Tweco 15XC User Manual
®
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
Copyright 1990 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in 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
2)
• Argon/Hydrogen
(Ar/H
• Nitrogen (N
2)
2)
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
2)
• Carbon Dioxide
(CO
2)
• 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)
o
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
2
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
11
12
L3
13
15
14
6
7
L2
8
10
9
1
2
L1
3
5
4
380, 415,
or 460
11
12
L3
13
15
14
6
7
L2
8
10
9
1
2
L1
3
5
4
500, or 575
11
12
L3
13
15
14
6
7
L2
8
10
9
1
2
L1
3
5
4
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
L3
L2
Busbars
L1
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
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