Tweco M-42 RPT User Manual
Manual 0-2856
82 Benning Street, West Lebanon, NH 03784 USA
(603) 298-5711 • www.thermal-dynamics.com
General Information
The PCH / M-42 RPT Replacement Torches are suitable
for use with various Power Supplies and are connected
using various Adapter Kits purchased separately.
The Torches are supplied with 20 ft (6.1 m), 25 ft (7.6 m)
or 50 ft (15.2 m) Leads as follows:
Description Catalog #
PCH-42R RPT Hand Torches With Standard Handle
70° Head, 20 ft (6.1 m) Leads 7-4226
90° Head, 20 ft (6.1 m) Leads 7-4227
PCH-42ER RPT Hand T orches W ith Ergonomic Handle
70° Head, 20 ft (6.1 m) Leads 7-4220
90° Head, 20 ft (6.1 m) Leads 7-4222
70° Head, 50 ft (15.2 m) Leads 7-4221
90° Head, 50 ft (15.2 m) Leads 7-4223
PCM-42 RPT Machine Torches
180° Head, 25 ft (7.6 m) Leads 7-4224
180° Head, 50 ft (15.2 m) Leads 7-4225
These instructions are supplied to ensure the proper installation of the Replacement T orches. It is recommended
to thoroughly read the instructions first, befor e attempting the installation of the kit.
PCH / M-42 RPT
Replacement Torches
Installation Instructions
General T orch Description
The Replacement T or ches pr ovide cutting capabilities of
up to 40 amperes. In the torch, a single torch lead provides gas from a single source to be used as both the
plasma and secondary gas. The gas flow is divided inside the torch head. Single - gas operation provides a
smaller sized torch and inexpensive operation.
Torch Specifications & Design
Features
The following applies to the Replacement Torches only:
A. Torch Configurations
1. Hand T or ches
A vailable with torch head at 70° or 90° to the torch
handle. The hand torches include a torch handle
and torch switch assembly.
Torches with 20 ft (6.1 m) leads use the standard
handle with top mounted switch or the ergonomics handle with bottom mounted switch.
Torches with 50 ft (15.2 m) leads use only the ergonomics type handle and switch.
70o Hand Torches
A-02540
Supplied Parts
The following parts are supplied:
• PCH-42R, PCH-42ER or PCM-42 RPT Torch With
Leads - 1 each
• Installation Instructions - 1 each
'R' Type
Handle
© 2001 by Thermal Dynamics Corp., Printed in USA
January 23, 2004 1 Manual 0-2856
o
Hand Torches
90
'ER' Type
Handle
2. Machine T or ches
E. Parts - In - Place (PIP)
Available with fiberglass mounting tube & rack
and phenolic (plastic) pinch block assembly.
B. Torch Leads Lengths
• Hand Torches:
20 ft (6.1 m) or 50 ft (15.2 m)
• Machine Torches:
25 ft (7.6 m) or 50 ft (15.2 m)
C. Torch Ratings
Torch Ratings
Ambient
Temperature
Duty Cy cle
100% @ 40 Amps @ 200 scfh
104° F
(40° C)
A-02812
The torch head has built - in contacts called Parts - In
- Place (PIP). These two contacts are made through
the inside of the shield cup when it is installed. The
torch will fail to operate if these contacts are not made.
Torch Switch
PIP Pin
To Control
Cable Wiring
PIP Pin
Shield Cup
A-00458
PIP Circuit - Machine Torch
To Control
Cable Wiring
A-03540
Torch Switch
PIP Pins
Torch Trigger
Shield Cup
PIP Circuit - Hand Torch
Maxi mu m C u r r e n t
Voltage (V
peak
)
Arc Stri king Voltag e
40 Amps
500V
12 kV
NOTE
Power Supply characteristics will determine material thickness range.
D. Torch Parts
Gas Distributor , Electrode, Tip, Shield Cup
F. Gas Requirement
1. Single Plasma / Secondary Gas
Compressed Air
2. Pressure
70 psi (4.8 bar)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
3. Total Flow
Cutting: 200 scfh (94.4 lpm)
Gouging: 230 scfh (108.5 lpm)
scfh = standard cubic feet per hour
January 23, 2004 2 Manual 0-2856
G. Dimensions
2.95 in
(75 mm)
Connecting T orch
1. Follow the instructions supplied with the appro-
priate Adapter Kit to connect the torch lead connections to the Adapter Kit parts for connection
to the Power Supply.
1.4 in
(35.6 mm)
7.98 in (203 mm)
7.31 in (186 mm)
10.5 in (266.7 mm)
9.86 in (250.4 mm)
0.6 in
(15.2 mm)
14.1 in (358 mm)
5.1 in
(130 mm)
3.13 in
(80 mm)
(76.2 mm)
3.18 in
(80.8 mm)
(27.9 mm)
A-03024
3 in
1.1 in
2. Refer to Tor ch Parts Selection and check the torch
for proper parts assembly (see CAUTION).
CAUTION
The torch parts must correspond with the type of
operation. Refer to Torch Parts Selection.
Torch Parts Selection
The type of operation to be done determines the torch
parts to be used.
Torch parts:
Shield Cup, Cutting Tip, Electrode and Gas Distributor
Type of operation:
Drag cutting, standoff cutting or gouging
NOTE
Refer to the section titled T or ch Consumables for
the various torch parts that are used depending on
the application.
I. Direct Contact Hazard
For exposed tip the recommended standoff is 1/8" 3/8" ( 3 - 9 mm).
January 23, 2004 3 Manual 0-2856
Change the torch parts for a different operation as follows:
NOTE
The shield cup holds the tip and gas distributor in
place. Position the torch with the shield cup facing upward to prevent these parts from falling out
when the cup is removed.
1. Unscrew and remove the shield cup from the torch
head.
General T orc h Maintenance
A. Cleaning T orch
Even with only clean air , eventually the inside of the
torch becomes coated with residue. This buildup can
affect the pilot arc initiation and the overall cut quality of the torch.
WARNINGS
Electrode
Gas
Distributor
Torch Head Assembly
(70˚ Hand Torch Shown)
Tip
A-03025
Shield Cup
2. Tilt the torch head to r emove the tip and gas distributor .
3. Remove the SureLok Electrode by pulling it straight
out of the Torch Head.
4. Install the SureLok Electrode by pushing it straight
into the torch head until it clicks.
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet
rag. In severe cases, the torch can be removed from
the leads and cleaned more thoroughly by pouring
electrical contact cleaner into the torch and blowing
it through with compressed air.
CAUTION
Dry the torch thoroughly before reinstalling.
B. Checking Center Insulator
The center insulator separates the negative and positive
sections of the torch. If the center insulator does not provide adequate resistance, current which is intended for
the pilot arc may be dissipated into the torch head, resulting in torch failure.
The SureLok Electrode can only be used with the
SureLok Torch Head.
WARNINGS
The use of any consumable parts other than
those specified by the Manufacturer may cause
irreparable damage to the torch head.
5. Install the desired gas distributor and tip for the op-
eration into the torch head.
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
6. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the
cup, check the threads before proceeding.
January 23, 2004 4 Manual 0-2856
1. Remove the shield cup, tip, gas distributor, and electrode from the torch. Disconnect the tor ch leads from
the power supply to isolate the torch from power supply circuits.
Inspection and Replacement of
Consumable T orch Parts
2. Using an ohmmeter (set to 10K or higher), check for
continuity between the positive and negative torch
fittings. Infinite resistance (no continuity) should be
found. If continuity is found there is a problem in the
Torch or Torch Leads.
Common Operating Faults
The following lists the more common cutting faults and
the possible causes:
1. Insufficient Penetration
a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non - Genuine Thermal Dynamics Parts
2. Main Arc Extinguishes
a. Cutting speed too slow
b. Tor ch standoff too high from workpiece
WARNINGS
Disconnect primary power to the system before
disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the
AC indicator light of the Power Supply is ON.
Remove the consumable torch parts as follows:
NOTE
The tip and gas distributor are held in place by the
shield cup. Position the torch with the shield cup
facing upward to prevent these parts from falling
out when the cup is removed.
1. Unscrew and remove the shield cup from the torch.
NOTE
Slag built up on the shield cup that cannot be removed may effect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace
if damaged.
c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts
f. Non - Genuine Thermal Dynamics Parts
3. Excessive Dross Formation
a. Cutting speed too slow
b. Tor ch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non - Genuine Thermal Dynamics Parts
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch
Electrode
Gas
Distributor
Torch Head Assembly
(70˚ Hand Torch Shown)
Tip
A-03025
Shield Cup
3. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Clean or replace the tip if necessary.
Good Tip
Worn Tip
f. Non - Genuine Thermal Dynamics Parts
A-00323
January 23, 2004 5 Manual 0-2856
4. Remove the gas distributor and check for excessive
wear , plugged gas holes, or discoloration. Replace if
necessary.
5. Remove the SureLok Electrode by pulling it straight
out of the Torch Head. Refer to the following figure
and check the face of the electrode for excessive wear .
Electrode Selection
The new SureLok PCH / M-42 RPT Torch offers a new
General Purpose Electrode. The information supplied in
this section is to describe the new electrode.
General Purpose SureLok
Electrode (Cat. No. 9-6542)
New Electrode
A-03026
Worn Electrode
6. Reinstall the SureLok Electrode by pushing it straight
into the torch head until it clicks.
7. Reinstall the gas distributor and tip into the torch head.
8. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the
cup, check the threads before proceeding.
• General Purpose - Good performance with all
systems.
• Design of electrode is similar to previous designed
electrodes used in the PCH / M-25, 26, 28, 35, and
40 Torches.
• New patented locking design offers improved
parts life, excellent piloting, improved arc transfer distance and excellent arc characteristics as
compared to older electrode designs.
• The General Purpose electrode is the standard
electrode offered with Sur eLok RPT Replacement
T orches providing good all ar ound characteristics
and performance when applied to the wide range
of older Thermal Dynamics Systems and different manufacturers’ systems.
• New innovative patented "fluted" design.
January 23, 2004 6 Manual 0-2856
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