Tweco PCM -102 User Manual

PLASMA

CUTTING TORCH

• Model PCH - 102 Hand Torch

• Model PCM - 102 Machine Torch

Instruction Manual

December 6, 2004 Manual No. 0-2818

W ARNINGS

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

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

Plasma Cutting T orch
Model PCH - 102 & PCM - 102
Instruction Manual Number 0-2818

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

www .thermal-dynamics.com

Copyright 2000 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 6, 2004

Record the following information for W arranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

T orch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMA TION................................................................................................. 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 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 .................................................................................. 2-2

SECTION 3:

INST ALLATION .................................................................................................................. 3-1

3.01 Introduction ................................................................................................... 3-1

3.02 Site Location ................................................................................................ 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Setting Up Hand T orch.................................................................................. 3-1

3.05 Setting Up Machine T orch............................................................................. 3-1

3.06 Connecting T orch .......................................................................................... 3-2

3.07 Gas Connection ............................................................................................ 3-6

SECTION 4:

OPERA TION...................................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-1

4.02 Functional Overview ...................................................................................... 4-1

4.03 Getting Started ............................................................................................. 4-1

4.04 T orch Parts Selection.................................................................................... 4-2

4.05 Cut Quality ................................................................................................... 4-2

4.06 General Cutting Information........................................................................... 4-3

4.07 Hand T orch Operation ................................................................................... 4-4

4.08 Machine T orch Operation .............................................................................. 4-6

4.09 Recommended Cutting Speeds..................................................................... 4-7

4.10 Gouging ........................................................................................................ 4-7

T ABLE OF CONTENTS (continued)

SECTION 5:

SERVICE .......................................................................................................................... 5-1

5.01 Introduction ................................................................................................... 5-1

5.02 General T orch Maintenance .......................................................................... 5-1

5.03 Common Operating Faults ............................................................................ 5-2

5.04 Inspection and Replacement Consumable T orch Parts.................................. 5-2

5.05 Troubleshooting Guide .................................................................................. 5-3

5.06 T orch & Leads Troubleshooting ..................................................................... 5-5

5.07 Servicing Hand T orch (PCH) Components ..................................................... 5-6

5.08 Servicing Machine T orch (PCM) Components...............................................5-10

SECTION 6:

P ARTS LISTS .................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-1

6.02 Ordering Information...................................................................................... 6-1

6.03 Replacement Hand T orch Parts (Ergonomic Handle)..................................... 6-2

6.04 Replacement Machine Torch With Pinch Block Mounting Parts.................... 6-4

6.05 Replacement Machine T orch Lead Parts....................................................... 6-6

6.06 Complete Assembly Replacement ................................................................ 6-8

6.07 Options & Accessories ................................................................................. 6-8

6.08 Torch Consumables ....................................................................................6-10

6.09 T orch S p are Parts Kits ................................................................................. 6-11

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERA TION BLOCK DIAGRAM................ A-1

APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS A-2

APPENDIX 3: GENERAL APPLICA TION NOTES ...................................................................... A-4

APPENDIX 4: CUTMASTER 75 SYSTEM DA T A........................................................................ A-6

APPENDIX 5: CUTMASTER 80XL SYSTEM DA T A .................................................................... A-8

APPENDIX 6: CUTMASTER 100 SYSTEM DA TA.................................................................... A-10

APPENDIX 7: P AK MASTER 75XL PLUS SYSTEM DATA ...................................................... A-12

APPENDIX 8: P AK MASTER 100XL PLUS SYSTEM DATA.....................................................A-14

APPENDIX 9: CE P AK MASTER 75XL PLUS SYSTEM DATA.................................................A-16

APPENDIX 10: CE P AK MASTER 100XL PLUS SYSTEM DATA............................................. A-18

APPENDIX 1 1: TORCH CONNECTION DIAGRAMS ................................................................ A-20

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: January 27, 2004 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 where
fire hazards may exist.

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

GENERAL INFORMATION 1-2 Date: January 27, 2004

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain­able from American National Standards Institute, 1430
Broadway, New Y ork, NY 10018

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

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 RESPIRA TOR 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: January 27, 2004 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 PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper . Le gas hydrogène accumulé
explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le
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: January 27, 2004

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: January 27, 2004 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Date: January 27, 2004

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.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro­pean Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.

National Standard and Technical Specifications

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

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

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

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

associated 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 according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.

Manufacturers responsible repr esentative: Steve W ard

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

Date: January 27, 2004 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 W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A P ARTICULAR
PURPOSE.

LIMIT A TION OF LIABILITY : Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not

limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or 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 Year 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: November 15, 2001

GENERAL INFORMATION 1-8 Date: January 27, 2004

SECTION 2:

)

)

INTRODUCTION

2.03 Specifications & Design Features

NOTE

2.01 Scope of Manual

This manual contains descriptions, operating instructions and
maintenance procedures for the PCH/M-102 T or ch using the
SureLok electrode design. 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 W arranty .

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 T orch provides cutting capacity of up to 1 inch (25.4 mm) at
100 amperes. In the torch, a single torch lead provides com­pressed air from a single source to be used as both the plasma
and secondary gas. The air flow is divided inside the torch
head. Single-gas operation provides a smaller sized torch and
inexpensive operation.

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.

Refer to Appendix Pages for additional specifica­tions as related to the Power Supply used.

A. Torch Configurations and Dimensions

1. Hand T orch
A vailable with torch head at 70° or 90° to the torch

handle. The hand torches include a torch handle
and torch switch assembly.

2. Machine Torch
The standard machine torch has a fiberglass posi-

tioning tube with rack & pinch block assembly .
A vailable options include a kit with metal mount-

ing tube with rack & pinion assembly or a kit with
the pinion assembly only .

10.5 in

(267 mm)

3.0 in

(76.2 mm

1.1in

(28 mm)

10.0 in

(254 mm)

3.4 in

(86.4 mm

1.1in

(28 mm)

14.1 in

(358 mm)

1.4 in

(35.6 mm)

0.62 in

(15.2 mm)

13.5 in (343 mm) Max

3.7 in (94 mm) Min

0.75 in

(19 mm)

5.1 in

(129.5 mm)

1.1 in

(28 mm)

A-02804

Figure 2-1 Torch Configurations and Dimensions

Manual 0-2818 2- 1 INTRODUCTION

B. Torch Leads Lengths

fh

2.04 Options And Accessories

• Hand T orches

20 ft (6.1 m) or 50 ft (15.2 m)

• Machine T orches

25 ft (7.6 m) or 50 ft (15.2 m)

C. Torch Parts

Gas Distributor , Electrode, Tip, Shield Cup

D. Parts-In-Place (PIP)

T orch Head has built-in contacts
12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch

F. Torch Ratings

Torch Ratings

Ambient

Temperature

Duty Cy c le

Maximum Curren t

Voltage (V

Arc Striking Vol tage

peak

)

100% @ 100 Amps @ 400 sc

104° F

(40° C)

100 Amps

500V

12 kV

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).

• Spare Parts Kits - Various kits containing replace­ment front-end torch parts for various applications.

• Circle Cutting Guide Kit - Easy add-on attachments
to allow for straight line, circle cutting, and beveling
with a hand torch. The guide fits both the 70° and
90° hand torches.

• Standoff Cutting Guide - Simple push-on attachment
to allow for torch dragging without risk of touching
tip to workpiece.

• 1 - 3/8" Metal Mounting Tube with Rack & Pinion
Assembly

• Pinion Assembly

• Computer Control (CNC) Cable 25 Ft (7.6 m) or 50 Ft
(15.2 m)

• Hand Pendant Control Assembly - Used for ma­chine applications. Hand Pendant Control has
20 ft. (6.1 m) cable which provides ON & OFF
signals to the Power Supply.

• Extension Cable for Hand Pendant Control - 25 ft
(7.6 m) cable which can be added to the Hand Pen­dant Control cable to provide a total control cable
length of 50 ft (15.2 m).

2.05 Introduction to Plasma

G. Plasma Power Supply Used With

• CutMaster 75

• CutMaster 80XL

• CutMaster 100

• Pak Master 75XL Plus

• Pak Master 100XL Plus

• CE Pak Master 75XL Plus

• CE Pak Master 100XL Plus

H. Direct Contact Hazard

For exposed tip the recommended standoff is 1/8 ­3/8 inch or 3 - 9.5 mm.

A. Plasma Gas Flow

Plasma is defined as 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 use 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 Torch a cool gas 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.

INTRODUCTION 2-2 Manual 0-2818

D. Capacitive Discharge

8

p

C

A

er

Because direct current (DC) alone is not sufficient to strike
and maintain the pilot arc, capacitive discharge is also used.
The high voltage jumps between the tip and electrode with
the DC following.

_

Power

Supply

+

Workpiece

C

Figure 2-2 Typical Torch Head Detail

By forcing the plasma gas and electric arc through 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 (Figure 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.

B. Gas Distribution

The single gas used is internally split into plasma and sec­ondary gases.

A-00002

B

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

A

torch lead. The positive output is connected to the work­piece via the work cable and to the torch through a pilot
wire.

F. Interlocks

One pressure switch acts as an interlock for the gas sup­ply . If supply pressure falls below minimum requirements
the pressure switch will open, shutting of f the DC power,
and the GAS indicator will go off. When adequate gas
supply pressure is available the pressure switch will close,
allowing power to be resumed for cutting.

G. Parts-In-Place (PIP)

The torch head has built-in contacts called Parts-In-Place
(PIP). These two contacts are made through the canted
coiled spring inside the shield cup when it is installed. The
torch will fail to operate if these contacts are not made.

To Control

able Wiring

Torch Switch

PIP Pin

Shield Cu

PIP Pin

A-0045

The plasma gas flows into the torch through the negative
lead, through the gas distributor , around the electrode,
and out through the tip orifice.

Figure 2-3A Parts-In-Place (PIP) Diagram - Machine

Torch

The secondary gas flows 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 be-

To Control

Torch Switch

Cable Wiring

PIP Switch

-03761

Torch Trigg

Shield Cup

tween the electrode and cutting tip. This pilot arc creates
a path for the main arc to transfer to the work.

Figure 2-3B Parts-In-Place (PIP) Diagram - Hand

Torch

Manual 0-2818 2- 3 INTRODUCTION

INTRODUCTION 2-4 Manual 0-2818

SECTION 3:

W

INSTALLATION

3.01 Introduction

This section describes installation of the Torch. These
instructions apply to the Torch and Leads Assemblies
only; installation procedures for the Power Supply, Op­tions and Accessories are given in Manuals specifically
provided for those parts.

The complete installation consists of:

• Site Selection

• Unpacking

• Setting Up T or c h

• Connecting T orch

• Gas Connection

3.05 Setting Up Machine T orch

WARNING

Disconnect primary power at the source before dis­assembling the torch or torch leads.

The machine torch is factory assembled to the Power Sup­ply and includes a fiberglass positioning tube with rack
and pinch block assembly. A metal mounting tube with
rack & pinion assembly or the pinion assembly only are
available as options.

1. Mount the torch assembly on the cutting table.

2. T o obtain a clean vertical cut, use a squar e to align
the torch perpendicular to the surface of the work­piece.

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 and protected
with a carton and packing material to prevent damage
during shipping.

1. Unpack each item and remove all packing material.

2. Locate the packing list 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.

3.04 Setting Up Hand T orch

The hand torch is factory assembled to the Power Supply
and requires no special set up. The proper torch parts
(shield cup, tip, gas distributor, and electrode) must be
installed for the type of operation. Refer to Section 4.04,
Torch Parts Selection for more information.

Pinch Block
Assembly

Square

orkpiece

A-02585

Figure 3-1 Machine Torch Set-Up

3. The proper torch parts (shield cup, tip, gas dis­tributor, and electrode) must be installed for the
type of operation. Refer to Section 4.04, Torch
Parts Selection for more information.

Manual 0-2818 3-1 INST ALLATION

3.06 Connecting T orch

r

C

The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub-section covers connecting the Torch for
the following applications:

3. Secure the Through-hole Pr otector with the retain­ing nut removed earlier.

4. Connect the torch Negative & Plasma Lead to the bulk­head connection inside the Power Supply .

A. Hand Systems
B. Machine Systems (Unshielded Leads)
C. Machine Systems (Shielded Leads)
D. Remote Pendant Control (Optional)

The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.

NOTE

Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.

A. Hand Systems

WARNING

Disconnect primary power at the source before dis­assembling the torch or torch leads.

1. Remove the retaining nut from the Through-hole
Protector.

Note: Actual Bulkhead
configuration may
differ from that shown.

Adapter

Adapter

ontrol Circuit

Connectors

Negative/Plasma
Lead Connection

Torch Lead

Assembly

or ATC Adapter

Pilot Lead

Negative/Plasma

Lead

Connecto

Pilot Lead Stud

A-03542

Figure 3-3 Hand Torch Lead Connections

5. Connect the Cables to the mating connectors on the
Adapter supplied on the Power Supply .

6. Remove the top nut and washer from the Pilot Stud.

7. Place the lug on the Pilot Control Wi re onto the stud

Remove Tie Wrap ,
Remove Insulator,
Disconnect Wires

Torch Leads

Assembly

Through - Hole

Protector

and secure with the nut and washer removed in the
above Step.

8. Tighten the Thr ough-hole Protector onto the T or ch
Leads.

9. Check the torch for proper parts assembly.

CAUTION

The torch parts must correspond with the type of

Through - Hole

Protector Nut

Art #A-03848

operation. Refer to Section 4.04, Torch Parts Se­lection.

Figure 3-2 Retaining Nut Removal

2. Feed the torch lead ends and the Through-hole
Protector into the hole in the unit.

INST ALLATION 3-2 Manual 0-2818

B. Machine Systems (Unshielded Leads)

7

a
n

R
C
C

d

a
n

Shield Connectors (Not Used)

R

1 . Remove the Through-hole Protector Nut from the

Through-hole Protector .

Torch Leads

Assembly

Thru - Hole Protector

Art # A-0384

Thru - Hole

ProtectorNut

Figure 3-4 Through-hole Protector Nut Removal

2. The Adapter supplied with the Power Supply
must be installed as follows:

a. Inside the Power Supply Bulkhead area, route

the connector on the free end of the Adapter
through the Through-hole Protector Nut.

Control Connector

Negative/Plasm

Control Connector

Plug

Shield Connectors

(Not Used)

Control (PIP) Circuit

Connectors

emote
able
onnector

Negative/Plasma

Torch Lead

Assembly

Lead Connectio

Lead

Figure 3-5A Unshielded Machine Torch Lead

Connections

Pilot Lead

Stud

Pilot Lead

A-02843

b. Continue routing the connector out the hole

in the front of the Power Supply.

Power Supply Adapter

c. Feed the end of the torch lead and the

Through-hole Protector into the hole in the unit
while routing the single black wire into the
notch of the Through-hole Protector.

Control Circuit

Connectors

Pilot Lea

d. Tighten the Through-hole Protector Nut to

secure the Through-hole Protector to the
Power Supply .

emote Pendant

Connector

Torch Lead

Assembly

Negative/Plasm
Lead Connectio

Negative/Plasma Lead

Art # A-04323

Manual 0-2818 3-3 INST ALLATION

Figure 3-5B Unshielded Machine Torch Connection Detail

3. Connect the torch Negative / Plasma Lead to the bulk-

9

head connection inside the Power Supply .

4. Connect the Control (PIP) Circuit Connectors to the
mating connectors on the Adapter supplied on the
Power Supply (see W arning).

WARNING

The Adapter supplied with the Power Supply has
two additional Shield Connectors that are used for
Shielded Systems only. These two connectors are
not used and need to be taped out of the way to
prevent contacting the Negative & Plasma or Pi­lot Leads.

5. Remove the top nut and washer from the Pilot
Stud.

6. Place the lug on the Pilot Control Wire onto the
stud and secure with the nut and washer removed
in the above Step.

7. Tighten the Thr ough-hole Protector onto the T or ch
Leads.

8. Check the torch for proper parts assembly .

C. Machine Systems (Shielded Leads)

1 . Remove the Through-hole Protector Nut from the

Through-hole Protector .

Torch Leads
Assembly

Through - Hole
Protector

Through - Hole
Protector Nut

Art # A-0384

Figure 3-6 Through-hole Protector Nut Removal

2. The Adapter supplied with the Power Supply must be
installed per the following:

a. Inside the Power Supply Bulkhead area, route the

connector on the free end of the Adapter thr ough
the Through-hole Protector Nut.

CAUTION

The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Se­lection.

b. Continue routing the connector out the hole in the

front of the Power Supply .

c. Feed the end of the torch lead and the Through-

hole Protector into the hole in the unit while rout­ing the single black wire into the notch of the
Through-hole Protector .

d . Tighten the Through-hole Protector Nut to secure

the Through-hole Protector to the Power Supply .

INST ALLATION 3-4 Manual 0-2818

a
n

S

D. Remote Pendant Control (Optional)

C

Adapter Connector

Lead

Negative/Plasm
Lead Connectio

Pilot Lead

Stud

Pilot Lead

A-02829

Adapter
(Supplied With
Power Supply)

Control (PIP) Circuit

Connectors

hield Connectors

Negative/Plasma

Torch Lead

Assembly

Figure 3-7 Shielded Machine Torch Lead Connections

3. Connect the torch Negative & Plasma Lead to the bulk­head connection inside the Power Supply .

In machine type operations the Power Supply has an
Adapter that has a cable connector supplied at each
end of the Adapter. One end is connected at the fac­tory to the mating connector on the Power Supply
Bulkhead area. The other end allows connection of a
Remote Pendant. The remote pendant lead connec­tor allows connection to a remote pendant or CNC
cable while using PIP connections in the Torch As­sembly.

Connect the remote pendant control cable to the con­nector provided on the Adapter fr om the Power Sup­ply.

Remote Pendant/CNC

Cable Connector

ontrol

OK-To-Move

3

4
12
14
13

PIP

Circuit

Torch Control

Cable Connector

2
3

4
12
14
13

4. Connect the PIP and Shield Cables to the mating con­nectors on the Adapter supplied on the Power Supply .

5. Remove the top nut and washer from the Pilot Stud.

6. Place the lug on the Pilot Control Wi re onto the stud

A-01366

and secure with the nut and washer removed in the
above Step.

7. Tighten the Thr ough-hole Protector onto the T or ch
Leads.

8. Check the torch for proper parts assembly.

Figure 3-8 Remote Pendant Connector Diagram

NOTE

Refer to Appendix 2, Torch Control Cable Wiring
Diagram For Mechanized Systems, for detailed
schematic of the Adapter.

CAUTION

The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Se­lection.

Manual 0-2818 3-5 INST ALLATION

3.07 Gas Connection

A. Connection

Connect the gas, compressed air only, to the Power
Supply as described in the Manual supplied with the
Power Supply.

CAUTION

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.

B. Checking Air Quality

T o test the quality of air, place a welding filter lens in
front of the torch and turn on the gas. Any oil or
moisture in the air will be visible on the lens. Do not
initiate an arc!

C. Filtering

An in-line pneumatic dryer & evaporator type air fil­ter , capable of filtering to at least 5 microns, is required
when using air from a compressor. This type filter
will insure that moisture, oil, dirt, chips, rust particles,
and other contaminants from the supply hose do not
enter the torch. For highly automated applications,
a refrigerated drier may be used.

INST ALLATION 3-6 Manual 0-2818

SECTION 4:

OPERATION

4.01 Introduction

This section provides a description of the PCH & M-102
T o r ch Assembly followed by operating procedures.

4.02 Functional Overview

The T orch is designed to operate with various Power Sup­plies to provide a plasma cutting system which can cut
most metals from gauge thickness up to 1 inch (25.4 mm).
Using gouging torch parts the torch can be used for
plasma arc gouging up to 1/4 inch (6.4 mm) wide and
3/16 inch (4.8 mm) deep in a single pass on carbon steel.

NOTE

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

4.03 Getting Started

This procedure should be followed at the beginning of
each shift:

NOTE

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

E. Power On

Place the ON - OFF Switch on the Power Supply to
the ON position. If the RUN - SET - or RUN - SET ­LATCH switch is in SET position, gas will flow. If
the switch is in RUN position there will be no gas
flow.

F. RUN - SET or RUN - SET - LATCH Switch

If the RUN - SET or RUN - SET - LA TCH switch is in
SET position, gas will flow. If the switch is in RUN
position there will be no gas flow.

G. Current Output Level

At the Power Supply, set the desired current output
level to a maximum of 100 amperes. For drag cut­ting set the control at 35 amps or less only.

H. Pressure Settings

Place the RUN - SET or RUN - SET - LATCH switch
to the SET position. Adjust the gas pressure control
on the Power Supply for the proper gas pressur e (see
Note).

WARNING

Disconnect primary power at the source before as­sembling or disassembling power supply, torch
parts, or torch and leads assemblies.

A. Torch Part s

Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to Sec­tion 4.04, Torch Parts Selection).

B. Input Power

Check the power source for proper input voltage.
Close main disconnect switch or plug unit in to sup­ply primary power to the system.

C. Work Cable

Check for a solid cable connection to the workpiece.

D. Gas Supply

Select desired single gas supply. Make sure gas
sources meet requirements (see Note). Check con­nections and turn gas supply on.

NOTE

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

I. Ready for Operation

Return the RUN - SET or RUN - SET - LA TCH switch
to RUN position.

NOTES

For general cutting, use the RUN position which
provides normal torch operation where the torch
switch must be held throughout the main arc trans­fer.

For specific applications, use the LATCH position
where the torch switch can be r eleased after the main
arc transfer . The torch r emains activated until the
main arc breaks from the workpiece.

Refer to Appendix 1 for a typical detailed block dia­gram of Sequence of Operation.

The system is now ready for operation.
Start the pilot arc. On Hand T or ches press the T or ch T rig-

ger . On Machine T or ches press the switch on the Remote
Pendant or supply a Start Signal from the CNC control.
There is a 2 second pre-flow before the arc starts.

Manual 0-2818 4-1 OPERATION

4.04 Torch Parts Selection

7

4.05 Cut Quality

Depending on the type of operation to be done determines
the torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Gas Dis­tributor

NOTE

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

Change the torch parts for a different operation 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
head.

Torch Head Assembly

o

(70

Hand Torch Shown)

Electrode

Gas

Distributor

NOTES

Cut quality depends heavily on setup and param­eters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and op­erator ability.

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

Cut quality requirements differ depending on applica­tion. For instance, nitride build-up and bevel angle may
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish cut
quality is desired to avoid a secondary cleaning opera­tion. The following cut quality characteristics are illus­trated in the following figure:

Kerf Width

Cut Surface
Bevel Angle

Top

Spatter

Top Edge
Rounding

Dross

Build-Up

Cut Surface

Drag Lines

A-0000

Tip

A-02793

Shield Cup

Figure 4-1 Torch Parts

2. Tilt the torch head to remove the tip and gas distribu­tor .

3. Remove the SureLok Electrode by pulling it straight
out of the Torch Head.

4. Install the desired SureLok Electrode by pushing it

straight into the torch head until it clicks.

5. Install the desired gas distributor and tip for the op-

eration into the torch head.

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.

Figure 4-2 Cut Quality Characteristics

A. Cut Surface

The desired or specified condition (smooth or rough)
of the face of the cut.

B. Nitride Build-Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material
is to be welded after the cutting process.

C. Bevel Angle

The angle between the surface of the cut edge and a
plane perpendicular to the surface of the plate. A per­fectly perpendicular cut would result in a 0° bevel
angle.

D. Top-Edge Rounding

Rounding on the top edge of a cut due to wearing
from the initial contact of the plasma arc on the work­piece.

OPERATION 4-2 Manual 0-2818

E. Bottom Dross Buildup

2

C. Edge Starting

Molten material which is not blown out of the cut
area and resolidifies on the plate. Excessive dross
may require secondary cleanup operations after cut­ting.

F . Kerf Width

The width of the cut (or the width of material re­moved during the cut).

G. Top Spatter (Dross)

Top spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting
tip whose orifice has become elongated.

4.06 General Cutting Information

WARNINGS

Disconnect primary power at the source before dis­assembling the power supply, torch, or tor ch leads.

Frequently review the Important Safety Precau­tions at the front of this manual. 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 torch is activated.

CAUTION

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

NOTE

Handle torch leads with care and protect them fr om
damage.

A. Piloting

Piloting is harder on parts life than actual cutting be­cause the pilot arc is directed from the electrode to
the tip rather than to a workpiece. Whenever pos­sible, avoid excessive pilot arc time to improve parts
life.

B. Torch Standoff

Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as well
as shield cup life. Standoff may also significantly
affect the bevel angle. Reducing standoff will gener­ally result in a more square cut.

For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip near (not touch­ing) the edge of the workpiece at the point where the
cut is to start. When starting at the edge of the plate,
do not pause at the edge and force the arc to "reach"
for the edge of the metal. Establish the cutting arc as
quickly as possible.

D. Direction of Cut

In the torches, the plasma gas stream swirls as it leaves
the torch to maintain a smooth column of gas. This
swirl effect results in one side of a cut being more
square than the other . Viewed along the direction of
travel, the right side of the cut is more square than
the left.

Left Side

Cut Angle

Right Side

Cut Angle

A-0051

Figure 4-3 Side Characteristics Of Cut

T o make a square-edged cut along an inside diameter of a
circle, the torch should move counterclockwise around the
circle. T o keep the square edge along an outside diameter
cut, the torch should travel in a clockwise direction.

E. Dross

When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed
dross" is normally present on the bottom edge of the
plate. It can vary from a light to heavy bead, but
does not adhere tightly to the cut edge, and can be
easily scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a trouble­some steel, it is sometimes useful to reduce the cut­ting speed to produce "slow speed dross". Any re­sultant cleanup can be accomplished by scraping, not
grinding.

Manual 0-2818 4-3 OPERATION

4.07 Hand Torch Operation

S

8"

N

0

A. Standoff Cutting With Hand Torch

NOTE

For best performance and parts life, always use
the correct parts for the type of operation.

1 . The torch can be comfortably held in one hand or

steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the back
end for maximum heat protection. Choose the holding
technique that feels most comfortable and allows good
control and movement.

NOTE

The tip should never come in contact with the
workpiece except during drag cutting operations.

2 . Depending on the cutting operation, do one of the

following:
a. For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start.

4. Once on, the main arc remains on as long as the T orch
Trigger is held down, unless the torch is withdrawn
from the work or torch motion is too slow . If the cutting
arc is interrupted, the pilot arc comes back on auto­matically .

NOTE

Most cutting is performed with the power supply
in the RUN position. For specific applications, the
LATCH position may be pr eferred where the Torch
Trigger can be released after the main arc transfer .
The torch remains activated until the main arc
breaks from the workpiece.

5. T o shut off the tor ch simply release the T or ch T rig­ger . When the trigger is released a 20 second post­flow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.

B. Crown Shield Cup With Straight Edge

The crown shield cup can be used with a noncon­ductive straight edge to make straight cuts by hand.

WARNING

b. For standoff cutting, hold the torch 1/8 - 3/8

in (3-9 mm) from the workpiece as shown be­low.

Torch

hield Cup

A-00024

Standoff

Distance 1/8" - 3/

Figure 4-4 Standoff Distance

The straight edge must be non-conductive.

Torch

Crown Shield

Cup

on-Conductive
Straight Edge
Cutting Guide

A-0260

Figure 4-5 Using Crown Shield Cup With Straight

Edge

3. W ith the torch in starting position, press and hold
the T orch Trigger. After an initial two second pre­flow, the pilot arc will come on and remain on
until the cutting arc starts.

The crown shield cup functions best when cutting
3/16 inch (4.7 mm) solid metal with relatively
smooth surface. Use drag cutting for thinner
metal.

OPERATION 4-4 Manual 0-2818

C. Drag Cutting With a Hand Torch

D. Piercing With Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm) thick or
less.

NOTE

For best parts performance and life, always use
the correct parts for the type of operation.

1. Install the drag cutting tip and set the output current
to 35 amps or less.

2 . The torch can be comfortably held in one hand or

steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the holding technique that feels most comfortable
and allows good control and movement.

3. Keep the torch in contact with the workpiece dur­ing the cutting cycle.

4. Press the Torch Trigger, and after an initial two
second pre-flow, the pilot arc will come on and
remain on until the cutting arc starts.

5. Once on, the main arc remains on as long as the
Torch Trigger is held down, unless the torch is
withdrawn from the work or torch motion is too
slow. If the cutting arc is interrupted, the pilot
arc comes back on automatically.

1 . The torch can be comfortably held in one hand or

steadied with two hands. Position the hand to
press the Trigger on the torch handle. With the
hand torch, the hand may be positioned close to
the torch head for maximum control or near the
back end for maximum heat protection. Choose
the technique that feels most comfortable and al­lows good control and movement.

NOTE

The tip should never come in contact with the work­piece except during drag cutting operations.

2. Angle the torch slightly to direct blowback par­ticles away from the torch tip (and operator) rather
than directly back into it until the pierce is com­plete.

3. In a portion of the unwanted metal start the pierce
off the cutting line and then continue the cut onto
the line. Hold the torch perpendicular to the work­piece after the pierce is complete.

4. Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying the shield
cup in anti-spatter compound will minimize the
amount of scale which adheres to it.

NOTE

Most cutting is performed with the power supply
in the RUN position. For specific applications,
the LATCH position may be preferred where the
Torch Trigger can be released after the main arc
transfer . In the LATCH position, the tor ch remains
activated until the main arc breaks from the work­piece.

6. T o shut off the tor ch simply release the T orch Trig­ger . When the T rigger is released a 20 second post­flow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.

Manual 0-2818 4-5 OPERATION

4.08 Machine Torch Operation

A. Cutting With Machine Torch

The machine torch can be activated by remote control
pendant or by a remote interface device such as CNC.

1. Use a square to check that the torch is perpendicu­lar to the workpiece to obtain a clean, vertical cut

Pinch Block
Assembly

Square

Workpiece

A-02585

2. Leading Arc

The leading arc is directed in the same direction as
torch travel. A five degree leading arc is generally
recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc-

.

tion as torch travel. Generally recommended for
Nitrogen plasma.

Direction of Torch Travel

Standoff Distance

Figure 4-6 Checking Alignment

2. To start a cut at the plate edge, position the center
of the torch along the edge of the plate (refer to
Figure 4-7).

B. Travel Speed

Proper travel speed is indicated by the trail of the arc
which is seen below the plate ( Figure 4-7). The arc
can be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiece
surface. This arc is generally recommended for the
best cut using air plasma on stainless or alumi­num.

Straight Arc

Trailing Arc

A-02586

Leading Arc

Figure 4-7 Machine Torch Operation

For optimum smooth surface quality, the travel speed
should be adjusted so that only the leading edge of
the arc column produces the cut. If the travel speed
is too slow, a rough cut will be produced as the arc
moves from side to side in search of metal for trans­fer.

Travel speed also affects the bevel angle of a cut.
When cutting in a circle or around a corner, slowing
down the travel speed will result in a squarer cut.
The power source output should be reduced also.
Refer to the appropriate Control Module Operating
Manual for any Corner Slowdown adjustments that
may be required.

OPERATION 4-6 Manual 0-2818

C. Piercing With Machine Torch

T o pierce with a machine torch, the arc should be started
with the torch positioned as high as possible above the
plate while allowing the arc to transfer and pierce. This
standoff helps avoid having molten metal blow back onto
the front end of the torch.

When operating with a cutting machine, a pierce or dwell
time is required. T orch travel should not be enabled until
the arc penetrates the bottom of the plate. As motion be­gins, torch standoff should be reduced to the recommended
1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cut
quality . Clean spatter and scale from the shield cup and
the tip as soon as possible. Spraying or dipping the shield
cup in anti-spatter compound will minimize the amount of
scale which adheres to it.

4.10 Gouging

W ARNINGS

Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection and that
all safety precautions at the front of this manual
have been followed. Make sure no part of the
operator’s body comes in contact with the work­piece when the torch is activated.

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

4.09 Recommended Cutting Speeds

Cutting speed depends on material, thickness, and the operator’s
ability to accurately follow the desired cut line. The following
factors may have an impact on system performance:

• T orch parts wear

• Air quality

• Line voltage fluctuations

• Torch standof f height

• Proper work cable connection

NOTES

This information represents realistic expectations
using recommended practices and well-maintained
systems. Actual speeds may vary up to 50% from
those shown.

Refer to Appendix Pages for cutting speed chart
information as related to the Power Supply used.

CAUTIONS

Sparks from plasma gouging can cause damage to
coated, painted or other surfaces such as glass, plas­tic, and metal.

Check torch parts. The torch parts must correspond
with the type of operation. Refer to Section 4.04,
Torch Parts Selection.

A. Gouging Parameters

Gouging performance depends on parameters such
as torch travel speed, current level, lead angle (the
angle between the torch and workpiece), and the dis­tance between the torch tip and workpiece (stand­off).

B. Torch T ravel Speed

NOTE

Refer to Appendix Pages for additional informa­tion as related to the Power Supply used.

Optimum torch travel speed is dependent on current
setting, lead angle, and mode of operation (hand or
machine torch).

C. Current Setting

Current settings depend on torch travel speed, mode
of operation (hand or machine torch), and the amount
of material to be removed.

Manual 0-2818 4-7 OPERATION

D. Lead Angle

5˚

A

The angle between the torch and workpiece depends on
the output current setting and torch travel speed. At 80
amps, the recommended lead angle is 35° (refer to Figure 4-

8). At a lead angle greater than 45° the molten metal will
not be blown out of the gouge and may be blown back
onto the torch. If the lead angle is too small (less than 35°),
less material may be removed, requiring more passes. In
some applications, such as removing welds or working
with light metal, this may be desirable.

Torch Head

Standoff Height

1/8 - 1/4"

Workpiece

-00941

3

Figure 4-8 Gouging Angle and Standoff Distance

E. Standoff Distance

The tip to work distance affects gouge quality and depth.
Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for
smooth, consistent metal removal. Smaller standoff dis­tances may result in a severance cut rather than a gouge.
Standoff distances greater than 1/4 inch (6 mm) may result
in minimal metal removal or loss of transferred main arc.

F. Slag Buildup

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

OPERATION 4-8 Manual 0-2818

SECTION 5:

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.

WARNINGS

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.

Refer to Section 5.07, Servicing Hand Torch (PCH)
Components, or Section 5.08, Servicing Machine
Torch Components (PCM) for disassembling the
Torch and Leads Assembly.

CAUTION

Dry the torch thoroughly before r einstalling.

Disconnect primary power at the source before dis­assembling the torch or torch leads.

Frequently review the Important Safety Precau­tions at the front of this Manual. 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 torch is activated.

CAUTION

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

NOTE

Handle torch leads with care and protect them fr om
damage.

5.02 General T orch Maintenance

A. Cleaning Torch

Even if precautions are taken to use only clean air
with a torch, 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

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.

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.

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.

1. Remove the shield cup, tip, gas distributor, and
electrode from the torch. Disconnect the torch
leads from the power supply to isolate the torch
from power supply circuits.

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, refer to
Section 5.06, Torch and Leads Troubleshooting.

C. O-Ring Lubrication

The external o-ring on the Torch Head Assembly
(shield cup) requires lubrication on a scheduled ba­sis. This will allow the o-ring to remain pliable and
provide a proper seal. The o-ring will dry out, be­coming hard and cracked, if the o-ring lubricant is
not used on a regular basis. This can lead to poten­tial leaks of the secondary gas around the end of the
shield cup.

It is recommended to apply a very light film of o­ring lubricant (Catalog # 8-4025) to the o-ring on a
weekly basis.

Manual 0-2818 5-1 SERVICE

NOTE

DO NOT use other lubricants or grease, they may

not be designed to operate within high tempera­tures or may contain “unknown elements” that
may react with the atmosphere. This reaction can
leave contaminants inside the torch. Either of these
conditions can lead to inconsistent performance or
poor parts life.

5.03 Common Operating Faults

The following lists the more common cutting faults and
possible causes:

1. Insufficient Penetration

a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts

5.04 Inspection and Replacement Consumable T orch Part s

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 per the following
procedure:

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.

e. Cutting current too low
f. Non - Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow
b. Torch standoff too high from workpiece
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. Torch standoff too high from workpiece
c. Worn torch parts
d. Improper cutting current
e. Non - Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

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.

Torch Head Assembly

o

(70

Hand Torch Shown)

Electrode

A-02793

Gas

Distributor

Tip

Shield Cup

Figure 5-1 Consumable Parts

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
f. Non - Genuine Thermal Dynamics Parts

SERVICE 5-2 Manual 0-2818

3. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Clean or re­place the tip if necessary.

Good Tip

A-00942

Worn Tip

Figure 5-2 Tip Wear

4. Remove the gas distributor and check for excessive
wear , plugged gas holes, or discoloration. Replace if
necessary.

5.05 T roubleshooting Guide

This subsection covers troubleshooting that requires dis-
assembly and electronic measurements. It is helpful for
solving many of the common problems that can arise with
this torch assembly.

How to Use This Guide

The following information is a guide to help the Customer
/ Operator determine the most likely causes for various
symptoms.

This guide is set up as follows:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

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 .

New Electrode

A-02794

Worn Electrode

Figure 5-3 Electrode Wear

6

. Reinstall the SureLok Electrode by pushing it straight

into the torch head until it clicks.

7. Reinstall the desired 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.

a. Check / Remedy (Text Type)

Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
unit is fully operational after any repairs.

T roubleshooting

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN / SET / LATCH switch in SET
position

a. Place RUN / SET / LA TCH switch to RUN po-

sition.

2. Parts - In - Place (PIP) not satisfied.
a. Check canted coiled spring inside shield cup

3. Faulty Torch Switch

a. Check for continuity

4. Faulty torch parts

a. Inspect torch parts and replace if necessary. Re-

fer to Section 5.04, Inspection and Replacement
Consumable Torch Parts

5. Gas pressure too high

a. Set proper operating gas pressure.

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads
Troubleshooting.

7. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

Manual 0-2818 5-3 SERVICE

B. No cutting output

5. Torch tip dragged across workpiece

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached

to power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated against

torch head (do not overtighten)

3. Parts - In - Place (PIP) not satisfied.

a. Check canted coiled spring inside shield cup

4. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads
Troubleshooting.

5. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads
Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

D. Erratic or improper cutting output

1. Poor input or output connections to power supply

a. When the tip is dragged across the workpiece,

the amperage automatically cuts back to 35
amps (see Note).

NOTE

All power supplies may not have this feature.

E. No gas flow

1. Gas not connected or pressure too low

a. Check source for proper operating gas pressur e

(refer to Appendix Page for Power Supply
used).

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.06, Torch & Leads
Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

F. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

face while purging and observe oil or moisture
buildup (do not activate torch)

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix Page

for the Power Supply being used).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.2 mm) from clean sur-

face while purging and observe oil or moisture
buildup (do not activate torch).

SERVICE 5-4 Manual 0-2818

5.06 T orch & Leads T roubleshooting

A. General Information

Failures in the T orch and Leads can be isolated to the Torch
Head or T orch Lead components. To properly isolate the
failed part requires the use of an ohmmeter and a Hi-Pot
Tester.

WARNING

4. Remove the torch head from the leads (refer to
the proper Section on servicing the Torch Com­ponents).

5. With the torch head disconnected from the leads,
measure the resistance between negative fitting
or cathode body of the torch head and the posi­tive fitting or anode body of the torch head.

No continuity (infinite resistance) should be mea­sured between negative and positive sections of
the torch head.

The use of a Hi - Pot Tester should be performed
only by a qualified electronic technician.

In the T orch Head the center insulator separates the nega­tive and positive charged 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.

In the Torch Leads the negative and positive leads are
isolated from each other. If there is not adequate resis­tance between the leads then torch failure may occur.

B. Quick Check Procedure

This quick check will identify major isolation failures in
the T orch Head or T or ch Lead components using an ohm­meter.

The actual assembly and consumables may vary for dif­ferent torches but the basic procedure is the same for all
torches. Make the quick check on the Torch Head and
Leads as follows:

• If there is continuity, torch head must be re­placed.

• If no continuity (infinite resistance) is found
proceed to Step 6.

6. Check the torch leads by measuring the resistance
between the positive pilot lead connector and the
negative lead fitting.

• If there is continuity, torch leads must be re­placed.

• If no continuity (infinite resistance) is found
proceed to paragraph ‘C’ (see NOTE).

NOTE

It is possible that the Torch Head and Torch Leads
will test properly with an ohmmeter. The Torch
Head and Torch Leads should be tested further for
insulation breakdown if no other fault can be found.

C. Checking Proper Isolation Resistance

Procedure

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.

1. Remove the consumables from the torch.

2. Disconnect the torch leads from the power sup­ply to isolate the torch from power supply circuits.

3. Using an ohmmeter (set to 10K or higher), check
for continuity between the positive and negative
torch fittings.

• If there is continuity between the two torch fit­tings proceed to Step 4.

• If no continuity (infinite resistance) is found
between the two torch fittings proceed to para­graph C.

Manual 0-2818 5-5 SERVICE

The Torch Head and Torch Leads should be tested fur­ther for insulation breakdown if no other fault has been
found. This procedure requir es the use of a Hi-Pot T ester .

WARNING

This procedure should be performed only by a quali­fied electronic technician.

1. To test the T orch Head center insulator for insula­tion breakdown use the following procedur e:

a. Remove the Torch Head Assembly from the

Torch Leads if not already done.

b. Remove the consumables from the T orch Head

Assembly if not already done.

c. Connect a Hi-Pot Tester capable of pr oducing

2500 V AC between the positive pilot lead and
the negative lead fittings.

d. Increase the output of the Hi-Pot Tester to a

8

p

C

A

er

lf

maximum of 2500 VAC

• If the voltage drops to 0 VAC or leakage
current is detected, then the Torch Head
center insulator is breaking down and the
Torch Head must be replaced.

• If the Torch Head center insulator passes
the test, then proceed to Step 2.

2. To test the Torch Leads for insulation breakdown
use the following procedure:

a. Connect the Hi-Pot Tester between the posi-

tive pilot lead and the negative lead fittings.
The fitting on the other end of the T orch Leads
must be separated (isolated) from each other.

b. Increase the output of the Hi-Pot Tester to a

maximum of 2500 VAC.

• If the voltage drops to 0 VAC or leakage
current is detected, then the insulation be­tween the Torch Leads is breaking down
and the Torch Leads must be replaced.

• If the Torch Leads passes the test, then pr o­ceed to Step 3.

3. Visually check that the PIP wires, torch switch
wires, pilot lead connection, and negative lead
connections are properly connected and in good
condition (no shorts or arcing).

4. Check the pilot lead, negative lead and switch con­trol wires for opens from one end of the torch leads
to the other.

• If open, replace leads or open component of
the Torch Leads Assembly.

• If not open, then proceed to Step 5.

5. Check the pilot and switch control wires for shorts
to other components in the Torch Leads.

• If shorted, then replace Torch Leads.

• If not shorted, then proceed to Step 6.

6. Carefully reassemble the components and r echeck
the completed assembly per paragraph ‘B’, Step
3 to confirm that the components have been prop­erly assembled.

This completes the checks for the proper operation of the
Torch Head and Torch Leads.

5.07 Servicing Hand Torch (PCH) Components

WARNINGS

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

Torch Switch

To Control

able Wiring

PIP Pin

Shield Cu

PIP Pin

A-0045

Figure 5-4A Torch Switch and PIP Schematic -

Machine Torch

To Control

Torch Switch

Cable Wiring

PIP Switch

-03761

Torch Trigg

Shield Cup

Figure 5-4B Torch Switch and PIP Schematic - Hand

Torch

• If problems are evident, repair or r eplace as re­quired.

• If there are no visual problems, then proceed
to Step 4.

NEVER touch any internal torch parts while the
AC indicator light on the Power Supply is ON.

A. Removing the Hand Torch Head Assembly

The removal of the T or ch Head Assembly r equires disas­sembly of the torch handle and leads per the following
procedure:

1. Remove the five screws from the Torch Handle
Assembly. Pull the halves apart and set aside.

A-02823

Handle Ha

Handle Screws

(Five Places)

Figure 5-5 Torch Handle Screw Removal

SERVICE 5-6 Manual 0-2818

2. Disconnect both torch head wire connectors.

l

L

3. Slide the insulation sleeve on the Pilot Lead back
towards the Lead.

B. Reassembling the Hand Torch Head

Assembly

4. Remove the screw and star washer securing the
Pilot Lead to the head assembly.

5. Slide the insulation sleeving on the Negative /
Plasma Lead back towards the Lead.

NOTE

Some units may have shrink on tubing instead of
insulation sleeving. If this is the case, remove the
shrink on tubing from the Negative / Plasma Lead,
being careful not to damage the lead under the
shrink on tubing.

Negative / Plasma Lead
Insulation Sleeving

Handle Shell

Pilot Lead
Insulation
Sleeving

A-03544

Torch
Switch

WARNING

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

T o install the T orch Head Assembly use the following pro-

cedure:

IMPORTANT

The insulation sleevings are critical for safety. Be
sure both are properly installed and not damaged
during reassembly.

1. Slide the replacement insulation sleeving over the
Negative / Plasma Lead.

2. Connect the Negative / Plasma Lead to the re­placement Torch Head Assembly.

3. Carefully position the insulation sleeving over the
connectors as shown below.

Spring

Trigger

Handle Shel

Negative/Plasma

ead Insulation Sleeving

Figure 5-6 Hand Torch Assembly

6. Disconnect the Negative / Plasma Lead from the
Torch Head.

7. Remove the defective Torch Head.

A-03545

Figure 5-7 Insulation Sleeving Position for the

Negative / Plasma Lead

4. Insert the screw through the Pilot Lead lug and
then install the star washer before securing it to
the Torch Head Assembly.

5. Carefully position the Insulation Sleeve over the
Pilot connection.

Manual 0-2818 5-7 SERVICE

Pilot Lead

n

n

lf

Insulation Sleeving

d. Check the T orch Trigger for proper operation.

It should move freely and not bind. If the trig­ger binds, loosen the center screw only until
the Trigger moves freely.

A-03546

Figure 5-8 Insulation Sleeving Position for the Pilot

Connection

6. Reconnect the two torch head wires to the mating
connectors in the leads assembly.

7. Place the T orch Head Assembly in the handle shell
halves keeping in mind the following:

• Place the Torch Head Assembly switch leads
so that no connectors or wires extend beyond
the edge of the handle.

• Allow sufficient slack in the leads to avoid pull­ing the leads tightly around the edge of the
handle.

• Position Pilot Lead under the Negative /
Plasma Lead.

• Position the Pilot Lead so that the screw will
not penetrate the Insulation Sleeve when the
handle halves are reassembled.

NOTE

For safety reasons, do NOT use the sleeving if it is
damaged during reassembly. Replace sleeving if
damaged.

A-02824

Handle Half

#3

#1

Install Screws I

Sequence Show

#2

Figure 5-9 Torch Handle Screw Installation

9. Install the front end torch parts.

C. Removing Hand Torch Control Switch

To remove the Torch Control Switch Assembly re­quires gaining access to the switch wiring and par­tial disassembly of the torch handle per the follow­ing procedure:

1. Remove the five screws from the Torch Handle
Assembly. Pull the halves apart and set aside.

A-02823

Handle Ha

Handle Screws

(Five Places)

8. Place the torch handle halves together and install
the five assembly screws as follows:

Figure 5-10 Torch Handle Screw Removal

a. Insert the two screws at the Torch Head end

of the Handle and torque to 15 in-lbs.

b. Insert the two screws at the T orch Lead end of

the Handle and torque to 15 in-lbs.

c. Insert the center screw and torque to 15 in-lbs.

SERVICE 5-8 Manual 0-2818

2. Cut the Torch Switch leads between the butt

l

n

n

splices and the torch leads, and as close as pos­sible to the splices.

Negative / Plasma Lead
Insulation Sleeving

Handle Shell

Pilot Lead
Insulation
Sleeving

A-03544

Torch
Switch

5. Replace the handle and secure with five screws
as follows:

a. Insert the two screws at the Torch Head end

of the Handle and torque to 15 in-lbs.

b. Insert the two screws at the T orch Lead end of

the Handle and torque to 15 in-lbs.
c. Insert the center screw and torque to 15 in-lbs.
d. Check the T orch Trigger for proper operation.

It should move freely and not bind. If the trig-

ger binds, loosen the center screw only until

the Trigger moves freely.

Spring

Trigger

Handle Shel

Figure 5-11 Hand Torch Assembly

3. Remove the defective Torch Switch from the
handle.

D. Reassembling Hand Torch Control Switch

Assembly

1. Strip back the insulation from the Torch Switch
leads approximately 3/16". Install heat-shrink
insulation on the T orch Switch leads. Crimp butt
splices onto the two T or ch Switch leads and onto
the switch leads in the Torch Leads assembly.
Slide the sheat-shrink insulator over the butt
splices. Use a heat gun to shrink the heat-shrink
insulation into position on the butt splices.

2. Position Torch Head and Torch Control Switch in
handle, making sure all connectors and leads do
not extend beyond the edge of the handle.

A-02824

Handle Half

#3

#1

Install Screws I

Sequence Show

#2

Figure 5-12 Torch Handle Screw Installation

3. Position Pilot Lead under the Negative / Plasma
Lead.

4. Position the Pilot Lead so that the screw will not
penetrate the Insulation Sleeving when the handle
halves are reassembled.

NOTE

For safety reasons, it is critical that the sleeving
not be used if it is damaged during reassembly.
Replace sleeving if damaged.

Manual 0-2818 5-9 SERVICE

5.08 Servicing Machine Torch (PCM)

e

N
L

Components

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.

A. Removing Machine Torch Head

egative/Plasma

ead Connection

Pilot Lead
Connection

Parts-in-Plac
Wires

A-02581

1. Unscrew the positioning tube from the Torch
Head.

2. Slide the positioning tube back over the leads to
expose the Negative / Plasma Lead connection,
Pilot Lead connection, and two PIP (parts-in-place
circuit) connectors.

Pinch Block Assembly

Positioning
Tube

A-02587

Machine T orch Head

Figure 5-13 Torch Mounting Assembly

Figure 5-14 Torch Head Removal

B. Reassembling Machine Torch Assembly

1. Connect the two PIP lead connectors, the Nega­tive / Plasma Lead and Pilot Lead.

NOTE

T ape the PIP lead connectors to the leads covering.

2. Screw the positioning tube tightly onto the Torch
Head.

3. Disconnect the Negative / Plasma Lead, Pilot
Lead and the PIP connectors to allow removal of
the Torch Head Assembly.

SERVICE 5-10 Manual 0-2818

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable
components. T orch Assemblies are field serviceable, so a
complete breakdown of parts is provided. The parts lists
are arranged as follows:

Section 6.03: Replacement Hand T or ch Parts
Section 6.04: Replacement Machine Torch Parts
Section 6.05: Replacement Machine Torch Leads
Section 6.06: Complete Assembly Replacements
Section 6.07: Options & Accessories
Section 6.08: Tor ch Consumable Parts
Section 6.09: Spare Parts Kits

NOTE

Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.

B. Returns

If a product must be returned for service, contact your
authorized distributor . Materials returned 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 parts
list for each type item. Also include the model and serial
number of the torch. Addr ess all inquiries to your autho­rized distributor .

Manual 0-2818 6-1 P ARTS LISTS

6.03 Replacement Hand Torch Parts (Ergonomic Handle)

Item # Qty Description Catalog #

1 1 Assembly, Torch Head (Includes items # 2 & 3)

1 PCH - 102 RPT 70° Torch Head 9-8405

1 PCH - 102 RPT 90° Torch Head 9-8404
2 1 # 6-32 x 3/16 Phillips Pan Head Screw See Note
3 1 # 6 Internal Star Washer See Note
4 1 Negative / Plasma Lead Insulation Sleeving 9-8067
5 1 Pilot Wir e Insulation Sleeving 9-8057
6 3 Pin Housing (Used with item # 7) 9-8111
7 3 Pin 9-8101
8 3 Socket Housing (Used with item # 9) 9-81 12
9 3 Socket 9-8102

Handle, Split, with Trigger (includes items # 10-14) 9-8105
10 1 Trigger, Lexan, Orange 9-8059
11 1 Handle 9-8065
12 1 Spring 9-8061
13 1 Tor ch Switch Assembly 9-8063
14 1 Torch Handle Socket Head Cap Screw Kit (5 pieces # 6-32 x 1/2") 9-8062
15 1 Lead Assembly, including items No. 11, 13, and 14

20 ft (6.1 m) Length 4-7530

50 ft (15.2 m) Length 4-7529
16 1 Through - Hole Protector with Nut (included in Item #17) 9-7571
17 1 Adapter, Torch Control Cable (Includes Item #16) 7-3447

NOTE: Item can be purchased locally.

P ARTS LISTS 6-2 Manual 0-2818

Art # A-03550

5

8 & 9

4

11

3

6 & 7

13

12

1

2

10

14

11

16

15

17

Manual 0-2818 6-3 P ARTS LISTS

6.04 Replacement Machine Torch With Pinch Block Mounting Parts

Item # Qty Description Catalog #

1 1 Assembly, Torch Head, PCM - 102 RPT (Includes items # 2-3) 9-8403
2 1 # 6-32 x 3/16 Phillips Pan Head Screw See Note
3 1 # 6 Internal Star Washer See Note

1 Lead Assembly, Cable Complete

4A Unshielded Lead Assembly

25 ft (7.6 m) Length 4-7522
50 ft (15.2 m) Length 4-7523

4B Shielded Lead Assembly

25 ft (7.6 m) Length 4-7531

50 ft (15.2 m) Length 4-7532
5 1 Positioning T ube With Rack, Fiberglass 9-7835
6 2 Body, Mounting, Pinch Block Phenolic (Plastic) 9-4513
7 1 Pin, Mounting, Pinch Block 9-4521
8 1 Torch Holder Sleeve 7-2896
9 3 # 10-32 x 5/8" Phillips Pan Head Screw See Note

10 2 # 10-32 x 32 x 1 - 1/4 Large Phillips Pan Head Screw See Note
11 2 # 10-32 Regular Nylon Lock Nut See Note
12 1 Through - hole protector , Notched (Supplied with Nut) 9-7016
13 1 Adapter, Torch Control Cable 7-3448
14 1 Pinch Block Mounting Kit (includes items #6-11) 7-3252

NOTE: Item can be purchased locally.

P ARTS LISTS 6-4 Manual 0-2818

U

10

6

14

9

6

5

7

1

3

2

4A

8

OR / O

12

13

4B

12

Art # A-03092

Manual 0-2818 6-5 P ARTS LISTS

6.05 Replacement Machine Torch Lead Parts

Item # Qty Description Catalog #

1 Nylon Sleeving

1 25 ft (7.6 m) Length 8-1000

1 50 ft (15.2 m) Length 8-7051
2 1 Through - hole protector , Notched (Supplied with Nut) 9-7016
3 1 Boot 9-7017
4 Lead, Pilot Return, 14 AWG

1 25 ft (7.6 m) Length 8-6460

1 50 ft (15.2 m) Length 8-6461
5 Lead, Gas Cooled, Negative, # 5

1 25 ft (7.6 m) Length 9-7665

1 50 ft (15.2 m) Length 9-7796
6 Assembly , Control Cable

Unshielded Leads
1 25 ft (7.6 m) Length 8-6462
1 50 ft (15.2 m) Length 8-6463

Shielded Leads
1 25 ft (7.6 m) Length 8-6456
1 50 ft (15.2 m) Length 8-6457

7 PVC Sleeving

1 25 ft (7.6 m) Length 8-6478
1 50 ft (15.2 m) Length 8-6479

8 Shield Braid

1 25 ft (7.6 m) Length 8-6458
1 50 ft (15.2 m) Length 8-6459

P ARTS LISTS 6-6 Manual 0-2818

PCM - 102 Unshielded T orch Leads

4

3

4

5

3

1

2

A-02802

6

PCM - 102 Shielded T orch Leads

7

8

1

5

2

3

A-0280

6

Manual 0-2818 6-7 P ARTS LISTS

6.06 Complete Assembly Replacement

NOTE

The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter (refer to
Section 6.03 or 6.04)

Description Catalog #

Hand Torches with Ergonomic Handle:

PCH - 102 RPT 70° Hand Torch, 20 ft (6.1 m) Leads 7-7530-SL
PCH - 102 RPT 70° Hand Torch, 50 ft (15.2 m) Leads 7-7532-SL

PCH - 102 RPT 90° Hand Torch, 20 ft (6.1 m) Leads 7-7531-SL
PCH - 102 RPT 90° Hand Torch, 50 ft (15.2 m) Leads 7-7533-SL

Machine Torches with Unshielded Leads (Fiberglass Mounting Tube with Rack & Phenolic Pinch Block Assembly):

PCM - 102 RPT Machine Torch, 25 ft (7.6 m) Leads 7-7536-SL
PCM - 102 RPT Machine Torch, 50 ft (15.2 m) Leads 7-7537-SL

Machine Torches with Shielded Leads (Fiberglass Mounting Tube with Rack & Phenolic Pinch Block Assembly):

PCM - 102 RPT Machine Torch, 25 ft (7.6 m) Leads 7-7538-SL
PCM - 102 RPT Machine Torch, 50 ft (15.2 m) Leads 7-7539-SL

6.07 Options & Accessories

Qty Description Catalog #

1 Circle Cutting Guide 7-8910
1 Standof f Cutting Guide

For Use With 8-7500 Standard Shield Cup 8-7575

1 Remote Hand Pendant Control with 20 ft. Cable 7-3460
1 Hand Pendant Extension - 25 ft 7-7744

1 Computer Contr ol (CNC) Cable

25 Ft (7.6 m) 8-5557

50 Ft (15.2 m) 8-5558

Kevlar Sleeving:
1 25 ft. (7.6 m) 9-7905
1 50 ft. (15.2 m) 9-7906

P ARTS LISTS 6-8 Manual 0-2818

Item # Qt y Description Catalog #

1 1 - 3/8" Metal Positioning T ube with Rack & Pinion Assembly Kit 7-7745

1 Pinion Assembly Only 7-2827
1 1 T orch Holder Sleeve 7-2896
2 1 Pinion Gear-Short 8-6074
3 1 Handwheel (Tor ch Holder) 9-4514
4 1 Low Profile T orch Holder (1 - 3/8 Diameter) without Hardware 9-4515
5 1 Calibrated T orch Holder Bushing 9-4366
6 1 5/32 Diameter x 5/8 Large Slotted Spring Pin See Note
7 1 3/8 - 24 x 3/8 Socket Head Set Screw , Cup Point See Note
8 2 1/4 - 20 x 5/8 Hex Socket Head Screw See Note
9 1 # 10 - 24 x 3/8 Hex Socket Set Screw , Cup Point See Note

NOTE: Item can be purchased locally .

8

7

8

3

6

4

2

9

A-02737

5

1

Manual 0-2818 6-9 P ARTS LISTS

G

)

G

A

6.08 T orch Consumables

The illustration shows all consumable parts for the PCH & M-102 torches. Refer to the section covering the
power supply being used to ensure proper selection for the application.

Cutting Consumables

Shield Cups

Tips

Air

SureLok

Electrodes

eneral Purpose

9-8402

MaximumLife™

9-8407

A-03020

SureLok

Electrodes

Gas

Distributor

8-7501

35/40 Amp

8-7503

60 Amp

9-7726

60/70 Amp

8-7505

80 Amp

9-7728

Gouging Consumables

Shield Cups

Standard

8-7500

Copper

8-7496

Hi-Vis (Black)

8-7525

Crown (Castle)

8-7507

Body

8-7498

Body

8-7498

Copper

8-7497

Crown (Castle

8-7499

A-03021

eneral Purpose

9-8402

MaximumLife™

9-8407

Gas

Distributor

8-7508

Tip
Air

Orifice
8-7506

Standard

8-7500

Copper

8-7496

Body

8-7498

Copper

8-7497

Canted Coil Spring

-03022

P ARTS LISTS 6-10 Manual 0-2818

Inside Shield Cups (All)

9-7501

6.09 Torch Spare Parts Kits

A. For CutMaster 75 Applications

Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-0018
5 Electrode (SureLok), MaximumLife 9-8407
5 Tip, Cutting, Air, 60 Amp 9-7726
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Standoff Guide 8-7575
1 Box, Utility 8-3141

B. For CutMaster 80XL Applications

Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-7580
5 Electrode (SureLok), General Purpose 9-8402
5 Tip, Cutting, Air, 60 Amp 9-7726
2 Tip, Cutting / Drag, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Adapter Fitting 1/4" Hose to 1/4 NPT 8-4264
1 Lubricant 8-4025
1 Box, Utility 8-3141

C. For CutMaster 100 Applications

Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-0019

5 Electrode (SureLok), MaximumLife 9-8407

5 Tip, Cutting, Air, 80 Amp 9-7728
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Standoff Guide 8-7575
1 Box, Utility 8-3141

Manual 0-2818 6-11 P ARTS LISTS

D. For Pak Master 75XL Plus Applications

1. For Non-CE Pak Master 75XL Plus Applications
Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-7509
5 Electrode (SureLok), MaximumLife 9-8407
5 Tip, Cutting, Air, 60 Amp 9-7726
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Adapter Fitting 1/4" Hose to 1/4" NPT 8-4264
1 Lubricant 8-4025
1 Box, Utility 8-3141
1 Standoff Guide 8-7575

VIP Spare Parts Kit Includes: 5-7510

20 Electrode (SureLok), MaximumLife 9-8407
40 Tip, Cutting, Air, 60 Amp 9-7726
10 Tip, Cutting / Drag, Air, 40 Amp 8-7503

2 Gas Distributor 8-7501
1 Standard Shield Cup 8-7500
1 Shield Cup, Castle 8-7507
5 O-Ring 8-0532
3 Canted Coil Spring 9-7501
1 Standoff Guide 8-7575

Gouging Spare Parts Kit Includes: 5-0011

10 Electrode (SureLok), MaximumLife 9-8407
15 Tip, Gouging, Air 8-7506

2 Gas Distributor , Gouging 8-7508
2 Standard Shield Cup 8-7500
5 O-Ring 8-0532
3 Canted Coil Spring 9-7501
1 Box, Utility 8-3141

2. For CE Pak Master 75XL Plus Applications
Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-7613
5 Electrode (SureLok), General Purpose 9-8402
5 Tip, Cutting, Air, 60 Amp 9-7726
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Adapter Fitting 1/4" Hose to 1/4" NPT 8-4264
1 Lubricant 8-4025
1 Box, Utility 8-3141
1 Standoff Guide 8-7575

P ARTS LISTS 6-12 Manual 0-2818

E. For Pak Master 100XL Plus Applications

1. For Non-CE Pak Master 100XL Plus Applications
Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-0009
5 Electrode (SureLok), MaximumLife 9-8407
5 Tip, Cutting, Air, 80 Amp 9-7728
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Adapter Fitting 1/4" Hose to 1/4" NPT 8-4264
1 Lubricant 8-4025
1 Box, Utility 8-3141
1 Standoff Guide 8-7575

VIP Spare Parts Kit Includes: 5-0010

20 Electrode (SureLok), MaximumLife 9-8407
40 Tip, Cutting, Air, 80 Amp 9-7728
10 Tip, Cutting / Drag, Air, 40 Amp 8-7503

2 Gas Distributor 8-7501
1 Standard Shield Cup 8-7500
1 Shield Cup, Castle 8-7507
5 O-Ring 8-0532
3 Canted Coil Spring 9-7501
1 Standoff Guide 8-7575

Gouging Spare Parts Kit Includes: 5-0011

10 Electrode (SureLok), MaximumLife 9-8407
15 Tip, Gouging, Air 8-7506

2 Gas Distributor , Gouging 8-7508
2 Standard Shield Cup 8-7500
5 O-Ring 8-0532
3 Canted Coil Spring 9-7501
1 Box, Utility 8-3141

2. For CE Pak Master 100XL Plus Applications
Qty Description Catalog #

Standard Spare Parts Kit Includes: 5-7612
5 Electrode (SureLok), General Purpose 9-8402
5 Tip, Cutting, Air, 80 Amp 9-7728
2 Tip, Cutting / Drag, Air, 40 Amp 8-7503
1 O-Ring 8-0532
1 Canted Coil Spring 9-7501
1 Adapter Fitting 1/4" Hose to 1/4" NPT 8-4264
1 Lubricant 8-4025
1 Box, Utility 8-3141
1 Standoff Guide 8-7575

Manual 0-2818 6-13 P ARTS LISTS

P ARTS LISTS 6-14 Manual 0-2818

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF

OPERATION BLOCK DIAGRAM

LATCH

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on.

Pilot relay closes.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator blinks for 8
seconds then steady on.

Fans on.

Power circuit ready.

RUN/SET/LATCH switch

gas flows to set pressure.

PILOT ARC

ACTION

to SET.

RESULT

Gas solenoid open,

GAS indicator on.

ACTION

RUN/SET/LATCH

switch to RUN.

RESULT

Gas flow stops.

GAS indicator off.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc automatically

restarts.

ACTION

Torch moved within

ACTION

Torch deactivated (by torch switch

release or by remote device).

RESULT

(Power supply enable signal removed.)

post-flow, pilot arc will immediately restart.

If torch is within transfer distance (3/8 in) of

Gas solenoid closes, gas flow stops.

Main arc stops.

Gas flows (15 seconds)

NOTE - If torch is activated during

workpiece, main arc will transfer.

After post-flow:

GAS indicator off.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply fans off.

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

ACTION

Open external

disconnect.

RESULT

No power to system.

ACTION

Torch Switch

can be released.

RESULT

Transfer will continue

until torch is removed

from workpiece.

A-02461

Manual 0-2818 A-1 APPENDIX

y

or

T o Torch

C

d

P

O

APPENDIX 2: TORCH CONTROL CABLE WIRING

ontrol Device

DIAGRAM FOR MECHANIZED SYSTEMS

Torch Control

Cable

Torch Control

Connectors

Control Shield

Connector

Control Connector

Plug with Connectors

To Power Suppl

Control Connect

Shield

Return

ower Supply

Control

K-To-Move

Relay

A-02821

12
14

Torch Lead

Assembly

Mate & Lock

2

1

3

4

Connectors

Lead Shield

Connector

Torch Leads

Connectors only on

Shielded Leads

Mate & Lock

Connectors

Torch Head

PIP Pin

Shield Cup

PIP Pin

3
4

12

OK-To-Move

14

Art # A-02801

Control

13

Torch Control

Cable Connector

Remote Pendant/CNC

13

Pendant Groun

Cable Connector

APPENDIX A-2 Manual 0-2818

This Page Left Blank

Manual 0-2818 A-3 APPENDIX

Electrode

APPENDIX 3: GENERAL APPLICATION NOTES

A. Electrode Selection

There are two SureLok Electrodes, General Purpose and MaximumLife. The information in this section is to help
determine which electrode to use for best performance.

General Purpose SureLok

Electrode (Catalog No. 9-8402)

• General Purpose- Good performance with all systems.

• Design of electrode is similar to previous designed electrodes used in the PCH & M - 60, 75, 76, 80, and 100XL
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 SureLok RPT Replacement Torches
providing good all around characteristics and performance.

MaximumLife SureLok Electrode (Catalog No. 9-8407)

• New innovative patented “fluted” design.

• Fluted design optimizes electrode cooling in most applications resulting in a significant improvement in
consumable parts life.

Suggested Applications

System

CutMas ter 75 Opt i onal Sugges t ed
CutMas ter 80XL Sugges t ed Optional
CutMas ter 100 Optional S ugges t ed
Pak M as ter 75XL Plus Optional Sugges t ed
Pak M as ter 100XL Plus Optional Sugges t ed
CE P ak M as t er 75XL Plus Sugges t ed Optional
CE P ak M as t er 100XL Plus S uggested Opt i onal

General Purpose
Ca ta log # 9-8402

MaximumLife

Catalog # 9-8407

APPENDIX A-4 Manual 0-2818

B. Hand Cutting Versus Machine (Mechanized) Cutting Speeds

7

A-0294

Hand Cutting Speeds

(Shaded Area)

Machine Cutting

Speeds

Speed

Material Thickness

Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand
cutting application speeds mostly depend on operator experience. The cut quality obtained at slower speeds for a
Hand application is just as good as those obtained from a Machine application. As the cut speeds increase or de­crease from the Machine applications the following may occur:

• If cut speed is too fast the cut may exhibit one or more of the following: Insufficient Penetration, High Speed
Dross, Poor Consumable Life, Excessive Bevel Angle.

• If cut speed is too slow the cut may exhibit one or more of the following: Main Arc Extinguishes, Slow Speed
Dross, Wandering (Unstable) Arc, Poor Consumable Life.

C. Frequently Asked Questions

Q. What Electrode can be used?

A. Only SureLok Electrodes, 9-8402 and 9-8407 may be used. Depending on the application and power supply

the General Purpose Electrode (9-8402) provides good all around characteristics and performance. The
MaximumLife Electrode (9-8407) design offers improved electr ode cooling resulting in a significant improve­ment in parts life.

Q. Which Tip can be used?

A. All the Tips listed on the Appendix Page for the selected Power Supply application can be used. Select the

proper T ip for the desired application. It is r ecommended to use the Cutting / Drag T ip for general purpose
drag and light cutting applications. The Gouging Tip is recommended for gouging applications only. The
Standoff T ip can be used for standoff cutting applications for improved cut quality and speed.

Q. What if Electrode parts life is low?

A. Try using the MaximumLife Electrode.

Manual 0-2818 A-5 APPENDIX

C

APPENDIX 4: CUTMASTER 75 SYSTEM DATA

Torch Specifica tions For

CutMaste r 75 Pow er Supply

Cutti ng Ra nge

Material Most Metals

Up to 3/4 inch (19 mm )

Speed 9 ipm (0.23 mpm)

Pierce Rating

Materi al Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance
Gouging

Wi dt h 3/16 i nch (4.76 mm)
Depth 1/8 inch (3.18 mm)

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Materi al Thic kness 1/2 inc h (13 mm)

Gas Requirem ent

Type Gas Air

Operating P ressure 70 ps i (4.8 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

1/4 inch (6.3 mm)

400 scfh (190 lpm)

Cut Quality on Various Materials and

Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

3/4 inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

tip orifice diameter), some dross (easily removed),
medium-smooth cut surface, slight top edge round­ing.

Consumable M atr i x For CutM aster 75

Application Electrode Gas Distributor Tip Shi eld Cup

Drag Cut ting 9-8407 8-7501 8-7503 8-7500

utting (without S tandoff Cup) 9-8407 8-7501

Cutt i ng (with Standoff Cup) 9-8407 8-7501 9-7726 8-7500

Gouging 9-8407 8-7508 8-7506 8-7500

APPENDIX A-6 Manual 0-2818

8-7503 (40A)

or 9-7726 (60A)

8-7500

Plasma Gas Press

Plasma Gas Pr ess

Plasma Gas Pr ess

Cutting Speed Charts

Air Plasma Cutting Speed Data Chart For CutMaster 75
Type Torch: PCM-102 Type Material: Aluminum
Ty p e Plasma G as : A ir Type Secondar y G as: Single G as Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff

Inches

0.06 1.3 9-7726 100 60 370 9.40 0.19 4.8 70 4.8 80 387 0 0.19 4.8

0.102 2.6 9-7726 103 60 195 4.95 0.1 9 4.8 70 4.8 80 387 0 0.19 4.8
1/4 6.4 9-7726 106 60 96 2.44 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/8 9.5 9-7726 111 60 52 1.32 0.19 4.8 70 4.8 80 387 0 0.19 4.8

1/2 12.7 9-7726 112 60 26 0.66 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/4 19.1 9-7726 117 60 12 0.30 0.19 4.8 70 4.8 80 387 NR 0.19 4.8

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

Air Plasma Cu tting Speed Data Chart For CutMaster 75
Ty p e Torc h : PCM - 102 T ype Material: Mi l d Stee l
Ty p e Plasma G as : A ir Typ e Secondary G as: Single Gas Torch

Thickness Tip Output Volts Am perage Speed (Per Minute) Standoff

Inches

0.06 1.3 9-7726 95 60 350 8.89 0.19 4.8 70 4.8 80 387 0 0.19 4.8

0.102 2.6 9-7726 98 60 175 4.45 0.19 4.8 70 4.8 80 387 0 0.19 4.8
1/4 6.4 9-7726 102 60 80 2.03 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/8 9.5 9-7726 109 60 44 1.12 0.19 4.8 70 4.8 80 387 0 0.19 4.8

1/2 12.7 9-7726 115 60 23 0.58 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/4 19.1 9-7726 117 60 11 0.28 0.19 4.8 70 4.8 80 387 NR 0.19 4.8

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

Flow (SCFH) Pierce Pierce Height

Flow (SCFH) Pierce Pierce Height

Air Plasma Cutting Speed Data Chart For CutMaster 75
Ty p e Torc h : PCM - 102 Type Mater i al: Stainless S t e el
Ty p e Plasma G as : Air T ype Seco ndary Gas: Si ngle G as Torch

Thickness Tip Output Volts Am perage Speed (Per Minute) Standoff

Inches

0.06 1.3 9-7726 95 60 350 8.89 0.19 4.8 70 4.8 80 387 0 0.19 4.8

0.102 2.6 9-7726 98 60 162 4.11 0.19 4.8 70 4.8 80 387 0 0.19 4.8
1/4 6.4 9-7726 102 60 74 1.88 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/8 9.5 9-7726 109 60 37 0.94 0.19 4.8 70 4.8 80 387 0 0.19 4.8

1/2 12.7 9-7726 115 60 17 0.43 0.19 4.8 70 4.8 80 387 0 0.19 4.8
3/4 19.1 9-7726 117 60 9 0.23 0.19 4.8 70 4.8 80 387 NR 0.19 4.8

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

Flow (SCFH) Pierce Pierce Height

Manual 0-2818 A-7 APPENDIX

APPENDIX 5: CUTMASTER 80XL SYSTEM DATA

Torch Specifica tions For

CutMaste r 80XL Power Supply

Cutti ng Ra nge

Material Most Metals

Up to 7/ 8 inch (22.2 mm)

Speed 10 ipm (0. 25 m pm)

Pierce Rating

Materi al Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance
Gouging

Wi dt h 3/16 i nch (4.76 mm)
Depth 1/8 inch (3.18 mm)

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Materi al Thic kness 1/2 inc h (13 m m )

Gas Requirem ent

Type Gas Air

Operating P ressure 60 ps i (4.1 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

310 scfh (146 lpm)

Cut Quality on Various Materials and

Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

3/4 inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

Consumable Matrix For CutMaster 80XL

Application Electrode Ga s Distri butor Tip Shi eld Cup

Drag Cutting 9-8402 8-7501 8-7503 8-7500

9-8402 8-7501 9-7726 8-7500

Cutti ng (wit h Standoff Cup) 9-8402 8-7501 9-7726 8-7507

Gouging 9-8402 8-7508 8-7506 8-7500

APPENDIX A-8 Manual 0-2818

Plasma Gas Press

Cutting Speed Charts

Air Plasma Cutting Speed Data Chart For CutMaster 80XL
Ty p e Torch: PC M - 10 2 Type Material: A l umin um
Ty p e Plasma Ga s: A i r T ype Seco ndary G as : S ing l e Gas To r ch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/16 1.6 9-7 726
1/8 3.2 9-7 726
1/4 6.4 9-7 726
1/2 12.7 9-7 726

Thickness Tip Output Volts Amperage Speed (Per M inute) Standoff

Inches

1/16 1.6 9-7726
1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
3/4 19.1 9-7726

1 25.4 9-7726

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 60 375 9.53 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 225 5.72 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 90 2.29 0.188 4.8 60 4.1 50 275 0.15 0.25 6.4
100 60 30 0.76 0.188 4.8 60 4.1 50 275 NA NA NA

Air Plasma Cutting Speed Data Chart For CutMaster 80XL
Type Torch: PCM-102 Type Material: Mild S teel
T yp e P l a sm a G as: Air Type Seco ndary G as: Single Gas Torch

Flow (SCFH) Pierce Pierce Height

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 60 300 7.62 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4

95 60 145 3.68 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 65 1.65 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 45 1.14 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 22 0.56 0.188 4.8 60 4.1 50 275 0.50 0.25 6.4
115 60 10 0.25 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 5 0.13 0.188 4.8 60 4.1 50 275 NA NA NA

Ai r Plasma C u ttin g Spee d Data C hart F or Cu t M ast er 80XL
Type To r ch: PC M - 10 2 Typ e M at e rial: S ta i nless St ee l
Type Plasm a G as: A ir Typ e S e cond ary G as: Single Gas Torch

Thickness Tip Output Volts Amperage Spee d (Per Mi nute) Standoff Pl asma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
5/8 15.9 9-7726
3/4 19.1 9-7726

(Cat. No.) (V DC) (Amps) Inches M eters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

95 60 130 3.30 0.188 4.8 60 4.1 50 275 0.25 0.20 5.1
100 60 45 1.14 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
100 60 25 0.64 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
105 60 16 0.41 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 12 0.30 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 8 0.20 0.188 4.8 60 4.1 50 275 NA NA NA

Manual 0-2818 A-9 APPENDIX

C

APPENDIX 6: CUTMASTER 100 SYSTEM DATA

Torch Specifica tions For

CutMaste r 100 Power Supply

Cutti ng Ra nge

Material Most Metals

Up to 1 inch (25.4 mm )

Speed 10 ipm (0. 25 m pm)

Pierce Rating

Materi al Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance
Gouging

Width 1/4 inch (6.3 mm)
Depth 3/16 inch (4.8 mm)

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Materi al Thic kness 1/2 inc h (12.7 m m )

Gas Requirem ent

Type Gas Air

Operating P ressure 70 ps i (4.8 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

400 scfh (190 lpm)

Cut Quality on Various Materials and

Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

one inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

Consumable Matr i x For CutM aster 100

Application Electrode Ga s Distri butor Tip Shield Cup

Drag Cutting 9-8407 8-7501 8-7503 8-7500

utt i ng (wit hout S tandoff Cup) 9-8407 8-7501 8-7503 (40A) or 9-7728 (80A) 8-7500

Cutt ing (wit h Standoff Cup) 9-8407 8-7501 9-7728 8-7500

Gouging 9-8407 8-7508 8-7506 8-7500

APPENDIX A-10 Manual 0-2818

Plasma Gas Press

Cutting Speed Charts

Plasma Gas Press

Air Plasma Cu tting Speed Data Chart For CutMaster 100
Type Torch: PCM-102 Type Material: Aluminum
T ype Plasma Gas: Air Type Second ary Gas: Sin gle G as Torc h

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff

Inches

0.05 1.3 9-7728

0.102 2.6 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728

1/2 12.7 9-7728 112 80 45
3/4 19.1 9-7728 117 80 21

1 25.4 9-7728 120 80 13

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 80 373 9.47 0.19 4.83 70 4.8 47 387 0 0.19 4.83
103 80 253 6.43 0.19 4.83 70 4.8 47 387 0 0.19 4.83
106 80 135 3.43 0.19 4.83 70 4.8 47 387 0 0.19 4.83
111 80 66 1.68 0.19 4.83 70 4.8 47 387 0 0.19 4.83

1.14 0.19 4.83

0.53 0.19 4.83

0.33 0.19 4.83

Ai r Plasma C utting S peed D at a Chart For C utMaster 100
Type Torch: PCM-102 Type Material: Mild Steel
Type Plasm a G as: Air Type Seco ndary G as: Sin gle Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Sta ndof f

Inches

0.05 1.3 9-7728

0.134 3.4 9-772 8
1/4 6.4 9-7728
3/8 9.5 9-7728

1/2 12.7 9-7728 112 80 38
3/4 19.1 9-7728 117 80 18

1 25.4 9-7728 120 80 10

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 80 350 8.89 0.19 4.83 70 4.8 47 387 0 0.19 4.83
103 80 230 5.84 0.19 4.83 70 4.8 47 387 0 0.19 4.83
106 80 112 2.84 0.19 4.83 70 4.8 47 387 0 0.19 4.83
111 80 55 1.40 0.19 4.83 70 4.8 47 387 0 0.19 4.83

0.97 0.19 4.83

0.46 0.19 4.83

0.25 0.19 4.83

70
70
70

70
70
70

Flow (SCFH) Pierce Pierce Height

4.8 47

4.8 47

4.8 47

4.8 47

4.8 47

4.8 47

387 0
387 NR
387 NR

Flow (SCFH) Pierce Pierce Height

387 0
387 NR
387 NR

0.19 4.83

0.19 4.83

0.19 4.83

0.19 4.83

0.19 4.83

0.19 4.83

Thickness Tip Output V olts Amperage Speed (Per Minute ) Standoff Plasma Gas Press Flow ( SCFH) Pierce Pierce Heig ht

Inches

0.05 1.3 9-7728

0.134 3.4 9-77 28
1/4 6.4 9-7728
3/8 9.5 9-7728

1/2 12.7 9-7728 112 80 30
3/4 19.1 9-7728 117 80 14

1 25.4 9-7728 120 80 10

Air Plasma Cutting Sp eed Data Chart For Cu tMaster 100
Ty pe To r ch: PCM-102 Type Materi a l : Stai nless Steel
Ty p e P lasma Gas: A i r Typ e S econd ary Gas: Single Gas T orch

(Cat. N o.) (VDC) (Amps) Inches Meters Inches mm psi bar Plas ma Total Delay (S ec) Inches mm

mm

100 80 350 8.89 0.19 4.83 70 4.8 47 387 0 0.19 4.83
103 80 230 5.84 0.19 4.83 70 4.8 47 387 0 0.19 4.83
106 80 110 2.79 0.19 4.83 70 4.8 47 387 0 0.19 4.83
111 80 48 1.22 0.19 4.83 70 4.8 47 387 0 0.19 4.83

0.76 0.19 4.83

0.36 0.19 4.83

0.25 0.19 4.83

70
70
70

4.8 47

4.8 47

4.8 47

387 0
387 NR
387 NR

0.19 4.83

0.19 4.83

0.19 4.83

Manual 0-2818 A-11 APPENDIX

APPENDIX 7: PAK MASTER 75XL PLUS SYSTEM DATA

Torch Specifica tions For

Pa k Ma ster 75XL Pl us Powe r S upply

Cutti ng Ra nge

Material Most Metals

Up to 3/4 inch (19 mm )

Speed 10 ipm (0. 25 m pm)

Pierce Rating

Materi al Carbon St eel

Thickness 3/8 inch (9.5 mm)

Transfer Distance
Gouging

Width 1/8 inch (3.2 mm)
Depth 1/8 inch (3.2 mm)

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Material Thickness 1/4 inch (6.3 mm)

Gas Requirem ent

Type Gas Air

Operating P ressure 60 ps i (4.1 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

300 scfh (142 lpm)

Cut Quality on Various Materials and Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

3/4 inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

NOTE

For CE Applications refer to Appendix 9.

Consumabl e Matri x For Pak Master 75XL Pl us

Application Electrode Gas Distri butor Tip Shi eld Cup

Drag Cutti ng 9-8407 8-7501 8-7503 8-7500

Cutt ing (without Standoff Cup) 9-8407 8-7501 9-7726 8-7500

Cutt ing (with Standoff Cup) 9-8407 8-7501 9-7726 8-7507

Gouging 9-8407 8-7508 8-7506 8-7500

APPENDIX A-12 Manual 0-2818

Plasma Gas Press

Cutting Speed Charts

Air P l asma C utting Speed D at a Chart Fo r P A K Master 75XL Plus
Ty p e Torch: PC M - 10 2 Type Mater i al : Alu m i num
Ty p e Plasma Ga s: A ir Type Seco ndary G as : S ing l e Gas To r ch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/16 1.6 9-7 726
1/8 3.2 9-7 726
1/4 6.4 9-7 726
1/2 12.7 9-7 726

Thickness Tip Output Volts Amperage Speed (Per M inute) Standoff

Inches

1/16 1.6 9-7726
1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
3/4 19.1 9-7726

1 25.4 9-7726

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 60 375 9.53 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 225 5.72 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 90 2.29 0.188 4.8 60 4.1 50 275 0.15 0.25 6.4
100 60 30 0.76 0.188 4.8 60 4.1 50 275 NA NA NA

Air Plasma Cutting Speed Data Chart For PAK Master 75XL Plus

Type To rch: P CM- 102 Type Material: Mild Steel
T yp e P l a sm a G as: Air Type Seco ndary G as: Single Gas Torch

Flow (SCFH) Pierce Pierce Height

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 60 300 7.62 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4

95 60 145 3.68 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 65 1.65 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 45 1.14 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 22 0.56 0.188 4.8 60 4.1 50 275 0.50 0.25 6.4
115 60 10 0.25 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 5 0.13 0.188 4.8 60 4.1 50 275 NA NA NA

Air Plasma Cutting Speed Data Chart For PAK Master 75XL Plus
Type To r ch: PC M - 10 2 Typ e M at e rial: S ta i nless St ee l
Type Plasm a G as: A ir Typ e S e cond ary G as: Single Gas Torch

Thickness Tip Output Volts Amperage Spee d (Per Mi nute) Standoff Pl asma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
5/8 15.9 9-7726
3/4 19.1 9-7726

(Cat. No.) (V DC) (Amps) Inches M eters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

95 60 130 3.30 0.188 4.8 60 4.1 50 275 0.25 0.20 5.1
100 60 45 1.14 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
100 60 25 0.64 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
105 60 16 0.41 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 12 0.30 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 8 0.20 0.188 4.8 60 4.1 50 275 NA NA NA

Manual 0-2818 A-13 APPENDIX

APPENDIX 8: PAK MASTER 100XL PLUS SYSTEM DATA

Torch Specifica tions For

CE Pa k Ma ster 100XL Plus Powe r S uppl y

Cutti ng Ra nge

Material Most Metals

Up to 1 inch (25.4 mm )

Speed 6 ipm (0.15 mpm)

Pierce Rating

Materi al Carbon St eel

Distance 3/8 inc h (9.5 mm)

Transfer Distance
Gouging

Width 1/4 inch (6.3 mm)
Depth 3/16 inc h (4. 76 m m )

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Materi al Thic kness 1/2 inc h (13 m m )

Gas Requirem ent

Type Gas Air

Operating P ressure 70 ps i (4.8 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

400 scfh (190 lpm)

Cut Quality on Various Materials and Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

one inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

NOTE

For CE Applications refer to Appendix 10.

Consumable M a t rix For Pak Maste r 10 0XL Plus

Application Electrode Gas Distributor Tip Shie l d Cup

Drag Cutt i ng 9-8407 8-7501 8-7503 8-7500

Cutt ing (without Standoff Cup) 9-8407 8 -7501 9-7726 (60A) or 9-7728 (80A) 8-7500

Cutt ing (with S tandoff Cup) 9-8407 8 -7501 9-7726 (60A) or 9-7728 (80A) 8-7507

Gouging 9-8407 8-7508 8-7506 8-7500

APPENDIX A-14 Manual 0-2818

Plasma Gas Press

Plasma Gas Press

Plasma Gas Press

Cutting Speed Charts

Air Plasma Cutting Speed Data Chart For PAK Master 100XL Plus
Type Torch: PCM-102 Type Material: Aluminum
T ype Plasm a G a s: A i r Type S econd ar y G as: Single Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff

Inches

1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff

Inches

1/16 1.6 9-7728
1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

1 25.4 9-7728

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

105 80 225 5.72 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
105 80 115 2.29 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
110 80 60 0.76 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
120 80 30 0.76 0.188 4.8 70 4.8 85 365 NA NA NA
125 80 10 0.25 0.188 4.8 70 4.8 85 365 NA NA NA

Air Plasma Cutting Speed Data Chart For PAK Master 100XL Plus
Type Torch: PCM-102 Type Material: Mild Steel
T ype Plasm a G a s: A i r Type S econd ar y G as: Single Gas Torch

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 80 400 1 0.16 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
105 80 180 4.57 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 90 2.29 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 50 1.27 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
110 80 30 0.76 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
120 80 12 0.30 0.188 4.8 70 4.8 85 365 NA NA NA
120 80 6 0.15 0.188 4.8 70 4.8 85 365 NA NA NA

Flow (SCFH) Pierce Pierce Height

Flow (SCFH) Pierce Pierce Height

Air Plasma Cutting Speed Data Chart For PAK Master 100XL Plus
T ype To r ch: PC M - 102 Type Mater i al : Stain less Steel
T ype Plasm a G a s: A i r Type S econd ar y Gas: Si ngle G a s Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Sta ndoff

Inches

1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm ps i bar Plasma Total Delay (Sec) Inches mm

mm

105 80 150 3.81 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 75 1.91 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 40 1.02 0.188 4.8 70 4.8 85 365 0.2 0.20 5.1
110 80 18 0.46 0.188 4.8 70 4.8 85 365 NA NA NA
125 80 10 0.25 0.188 4.8 70 4.8 85 365 NA NA NA

Flow (SCFH) Pierce Pierce Height

Manual 0-2818 A-15 APPENDIX

APPENDIX 9: CE PAK MASTER 75XL PLUS SYSTEM DATA

Torch Specifica tions For

CE P ak Master 75XL Plus Powe r Suppl y

Cutti ng Ra nge

Material Most Metals

Up to 3/4 inch (19 mm )

Speed 10 ipm (0. 25 m pm)

Pierce Rating

Materi al Carbon St eel

Distance 3/8 inc h (9.5 mm)

Transfer Distance
Gouging

Width 1/8 inch (3.2 mm)
Depth 1/8 inch (3.2 mm)

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Material Thickness 1/4 inch (6.3 mm)

Gas Requirem ent

Type Gas Air

Operating P ressure 60 ps i (4.1 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

300 scfh (142 lpm)

Cut Quality on Various Materials and

Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

3/4 inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

NOTE

For Non- CE Applications refer to Appendix 7.

Consumable Matrix For CE Pak Master 75XL Plus

Application Electrode Gas Distributor Tip Shield Cup

Drag Cutting 9-8402 8-7501 8-7503 8-7500

Cutt ing (without S tandoff Cup) 9-8402 8-7501 9-7726 8-7500

Cutt i n g (wit h Standoff Cup) 9-8402 8-7501 9-7726 8-7507

Gouging 9-8402 8-7508 8-7506 8-7500

APPENDIX A-16 Manual 0-2818

Plasma Gas Press

Plasma Gas Press

Plasma Gas Press

Cutting Speed Charts

Air Plasma Cu tting Speed Data Chart For CE PAK Master 75XL Plus
Type Torch: PCM-102 Type Material: Aluminum
T yp e Plasma G as: Air T ype Seco ndary Gas: Si ngl e G as Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff

Inches

1/16 1.6 9-7 726
1/8 3.2 9-7 726
1/4 6.4 9-7 726
1/2 12.7 9-7 726

Thickness Tip Output Volts Amperage Speed (Per M inute) Standoff

Inches

1/16 1.6 9-7726
1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
3/4 19.1 9-7726

1 25.4 9-7726

(Cat. No.) (VDC) (Amps) I nches Meters Inches mm psi bar Plasma Total Delay (S ec) Inches mm

mm

100 60 375 9.53 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 225 5.72 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4
100 60 90 2.29 0.188 4.8 60 4.1 50 275 0.15 0.25 6.4
100 60 30 0.76 0.188 4.8 60 4.1 50 275 NA NA NA

Ai r P lasma Cu ttin g Spee d Data C hart F or CE P AK Mast er 75XL Plus
Type Torch: PCM-102 Type Material: Mild S teel
T yp e P l a sm a G as: Air Type Seco ndary G as: Single Gas Torch

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

100 60 300 7.62 0.188 4.8 60 4.1 50 275 0.10 0.25 6.4

95 60 145 3.68 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 65 1.65 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 45 1.14 0.188 4.8 60 4.1 50 275 0.25 0.25 6.4
105 60 22 0.56 0.188 4.8 60 4.1 50 275 0.50 0.25 6.4
115 60 10 0.25 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 5 0.13 0.188 4.8 60 4.1 50 275 NA NA NA

Flow (SCFH) Pierce Pierce Height

Flow (SCFH) Pierce Pierce Height

Ai r Plasma C u ttin g Spee d Data C hart F or CE P AK Mast er 75XL Plus
Ty p e Torch: PCM-102 Typ e Material: Stainless St eel
Ty p e Plasma G as: Air Type Seco ndary G as: Sin gle Gas Torch

Thickness Tip Output Volts Amperage Spe ed (Per Minute) Standoff

Inches

1/8 3.2 9-7726
1/4 6.4 9-7726
3/8 9.5 9-7726
1/2 12.7 9-7726
5/8 15.9 9-7726
3/4 19.1 9-7726

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

mm

95 60 130 3.30 0.188 4.8 60 4.1 50 275 0.25 0.20 5.1
100 60 45 1.14 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
100 60 25 0.64 0.188 4.8 60 4.1 50 275 0.50 0.20 5.1
105 60 16 0.41 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 12 0.30 0.188 4.8 60 4.1 50 275 NA NA NA
115 60 8 0.20 0.188 4.8 60 4.1 50 275 NA NA NA

Flow (SCFH) Pierce Pierce Height

Manual 0-2818 A-17 APPENDIX

APPENDIX 10: CE PAK MASTER 100XL PLUS SYSTEM

DAT A

Torch Specifica tions For

CE Pa k Ma ster 100XL Plus Powe r S uppl y

Cutti ng Ra nge

Material Most Metals

Up to 1 inch (25.4 mm )

Speed 6 ipm (0.15 mpm)

Pierce Rating

Materi al Carbon St eel

Distance 3/8 inc h (9.5 mm)

Transfer Distance
Gouging

Width 1/4 inch (6.3 mm)
Depth 3/16 inc h (4. 76 m m )

Number Pas ses S i ngle

Speed 20 ipm (0.5 mpm)

Bevel Cut Capability

Degrees 0° to 45°

Materi al Thic kness 1/2 inc h (13 m m )

Gas Requirem ent

Type Gas Air

Operating P ressure 70 ps i (4.8 bar)

Max Input P ressure 125 psi (8.6 bar)

Cutt ing & G ouging

Tota l Flow

3/8 inch (9.5 mm)

400 scfh (190 lpm)

Cut Quality on Various Materials and

Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gage

to

one inch

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

Carbon Stee l Air Go od - Excellent

Stainless Air Good - Excellent

Aluminum Air Good - Excellent

orifice diameter), little or no dross, smooth cut
surface.

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge rounding.

NOTE

For Non- CE Applications refer to Appendix 8.

Consumable Matrix For CE Pak Master 100XL Plus

Application Electrode Gas Di stributor Tip Shi e ld Cup

Drag C ut ting 9-8402 8-7 50 1 8-750 3 8-750 0

Cutting (without Standoff Cup) 9-8402 8-7501 9-7726 (60A ) or 9-7728 (80A) 8-7500

Cutting (with S t andoff Cup) 9-8402 8-7501 9-7726 (60A) or 9-7728 (80A) 8-7507

Gouging 9-8402 8-7508 8-7506 8-7500

APPENDIX A-18 Manual 0-2818

Cutting Speed Charts

Ai r Plasma C utting S peed D at a Chart For CE PAK Mast er 10 0XL P l us
Type Torch: PCM-102 Type Material: Aluminum
T yp e Plasma Gas : Air Type Seco ndary Gas: Si ngle Gas To rc h

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/16 1.6 9-7728
1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

1 25.4 9-7728

(Cat. No.) (VDC) (Amps ) Inches Meters Inches mm psi bar Plasma Total Delay (S ec) Inches mm

mm

105 80 225 5.72 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
105 80 115 2.29 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
110 80 60 0.76 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
120 80 30 0.76 0.188 4.8 70 4.8 85 365 NA NA NA
125 80 10 0.25 0.188 4.8 70 4.8 85 365 NA NA NA

Ai r Plasma C utting S peed D at a Chart For CE PAK Mast er 100XL P l us
T yp e Torch : PCM - 102 Type Material: Mi ld St ee l
T yp e Plasma Gas : Air Type Seco ndary Gas: Si ngle Gas To rc h

(Cat. No.) (VDC) (Amps ) Inches Meters Inches mm psi bar Plasma Total Delay (S ec) Inches mm

mm

100 80 400 10.16 0.188 4.8 70 4.8 85 365 0.0 0.20 5.1
105 80 180 4.57 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 90 2.29 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 50 1.27 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
110 80 30 0.76 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
120 80 12 0.30 0.188 4.8 70 4.8 85 365 NA NA NA
120 80 6 0.15 0.188 4.8 70 4.8 85 365 NA NA NA

Ai r Plasma C utting S peed D at a Chart For CE PAK Mast er 10 0XL P l us
T yp e Torch : PCM - 102 Type Material: S t ai nless Steel
T yp e P lasma Gas: Air Type Seco ndary Gas: Si ngle Gas To rc h

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches

1/8 3.2 9-7728
1/4 6.4 9-7728
3/8 9.5 9-7728
1/2 12.7 9-7728
3/4 19.1 9-7728

(Cat. No.) (VDC) (Amps ) Inches Meters Inches mm psi bar Plasm a Total Delay (Sec) Inches mm

mm

105 80 150 3.81 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 75 1.91 0.188 4.8 70 4.8 85 365 0.1 0.20 5.1
105 80 40 1.02 0.188 4.8 70 4.8 85 365 0.2 0.20 5.1
110 80 18 0.46 0.188 4.8 70 4.8 85 365 NA NA NA
125 80 10 0.25 0.188 4.8 70 4.8 85 365 NA NA NA

Manual 0-2818 A-19 APPENDIX

APPENDIX 11: TORCH CONNECTION DIAGRAMS

ly

y
or

T o Torch

C

Hand Torch Connection:

Hand Torch and Leads

Torch Head

PIP

Contacts

Torch

Switch

Pilot

Art # A-03863

MachiineTorch Connection:

ontrol Device

Torch Control

Cable

Torch Leads

Black

Orange

Green

White

Negative / Plasma

Torch Control

Connectors

Power Supply

Adapter

Pilot

Control Connector

Plug with Connectors

Power Supp

Bulkhead

To Power Suppl

Control Connect

Control Shield

Connector

Torch Lead

Assembly

Lead Shield

Connector

Connectors only on

Shielded Leads

Art # A-02801

APPENDIX A-20 Manual 0-2818