GAS CONTROL
Model GC-3000
PLASMA
Air
Oxygen
Nitrogen
Argon/Hydrogen
SECONDARY
Air
Nitrogen
Gas Contro
Other
Water
A-01123
August 25, 1999
Instruction Manual
Manual No. 0-2477
WARNING
WARNING
Read and understand this entire Instruction Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Thermal Dynamics Gas Control Model GC-3000
Instruction Manual Number 0-2477
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1996
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 liabil-
ity to any party for any loss or damage caused by any error or
omission in the Thermal Dynamics Gas Control Model GC-3000
Instruction Manual, whether such error results from negligence,
accident, or any other cause.
August 25, 1999
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION .................................................................................................. 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et A v ertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 7
1.08 Statement of W arr anty................................................................................... 8
SECTION 2:
INTRODUCTION & DESCRIPTION..................................................................................... 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description....................................................................................... 9
2.03 Specifications & Design Features .................................................................. 9
SECTION 3:
INST ALLATION PROCEDURES ........................................................................................ 11
3.01 Introduction.................................................................................................. 11
3.02 Site Location................................................................................................ 11
3.03 Unpacking ................................................................................................... 11
3.04 Installation - General.................................................................................... 11
3.05 Mounting Bracket Assemb ly Installation....................................................... 11
3.06 Gas Control Assembly Installation ............................................................... 12
3.07 Installation With Merlin 3000 Systems ........................................................ 13
3.08 External Cable Connection .......................................................................... 16
3.09 Gas Supply Connections .............................................................................. 17
SECTION 4:
OPERATION ...................................................................................................................... 19
4.01 Introduction.................................................................................................. 19
4.02 Functional Overview .................................................................................... 19
4.03 Operating Controls ...................................................................................... 19
4.04 Sequence Of Operation................................................................................ 19
SECTION 5:
CUSTOMER/OPERATOR SER VICE.................................................................................. 21
5.01 Introduction.................................................................................................. 21
5.02 Routine Maintenance................................................................................... 21
SECTION 6:
PARTS LISTS.....................................................................................................................23
6.01 Introduction.................................................................................................. 23
6.02 Ordering Information.................................................................................... 23
6.03 Gas Control Assembly P arts........................................................................ 24
6.04 Replacement External Control Cables......................................................... 25
6.05 System Retrofit............................................................................................ 25
APPENDIX I: GAS CONTR OL ACCESSORY - WIRING DIAGRAM .......................................... 27
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
W ARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: 6/22/99 1 GENERAL INFORMA TION
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
ELECTRIC SHOCK
• Never touch any parts that are electrically “live” or
“hot.”
• W ear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area wher e
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydr ogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o pr otect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND F ACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION 2 Date 6/22/99
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFP A Standar d 70, NA TIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
A VERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédur e pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
Date: 6/22/99 3 GENERAL INFORMA TION
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
P AS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
RAYONS D’ARC DE PLASMA
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
GENERAL INFORMATION 4 Date 6/22/99
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L ’ARC ET AU GAZ, disponible aupr ès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRA TIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L ’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American W elding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W1 17.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103
Date: 6/22/99 5 GENERAL INFORMA TION
14. Norme A WSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION 6 Date 6/22/99
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used accor ding to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured pr oduct meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible repr esentative: Steve W ard
Director of Operations
Thermadyne UK
Chorley England
Date: 6/22/99 7 GENERAL INFORMA TION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry prac tice,
and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PA R TICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus Series & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 6, 1999
GENERAL INFORMATION 8 Date 6/22/99
SECTION 2:
INTRODUCTION &
2. Front Panel Controls
PLASMA Gas Switch for Air, Oxygen, Nitrogen, or
Argon/Hydrogen
DESCRIPTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the GC3000 Gas Control Accessory. 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
The GC3000 Gas Control Accessory extends the necessary system gas controls away from the power supply to
enable remote selection of Plasma and Secondary Gases.
The accessory is for use with standard machine torch systems. The unit consists of two front panel selector
switches, internal wiring and one rear panel connector.
The connection at the rear panel connects to the Power
Supply.
SECONDARY Gas Switch for Air , Nitrogen, Other, or
W ater
3. Rear Panel Connection
Gas Control Interface Cable Connection
4. Dimensions (H xW xL)
2.62 x 12.12 x 10 inches (66 x 308 x 254 mm)
5. Weight
5 lbs (2.5 kg)
PLASMA
Air
Oxygen
Nitrogen
Argon/Hydrogen
SECONDARY
Air
Nitrogen
Gas Contro
Other
Water
A-01123
Figure 2-1 GC-3000 Gas Control
2.03 Specifications & Design Features
The following applies to the Gas Control Assembly only.
1. System Compatiblility
The Gas Control Accessory was designed to be used
with the Merlin 3000 Plasma Cutting System
Manual 0-2477 9 INTRODUCTION & DESCRIPTION
INTRODUCTION & DESCRIPTION 10 Manual 0-2477
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
This Section describes installation of the Gas Control Accessory. These instructions apply to the Gas Control Accessory only; installation procedures for the Plasma
Power Supply and Torches are given in Manuals specifically provided for those units.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system
installation.
3.04 Installation - General
WARNING
Disconnect primary power to the plasma cutting
system before installating the Gas Control.
The complete installation consists of:
1. Site Selection
2. Unpacking
3. Installing Gas Control Assembly
4. External Cable Connection
5. Operator Training
3.02 Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged separately and
protected with a carton and packing material to prevent
damage during shipping. Components are packaged as
follows:
A. Gas Control Components
Gas Control Accessory components are packaged separately and include:
The installation of the Gas Control Accessory requires
mounting the Gas Control and connecting all required
cables.
The installation instructions are divided into Sub-Sections
for the component to be installed. The Sub-Sections are
as follows:
Section 3.05 Mounting Bracket Assembly Installa-
tion
Section 3.06 Gas Control Assembly Installation
Section 3.07 Installation With Merlin 3000 Systems
Section 3.08 External Cable Connection
Section 3.09 Gas Connections
The Gas Control Assembly and external cable installation is the same for all systems.
3.05 Mounting Bracket Assembly
Installation
The Mounting Bracket Assembly is used to mount the
Gas Control Assembly and must be installed in a suitable
location where it is easily accessible to the system operator. The unit can be mounted on top of or underneath a
mounting surface.
• Gas Control Assembly
• Cable
• Instruction Manual
B. Other Equipment and Accessories
Items such as Plasma Cutting Power Supply and Torch
are order ed and packaged separately from the Gas Control components.
C. Unpacking Procedure
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.
Manual 0-2477 11 INST ALLATION PROCEDURES
Install the Mounting Bracket Assembly per the following
procedure:
1. Select the mounting surface for the Mounting
Bracket.
2. Mount the bracket to the surface either on top of or
underneath the surface using four 1/4" bolts (not
supplied). It is recommended to use at least four
bolts to mount the bracket but a minimum of two
are required.
NOTE
There are seven holes provided in the Mounting
Bracket. Use any four holes that are convenient
for the application.
1/4" Mounting Bolts
(Not Supplied)
Install the Gas Control Assembly per the following procedure:
1. Install the Mounting Bracket per Section 3.05.
2. If the Gas Control is to be installed together with
the Remote and Standoff Controls do the following:
a. Decide which unit will be the top unit, the Gas
Control, Remote Control, or Standof f Contr ol.
b. Secure the two units together with four #6-
32x1/2 inch thread forming screws (supplied)
inserted at the front and rear panels (two
screws each) in the holes provided.
A-00671
Mounting Holes
(Seven Places)
Figure 3-1 Bracket Mounting On Top Of Surface
Mounting Holes
(Seven Places)
A-00672
1/4" Mounting Bolts
(Not Supplied)
Figure 3-2 Bracket Mounting Underneath Surface
RUN
PURGE
SET
#6-32 x 1/2"
Thread Forming
Screw
A-01124
Figure 3-3 Screw Installation
3. Insert the head of the two #10-32 x 3/8" hex head
bolts into the slots on each side of the bottom or
top unit per one of the following:.
• Bracket Mounted On Top Of Surface
Insert bolts in the bottom unit if the Mounting
Bracket was installed for top surface mounting.
• Bracket Mounted Underneath Surface
3.06 Gas Control Assembly Installation
The Gas Control can be installed separately, or together
with the Remote Control and Standoff Control Accesso-
Bracket was installed for underneath surface
mounting.
The slot prevents the bolts from turning when the
knobs are installed.
ries. The enclosures for all units are designed to be placed
one on top of the other and secured together with four
#6-32x1/2 inch thread forming screws, two in front panel
and two in rear panel. It makes no difference which unit
goes on top as the installation is the same.
INST ALLATION PROCEDURES 12 Manual 0-2477
Insert bolts in the top unit if the Mounting
Hex Head Bolt
#10-32 x 3/8"
Figure 3-4 Bolt Installation
A-01125
Slot
Knob
3.07 Installation With Merlin 3000 Systems
NOTE
This Sub-Section is only for Systems ordered
WITHOUT the factory installed Gas Control Accessory.
Merlin 3000 Systems that were ordered without the Gas
Control Accessory r equire installation of various parts in
the Power Supply. For systems that were ordered with
the Gas Control Accessory factory installed proceed to
the next Section 3.08.
WARNING
4. Set the assembled units into the Mounting Bracket
being sure the four bolts are in the mounting slots.
Mounting Bracket
Knob
Hex Head
Bolts
A-00674
Knob
Figure 3-5 Knob Installation
5. Place one knob on each of the bolts protruding from
the bracket slots.
6. The assembled units can be adjusted for the best
viewing angle. The units can be tilted up to 10°.
Adjust the viewing angle per the following:
a. Loosen the four knobs sercuring the assemblied
units to the Mounting Bracket.
b. Adjust the assembled units for the desired
angle.
c. Tighten all four knobs.
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
Parts of the Gas Control must be installed inside the Merlin 3000 Power Supply Assembly. The instructions in this
section cover only the installation of those parts.
NOTE
These instructions are for the Merlin 3000 Power
Supply Only.
Gas Control components to be installed inside the Power
Supply include:
• Gas Control W ire Harness - 1 each
• Secondary Gas Hose Assembly - 1 each
• Plasma Gas Manifold Assembly - 1 each
• Nitrogen/Other Secondary Gas Assembly - 1 each
• Plasma Gas Hose Assembly - 1 each (See Note)
NOTE
The Plasma Gas Hose Assembly is installed on the
outside of the Power Supply after all internal parts
are installed.
The left side panel of the Power Supply must be removed
to install some of the Gas Control Accesory parts.
d. If the angle is not correct, loosen knobs, read-
A. Plasma Gas Manifold Assembly
just until proper viewing angle is found, and
retighten all knobs.
1. Remove the four screws securing the plate over the
plasma gas cutout on the rear panel.
Manual 0-2477 13 INST ALLATION PROCEDURES
Power Supply
Rear Panel
Plasma Gas
Manifold Panel
A-01157
Figure 3-6 Plasma Gas Plate Location
2. Place the Plasma Gas Manifold Assembly into the cutout. The four solenoids should be towards the inside
of the Power Supply.
B. Nitrogen (N2)/OTHER Secondary Gas
Assembly
1. Locate the two snap in plugs in the Nitrogen(N2)/
OTHER Gas cutouts on the Power Supply Rear Panel.
Power Supply
Rear Panel
N2 Secondary
Gas Supply Plug
OTHER Secondary
Gas Supply Plug
A-01159
Figure 3-8 Nitrogen (N2)/OTHER Gas Plugs
2. Using a screwdriver pry the two plugs from the Rear
Panel.
Plasma Manifold
Mounting Screws
and Washers
(Four Places)
Plasma Gas
Manifold Assembly
Power Supply
Rear Panel
A-01156
3. Place the two internal star washers over the ends of
the gas fittings on the two solenoid assemblies.
4. Place the assembly into the two holes making sure
that the elbow fitting is facing up.
A-01160
Hex Nut
Internal Star
Washer
Nitrogen (N2) and
OTHER Secondary Gas
Solenoid Assembly
Figure 3-7 Plasma Gas Manifold Installation
Figure 3-9 Nitrogen N2)/OTHER Secondary Gas
3. Secure the Plasma Gas Manifold Assembly to the r ear
Assembly Installation
panel with the screws removed in step 1.
INST ALLATION PROCEDURES 14 Manual 0-2477
5. Secure the assembly to the Rear Panel with the two
nuts provided.
5. On the existing wire harness in the Power Supply disconnect the connector at J51.
C. Wiring Harness Assembly
1. Locate the Wiring Harness Assembly included with
the Gas Control components.
2. Locate the snap in plug in the Output Connector cutout on the Power Supply Rear Panel.
Power Supply
Rear Panel
Output Connector
Snap In Plug
A-01161
Figure 3-10 Output Connector Cutout Plug
3. Place the output connector (J63) on the Wiring Harness Assembly into the cutout.
6. Connect the three connectors on the Gas Control W ir ing Harness Assembly as follows (refer to the following figure for details):
• One connector, 12 circuit, to the Plasma Gas Manifold Assembly (J60)
• One connector , 6 circuit, to the Nitrogen/Other Secondary Gas Assembly (J61)
• One connector, 8 circuit, to the existing wiring harness connector (J51)
J60
Gas Control
Wire Harness
4. Secure the output connector to the Rear Panel with the
two screws and nuts provided.
Mounting
Screws
Output
Connector
Mounting
Nuts
A-01162
Figure 3-11 Output Connector Installation
Existing Wire Harness
Old J51
(No Connection)
J51
A-01164
J61
Figure 3-12 Gas Control Wiring Harness Assembly
Installation
7. Connect the green/yellow ground wire to the gr ound
stud on the Rear Panel with the nut and washer provided.
Manual 0-2477 15 INST ALLATION PROCEDURES
Ground
Stud
Output Wiring
Nut
Harness Ground
Star Washer
A-01163
Figure 3-13 Ground Wire Connection
D. Hose Assemblies
1. Locate the Secondary Gas Hose Assembly in the Gas
Control components.
2. Connect one end of the Hose Assembly to the elbow
fitting on the Nitrogen/Other Secondary Gas Assembly .
3. Locate the Secondary Gas Solenoid on the inside of
the Power Supply Rear Panel.
4. Remove the cover installed over the end of the T-fitting.
5. Connect the othe end of the Hose Assembly to the Tfitting.
6. Reinstall the Power Supply Left Side Panel.
This completes the installation of the components inside
the Merlin 3000 Power Supply.
E. Plasma Gas Hose Connection (External)
1. Locate the Plasma Gas Hose Assembly in the Gas Control components.
2. Apply thread sealant to the NPT fitting on the end of
the Hose Assembly.
3. Connect the NPT fitting to the PLASMA GAS fitting
on the Power Supply Rear Panel.
Plasma Gas Manifold
OUTPUT Fitting
OUTPUTOUTPUT
TOTO
CONTROLCONTROL
MODULEMODULE
PLASMA GASPLASMA GAS
AIR
PLASMAPLASMA
INPUTINPUT
2
N
PLASMAPLASMA
INPUTINPUT
2
O
PLASMAPLASMA
INPUTINPUT
2
Ar/H
PLASMAPLASMA
INPUTINPUT
Secondary Gas
Solenoid
Secondary Gas
T-Fitting
Secondary Gas
Hose
Elbow Fitting
Nitrogen/Other Secondary
Gas Assembly
A-01165
Figure 3-14 Secondary Hose Assembly Installation
Plasma Gas
Hose Assembly
PLASMA GAS
A-01158
Input Fitting
Figure 3-15 Plasma Hose Assembly Installation
4. Connect the Inert-B fitting of the Hose Assembly to
the Plasma Gas Manifold OUTPUT connection at the
rear of the Power Supply.
3.08 External Cable Connection
The Gas Control has only one output connector on the
rear panel. The Gas Control Interface Cable is connected
to this output. The other end of the cable is connected to
the Power Supply.
INST ALLATION PROCEDURES 16 Manual 0-2477
NOTE
Refer to the Operating Manual supplied with the
Power Supply for proper connection of the Gas
Control Cable to the Power Supply
Gas Control
Output Connector
J53
A-01126
Gas Control
Interface Cable
Figure 3-16 Cable Connection
3.09 Gas Supply Connections
The Plasma and Secondary supply gases connect to the
fitting on the Rear Panel of the Power Supply.
NOTE
Refer to the Operating Manual supplied with the
Power Supply for making proper gas supply connections for the application.
Manual 0-2477 17 INST ALLATION PROCEDURES
INST ALLATION PROCEDURES 18 Manual 0-2477
SECTION 4:
4.04 Sequence Of Operation
OPERATION
4.01 Introduction
This Section provides a description of the Gas Control
Accessory.
4.02 Functional Overview
The Gas Control Accessory extends the necessary system
gas controls away from the power supply and is as an
accessory with standard machine torch systems. There is
a rear panel connection available at the Gas Control Accessory for the gas control cable.
4.03 Operating Controls
A. Front Panel
1
Air
PLASMA
Oxygen
Nitrogen
Argon/Hydrogen
SECONDARY
Figure 4-1 Front Panel Operating Controls
2
R
Air
Water
Nitrogen
Other
GC3000
Gas Control
A-01127
1. Connect the required gas supplies (or water for secondary water) to the correct plasma and secondary
inlets on the Plasma Power Supply. Refer to the Operating Manual supplied with the Plasma Power Supply being used to make connections.
For the Merlin 3000 the front panel secondary gas selector switch should always be in the GAS position
and the gas selected from the GC 3000 Gas Control.
2. Turn ON the gas supplies.
3. Set the gas bottle regulators, if used, to the proper pr essure and check for leaks.
NOTE
While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to do so. It may cause pressure or flow
fluctuations that may damage torch parts or the
piece being cut.
4. Select the desired plasma and secondary gases by setting the GC 3000 Gas Control front panel switches to
the desired gas position.
5. Refer to the Operating Manual supplied with the Power
Supply and do the following:
a. Turn ON power to the Power Supply.
1. PLASMA Gas Selection Switch
The switch selects one of four plasma gases for the
operation.
• Air
• Oxygen (O2)
• Nitrogen (N2)
• Argon/Hydrogen (ArH2)
2. SECONDARY Gas Selection Switch
The switch selects one of four secondary gases for the
operation.
• Air
• Nitrogen (N2)
• Other
• Water (H2O)
B. Rear Panel
The Gas Control rear panel includes a connector for the
Gas Control Interface Cable.
b. Set Power Supply pressure regulators to the de-
sired pressures.
c. Purge the system. When switching gases between
operations, allow enough purge time to clear the
old gas from the torch leads.
Manual 0-2477 19 OPERA TION
OPERA TION 20 Manual 0-2477
SECTION 5:
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
This Section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than properly
trained personnel.
W ARNINGS
Disconnect primary power at the source before disassembling any part of the cutting system.
Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with
proper gloves, clothing, eye and ear protection.
Make sure no part of the operator’s body comes into
contact with the workpiece while the cutting system is activated.
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
5.02 Routine Maintenance
The only routine maintenance required for the Gas Control components is a thorough cleaning and inspection,
with the frequency depending on the usage and the operating environment.
To clean the Gas Control, first make sure that the power
is disconnected. Blow off 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.
Manual 0-2477 21 SERVICE
SERVICE 22 Manual 0-2477
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. The parts lists are arranged as follows:
Section 6.03: Gas Control Assembly Parts
Section 6.04: Replacement External Control Cables
NOTE
Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers
shown.
B. Returns
If a Thermal Dynamics product must be returned for service, contact your Thermal Dynamics distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted.
6.02 Ordering Information
Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the description column of the Parts List. Also include the model
and serial number of the torch. Address all inquiries to
your authorized Thermal Dynamics distributor .
Manual 0-2477 23 P A RTS LISTS
6.03 Gas Control Assembly Parts
The replacement parts are limited as the Gas Control Accessory is designed as a complete replacement if failures
occur.
Item # Qty Description Catalog #
1 Gas Contr ol Assembly W ith Items #2 - 5 7-3411
2 1 Mounting Bracket 8-3483
3 4 Clamping Knob 8-3480
4 4 Machine Screw, #10-32 x 1/2", Plain Hex Head See Note
5 2 1" Black Instrument Knob W ith Line 9-4233
NOTE: Item can be purchased locally.
1
PLASMA
Air
Oxygen
Nitrogen
Argon/Hydrogen
SECONDARY
Air
Water
Nitrogen
Other
Gas Contro
4
4
3
5
3
2
A-01128
PARTS LISTS 24 Manual 0-2477
6.04 Replacement External Control Cables
Qty Description Catalog #
Gas Control Interface Cable (Gas Control to Power Supply
1 25 ft (7.62 m) 9-4579
1 50 ft (15.24 m) 9-4580
1 75 ft (22.86 m) 9-4581
1 100 ft (30.48 m) 9-4582
6.05 System Retrofit
When adding the Gas Control to a cutting system already installed the following assemblies are r equir ed:
Qty Description Catalog #
1 Gas Control Assembly With Mounting Bracket 7-3411
1 Gas Control Interface Cable ( see Section 6.04)
1 Power Supply Gas Manifold Kit 7-6002
Manual 0-2477 25 P A RTS LISTS
PARTS LISTS 26 Manual 0-2477
APPENDIX I: GAS CONTROL ACCESSORY - WIRING
DIAGRAM
A-01129
Manual 0-2477 27 APPENDIX
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