remote cable plugged into J15; remote control panel not connected on other end of cable

8. Remote panel E-stop button activated (or faulty)

5. See Section 5.12-Test C and replace contactor if necessary

6. See Section 5.12-Test C, Step 3

7. Remove cable plug from J15 or connect remote panel correctly

8. Twist button clockwise to release. If necessary, check for continuity from J37-35 to J37-36

(continued)

5.11 TROUBLESHOOTING GUIDE (continued)

SYMPTOM POSSIBLE CAUSE REMEDY

C. Fuse blown at disconnect

when primary power is connected

D. Fuse blown at disconnect

when main contactor (W1 or W2) closes

1. Voltage selection bus bars connected incorrectly

2. One leg of three-phase primary connected to chassis ground

3. Main transformer shorted

1. Shorted input diode (D1-D6)

2. Switching transistor (Q1) shorted to heatsink

3. Shorted input capacitor (C7-C12)

4. Shorted diode (D11-D14)

5. Faulty voltage selection board

1. Check and correct if necessary.

2. Rewire input cable (see Section 3.4, Electrical Connections)

3. Replace main transformer

1. See Section 5.12-Test D and replace diode if necessary

2. Replace Q1, check heatsink for possible damage (see Section 5.12-Test D)

3. Replace capacitor if necessary

4. Check for proper 3-phase power at input terminal board, check diodes (see Section 5.12-Test D)

5. If W1 and W2 come on simultaneously replace board.

E. TEMP indicator lit (red).

F. No GAS indicator

6. Faulty main contactor (W1 or W2)

1. Unit overheated

2. Faulty thermal sensor (TS1, TS2, or TS3)

3. Faulty logic board

4. Faulty LED/current control board

1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary

2. Gas pressure set too low

6. Check and replace contactor if necessary

1. Clean radiator and check for obstruction.

2. See Section 5.12-Test E and replace sensors if necessary

3. See Section 5.12-Test E and replace board if necessary

4. See Section 5.12-Test E and replace board if necessary

1. Normal operation (purges plasma line only, secondary flow switch is not satisfied)

2. Adjust pressure

CUSTOMER/OPERATOR SERVICE 84 Manual 0-2251

5.11 TROUBLESHOOTING GUIDE (continued)

SYMPTOM POSSIBLE CAUSE REMEDY

F. No GAS indicator

(continued)

G. GAS indicator off, plasma

and/or secondary gas does not flow

3. Faulty pressure switch (PS1 or PS2)

4. Faulty logic board

5. Faulty LED/current control board

6. Faulty SW3-B (secondary mode set to O

2 or H2O )

1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary

2. Secondary mode set to O

3. Jump switches one at a time and check for indicator to determine which has failed. Replace switch if necessary

4. See Section 5.12-Test F and replace board if necessary

5. See Section 5.12-Test F and replace board if necessary

6. With secondary mode set to O

2 or H2O, check for

continuity from wire #52 to #55 on SW3-B. If open, replace SW3-B

1. Normal operation (purges plasma line only, secondary does not flow)

2. No secondary flow is normal operation in O

mode (but GAS indicator should be lit)

3. Low plasma pressure or faulty PS1

3. Check plasma pressure, check PS1 and replace if necessary

4. Secondary supply turned

4. Check secondary supply

off (or tank empty)

5. Faulty solenoid valve: SOL1 - plasma gas, SOL2 - secondary gas, SOL3 - secondary water

6. Faulty switch (SW3-A) (effects sec. gas or water only, not secondary O

5. Check solenoid for sticking or clogging. Check coil resistance (should be approx. 400 ohms)

6. Check SW3-A for continuity (wire 75 to 88 for secondary gas, 75 to 89 for secondary water)

7. Faulty logic board

7. See Section 5.12-Test G and replace board if necessary

(continued)

Manual 0-2251 85 CUSTOMER/OPERATOR SER VICE

5.11 TROUBLESHOOTING GUIDE (continued)

SYMPTOM POSSIBLE CAUSE REMEDY

H. COOLANT indicator off

I. Coolant conductivity

indicator off

1. Little or no pressure shown on gauge

2. Clogged torch or leads

3. Faulty flow switch (FS1)

4. Faulty logic board

5. Faulty LED/current control board

1. Ionized or contaminated coolant

1a.Check coolant level 1b. Check motor rotation and

rpm.

1c. Check and replace pump

if necessary

2. Check and torch and leads and replace if necessary. Flush coolant system

3. Check and replace flow switch if necessary

4. See Section 5.12-Test H and replace board if necessary

5. See Section 5.12-Test H and replace board if necessary

1. Check coolant conductivity and deionizer cartridge (Section 3.6). Replace both if necessary

J. DC indicator not lit (after

pre-flow), no main contactor closure

K. DC indicator not lit (after

pre-flow), main contactor comes on momentarily. No pilot, no main arc transfer

2. Faulty (or contaminated) conductivity probe

3. Faulty logic board

4. Faulty LED/current control board

1. RUN/SET/PURGE switch not set to RUN

2. Faulty torch switch, remote panel, or remote pendant

3. Open contactor coil (W1 or W2)

4. Faulty logic board

1. Switching transistor (Q1) not turning on

2. Clean conductivity probe and replace if necessary

3. See Section 5.12-Test I and replace board if necessary

4. See Section 5.12-Test I and replace board if necessary

1. Normal operation, set switch to RUN position

2. See Section 5.12-Test J

3. Coil should measure approx. 10 ohms

4. See Section 5.12-Test J

1. See Section 5.12-Test K

CUSTOMER/OPERATOR SERVICE 86 Manual 0-2251

5.11 TROUBLESHOOTING GUIDE (continued)

SYMPTOM POSSIBLE CAUSE REMEDY

L. No pilot arc. DC indicator

on, PCR not energized

M. No pilot. PILOT indicator

on, PCR energized, little or no spark at spark gap points

N. Weak or sputtering pilot.

HF stays on during pilot

1. Faulty logic board, switching board, or shunt amp board

1. Faulty PSR relay

2. Faulty HF transformer (T3)

3. Faulty capacitor (C31)

1. Plasma gas pressure too high

2. Low OCV (normal 290-

350) caused by improper connection of voltage selection bus bars

3. Low OCV caused by faulty voltage selection PC board

1. See Section 5.12-Test L

1. Check for faulty NC contacts or poor relay connection in socket

2. Check and replace if necessary.

3. Check capacitor and replace if necessary

1. Adjust pressure

2. Check input voltage connections (Section 3.4)

3. If three-phase input voltage is within the lower half of range (see Section

5.10, Troubleshooting Theory, Input Voltage Selection), D18 on voltage selection PC board should not be lit. If D18 is lit, replace the voltage selection PC board.

O. No pilot. PILOT indicator

on, strong spark visible at spark gap points

Manual 0-2251 87 CUSTOMER/OPERATOR SER VICE

1. Electrode shorted against tip

2. Shorted torch head

3. Faulty capacitor (C25)

4. Broken conductor in torch lead

5. Shorted torch lead

6. Dirty or wet torch lead

1. Thread electrode securely into torch head

2. Check and replace if necessary

3. Check and replace if necessary

4. Check and replace if necessary

5. Check and replace if necessary

6. Clean and dry torch lead

(continued)

5.11 TROUBLESHOOTING GUIDE (continued)

SYMPTOM POSSIBLE CAUSE REMEDY

P. Pilot arc on, no main arc

transfer (torch brought within range of work)

Q. Main arc starts but goes

out immediately and main contactor (W1 or W2) goes off

1. Work cable not connected

2. Defective current control pot (on front panel or remote)

1. Fault condition causes output greater than 175 amps

1. Connect work cable securely

2. If remote is in use, disconnect J15 and set current at front panel. If transfer is okay, replace remote. If remote is not in use, see Section 5.12-Test M

1. Shorted Q1 or faulty switching control PC board. See Section 5.12Test K

CUSTOMER/OPERATOR SERVICE 88 Manual 0-2251

5.12 SERVICE AND TEST PROCEDURES

The following tests are suggested for specific problems listed in the troubleshooting guide. The letter designations correspond to those listed in the “Remedy” column of the troubleshooting section.

Several of these tests involve voltage measurements that must be made with power on. Use extreme care when

WARNING

making these tests. Tests requiring voltage measurements are marked with the warning symbol. Disconnect primary

A. Voltage Selection

PC Board Check

28 VAC Test

When wall power is first turned on, the voltage selection PC board (see Figure 5-G) senses the low voltage AC present at J6-20, J6-22, and J6-24 (center tap). The voltage selection board determines whether the voltage is in the lower or higher part of the selected input voltage range. If the input voltage is within the upper part of the range, the board energizes K1, K4, and K5 relays (labeled ‘HV’ on the system schematic). If the input voltage is within the lower part of the range the board energizes the K2 and K3 relays (labeled ‘LV’ on the schematic). If HV is selected, the red LED indicator (D18) on the voltage selection board will be lit. The relays do not energize until SW1-B (one pole of the ON/OFF switch) is closed because the DC voltage to the coils passes through it.

1. Check the AC input from J6-24 to both J6-20 and J6-22 for 12 - 18 VAC.

2. Check the AC voltage from J6-24 to both J6-17 and J6-18 for 16 - 22 VAC.

3. If input voltages are correct, check output from J6-19 to J6-21 for 14 - 18 VAC.

4. If output is not present between J6-19 and J6-21, check between J6-24 (-) and both J6-16 and J6-23 (+) for 12 - 16 VDC. If voltage is present at both points or neither, replace the voltage selection board. If voltage is found at J6-23 but not at J6-16, check SW1-B and all wiring and connections.

Manual 0-2251 89 CUSTOMER/OPERATOR SER VICE

5.12 SERVICE AND TEST PROCEDURES (continued)

SWITCHING CONTROL PCB

(9)

(10)

SW1-A ON/OFF

(14)

(15)

A-00965

120 VAC Test

(8)

E-STOP

MC1

(4)

(3)

VOLTAGE SELECTION PCB

MC2

(21)

1. Check the voltage input from F2 (wire #10) to J6-9 for 100 - 120 VAC. Check the input from F2 to J6-10 for 120

- 140 VAC.

2. If the voltage input is present, check the red LED indicator (D18) on the voltage selection board. If the indicator is lit, measure voltage output between F2 (wire #10) and J6-7. If the indicator is not lit, measure between F2 and J6-12. The voltage output at either point should measure 110 - 130 VAC.

3. If both or neither J6-7 or J6-12 have high voltage present, replace the voltage selection board. Check voltage between J6-21 and wire #10 on fuse F2 for 110 - 130 VAC. This supplies 120 VAC to the rest of the unit.

J28 TO OPTIONAL STANDOFF CONTROL

-1

-3 (110)

(881)

SW3-A

(75)

LOGIC PCB

SOL3

(89)

PCR

(5)

(22)

(24)

(23)

(24)

SOL1

(50)

SOL2

K4K2

T3(HF)

(94)

PSR

Figure 5-J 120 VAC Circuits

B. Blown Fuse (F1 or F2)

1. A shorted or frozen motor will cause F1 to fail. To check the motors, disconnect J20 (pump motor) and J39 (fan motor). Reconnect one at a time to determine which is component faulty. A shorted or open fan motor starting capacitor (C32) may also cause F1 to fail.

2. F2 fuses the 110 VAC circuit. MC1 or MC2, T2 and the gas solenoids are energized when power is first applied. If shorted, any one of these components would cause F2 to fail. W1 or W2, PCR and T3 energize after the torch switch or remote start switch is activated. Disconnect all components and reconnect one at a time to establish which component is faulty.

CUSTOMER/OPERATOR SERVICE 90 Manual 0-2251

5.12 SERVICE AND TEST PROCEDURES (continued)

C. Motor Control

Contactor Check

(MC1 or MC2)

120 VAC is supplied to the motor control contactors (MC1 and MC2) from the voltage selection PC board, which selects the proper tap on the main transformer (T1). The return path (see Figure 5-J) travels from wire #110 through the remote connector (J15) on the rear panel to the E-Stop switch (or if no remote is used, through K1 on the switching control board) to wire #8, through the ON/OFF switch (SW1A) to wire #9, through fuse F2 to wire #10 and T1.

Only one of the MC contactors should have voltage applied. If the red LED indicator (D18) on the voltage selection board is lit, MC2 should be energized. If D18 is not lit, MC1 should be energized.

1. Check the voltage across the coil on the contactor for approximately 120 VAC. If voltage is present, replace the contactor. If it is not, perform the 120 VAC test (see Section 5.12-Test A) to check for a proper voltage supply from the voltage selection board. If okay, continue to step 2 to isolate the problem in the return path.

2. With one meter lead on the supply side of the contactor coil (wire #3 for MC1 or wire #4 for MC2) measure to wires #8, 9, and 10 to determine where the return circuit is broken. On the return path, F2, SW1-A, and E-Stop can be measured for continuity. K1 on the switching control board will normally be open when power is off.

D. Diode Check

3. When the remote control cable is installed, a jumper between J15-26 and J15-27 pulls J7-20 on the switching control board to 0 V (board connector J7-19). When the jumper is not in place (remote cable is not plugged in) J7-20 measures +15 VDC and K1 should energize, bypassing the E-stop function. If not, replace the switching control board.

There are fourteen diodes in the main heatsink area, including six large 150 amp input rectifier diodes (D1-6) and eight small 70 amp diodes (snubbing diodes D7-10 and freewheeling diodes D11-14). To check the diodes without removing them from the circuit, use an ohmmeter set to the Rx1 or Rx10 scale to measure the resistance of each diode in both directions. The readings should differ by at least a factor of ten. If they do not differ (both high and low), replace the diode. Check all diodes before turning on power to the system.

(continued)

Manual 0-2251 91 CUSTOMER/OPERATOR SER VICE

5.12 SERVICE AND TEST PROCEDURES (continued)

D. Diode Check

(continued)

E. Thermal Sensing

Circuit Check

If a diode fails, check the potential causes of diode failure to make sure the replacement diode will not also fail when it is installed:

1. Isolate and check each diode separately to determine which individual diode has failed.

2. High frequency protection for the input rectifier diodes (D1-6) is provided by capacitors C1 - C6 and MOV 1-3, which are located between each side of the diode heatsink on the input filter PC board. Except for the shorts, these components can not be checked with a volt/ohm meter. To be safe, the complete input filter board should be replaced any time an input diode fails.

3. Diodes can overheat if air flow over the heatsink is not adequate or if the diode is not properly fastened to the heatsink. Check that all small diodes (D7-14) are torqued to 20-25 in-lbs (2.3-2.8 Nm) and all large diodes (D1-6) are torqued to 34 in-lbs (3.8 Nm). Apply a light film of electrically conductive heatsink compound between the diode and heatsink. Make sure air passages in and out of the unit are not obstructed.

4. Diodes that are faulty at the time of manufacture are difficult to diagnose. These diodes generally fail within the first few hours of operation. Before deciding that this was the case, be sure to check out other possibilities.

1. Thermal sensors TS1, TS2, and TS3 are connected in series to J1-9 on the logic board. Check the voltage from J1-9 to test point TP1 (or J1-8) on the logic board for less than 7.5 VDC. If the voltage is greater than 7.5 VDC, the unit is overheated or a temperature sensor is faulty.

2. If the unit still operates but the TEMP indicator is red, the problem may be on the LED PC board. If the voltage is less than 7.5 VDC, check the voltage from J3-4 to test point TP1 (ground). If the voltage is greater than +4 VDC (and the TEMP indicator is lit red), replace the LED PC board. If the voltage at J3-4 is less than 4V, replace the logic board.

F. Pressure Sensing Circuit

Pressure switches PS1 and PS2 are connected in series to J1-7 on the logic PC board. PS2 is jumpered out by SW3-B when the unit is set to the O

2 or water secondary mode.

1. Check the voltage at J1-7 for less than 1V with gases flowing and operating pressure greater than 35 psi (2.4 BAR).

CUSTOMER/OPERATOR SERVICE 92 Manual 0-2251

5.12 SERVICE AND TEST PROCEDURES (continued)

F. Pressure Sensing Circuit

(continued)

G. Gas Solenoid Circuits

H. Coolant Flow Sensor

Circuit Check

2. If the voltage at J1-7 is less than 1V, check the voltage at J3-3. If the voltage at J3-3 is greater than 12 VDC, replace the logic board. If the voltage at J3-3 is less than 12 VDC, replace the LED board.

1. Set the RUN/SET/PURGE switch to SET position. Measure continuity between the center terminal of the switch (wire #62) and each outer terminal (wires #61 and 63). If the resistance is less than 1000 ohms, replace the RUN/SET/PURGE switch.

2. If the resistance is greater than 1000 ohms, check for 120 VAC between wire #110 and J2-8 for plasma and J2-10 for secondary. If 120 VAC is present at one point and not the other, replace the logic board.

3. If no voltage is present at J2-8 or at J2-10, check for 120 VAC at J2-1 (the logic board input). If 120 VAC is present at J2-1, replace the logic board. If not, check the 120 VAC voltage supply (see Section 5.12-Test A).

The flow sensor (FS1) for the coolant is calibrated for 0.75 gpm. When adequate coolant flow satisfies FS1 it closes, connecting J1-5 on the logic board to J1-4 (common).

I. Coolant Conductivity

Circuit

Measure voltage between J1-5 and J1-4 or TP1. If J1-5 is greater than 1 volt FS1 or connections to FS1 are faulty. If J1-5 measures close to 0 VDC, check J3-2. If J3-2 measures less than +12 VDC, and the coolant flow indicator is not lit, replace the LED PC board. If J3-2 measures greater than +12 VDC, replace the logic board.

The conductivity probe consists of two insulated pins that extend into the coolant reservoir. The logic PC board sends out an AC voltage level on J2-24 that varies with the conductivity of the coolant.

1. Disconnect one of the wires to the conductivity probe (wire #57 or 58). The logic PC board will see infinite resistance and the coolant conductivity LED indicator should be lit. If the coolant conductivity indicator is lit, replace the coolant. If the problem remains, replace the conductivity probe.

2. If the coolant conductivity indicator is not lit with the probe disconnected, measure between the logic board common (TP1) and J3-1. If the voltage measures below +12 VDC, replace the LED PC board. If the voltage measures above +12 VDC, replace the logic board.

Manual 0-2251 93 CUSTOMER/OPERATOR SER VICE

5.12 SERVICE AND TEST PROCEDURES (continued)

J. Main Contactor Circuit

(W1 and W2)

Only one of the two main contactors (W1 and W2) is used at any given time. The K5 relay on the voltage selection PC board selects which contactor is activated. If the red LED indicator (D18) on the voltage selection board is lit, W2 is selected. If D18 is not lit, W1 is selected.

There are three ways to initiate main contactor closure. Two are through the remote jack (J15). J15-14 is a momentary closure where a push-button (remote START switch) or CNC device momentarily (100 ms) connects J15-14 to the logic board common (J15-15).

The second is a maintained closure where a CNC device or the remote pendant connects J15-24 to the logic board common (J15-25) and maintains the connection until the contactor is opened.

The third is a maintained closure from J14-4 to logic common (J14-3) used for hand torch control. The momentary stop input (J15-16) used in conjunction with momentary start, disables all start inputs when connected to logic common (J15-17). The CNC station select function uses this input to prevent starting when the station is not selected.

Only one start switch may be activated at any given time, but any stop signal will stop the unit. For example, with the remote panel and a hand torch connected, if the unit is started with the hand torch switch, it may be stopped with the remote stop switch. Once stopped, it cannot be restarted with the remote start switch until the hand torch switch is released. When the system is started by the remote start switch, pressing and releasing the hand torch switch will stop it.

The start signal activates the red ‘start’ LED indicator (D57) on the logic PC board to indicate that the start signal was received by the logic board. D57 stays lit until the stop signal is received.

The start signal initiates the gas pre-flow, which is normally two seconds but may also be set for other time periods (see Section 4.5, Plasma Cutting Operation). After pre-flow is complete the K2 relay on the logic board closes, sending 120 VAC from J2-1 out through J2-12 on wire #23 to J6-5 on the voltage selection PC board and through the K5 relay to one of the main contactors.

CUSTOMER/OPERATOR SERVICE 94 Manual 0-2251

5.12 SERVICE AND TEST PROCEDURES (continued)

J. Main Contactor Circuit

(continued)

1. If the start LED (D57) does not light, use the negative voltmeter probe on the logic board common (TP1) or one of the J1 common pins, check the active ‘start’ input (J1-21 for momentary start, J1-19 for maintained start from CNC or remote pendant or J1-15 from hand torch) for at or near 0 VDC (check the momentary with the switch held closed). When not activated, the ‘start’ input should measure +12 - 15 VDC. If the ‘start’ input does not drop to 0 VDC when activated, the problem is wiring or a defective switch.

2. Check the ‘stop’ input at J10-17 for +12 - 15 VDC. Check that the ‘stop’ input does not stay at 0 VDC. If start and stop inputs are okay and start indicator is not lit even momentarily replace the logic PC board.

3. If no output voltage is produced within 75 ms, the logic removes the start signal. This makes troubleshooting difficult. Jumping TP1 to TP4 on the logic board disables this for troubleshooting. A red LED indicator (D38) on the logic board labeled ‘W ’ indicates that the K2 relay (which controls the 120 VAC to J2-12) has received the signal to turn on. If the start indicator comes on and W does not, replace the logic board. If W comes on, check for 120 VAC between wire #110 (120 VAC return) and J2-12. If 120 VAC is not present, replace the logic board.

4. If 120 VAC is present at J2-12, check J6-1 and J6-3 on the voltage selection board. If voltage is present at only one of the two points, replace the contactor. If voltage is present at neither or both points, replace the voltage selection board.

K. Switching Control Check

(Q1)

Manual 0-2251 95 CUSTOMER/OPERATOR SER VICE

To produce DC output, the main switch (Q1) must be turned on and off rapidly. Power supply output is controlled by the on-time. At the same time the main contactor (W1 or W2) closes, the logic board grounds pin 9 of the 34-pin ribbon cable (J3-9 on the logic board, J10-9 on the switching control board). This enables the pulse width modulator (PWM) on the switching control board.

If no DC voltage is detected within 75 ms at J1-24 on the logic board, the enable signal on J10-9 is removed and the main contactor opens. Connecting TP4 to TP1 (ground) on the logic board disables this function for troubleshooting if no DC output is found.

(continued)

5.12 SERVICE AND TEST PROCEDURES (continued)

K. Switching Transistor

Check (continued)

WARNING

The PWM compares shunt amp output on J9-5 with the current control signal (3.3 - 10 VDC) from the remote (J7-

18) or the panel control (J10-15). A faulty shunt amp could cause the output, normally 0 VDC with no cutting arc, to go higher, shutting off the PWM and thus producing no DC. If the shunt amp ribbon connector is disconnected or pin 1 is open, approximately 12 VDC is applied to J9-5, shutting down the PWM in the same manner as a shunt amp failure.

The switching control board sends pulses (+15 V) to the driver board on J8-1 and J8-3. The width of these pulses controls the on-time of Q1. The pulses are best observed with an oscilloscope, but an AC voltmeter should read about 6 - 7 VAC from J8-2 to both J8-1 and J8-3. If 0 VAC is measured at both J8-1 and J8-3, with the enable (J10-9) and shunt amp (J9-5) input low, replace the switching control board.

If switching pulses are present at J8-1 and J8-3, check the driver PC board output between base and emitter of Q1.

Both base and emitter are at -320 VDC potential.Use extreme caution when testing driver board output.

L. Pilot Contactor Check

(PCR)

The metric screws provided with the transistor are to be used for the transistor connections. Small metric screws are to be torqued to 12 in-lbs (1.4 Nm). Larger (M6) metric screws are to be torqued to 26 in-lbs (2.9 Nm).

The driver board output should measure about 1 VAC. If output measures 0 to -4 VDC replace the driver board.

1. If the pilot indicator is lit and no spark is detected at the spark gap points, check between the wire #10 and J2-4. If 120 VAC is not present, replace the logic board.

2. If spark is visible at the points, the logic board is operating properly. Check for a faulty PCR contactor.

3. If the pilot indicator is not lit, check J3-11. If J3-11 measures +15 VDC, replace the logic board.

4. If J3-11 measures low (near 0 VDC), the switching control board is falsely indicating main arc transfer. If the shunt amp output (J9-5) is 0 VDC, replace the switching control board. If shunt amp output does not measure 0 VDC, replace the shunt amp.

CUSTOMER/OPERATOR SERVICE 96 Manual 0-2251

Tweco 15XC User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.04 Note, Attention et Avertissement

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

SECTION 2: INTRODUCTION & DESCRIPTION

2.1 SYSTEM DESCRIPTION

2.2 POWER SUPPLY SPECIFICATIONS

2.3 TORCH SPECIFICATIONS

2.4 OPTIONS AND ACCESSORIES

2.5 THEORY OF OPERATION

SECTION 3: INSTALLATION PROCEDURES

3.1 UNPACKING THE SYSTEM

3.2 LOCATION

3.3 PLASMA AND SECONDARY CONNECTIONS

3.4 ELECTRICAL CONNECTIONS

3.5 WORK AND GROUND CONNECTIONS

3.6 COOLANT INSTALLATION

3.7 AUXILIARY CONNECTIONS

3.8 LIFTING THE POWER SUPPLY

SECTION 4: OPERATION

4.1 OPERATING CONTROLS

4.2 PRE-OPERATION SET-UP

4.3 TORCH PARTS SELECTION

4.4 GAS SELECTION FOR PLASMA CUTTING

4.5 PLASMA CUTTING OPERATION

4.6 HAND TORCH OPERATION

4.7 MACHINE TORCH OPERATION

4.8 PIERCING

4.9 GOUGING OPERATION

4.10 COMMON OPERATING ERRORS

4.11 CUTTING SPEEDS

4.12 SEQUENCE OF OPERATION

SECTION 5: CUSTOMER/OPERATOR SERVICE

5.1 TORCH MAINTENANCE

5.2 HAND TORCH HEAD REPLACEMENT

5.3 MACHINE TORCH HEAD REPLACEMENT

5.4 HAND TORCH SWITCH REPLACEMENT

5.5 HAND TORCH LEADS REPLACEMENT

5.6 MACHINE TORCH LEADS REPLACEMENT

5.7 LEADS EXTENSION KITS - HAND TORCH

5.8 LEADS EXTENSION KITS - MACHINE TORCH

5.9 POWER SUPPLY MAINTENANCE

5.10 TROUBLESHOOTING THEORY

5.11 TROUBLESHOO TING GUIDE

5.12 SERVICE AND TEST PROCEDURES