Tweco 300 User Manual
LIQUID COOLED
PLASMA TORCH
Model Maximizer 300
For Use With:
• Merlin 15XC Cutting Systems
Instruction Manual
December 1, 2003 Manual No. 0-2554
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Liquid Cooled Plasma Torch
Model Maximizer 300 Used With Merlin15XC System
Instruction Manual No. 0-2554
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
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: December 1, 2003
Record the following information for W arranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and W arnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications.................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes........................................................... 1-3
1.06 Documents De Reference ............................................................................ 1-5
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty.................................................................................. 1-8
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications & Design Features................................................................. 2-1
2.04 Options And Accessories ............................................................................. 2-2
2.05 Introduction to Plasma.................................................................................. 2-3
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Location ................................................................................................ 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Setting Up Machine Torch ............................................................................ 3-1
3.05 Connecting Torch ......................................................................................... 3-2
3.06 Gas Selection............................................................................................... 3-2
3.07 Gas Connection ........................................................................................... 3-4
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction ................................................................................................. 4-1
4.02 Functional Overview..................................................................................... 4-1
4.03 Getting Started............................................................................................. 4-1
4.04 Torch Parts Selection ................................................................................... 4-2
4.05 Cut Quality ................................................................................................... 4-3
4.06 Operating the System .................................................................................. 4-4
4.07 Machine Torch Oper ation ............................................................................. 4-5
4.08 Recommended Cutting Speeds.................................................................... 4-7
4.09 Gouging ....................................................................................................... 4-7
TABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Torch Maintenance ......................................................................... 5-1
5.03 Common Operating Faults ........................................................................... 5-2
5.04 Inspection and Replacement Consumable Torch Parts ................................ 5-2
5.05 Troubleshooting Guide ................................................................................. 5-4
5.06 Servicing Machine Torch Components ......................................................... 5-5
5.07 T orch & Leads Troubleshooting .................................................................... 5-6
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction ................................................................................................. 6-1
6.02 Ordering Information ................................................................................... 6-1
6.03 Replacement Machine Torch P arts.............................................................. 6-2
6.04 Torch Consumables ..................................................................................... 6-4
6.05 Complete Assembly Replacements............................................................. 6-6
6.06 Torch Options And Accessories................................................................... 6-6
APPENDIX 1: SEQ UENCE OF OPERATION BLOCK DIAGRAM.............................................A-1
APPENDIX 2: CUTTING SPEED CHAR TS FOR MERLIN 15XC SYSTEMS............................A-2
APPENDIX 3: GAS FLO W COMPARISON CHART................................................................. A-24
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEAL TH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different pr ocesses. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
Date: No v ember 15, 2001 1-1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RA YS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND 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 FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard 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 W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: No v ember 15, 2001 1-3 GENERAL INFORMATION
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PA S
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper . Le gas hydrogène accumulé
explosera si enflammé.
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION 1-4 Date: Nov ember 15, 2001
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
RAYONS D’ARC DE PLASMA
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur . Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculair e.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
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.
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
Date: No v ember 15, 2001 1-5 GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARA TION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001
1.07 Declaration of Conformity
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.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and 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 representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: No v ember 15, 2001 1-7 GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PAR TICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years 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 Y ears 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
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 August 6, 2001
GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001
SECTION 2:
INTRODUCTION
2.03 Specifications & Design Features
A. Maximizer 300 Torch
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the Liquid Cooled Maximizer 300 T or ch and Torch Leads Assemblies. Service of
this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against
attempting repairs or adjustments not covered in this
manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
2.02 General Description
NOTE
Refer to Section 2.05, Introduction To Plasma, for
a more detailed description on plasma theory.
The Liquid Cooled Maximizer 300 T orch is a liquid cooled
torch that provides cutting capacity of up to 2 inches (50.8
mm), or 3/4 inches (19 mm) for production speed cutting, at 150 amperes. In the torch, two torch leads provide plasma and secondary gas to the torch head. The
leads also provide the closed loop for the liquid coolant
flow from the Power Supply.
Plasma torches are similar in design to the common automotive spark plug. They consist of negative and positive sections which are separated by a center insulator.
Inside the torch, the pilot arc is initiated in the gap between the negatively charged electrode and the positively
charged tip. Once the pilot arc has ionized the plasma
gas, the superheated column of gas flows through the
small orifice in the torch tip, which is focused on the metal
to be cut. The torch connects to a tool-free quick-connect
receptacle on the Arc Starter Box.
The following applies to the Liquid Cooled Maximizer
300 T o rch only:
1. Maximizer 300 Torch Configuration & Dimensions
Maximizer 300 Machine Torch is supplied with a
Metal Rack and Pinion Mounting Assembly. An optional Phenolic Pinch Block Mounting Assembly is
available.
17.350 in
(441 mm)
1.38 in
(35 mm)
1.875 in
(47.6 mm)
A-01023
Min. 6.750 in (171.5 mm)
Max. 11.125 in (282.6 mm)
1.937 in
(49.2 mm)
1.531 in
(38.9 mm)
0.718 in
(18.2 mm)
Figure 2-1 Maximizer 300 Machine Torch
2. Torch Leads Length
25 ft (7.6 m)
50 ft (15.2 m)
Extendable up to 100 ft (30.5 m) from the Power Sup-
ply
3. Torch Ratings
Torch Ratings
Ambien t
Temperature
104° F
(40° C)
Duty Cycle
Maximum Current
Vol ta g e (V
Arc Strikin g Voltage
peak
100% @ 150 Amps @ 0.5 gpm
(1.89 lpm) Coolant Flow Rate
300 Amps
)
500V
12 kV
Manual 0-2554 2-1 INTRODUCTION
4. Cutting Range
10. Secondary Water Requirements
Most materials up to 2 inch (50.8 mm)
Up to 3/4 inch (19 mm) for production speed cutting
5. Pierce Rating
3/4 inch (19 mm)
6. Transfer Distance
3/8 inch (10 mm)
7. Torch Parts
Gas Distributor , Electrode, T ip, Shield Cup Body , End
Cap
8. Plasma Gas Requirements
a. Plasma Gas: Compressed Air, Oxygen (O2), Ni-
trogen (N2), or Ar gon/Hydrogen (Ar/H2)
b. Pressure: 65 to 75 psi (4.5 to 5.2 bar)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
c. Hot Flow
Cutting: 22 - 28 scfh (10.4 - 13.2 lpm)
Gouging: 22 - 43 scfh (10.4 - 20.3 lpm)
scfh = standard cubic feet/hour
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.
9. Secondary Gas Requirements
a. Secondary Gas: Compressed Air, Carbon Diox-
ide (CO2), or Nitrogen (N2)
b. Pressure: 65 to 75 psi (4.5 to 5.2 bar)
a. Water Source (See Notes): Clean drinking qual-
ity tap water can be used as a secondary
b. Water Pressure: Minimum 50 psi (3.5 bar)
c. Water Flow: Cutting: 6 gph (35.2 lph)
NOTES
Tap water should only be used as a secondary on
machine torches.
The tap water source does not need to be deionized,
but in water systems with extremely high mineral
content a water softener is recommended.
Tap water with high levels of particulate matter
must be filtered.
11. Weight (without leads)
1.0 lb (0.45 kg)
2.04 Options And Accessories
These items can be used to customize a standard system
for a particular application or to further enhance performance (refer to Section 6 for ordering information).
• Phenolic (plastic) Pinch Block Mounting Assembly
For machine mounted torch applications where a nonmetal mounting assembly is desired.
• Torch Leads Extension
The leads extension is part of the system to extend
the Torch from the Power Supply. Accessories are
available to extend the T orch fr om the Power Supply
up to 100 ft (30.5 m).
• Spare Parts Kits
Kits contain replacement front-end torch parts and
tools. Spare parts kits are available for air, oxygen
(O2), nitrogen (N2), and argon-hydrogen (Ar/H2)
cutting.
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
c. Flow - Cutting or Gouging: 220 scfh (103 lpm)
scfh = standard cubic feet/hour
INTRODUCTION 2-2 Manual 0-2554
2.05 Introduction to Plasma
B. Gas Distribution
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging
process uses this plasma to transfer an electrical arc to
the workpiece. The metal to be cut or removed is melted
by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of the
material, plasma arc gouging is used to remove metals to
a controlled depth and width.
In a Plasma Cutting T o rch a cool gas such as air or nitr ogen (N2) enters Zone B (refer to Figure 2-2), where a pilot
arc between the electrode and the torch tip heats and ionizes the gas. The main cutting arc then transfers to the
workpiece through the column of plasma gas in Zone C.
_
Power
Supply
A
+
B
The plasma gas flows into the torch through the positive
lead, through the gas distributor, around the electrode,
and out through the tip orifice.
The secondary gas flows into the torch through the secondary gas hose, down around the outside of the torch
gas distributor, and out between the tip and shield cup
around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates
a path for the main arc to transfer to the work.
D. High Frequency
Because direct current (DC) alone is not sufficient to strike
the pilot arc, high frequency is also used. The high frequency jumps between the tip and electrode with the DC
following, then the high frequency turns off.
E. Main Cutting Arc
DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through
the torch lead. The positive output is connected to the
workpiece via the work cable and to the torch through a
pilot wire in the positive lead.
F. Interlocks
T wo pressur e switches act as an interlock for the gas supply . If supply pressur e falls below minimum requirements
the pressure switches will open, shutting off the power
to the contactors, and the GAS indicator , if supplied, will
go out. When adequate gas supply pressure is available
the pressure switches close, allowing power to be r esumed
for cutting.
A flow switch acts as an interlock for the closed loop coolant supply. If the flow switch does not activate then the
Power Supply will not power ON. The flow switch will
not activate if there is low coolant level, or torch front
end parts (tip or electrode) are not installed.
C
Workpiece
A-00002
Figure 2-2 Typical Torch Head Detail
By forcing the plasma gas and electric arc thr ough a small
orifice, the torch delivers a high concentration of heat to
a small area. The stiff, constricted plasma arc is shown in
Zone C (Figure 2-2). Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.
Zone A (Figur e 2-2) is used as a secondary gas that cools
the torch. This gas assists the high velocity plasma gas in
blowing the molten metal out of the cut allowing for a
fast, slag-free cut. Compressed air, supplied by either a
cylinder , plant air system or CO2 is normally used as the
secondary gas.
Manual 0-2554 2-3 INTRODUCTION
INTRODUCTION 2-4 Manual 0-2554
SECTION 3:
INSTALLATION
3.01 Introduction
This Section describes installation of the Liquid Cooled
Maximizer 300 Torch. These instructions apply to the
T orch and Leads Assemblies only; installation procedures
for the Power Supply , Options, and Accessories are given
in Manuals specifically provided for those units.
The complete installation consists of:
1. Site Selection
2. Unpacking
3. Setting Up Torch
4. Connecting Torch
5. Gas Connections
6. Operator Training
3.04 Setting Up Machine Torch
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
Metal mounting tubes with rack and pinion assemblies
are standard for machine tor ches.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a square to align the
torch perpendicular to the surface of the workpiece.
Rack and
Pinion Mounting
Assembly
3.02 Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
The product is packaged and protected to prevent damage during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify and account for each item.
3. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor
and/or shipping company before proceeding with
system installation.
Square
A-00660
Workpiece
Figure 3-1 Machine Torch Set-Up
Manual 0-2554 3-1 INST ALLATION
3.05 Connecting T orc h
7. Place the hose clamp over the shield and hub. T ighten
the hose clamp to secure the shielding braid to the
hub.
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
The Torch Leads connect directly to a bulkhead inside
the Power Supply. Connect the Torch Leads per the following procedure:
1. Remove the tape securing the shield of the torch leads
to the leads.
2. Unfold the shield towards the end of the leads.
3. Feed the torch leads through the boot on the front
panel of the Power Supply.
4. Feed the torch leads through the supplied Hose
Clamp.
5. Connect the torch leads connectors to the bulkhead
connections.
Plasma
Gas Lead
Secondary
Gas Lead
Torch Leads
Extension
Assembly
Hose Clamp
Torch Leads
Extension Boot
Coolant Return
Lead
Coolant Supply
Lead
A-01008
NOTE
Make sure that the shielding braid is pulled back
as far as possible from the bulkhead connections.
Leave any extra shielding braid between the hose
clamp and the front panel area.
8. Check the torch for proper parts assembly .
CAUTION
The torch parts (gas distributor , electr ode, tip, and
shield cup) must correspond with plasma and secondary selection, output current level, and type of
operation (cutting or gouging). Refer to Section
4.04, Torch Parts Selection.
3.06 Gas Selection
CAUTIONS
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
The type of operation will determine the best gases to be
used. Refer to the following and select the plasma and
secondary gases that best fit the operation(s):
A. Plasma Gases
NOTE
Refer to Appendix 2, Cutting Speed Charts, for
proper gas pressure and flow rates.
1. Air Plasma
Figure 3-2 Torch Leads Connection to Power
Supply
6. Pull the shielding braid towards the front panel as far
as it will go up and over the brass hub. The hub is
part of the Boot Assembly and provides the grounding point for the shielding in the torch leads.
• Most often used on ferrous or carbon base materials to obtain good quality at faster cutting speeds.
• 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
will substantially reduce torch parts life.
• Provides satisfactory results on nonferrous materials.
INST ALLATION 3-2 Manual 0-2554
2. Nitrogen (N2) Plasma
• Provides better cut quality on nonferrous materials
such as stainless steel and aluminum.
• Can be used in place of air plasma with air secondary or carbon dioxide (CO2).
• Provides much better parts life than air.
• A good clean welding grade nitrogen should be
used.
3. Argon/Hydrogen (Ar/H2) Plasma
2. Carbon Dioxide (CO
•CO
secondary is used with nitrogen or Ar/H2
2
) Secondary
2
plasma.
• Provides good cooling and maximizes torch parts
life.
• Provides good cut quality on ferrous or nonferrous
material.
• May reduce smoke when used with Ar/H2 plasma.
NOTE
• Recommended for use on 3/4 in (19 mm) and thicker
stainless steel. Recommended for 1/2 inch (12 mm)
and thicker nonferrous materials. Ar/H2 is not nor mally used for thinner nonferrous materials because
less expensive gases can achieve similar cut quality.
• Poor cut quality on ferrous materials (carbon steel).
• Provides faster cutting speeds and high cut quality
on thicker materials to offset the higher cost.
• A 65% argon/35% hydrogen mixture should be
used.
4. Oxygen (O
) Plasma
2
• Oxygen is recommended for cutting ferrous materials (carbon steel).
• 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).
B. Secondary Gases
NOTE
Refer to Appendix 2, Cutting Speed Charts, for
proper gas pressure and flow rates.
When CO2 is used as the secondary gas, twenty
(50 lb) cylinders must be manifolded together or a
bulk CO2 system used to get the required flow rate
of 220 scfh. Shop compressed air is a good alternative if providing the required CO2 flow rate is not
feasible.
3. Nitrogen (N2) Secondary
• Nitrogen secondary is used with Ar/H2 plasma.
• Provides smooth finishes on nonferrous materials.
• May be used with nitrogen plasma in order to operate from one compressed gas cylinder - but torch
parts life may be shorter than with CO2 secondary.
• May reduce smoke when used with Ar/H2 plasma.
4. Water Secondary
• W ater secondary should be used only in mechanized
applications - never in hand cutting!
• Normally used with nitrogen, Ar/H2, 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.
1. Compressed Air Secondary
• Air secondary is normally used when operating
with air plasma and occasionally with nitrogen
plasma.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.
Manual 0-2554 3-3 INST ALLATION
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