Tweco 15XCCE User Manual

PLASMA CUTTING

SYSTEM

CE Merlin® PAK® 15XC™

Instruction Manual

August 19, 2005 Manual No. 0-2529

W ARNINGS

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

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

Plasma Cutting System
CE Merlin P AK 15XC
Instruction Manual No. 0-2529

Published by:
Thermal Dynamics Corporation
82 Benning Street
W est Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

© Copyright 1996 by
Thermal Dynamics Corporation

All rights reserved.

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

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

Printed in the United States of America

Publication Date: August 19, 2005

Record the following information for W arranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

T or ch Serial #: _______________________________________

TABLE OF CONTENTS

GENERAL INFORMATION.............................................................................................................i

Notes, Cautions and Warnings ..................................................................................i

Important Safety Precautions ....................................................................................i

Publications..............................................................................................................ii

Note, Attention et Av ertissement ............................................................................. iii

Precautions De Securite Importantes...................................................................... iii

Documents De Reference ....................................................................................... v

Declaration of Conformity....................................................................................... vii

Statement of W arranty........................................................................................... viii

SECTION 1: INTR ODUCTION & DESCRIPTION..................................................................... 1-1

1.1 SYSTEM DESCRIPTION .............................................................................. 1-1

1.2 POWER SUPPLY SPECIFICATIONS ............................................................ 1-2

1.3 TORCH SPECIFICATIONS ........................................................................... 1-3

1.4 OPTIONS AND ACCESSORIES................................................................... 1-5

1.5 THEORY OF OPERATION............................................................................ 1-6

SECTION 2: INSTALLATION .................................................................................................... 2-1

2.1 UNPACKING THE SYSTEM .......................................................................... 2-1

2.2 LOCATION .................................................................................................... 2-2

2.3 PLASMA AND SECONDARY CONNECTIONS............................................. 2-2

2.4 ELECTRICAL CONNECTIONS..................................................................... 2-6

2.5 WORK AND GR OUND CONNECTIONS....................................................... 2-8

2.6 COOLANT INSTALLATION ........................................................................... 2-9

2.7 AUXILIARY CONNECTIONS ...................................................................... 2-10

2.8 LIFTING THE PO WER SUPPLY.................................................................. 2-12

SECTION 3: OPERATION ........................................................................................................ 3-1

3.1 OPERATING CONTROLS............................................................................. 3-1

3.2 PRE-OPERATION SET-UP ........................................................................... 3-4

3.3 TORCH PARTS SELECTION ........................................................................ 3-5

3.4 GAS SELECTION FOR PLASMA CUTTING................................................. 3-8

3.5 PLASMA CUTTING OPERATION ............................................................... 3-12

3.6 HAND T ORCH OPERATION ....................................................................... 3-16

3.7 MACHINE TORCH OPERATION ................................................................. 3-18

3.8 PIERCING................................................................................................... 3-21

3.9 GOUGING OPERATION ............................................................................. 3-22

3.10 COMMON OPERATING ERRORS............................................................ 3-25

3.11 CUTTING SPEEDS................................................................................... 3-26

3.12 SEQUENCE OF OPERATION................................................................... 3-38

TABLE OF CONTENTS (continued)

SECTION 4: SERVICE ............................................................................................................. 4-1

4.1 T ORCH MAINTENANCE............................................................................... 4-1

4.2 HAND TORCH HEAD REPLACEMENT ........................................................ 4-2

4.3 MACHINE TORCH HEAD REPLACEMENT.................................................. 4-4

4.4 HAND T ORCH SWITCH REPLACEMENT .................................................... 4-6

4.5 HAND T ORCH LEADS REPLACEMENT ...................................................... 4-7

4.6 MACHINE TORCH LEADS REPLACEMENT ................................................ 4-9

4.7 LEADS EXTENSION KITS - HAND TORCH ............................................... 4-11

4.8 LEADS EXTENSION KITS - MACHINE TORCH ......................................... 4-13

4.9 POWER SUPPLY MAINTENANCE ............................................................. 4-16

4.10 TR OUBLESHOO TING THEORY ............................................................... 4-17

4.11 TROUBLESHOOTING GUIDE ................................................................... 4-21

4.12 SERVICE AND TEST PROCEDURES ...................................................... 4-27

SECTION 5: PARTS LISTS....................................................................................................... 5-1

5.1 ABOUT THE PARTS LIST ............................................................................. 5-1

5.2 SYSTEM COMPONENTS AND ACCESSORIES.......................................... 5-2

5.3 ACCESS PANEL COMPONENTS................................................................. 5-4

5.4 FRONT PANEL/CHASSIS COMPONENTS................................................... 5-5

5.5 REAR PANEL COMPONENTS ..................................................................... 5-6

5.6 BASE COMPONENTS .................................................................................. 5-8

5.7 UPPER CHASSIS COMPONENTS............................................................. 5-10

5.8 MAIN HEATSINK COMPONENTS .............................................................. 5-12

5.9 TORCH COMPONENTS ............................................................................. 5-14

5.10 TORCH ACCESSORIES ........................................................................... 5-16

SECTION 6: ADDITIONAL INFORMATION .............................................................................. 6-1

6.1 LADDER DIAGRAM - 120 V AC ...................................................................... 6-1

6.2 LADDER DIAGRAM - 15 VDC........................................................................ 6-2

6.3 DIGITAL CURRENT CONTROL INTERFACE ................................................ 6-3

6.4 CNC INTERF ACE ......................................................................................... 6-4

6.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE................. 6-5

6.6 REMOTE CONTROL CHASSIS SCHEMATIC .............................................. 6-6

6.7 ROUTINE MAINTENANCE SCHEDULE....................................................... 6-7

6.8 SYSTEM SCHEMATIC .................................................................................. 6-8

GENERAL INFORMATION

GASES AND FUMES

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 background 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.

WARNING

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

Important Safety Precautions

W ARNINGS

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

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

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 ar ea where com­bustible or explosive gases or materials are located.

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

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

ELECTRIC SHOCK

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: January 27, 2004 i 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.

• 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.

• V entilate all flammable or explosive vapors from the work­place.

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

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

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

NOISE

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

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

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

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

PLASMA ARC RA YS

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

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

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

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

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

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

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

Publications

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

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

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

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

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

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable 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 Standards Institute, 1430 Broadway,
New Y ork, NY 10018

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

GENERAL INFORMA TION ii Date: January 27, 2004

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

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

10 . NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269

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

12. CSA Standar d W1 17.2, CODE FOR SAFETY IN WELD­ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3

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

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

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

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 :

AVERTISSEMENT

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

Precautions De Securite

Importantes

A VERTISSEMENTS

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.

NOTE

Toute opération, procédure ou renseignement

FUMÉE et GAZ

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

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

ATTENTION

• Eloignez toute fumée et gaz de votre zone de respiration.

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

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.

Date: January 27, 2004 iii GENERAL INFORMA TION

• 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 différents pr océdés. 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

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

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

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

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

Les chocs électriques peuvent blesser ou même tuer. Le

RAYONS D’ARC DE PLASMA

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.

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.

GENERAL INFORMA TION iv Date: January 27, 2004

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

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 1 2
400 - 800* 10 14

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

BRUIT

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

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

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

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 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 TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

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

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

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

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

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

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

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

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

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

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, Ar ­lington, V A 22202

Date: January 27, 2004 v GENERAL INFORMA TION

12 . Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE

SOUDAGE ET LA COUPE, disponible auprès de
l’Association des Normes Canadiennes, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W
1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU
SOUDAGE, disponible auprès de l’Association Nationale
de Fournitures de Soudage (National W elding Supply As­sociation), 1900 Arch Str eet, Philadelphia, P A 19103

14. Norme A WSF4.1 de l’Association Américaine de Soudage,
RECOMMANDA TIONS DE PRATIQUES SURES POUR
LA PRÉP ARA TION À LA COUPE ET AU SOUDAGE DE
CONTENEURS ET TUY AUX A Y ANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de la Ameri­can W elding Society , 550 N.W . LeJeune Rd., Miami, FL
33126

15 . Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRA TOIRE, disponible auprès de l’American Na­tional Standards Institute, 1430 Broadway , New Y ork, NY
10018

GENERAL INFORMA TION vi Date: January 27, 2004

Declaration of Conformity

S

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European
Council Directive 89/336/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 T echnical Specifications

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

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

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

* CENELEC EN50199 EMC Product Standard for Arc W elding Equipment.

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

ated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the

when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

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

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product 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

Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley , Lancashire,
England PR6 7BX

mark conform to EN50192

Date: January 27, 2004 vii GENERAL INFORMA TION

Statement of Warranty

LIMITED W ARRANTY: 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 stored, installed, operated, and maintained in accordance with Thermal’s
specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or
accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by
Thermal to be defective.

THIS W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR TICULAR
PURPOSE.

LIMIT A TION 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 fr om 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 her ein,
exceed the price of the goods upon which such liability is based.

THIS W ARRANTY BECOMES INV ALID IF REPLACEMENT P ARTS OR ACCESSORIES ARE USED WHICH MA Y IMP AIR THE SAFETY
OR PERFORMANCE OF ANY THERMAL PRODUCT .

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

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

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

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

Parts

XL Plus & Parts Parts

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

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

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

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

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 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: November 15, 2001

GENERAL INFORMA TION viii Date: January 27, 2004

SECTION 1: INTRODUCTION & DESCRIPTION

1.1 SYSTEM DESCRIPTION

PAK 15XC Power Supply

Work Cable

Figure 1-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging System

The Merlin PAK 15XC

System Includes:

NOTE

Torch Leads

PCM-150 Machine Torch

• PAK 15XC 150 Amp Power Supply
with Running Gear and Handle

• PCH-150 90° or 70° Hand Torch
(or) PCM-150 Machine Torch with Mounting Assembly

• 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

System options and accessories are listed on page 1-5.

Remote Control Panel

A-00875

Spare Parts Kit

Manual 0-2529 1 - 1 INTRODUCTION & DESCRIPTION

1.2 POWER SUPPLY SPECIFICATIONS

Shipping Weight

Enclosure Only:

Input Power

Output Power

Duty Cycle

A-00876

Voltage Frequency Phase Amperage

380 50 or 60 Hz 3 44
415 50 or 60 Hz 3 40

Table 2-A (page 2-7) 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 1-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 1 - 2 Manual 0-2529

1.3 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 Options and Accessories, page 1-5)

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)

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)

Min.50 psi

(3.4 bar)

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

Manual 0-2529 1 - 3 INTRODUCTION & DESCRIPTION

PCH-150 90o Hand Torch

13.31 in

(338 mm)

1.62 in

(41 mm)

3.81 in

(97 mm)

1.38 in

(35 mm)

PCH-150 70

o

Hand Torch

13.87 in

(352 mm)

3.96 in

(101 mm)

1.62 in

(41 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 1-C PCH/M-150 Torch Dimensions

1.62 in

(41 mm)

A-02685

INTRODUCTION & DESCRIPTION 1 - 4 Manual 0-2529

1.4 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 System Components and Accessories (page 5-2) 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 Torch Components (page 5-14) and Torch Accessories
(page 5-16) for ordering information.

Manual 0-2529 1 - 5 INTRODUCTION & DESCRIPTION

1.5 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 Thermal Arc 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 Thermal Arc 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 1-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 1-D Theory of Operation

Zone A
Zone B

Workpiece

Coolant

Plasma Gas

Secondary Gas

A-00900

INTRODUCTION & DESCRIPTION 1 - 6 Manual 0-2529

Plasma Gas Flow

(continued)

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 1-D). Direct current (DC) straight polarity
is used for plasma cutting, as shown in the illustration.

Secondary Flow

Coolant Flow

Pilot Arc

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 1-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 1-D), where the extra cooling
effect helps to increase parts life. The coolant then flows
back to the power supply through the return lead.

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.

Main Cutting Arc

The PAK 15XC accepts 380/415 VAC, 50 or 60 Hz, three­phase, line input. 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.

RF Shielding

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 0-2529 1 - 7 INTRODUCTION & DESCRIPTION

Interlocks

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.

Parts-In-Place Interlock

Gas Pressure Interlock

Thermal Interlock

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 1 - 8 Manual 0-2529

SECTION 2: INSTALLATION

2.1 UNPACKING THE SYSTEM

The power supply is skid-mounted and protected with a
carton and padding material to prevent damage during
shipment. The 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 2-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.

Shipping Brackets

A-00953

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 Pallet

Three Bolts
(Each Side)

Figure 2-A Unpacking the System

Manual 0-2529 2 - 1 INSTALLATION

2.2 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.

2.3 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 Gas Selection for Plasma Cutting (page 3-8) 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).

INSTALLATION 2 - 2 Manual 0-2529

Input Gas Connections

(Air Operation)

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

Air Line Filter Installation

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

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

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

Plasma Gas

Fitting

Female Elbow

of the air filter assembly. Tighten both sides securely.

rear panel marked PLASMA.

filter assembly.

Secondary Gas

Fitting

Y-Hose

Assembly

Hex Nipple

Hex Nipple

Street Elbow

Air Filter Assembly

(Plasma Line Only)

From Supply

A-00902

Figure 2-B Air Line Filter Installation

Manual 0-2529 2 - 3 INSTALLATION

Air Line Filter Installation

(continued)

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.

Input Gas Connections

(Multi-Gas Operation)

WARNING

CAUTION

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.

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
System Components and Accessories (page 5-2) 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 CO2
cylinders. Continuous flow requirements will depend on
the specific application and duty cycle.

INSTALLATION 2 - 4 Manual 0-2529

Secondary Water

Connections

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.

NOTE

Secondary Water

Plasma Gas

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

A-00874

Figure 2-C Rear Panel Connections

Manual 0-2529 2 - 5 INSTALLATION

2.4 ELECTRICAL CONNECTIONS

Electrical Requirements

Electrical Connections

WARNING

The PAK 15XC power supply is designed to accept a an
input voltage of 380/415 VAC.

The electrical power source must conform to local electric
code and the following recommended circuit protection
and wiring requirements (see Table 2-A, page 2-7).

1. Check the three-phase electrical power source for line
voltage and proper circuit protection and wiring (see
Table 2-A, page 2-7).

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

Refer to Figure 2-D (page 2-7) and:

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

3. Check the bus bar configuration (factory installed) on
the input voltage terminal board . The bus bar con­figuration must correspond with the 380 VAC line
voltage.

4. Insert the primary power cable (customer supplied)
through the strain relief in the rear panel of the power
supply.

WARNING

5. Locate the four input connectors, flat washers, conical
spring washers, and hex locking nuts supplied with
the power supply.

6. Install the input connectors, supplied, onto each of the
input power line leads of the power cable.

7. Connect the input power connectors to the EMI Input
Power Filter PC Board input studs with the supplied
hex locking nuts, conical spring washers, and flat
washers as follows:

• Input ground wire to G1.

• LI input line to X1.

• L2 input line to Y1.

• L3 input line to Z1.

8. Tighten the nuts being careful not to over-tighten.
Refer to the following WARNING.

Do Not over tighten the nuts securing the iput power
cable connectors as damage to the PC Board can occur.

INSTALLATION 2 - 6 Manual 0-2529

Voltage Power Input Current Frequency Phase Recommended

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

380 29 44 50 3 50 amps AWG 8
415 29 40 50 3 45 amps AWG 8

Table 2-A Line Voltages, Circuit Protection and Recommended Wire Size

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

PC Board

Power Stud

Flat Washer

Input

Connector

A-00908

Slotted Screw

Input Power Cable

(One Line)

Input Voltage Connector

Installation Detail

Conical Spring

Washer

Hex Locking

Nut

Input Power

Filter PC Board

and Bracket

Input Ground

Connection

INPUT

VOLTAGE

380/415

VAC

BUS BAR

CONNECTIONS

L1-3, 1-2
L2-8, 6-7

L3-13, 11-12

380/

415VAC

L3

L2

L1

Primary Power

Cable

L3

L2

L1

Strain Relief

Fitting

A-00896

Figure 2-D Input Voltage Connections and Bus Bar Configuration

Manual 0-2529 2 - 7 INSTALLATION

2.5 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 2-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 2-E Proper Work and Ground Cable Connections

INSTALLATION 2 - 8 Manual 0-2529

2.6 COOLANT INSTALLATION

Coolant Installation

CAUTION

Refer to Figure 2-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 2-F Coolant Reservior and De-ionizing Cartridge

Manual 0-2529 2 - 9 INSTALLATION

2.7 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 the CNC Interface Sche­matic on page 6-4).

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 (see Figure 2-G,
page 2-11). 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.

INSTALLATION 2 - 10 Manual 0-2529

POWER
SUPPLY

SC-5

D

CONTROL

B

CONSOLE

TORCH

POSITIONER

(LIFTER)

SC-5 REMOTE

CONTROL

A

E

C

F

CNC

CONTROL

POWER SUPPLY

REMOTE CONTROL

WORK

GROUND

A-00879

Cable Description Letter Designation

SC-5 Remote to Console A
SC-5 Torch Lifter (Positioner) to Console B
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 2-G Typical Mechanized System Installation and Cable Interconnection Diagram

Manual 0-2529 2 - 11 INSTALLATION

2.8 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 2-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 2-H Lifting the Power Supply

INSTALLATION 2 - 12 Manual 0-2529

SECTION 3: OPERATION

3.1 OPERATING CONTROLS

1 2

7

5 6

4

8

10

9

ON

OFF

RUN

PURGE

Figure 3-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.

DC

PILOT

A-00887

100

50

125

AC TEMP

150

AMPS

75

3

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 Cutting
Speeds (page 3-26) 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 0-2529 3 - 1 OPERATION

Figure 3-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 Gas Selection (page 3-8) 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.

OPERATION 3 - 2 Manual 0-2529

35

1

2

7

8

6

9

A-00575

Figure 3-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

E-STOP

RUN

PURGE

START STOP

4

AMPS

CURRENT

A

A

CSD

3
2
1

0

SPEED

LOW HIGH

PIERCE
DELAY

4567

10

11

10

8

9

Function

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

Non 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 Machine Torch Operation
(page 3-20) 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.

Non functional.

Manual 0-2529 3 - 3 OPERATION

3.2 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 Coolant Installation, page 2-9).

2. Check the torch for proper assembly (see Torch Main­tenance, page 4-1). Install proper torch parts for the
application (see Torch Parts Selection, page 3-5).

3. Select the desired pre-flow, post-flow, and auto-restart
settings (see Machine Torch Operation, page 3-13). 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
ten-second post-flow.

4. Check the power source for proper 380/415 VAC
three-phase input voltage. Make sure the input power
is properly connected to the EMI input filter PC board
(see Electrical Connections, page 2-6). 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

OPERATION 3 - 4 Manual 0-2529

5. Select desired plasma and secondary (see Gas Selec­tion, page 3-8). Make sure gas sources meet require­ments (see Plasma and Secondary Connections, page
2-2). 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 Cutting
Speeds (page 3-26).

8. Move the RUN/SET/PURGE switch to SET position.
Set plasma and secondary pressures (see Plasma and
Secondary Connections, page 2-2).

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.

3.3 TORCH PARTS SELECTION

not come on because

WARNING

Shield Cup Selection

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

Shield Cups (See Figure 3-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 3-D Shield Cup Selection

Manual 0-2529 3 - 5 OPERATION

WARNING

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

CAUTION

Tip Selection

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 3-E, page 3-7). Air tips
and electrodes have no rings, oxygen tips and electrodes
have one ring, nitrogen tips and multi-gas (N2 or Ar/H

)

2

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

Cutting Tips - Air Plasma Cat. No.

50 Amps (0.043 in)................................................... 9-5748

100 Amps (0.055 in) ................................................. 9-5747

150 Amps (0.070 in) ................................................. 9-5746

Cutting Tips - O

Plasma

2

50 Amps (0.043 in)................................................... 9-5753

100 Amps (0.057 in) ................................................. 9-5752

150 Amps (0.070 in) ................................................. 9-5751

Cutting Tips - N2

Plasma

Electrode Selection

50 Amps (0.043 in)................................................... 9-5765

100 Amps (0.052 in) ................................................. 9-5766

150 Amps (0.067 in) ................................................. 9-5767

Cutting Tips - ArH

Plasma

2

150 Amps (0.073 in) ................................................. 9-5775

Gouging Tips - Air or Multi-Gas

85 Amps (0.078 in)................................................... 9-5756

150 Amps (0.120 in) ................................................. 9-5755

Electrodes Cat. No.

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

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

Multi-Gas (N2 or Ar/H

)- Cutting ....................... 9-5754

2

OPERATION 3 - 6 Manual 0-2529

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

O

2 Plasma

100 Amp (.057) Tip

Cat. No. 9-5752

O

2 Plasma

150 Amp (.070) Tip

Cat. No. 9-5751

O

2 Plasma Electrode

Cutting or Gouging

Cat. No. 9-5760

N2 Plasma

50 Amp (.043) Tip

Cat. No. 9-5765

N

2 Plasma

100 Amp (.052) Tip

Cat. No. 9-5766

N

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 3-E Tip and Electrode Selection

Manual 0-2529 3 - 7 OPERATION

3.4 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

CO

2.

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 3-A Plasma Gas Selection for Plasma Cutting

OPERATION 3 - 8 Manual 0-2529

AIR SECONDARY

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

• Inexpensive - reduces operating costs.

• Improves cut quality on some ferrous materials.

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

2 SECONDARY

CO

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 3-B Secondary Selection for Plasma Cutting

Manual 0-2529 3 - 9 OPERATION

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 3-C (page 3-11) 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 3-F Cut Characteristics

OPERATION 3 - 10 Manual 0-2529

Description

Cut Characteristics:

GAS

Air Plasma

Air Secondary

Excellent

Good

Fair

NR

NOTE

MATERIAL

THICKNESS

Gage

Gage to 1 in.

1 to 2 in.

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 ori­fice), 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

Good/Excellent

Excellent
Excellent

Stainless Steel

Good/Excellent

Good
Good

Aluminum

Good/Excellent

Good
Good

Nitrogen Plasma

Air Secondary

or CO

2 Secondary

Nitrogen Plasma

Water Secondary

Ar/H

2 Plasma

N

2 or CO2

Secondary

Oxygen Plasma

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
Good/Excellent
Good/Excellent

Excellent

Good

NR

NR
NR
NR

Excellent

Good/Excellent
Good/Excellent
Good/Excellent

Good

Excellent

NR

NR

Good

Excellent

Good

Table 3-C Cut Quality: Plasma and Secondary Gas Selection

for Various Materials and Material Thicknesses

Good/Excellent
Good/Excellent
Good/Excellent

Good

Good/Excellent

NR

NR
Excellent
Excellent

NR

Manual 0-2529 3 - 11 OPERATION

3.5 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

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 Torch Parts Selection on pages
3-6 and 3-7).

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.

OPERATION 3 - 12 Manual 0-2529

Auto-Restart Options

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.

On/Off

Normal/Delayed

Pre-Flow Delay

Post-Flow Delay

Applications

• 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. Refer to setting charts.

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.

Manual 0-2529 3 - 13 OPERATION

Auto-Restart

(continued)

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

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)

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

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

7 1 (On) 0 (Off)

10 1 (On) 1 (On)

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

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 (On)

Post-Flow Time SW4-1 SW4-2

(Seconds) Position Position

1.25 0 (Off) 1 (On)

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

10 1 (On) 1 (On)

OPERATION 3 - 14 Manual 0-2529

Figure 3-G Control Logic PC Board - Setting Auto-Restart Options

Manual 0-2529 3 - 15 OPERATION

3.6 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 Torch Parts Selection on pages
3-6 and 3-7).

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 3-H Cutting with a Hand Torch

OPERATION 3 - 16 Manual 0-2529

Hand Torch Operation

(continued)

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.

NOTE

CAUTION

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
are NOT intended for hand cutting. Do not allow an
exposed torch tip to contact the workpiece.

Manual 0-2529 3 - 17 OPERATION

3.7 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 3-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 Auto-Restart Options, page 3-13). De-activating
the torch will shut off either the pilot or main arc
(depending on the mode of operation).

Figure 3-I Machine Torch Set-up

OPERATION 3 - 18 Manual 0-2529

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.
Cutting Speeds (page 3-26) 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 3-J).

Figure 3-J Machine Torch Operation

Manual 0-2529 3 - 19 OPERATION

Corner Slowdown (CSD)

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.

NOTE

Corner Slowdown Settings

NOTE

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 Operating Controls, page 3-3).

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.

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 (

not a percentage) of the main current setting. For
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

increase through the CSD

cycle.

For electrical connections, refer to the CNC Interface
Schematic (page 6-4.)

OPERATION 3 - 20 Manual 0-2529

3.8 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 3-K).

Pierce off the cutting line and then continue the cut as
shown in Figure 3-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 3-K Piercing with a Hand Torch

Manual 0-2529 3 - 21 OPERATION

3.9 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

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 Torch Parts Selection on pages
3-6 and 3-7).

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

Figure 3-L Gouging with a Hand Torch

OPERATION 3 - 22 Manual 0-2529

Gouging Parameters

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.

Torch Travel Speed

Current Setting

Lead Angle

(Travel Angle)

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 desir-

Figure 3-M Gouging Parameters

Manual 0-2529 3 - 23 OPERATION

Standoff Distance

Slag Build-up

GAS

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

MATERIAL

Carbon Steel

Stainless Steel

Aluminum

Air Plasma

Air Secondary

Nitrogen Plasma

Air Secondary

Nitrogen Plasma

CO

2 Secondary

2 Plasma

Ar/H

Nitrogen Secondary

Ar/H

2 Plasma

Argon Secondary

Table 3-D Recommended Gases for Plasma Arc Gouging

Excellent

Good

Good

Good

Good

Good

Good

Good

Excellent

Excellent

Fair

Fair

Good

Excellent

Excellent

OPERATION 3 - 24 Manual 0-2529

3.10 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 the Troubleshooting
Guide, page 4-21).

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 Cutting Speeds, page 3-26)

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 0-2529 3 - 25 OPERATION

a. High coolant conductivity

3.11 CUTTING SPEEDS

This Section contains information on cutting speeds for hand
and automated applications with PCH/M-150 Torch. The
information is organized into two subsections as follows:

A. Hand Cutting Speeds
B. Automated Cutting Speeds

Each subsection contains cutting speed charts for various
plasma and secondary combinations on different materi­als.

The following factors may have an impact on system
performance:

• Torch parts wear

• Plasma and secondary gas quality

• Operator experience

• Torch standoff height

• Proper work cable connection

• Alloy content of material

• Hand Cutting Notes

Hand cutting speed depends on material, thickness and
the operator's ability to follow the desired cut line.

The speed charts show the optimum cutting speed
ranges with various plasma and secondary combina­tions. The data was obtained using a machine torch
with the recommended 1/8 inch (3 mm) standoff.

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

• Automated Cutting Notes

Automated cutting speed depends on material, thick­ness and how well the system has been maintained.

The automated information represents realistic expecta­tions using recommended practices and well-main­tained systems. Actual speeds may vary from those
shown in the charts depending on the alloy content of
the selected material.

OPERATION 3 - 26 Manual 0-2529

A. Hand Cutting Speeds

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 3-E Cutting Speeds - Air Plasma on Mild Steel

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

10
16
24

Inches per Minute

15

10

5

.50

.25

050

Optimum Cutting Speeds

Air Plasma - Air Secondary

on Mild Steel

150 Amps
100 Amps

50 Amps

100 150 200

A-00881

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 3-N Cutting Speeds - Air Plasma on Mild Steel

Manual 0-2529 3 - 27 OPERATION

Hand 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 3-F Cutting Speeds - Oxygen Plasma on Mild Steel, CO

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

Inches per Minute

10
16
24

15

10

.50

.25

5

050

Optimum Cutting Speeds

Oxygen Plasma

on Mild Steel

150 Amps
100 Amps

50 Amps

100 150 200

Secondary

2

A-00883

250

Meters per Minute

1.0 2.0

3.0 4.0 5.0 6.00

CUTTING SPEED

Figure 3-O Cutting Speeds - Oxygen Plasma on Mild Steel

OPERATION 3 - 28 Manual 0-2529

Hand 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)

2

Table 3-G Cutting Speeds - Nitrogen Plasma on Stainless Steel

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

Inches per Minute

10
16
24

15

10

.50

.25

5

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 3-P Cutting Speeds - Nitrogen Plasma on Stainless Steel

Manual 0-2529 3 - 29 OPERATION

Hand 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)

2

Table 3-H Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

Inches per Minute

10
16
24

15

10

.50

.25

5

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 3-Q Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

OPERATION 3 - 30 Manual 0-2529

Hand 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)

2

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

Inches per Minute

10
16
24

15

10

.50

.25

5

Table 3-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 3-R Cutting Speeds - Air Plasma on Aluminum

Manual 0-2529 3 - 31 OPERATION

Hand 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)

2

Table 3-J Cutting Speeds - ArH

Gage MM Inches

2.00

50

45

1.75

40

1.50

35

1.25

30

1.00

25

20

.75

MATERIAL THICKNESS

Inches per Minute

10
16
24

15

10

.50

.25

5

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 3-S Cutting Speeds - ArH2 Plasma/Nitrogen Secondary on Aluminum

OPERATION 3 - 32 Manual 0-2529

B. Automated Cutting Speeds

Mild Steel

Electrode Tip Shield CupPCM-150 T orch Head

Air Plasma / Air Secondary

General purpose cutting

Plasma @ 60 psi (4.1 bar)

A-03448

Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.5 9-5747 9-5749
14 ga 1.9 9-5746 9-5749
10 ga 3.4 9-5746 9-5749

7 ga 4.6 9-5746 9-5749

1/4 6.4 9-5746 9-5749
3/8 9.5 9-5746 9-5749
1/2 12.7 9-5746 9-5749
3/4 19.1 9-5746 9-5749

1 25.4 9-5746 9-5749

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 300 7.62 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 250 6.35 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 225 5.72 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 185 4.70 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 130 3.30 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 95 2.41 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 50 1.27 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 25 0.64 0.312 7.9 0.500 12.7 1.5 0.065 1.7

Oxygen Plasma / Air Secondary

High quality, high speed, improved weld-ability

Kerf Width

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.5 9-5752 9-5760
14 ga 1.9 9-5752 9-5760
10 ga 3.4 9-5752 9-5760

7 ga 4.6 9-5752 9-5760

1/4 6.4 9-5752 9-5760
3/8 9.5 9-5752 9-5760
1/2 12.7 9-5752 9-5760
3/4 19.1 9-5752 9-5760

1 25.4 9-5752 9-5760

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 325 8.26 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 275 6.99 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 225 5.72 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 170 4.32 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 105 2.67 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 90 2.29 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 45 1.14 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 30 0.76 0.312 7.9 0.500 12.7 1.5 0.065 1.7

Kerf Width

NOTES:

1. Kerf widths are listed as the width of the cut at the bottom of the plate.

2. Speed, kerf width, voltage and standoff data represent realistic starting points. Adjustments may be
required to obtain optimum results.

3. The copper shield cup (9-5790) is recommended for general machine cutting. When the clear-the-plate
function of a height control is required, then the short copper shield cup (9-5801) is r ecommended.

Manual 0-2529 3 - 33 OPERATION

Automated Cutting Speeds (continued)

Stainless Steel

Electrode Tip Shield CupPCM-150 T orch Head

Air Plasma / Air Secondary

General purpose cutting

Plasma @ 60 psi (4.1 bar)

A-03448

Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.5 9-5747 9-5749
14 ga 1.9 9-5746 9-5749
10 ga 3.4 9-5746 9-5749

7 ga 4.6 9-5746 9-5749

1/4 6.4 9-5746 9-5749
3/8 9.5 9-5746 9-5749
1/2 12.7 9-5746 9-5749
3/4 19.1 9-5746 9-5749

1 25.4 9-5746 9-5749

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 300 7.62 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 250 6.35 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 225 5.72 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 185 4.70 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 130 3.30 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 95 2.41 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 50 1.27 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 25 0.64 0.312 7.9 0.500 12.7 1.5 0.065 1.7

Nitrogen Plasma / Air Secondary

High quality, low cost operation

Kerf Width

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.5 9-5766 9-5754
14 ga 1.9 9-5767 9-5754
10 ga 3.4 9-5767 9-5754

7 ga 4.6 9-5767 9-5754

1/4 6.4 9-5767 9-5754
3/8 9.5 9-5767 9-5754
1/2 12.7 9-5767 9-5754
3/4 19.1 9-5767 9-5754

1 25.4 9-5767 9-5754

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 325 8.26 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 275 6.99 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 200 5.08 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 170 4.32 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 130 3.30 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 95 2.41 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 35 0.89 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 25 0.64 0.312 7.9 0.500 12.7 1.5 0.065 1.7

Kerf Width

NOTES:

1. Kerf widths are listed as the width of the cut at the bottom of the plate.

2. Speed, kerf width, voltage and standoff data represent realistic starting points. Adjustments may be
required to obtain optimum results.

3. The copper shield cup (9-5790) is recommended for general machine cutting. When the clear-the-plate
function of a height control is required, then the short copper shield cup (9-5801) is r ecommended.

4. Nitrogen plasma with CO2 secondary may be used. CO2 flowrate is 240 scfh, which requires six 50 lb
cylinders manifolded together or a bulk CO2 system. Shop compressed air is a good alternative if pro­viding the required CO2 flowrate is not feasible.

OPERATION 3 - 34 Manual 0-2529

Automated Cutting Speeds (continued)

Electrode Tip Shield CupPCM-150 T orch Head

Stainless Steel

A-03448

Argon-Hydrogen Plasma / Nitrogen Secondary

Heavy duty, extended electrode life, extra square, oxide free, reduced smoke

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

3/8 9.5 9-5767 9-5754
1/2 12.7 9-5767 9-5754

3/4 19.1 9-5767 9-5754
1 25.4 9-5767 9-5754
1 1/2 38.1 9-5767 9-5754
2 50.8 9-5767 9-5754

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

130 150 60 1.52 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 50 1.27 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 35 0.89 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 20 0.51 0.312 7.9 0.500 12.7 1.5 0.065 1.7
160 150 10 0.25 0.375 9.5 NR NR NR 0.093 2.4
170 150 6 0.15 0.375 9.5 NR NR NR 0.093 2.4

Nitrogen Plasma / Water Secondary

Economical, reduced oxides on cut face, improved squareness

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Kerf Width

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.5 9-5766 9-5754
14 ga 1.9 9-5767 9-5754
10 ga 3.4 9-5767 9-5754

7 ga 4.6 9-5767 9-5754

1/4 6.4 9-5767 9-5754

3/8 9.5 9-5767 9-5754

1/2 12.7 9-5767 9-5754

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 100 250 6.35 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 225 5.72 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 200 5.08 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 175 4.45 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 125 3.18 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 80 2.03 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 60 1.52 0.312 7.9 0.375 9.5 0.6 0.055 1.4

Kerf Width

NOTES:

1. Kerf widths are listed as the width of the cut at the bottom of the plate.

2. Speed, kerf width, voltage and standoff data represent realistic starting points. Adjustments may be
required to obtain optimum results.

3. The copper shield cup (9-5790) is recommended for general machine cutting. When the clear-the-plate
function of a height control is required, then the short copper shield cup (9-5801) is r ecommended.

4. NR in chart means piercing not recommended. Drill starting hole or edge start the cut.

Manual 0-2529 3 - 35 OPERATION

Automated Cutting Speeds (continued)

Aluminum

Electrode Tip Shield CupPCM-150 T orch Head

Air Plasma / Air Secondary

General purpose cutting

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.3 9-5747 9-5749
14 ga 1.6 9-5746 9-5749
10 ga 2.6 9-5746 9-5749

7 ga 3.7 9-5746 9-5749

1/4 6.4 9-5746 9-5749
3/8 9.5 9-5746 9-5749
1/2 12.7 9-5746 9-5749
3/4 19.1 9-5746 9-5749

1 25.4 9-5746 9-5749

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 300 7.62 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 250 6.35 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 200 5.08 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 150 3.81 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 95 2.41 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 80 2.03 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 40 1.02 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 25 0.64 0.312 7.9 0.500 12.7 1.5 0.065 1.7

A-03448

Nitrogen Plasma / Air Secondary

Kerf Width

General purpose cutting

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

16 ga 1.3 9-5766 9-5754
14 ga 1.6 9-5767 9-5754
10 ga 2.6 9-5767 9-5754

7 ga 3.7 9-5767 9-5754

1/4 6.4 9-5767 9-5754
3/8 9.5 9-5767 9-5754
1/2 12.7 9-5767 9-5754
3/4 19.1 9-5767 9-5754

1 25.4 9-5767 9-5754

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

100 80 300 7.62 0.125 3.2 0.187 4.7 0.1 0.035 0.9
110 150 325 8.26 0.187 4.7 0.187 4.7 0.1 0.055 1.4
115 150 275 6.99 0.187 4.7 0.187 4.7 0.1 0.055 1.4
120 150 225 5.72 0.312 7.9 0.375 9.5 0.2 0.055 1.4
125 150 180 4.57 0.312 7.9 0.375 9.5 0.2 0.055 1.4
130 150 130 3.30 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 100 2.54 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 55 1.40 0.312 7.9 0.500 12.7 0.8 0.065 1.7
155 150 30 0.76 0.312 7.9 0.500 12.7 1.5 0.065 1.7

Kerf Width

NOTES:

1. Kerf widths are listed as the width of the cut at the bottom of the plate.

2. Speed, kerf width, voltage and standoff data represent realistic starting points. Adjustments may be
required to obtain optimum results.

3. The copper shield cup (9-5790) is recommended for general machine cutting. When the clear-the-plate
function of a height control is required, then the short copper shield cup (9-5801) is r ecommended.

4. Nitrogen plasma with CO2 secondary may be used. CO2 flowrate is 240 scfh, which requires six 50 lb
cylinders manifolded together or a bulk CO2 system. Shop compressed air is a good alternative if pro­viding the required CO2 flowrate is not feasible.

OPERATION 3 - 36 Manual 0-2529

Automated Cutting Speeds (continued)

Electrode Tip Shield CupPCM-150 T orch Head

Aluminum

A-03448

Argon-Hydrogen Plasma / Nitrogen Secondary

Heavy duty, extended electrode life, extra square, oxide free, reduced smoke

Plasma @ 60 psi (4.1 bar)
Secondary @ 60 psi (4.1 bar)

Material Thickne ss Tip Electrode Output Volts Amperage Speed (Per Minute) Standoff Pierce H eight Pierce

inches

3/8 9.5 9-5767 9-5754
1/2 12.7 9-5767 9-5754

3/4 19.1 9-5767 9-5754
1 25.4 9-5767 9-5754
1 1/2 38.1 9-5767 9-5754
2 50.8 9-5767 9-5754

mm

Cat # Cat # vdc Amps inches meters inches mm inches mm Delay (Sec) inches mm

130 150 110 2.79 0.312 7.9 0.375 9.5 0.4 0.055 1.4
135 150 90 2.29 0.312 7.9 0.375 9.5 0.6 0.055 1.4
145 150 55 1.40 0.312 7.9 0.500 12.7 0.8 0.065 1.7
150 150 35 0.89 0.312 7.9 0.500 12.7 1.5 0.065 1.7
160 150 15 0.38 0.375 9.5 NR NR NR 0.093 2.4
170 150 8 0.20 0.375 9.5 NR NR NR 0.093 2.4

NOTES:

1. Kerf widths are listed as the width of the cut at the bottom of the plate.

2. Speed, kerf width, voltage and standoff data represent realistic starting points. Adjustments may be
required to obtain optimum results.

Kerf Width

3. The copper shield cup (9-5790) is recommended for general machine cutting. When the clear-the-plate
function of a height control is required, then the short copper shield cup (9-5801) is r ecommended.

4. NR in chart means piercing not recommended. Drill starting hole or edge start the cut.

Manual 0-2529 3 - 37 OPERATION

3.12 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 3-T Sequence of Operation

OPERATION 3 - 38 Manual 0-2529

SECTION 4: SERVICE

4.1 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 4-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 Torch Parts Selection
on pages 3-6 and 3-7).

1

9

6

10

14

15

11

16

12

13

18

19

17

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

2

3

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

7

45

8

Figure 4-A PCH/M-150 Torch Components

Manual 0-2529 4 - 1 SERVICE

NOTE

If face of electrode is pitted or gouged more than 3/32 in
(2.4 mm) deep, the electrode should be replaced (see
Figure 4-B below).

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.

CAUTION

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 4-B Electrode Deterioration

4.2 HAND TORCH HEAD REPLACEMENT

Worn ElectrodeNew Electrode

WARNING

Hand Torch Head

Replacement

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

Refer to Figure 4-C (page 4-3) 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.

SERVICE 4 - 2 Manual 0-2529

Hand Torch Head

Replacement (continued)

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.

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 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 4-C Hand Torch Head Replacement

Manual 0-2529 4 - 3 SERVICE

4.3 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 4-D (page 4-5) 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.

SERVICE 4 - 4 Manual 0-2529

CAUTION

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.

Torch Head

A-00961

Electrical

Tape

Insulating T ape

Mounting

Coolant Return

Secondary

Lead

Lead

Plasma

Lead

Coolant Supply

Lead

Assembly

Figure 4-D Machine Torch Head Replacement

Shielded Inner

Leads Sleeving

Nylon Outer

Leads Sleeving

Electrical

Tape

Manual 0-2529 4 - 5 SERVICE

4.4 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 4-C (page 4-3) 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.

SERVICE 4 - 6 Manual 0-2529

4.5 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 4-C (page 4-3) 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.

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 4-E Leads Connections at the Power Supply

Manual 0-2529 4 - 7 SERVICE

NOTE

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.

CAUTION

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 4-E (page 4-7) 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.

SERVICE 4 - 8 Manual 0-2529

4.6 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 4-D (page 4-5) 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 0-2529 4 - 9 SERVICE

Machine Torch Leads

Replacement (continued)

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.

Power Supply Connections

Refer to Figure 4-E (page 4-7) 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.

SERVICE 4 - 10 Manual 0-2529

4.7 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 4-E (page 4-7) 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 4-F (page 4-12) 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.

Manual 0-2529 4 - 11 SERVICE

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 4-F Hand Torch Leads Extension Package

SERVICE 4 - 12 Manual 0-2529

4.8 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 4-E (page 4-7) 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.

Manual 0-2529 4 - 13 SERVICE

Connect Existing Leads to

Leads Extension

Refer to Figure 4-G (page 4-15) 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.

Connect Coolant Supply

Lead to Extension Package

Connect Plasma Lead to

Extension Package

Refer to Figure 4-F (page 4-12) and:

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

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.

SERVICE 4 - 14 Manual 0-2529

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

Refer to Figure 4-G (below) 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

Secondary

Lead

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

Lead

Coolant Return

Lead

12" Shielded

Inner Sleeving

Locate Clamp

Over Insulators

Electrical

Tape

To Torch

(Existing Leads)

From

Power Supply

(Extension Kit)

24" Nylon Outer Sleeving

To Torch

(Existing Leads)

A-00963

Figure 4-G Machine Torch Leads Extension

Manual 0-2529 4 - 15 SERVICE

4.9 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. Refer to page 6-7 for recommended routine
maintenance schedule.

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.

SERVICE 4 - 16 Manual 0-2529

4.10 TROUBLESHOOTING THEORY

Input Voltage Selection

Switch-Mode Power

Supply Operation

The main transformer (T1) has buss bar connections to
select the 380 VAC input voltage (see page 2-6). Each main
transformer secondary has two taps. The higher voltage
secondary tap is automatically selected by the voltage
selection PC board when primary power is applied. A red
LED indicator (D18) on the voltage selection PC board will
be ON. This arrangement provides secondary voltages
close to the optimum levels.

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 0-2529 4 - 17 SERVICE

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 by­passes 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.

Logic Board Functions

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 3-G, page 3-15). 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

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.

SERVICE 4 - 18 Manual 0-2529

Figure 4-H Major System Components - Front View

Manual 0-2529 4 - 19 SERVICE

Figure 4-I Major System Components - Rear View

SERVICE 4 - 20 Manual 0-2529

4.11 TROUBLESHOO TING GUIDE

TROUBLE 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 Steps C and D (page
4-22)

2. Blown fuse (F2)

3. Faulty ON/OFF switch
(SW1)

4. Faulty voltage selection
board

1. No primary power See
also Steps C and D (page
4-22)

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 test A (page 4-27) and
replace board if necessary

1. Check for proper three­phase power at input
terminal board

2. Check and replace fuse if
necessary. See Test B
(page 4-28)

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

4. See test A (page 4-27) 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 0-2529 4 - 21 SERVICE

6. Faulty switching control
board (relay K1 not ener­gized to bypass remote E­stop 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 test C (page 4-29) and
replace contactor if neces­sary

6. See test C. part 3 (page 4-

29)

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

TROUBLE 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
Electrical Connections,
page 2-6)

3. Replace main transformer

1. See test D (page 4-29) and
replace diode if necessary

2. Replace Q1, check heat­sink for possible damage,
perform test D (page 4-29)

3. Replace capacitor if
necessary

4. Check for proper 3-phase
power at input terminal
board, check diodes (see
test D, page 4-29)

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 test E (page 4-30) and
replace sensors if neces­sary

3. See test E (page 4-30) and
replace board if necessary

4. See test E (page 4-30) and
replace board if necessary

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

2. Adjust pressure

SERVICE 4 - 22 Manual 0-2529

TROUBLE 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

2

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

4. See test F (page 4-30) and
replace board if necessary

5. See test F (page 4-30) and
replace board if necessary

6. With secondary mode set

2 or H2O, check for

to O
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

2

mode (but GAS indicator
should be lit)

3. Low plasma pressure or
faulty PS1

4. Secondary supply turned
off (or tank empty)

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

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

2)

6. Faulty logic board

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

4. Check secondary supply

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

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

6. See test G (page 4-31) and
replace board if necessary

Manual 0-2529 4 - 23 SERVICE

TROUBLE 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

2. Faulty (or contaminated)
conductivity probe

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 test H (page 4-31) and
replace board if necessary

5. See test H (page 4-31) and
replace board if necessary

1. Check coolant conductiv­ity and deionizer cartridge
(page 2-9). Replace both if
necessary

2. Clean conductivity probe
and replace 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

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

3. See test I (page 4-31) and
replace board if necessary

4. See test I (page 4-31) and
replace board if necessary

1. Normal operation, set
switch to RUN position

2. See test J (page 4-32)

3. Coil should measure
approx. 10 ohms

4. See test J (page 4-32)

1. See test K (page 4-33)

SERVICE 4 - 24 Manual 0-2529

TROUBLE 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 test L (page 4-34)

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 (page 2-6)

3. If three-phase input
voltage is within the
lower half of range (see
Input Voltage Selection,
page 4-17), 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

1. Electrode shorted against
tip

2. Shorted torch head

1. Thread electrode securely
into torch head

2. Check and replace if
necessary

3. Faulty capacitor (C25)

3. Check and replace if
necessary

4. Broken conductor in torch
lead

5. Shorted torch lead

4. Check and replace if
necessary

5. Check and replace if
necessary

6. Dirty or wet torch lead

Manual 0-2529 4 - 25 SERVICE

6. Clean and dry torch lead

TROUBLE 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
Test M (page 4-35)

1. Shorted Q1 or faulty
switching control PC
board. See test K (page
4-33)

SERVICE 4 - 26 Manual 0-2529

4.12 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 4-G, page 4-19) 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 0-2529 4 - 27 SERVICE

120 VAC Test

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.

SWITCHING
CONTROL PCB

(9)

F2

(10)

SW1-A
ON/OFF

T1

(14)

(15)

A-00965

K1

(8)

E-STOP

K4

K3

VOLTAGE SELECTION PCB

B. Blown Fuse (F1 or F2)

K3

K4

(3)

MC1

(4)

MC2

J28 TO OPTIONAL STANDOFF CONTROL

-1

-3

(24)

SOL1

T2

(50)

(21)

K5

W1

(22)

K5

W2

(23)

(24)

Figure 4-J 120 VAC Circuits

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.

SOL2

K4K2

(110)

(881)

SW3-A

(75)

K3

LOGIC PCB

SOL3

(89)

K5

PCR

(5)

T3(HF)

(94)

PSR

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.

SERVICE 4 - 28 Manual 0-2529