Tweco PCM-120 User Manual

Download

LIQUID COOLED

PLASMA CUTTING

TORCH

• Model PCH-120 Hand Torch

• Model PCM-120 Machine Torch

For Use With:

• PakMaster 150XL Power Supply

Instruction Manual

October 15, 2002 Manual No. 0-2698

WARNINGS

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

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

Liquid Cooled Plasma Cutting T o rch Model PCH-120 & PCM-120 Instruction Manual Number 0-2698

Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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 errors or omissions in this Manual, whether such errors result from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: October 15, 2002

Record the following information for W arranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and 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 W arranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION & DESCRIPTION.................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description ..................................................................................... 2-1

2.03 Specifications & Design F eatures................................................................. 2-1

2.05 Introduction to Plasma.................................................................................. 2-3

SECTION 3:

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

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

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

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

3.05 Connecting T orch ......................................................................................... 3-1

3.06 Setting Up Machine Torch ............................................................................ 3-2

3.07 Gas Selection............................................................................................... 3-2

3.08 Gas Connections ......................................................................................... 3-3

SECTION 4:

OPERATION ..................................................................................................................... 4-1

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

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

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

4.04 Torch Parts Selection ................................................................................... 4-1

4.05 Cut Quality ................................................................................................... 4-3

4.06 Operating the System .................................................................................. 4-4

4.07 Hand T orch Operation .................................................................................. 4-5

4.08 Machine T orch Oper ation ............................................................................. 4-6

4.09 Recommended Cutting Speeds.................................................................... 4-8

4.10 Gouging ....................................................................................................... 4-8

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE................................................................................. 5-1

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

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

5.03 Common Operating F aults ........................................................................... 5-2

5.04 Inspection and Replacement Consumable Torch Parts ................................ 5-2

5.05 Troubleshooting Guide ................................................................................. 5-4

5.06 Servicing Hand T orch Components.............................................................. 5-6

5.07 Servicing Machine Torch Components ......................................................... 5-7

5.08 T orch And Leads Troubleshooting ................................................................ 5-8

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

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

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

6.03 Replacement Hand Torch Parts.................................................................... 6-2

6.04 Replacement Machine Torch Parts............................................................... 6-4

6.05 T orch Lead Component Replacement P arts (Unshielded Leads Only)......... 6-6

6.06 Complete Assembly Replacements.............................................................. 6-8

6.07 Spare Parts Kits ........................................................................................... 6-9

6.08 Options and Accessories........................................................................... 6-10

APPENDIX 1: CUTTING SPEED CHAR T S ..............................................................................A-1

APPENDIX 2: SEQUENCE OF OPERATION BLOCK DIAGRAM............................................. A-6

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

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

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different pr ocesses. Y ou must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

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

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

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

Date: No v ember 15, 2001 1-1 GENERAL INFORMATION

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

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

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

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

NOISE

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

• To protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others in the workplace.

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

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

PLASMA ARC RA YS

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

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

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

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

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

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

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

1.03 Publications

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

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

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

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

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND 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: Nov ember 15, 2001

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

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

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

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

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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

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

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

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

ATTENTION

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

AVERTISSEMENT

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

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

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

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

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

Date: No v ember 15, 2001 1-3 GENERAL INFORMATION

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votr e distributeur local si vous avez des questions.

FUMÉE et GAZ

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

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différ ents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

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

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

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

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

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

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

CHOC ELECTRIQUE

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

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

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

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

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE 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: Nov ember 15, 2001

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons

RAYONS D’ARC DE PLASMA

ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur . Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculair e.

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

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

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

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

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

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

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

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

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

BRUIT

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

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

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

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

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

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

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

Date: No v ember 15, 2001 1-5 GENERAL INFORMATION

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

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

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARA TION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requir ements. Among them are:

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

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

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

ated accessories.

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

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

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

Manufacturers responsible representative: Giorgio Bassi

Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy

Date: No v ember 15, 2001 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below , Thermal shall, upon notification thereof and substantiation that the product has been stor ed, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair , neglect, alteration, or accident, corr ect such defects by suitable r epair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

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

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

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

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

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

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

Parts

XL Plus & Parts Parts

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

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year Control PC Board 3 Y ears 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 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 char ges 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: Nov ember 15, 2001

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.03 Specifications & Design Features

The following applies to the Torch only:

A. Torch Configurations and Dimensions

2.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the PCH/M-120 Liquid Cooled Torch. 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 Torch is a liquid cooled torch that provides cutting capacity of up to 1-1/2 inches (38.1 mm) at 120 amperes. In the torch, one torch lead pr ovides plasma gas and one lead provides secondary gas to the torch head. The leads also provide the closed loop for the liquid coolant flow from the Power Supply.

1. Hand Torch (PCH) Torch is available with torch heads at 70° and 90°

to the torch handle. The hand torches include a torch handle and multi-position torch switch assembly.

2. Machine Torch (PCM) Machine T orch (180°) is supplied with a metal rack

and pinion mounting assembly , Remote ON/OFF Pendant (Unshielded Leads) or CNC Cable (Shielded Leads).

(35.6mm)

1.4 in.

14.3 in.

(363.2mm)

70˚

13.3 in.

(337mm)

3.3 in.

(83.8mm)

1.5 in.

(38.1mm)

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.

13.5 in.

(342.9mm)

3.5 in.

1.4 in.

(35.6mm)

3.4 in.

(86.4mm)

A-02683

90˚

17.4 in.

(44.2mm)

2.5 in.

(68.5mm)

1.5 in.(38.1mm)

(88.9mm)

1.5 in.

(38.1mm)

4.3 in.

(109.2mm)

1.9 in. (48.3mm)

180˚

Figure 2-1 Torch Dimensions and Configurations

Manual 0-2698 2-1 INTRODUCTION & DESCRIPTION

B. Torch Leads Lengths

2. Secondary

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

C. Cutting Range

Most materials up to 1- 1/2 inch (38.1 mm)

D. Pierce Rating

3/4 inch (19.05 mm)

E. Transfer Distance

3/8 inch (9.5 mm)

F. Torch Ratings

Torch Ratings

Ambient

Temperature

Duty Cy cle

Maximum Current

Volta ge (V

Arc Striking Voltag e

peak

)

100% @ 120 Amps @ 0.6 gpm

(2.3 lpm) Coolant Flow Rate

104° F

(40° C)

120 Amps

500V

12 kV

Gases: Compressed Air, Carbon Dioxide (CO2), Nitrogen (N2) only

Pressure: 60 psi (4.1 bar)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.62 bar)

Cold Flow:

Cutting: 340 scfh (160.4 lpm) Gouging: 235 scfh (110.9 lpm) scfh = standard cubic feet per hour

I. Plasma Power Supply Used With

• PakMaster 150XL

J. Weight

• Hand T orch

25 ft (7.6 m) Leads - 11.4 lbs (5.17 kg) 50 ft (15.2 m) Leads - 20.4 lbs (9.25 kg)

• Machine Torch

G. T o rch Parts

Gas Distributor , Electr ode, Tip, Shield Cup Water Tube Extension for Gouging Only

H. Gas Supply Requirements

1. Plasma

Gases: Compressed Air, Nitrogen (N2), Argon/ Hydrogen only

Pressure: 65 psi (4.5 bar)

CAUTION

Maximum input gas pressure must not exceed 125 psi (8.62 bar)

Cold Flow:

Cutting: 50-78 scfh (23.6-36.8 lpm) Gouging: 85-95 scfh (40.1-44.8 lpm) scfh = standard cubic feet per hour

25 ft (7.6 m) Leads - 12.8 lbs (5.81 kg) 50 ft (15.2 m) Leads - 20.8 lbs (9.43 kg)

NOTE

Cold flow is measured before the main arc is activated. When pressure is set correctly , the plasma gas flow rate is significantly lower when the arc is initiated.

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2698

2.05 Introduction to Plasma

A. Plasma Gas Flow

cut allowing for a fast, slag-free cut. Compressed air , supplied by either a cylinder , plant air system or CO is normally used as the secondary gas.

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 such as air or nitrogen (N2) enters Zone B (refer to Figure 2-2), where a pilot arc between the electrode and the tor ch tip heats and ionizes the gas. The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.

Power

Supply

Workpiece

Figure 2-2 Theory of Operation

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.

B. Secondary Gas Flow

Zone A (Figure 2-2) is where secondary gas flows to help cool the torch and and assist the high velocity plasma gas in blowing the molten metal out of the

A-00002

C. Coolant Flow

Liquid coolant is the primary means for cooling torch parts. The coolant flows from the coolant recir culator , through the coolant supply leads to the torch head and returns through the return coolant leads.

D. Gas Distribution

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

The secondary gas flows into the torch through the secondary gas hose, down around the outside of the torch gas distributor, and out between the tip and shield cup around the plasma arc.

E. Pilot Arc

When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work.

F. CD (Capacitive Discharge)

Because direct current (DC) alone is not sufficient to strike and maintain the pilot arc, high frequency is also used. The CD jumps between the tip and electrode with the DC following, then the CD turns off.

G. Main Cutting Arc

DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is connected to the workpiece via the work cable and to the torch through the plasma (+) lead.

H. Interlocks

T wo pr essur e switches act as an interlock for the gas supply. If supply pressure falls below minimum requirements the pressure switches will open, shutting off the power to the contactors, and the GAS indicator , if supplied, will go out. When adequate gas supply pressure is available the pressur e switches close, allowing power to be resumed for cutting.

A flow switch acts as an interlock for the closed loop coolant supply. If the flow switch does not activate, then the Power Supply will not power on. The flow switch will not activate if there is low coolant level, or if the front end torch parts (tip or electrode) are not installed.

Manual 0-2698 2-3 INTRODUCTION & DESCRIPTION

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2698

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

3.05 Connecting T orch

WARNING

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

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 components.

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Setting Up Torch

4. Connecting Torch

5. Gas Connections

6. Operator Training

3.02 Site Location

Select a clean, dry location with good ventilation and adequate working space around all components.

Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.

3.03 Unpacking

The Torch Leads must be properly installed to the Power Supply for proper operation. Make all torch connections to the Torch Bulkhead Panel per the following:

NOTE

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

1. Turn the two screw latches securing the fr ont ac-

cess panel to the power supply front panel.

Screw Latches

Access Panel

Torch Leads Shield Stud

Bulkhead

NOTE

Torches ordered as part of a system are factory assembled to the power supply and are pacckaged in one shipping carton.

Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping. Components are packaged as follows:

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify and account for each item.

3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping company before proceeding with system installation.

Manual 0-2698 3-1 INST ALLATION PR OCEDURES

Figure 3-2 Power Supply Front Access Panel

2. Lift up on the access panel to gain access to the torch bulkhead panel.

3. Feed the Control Cable Fitting through the rubber boot in the front panel.

NOTE

For hand torches, the Control Cable Fitting is part of the torch leads assembly. For machine torches, the Control Cable Fitting is separate from the torch and connects to either a Remote Hand Pendant or a CNC Computer or other device.

4. Feed the end of the torch leads through the rub-

ber boot in the front panel.

5. Connect Control Cable Fitting to Control Cable Connector .

A-02684

6. If installing a machine torch with shielded leads, complete the following:

a. Remove one nut and star washer from the

Torch leads Shield Stud.

b. Place the ring lug on the torch leads shield wire

over the stud and secure with nut and star washer .

7. Connect torch coolant and gas leads to connectors, as indicated on bulkhead.

8. Close the access panel and turn the two latching screws.

9. Connect the other end of the Control Cable to a CNC device, if applicable.

Rack and

Pinion Mounting

Assembly

Square

Plasma (+)

Gas

Secondary

Gas

Coolant

Supply (-)

A-02113

Torch Leads

Shield Stud

Control Cable

Connector

Coolant

Return

CNC Control

Cable

Shield Wire

With Ring Lug

Figure 3-3 Torch Leads Connections

3.06 Setting Up Machine Torch

WARNING

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

A-00660

Workpiece

Figure 3-4 Machine Torch Set-Up

3.07 Gas Selection

CAUTIONS

Maximum input gas pressure must not exceed 125 psi (8.6 bar)

Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.

The type of operation will determine the best gases to be used. Refer to the following and select the plasma and secondary gases that best fit the operation(s):

A. Plasma Gases

NOTE

A Metal Mounting Tube with Rack and Pinion Assembly is standard for machine torches. A Remote Hand Pendant is included with unshielded leads; a CNC Interface Cable is included with shielded leads.

1. Mount the torch assembly on the cutting table.

Refer to Section 2.03, Specifications & Design Features, for proper gas pressur e and flow rate.

1. Compressed Air Plasma

• Most often used on ferrous or carbon base materials to obtain good quality at faster cutting speeds.

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

• Air plasma is normally used with air secondary.

• Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substantially reduce torch parts life.

• Provides satisfactory results on non-ferrous materials.

INST ALLATION PROCEDURES 3-2 Manual 0-2698

2. Nitrogen (N2) Plasma

3. Nitrogen (N2) Secondary

• Provides cut quality similar to air on non-ferrous materials such as stainless steel and aluminum.

• Can be used in place of air plasma with air secondary or carbon dioxide (CO2).

• Provides much better parts life than air.

• A good clean welding grade nitrogen should be used.

3. Argon/Hydrogen (ArH

) Plasma

• Recommended for use on 3/4 inch (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) and thicker non-ferrous materials. Ar/H is not normally used for thinner non-ferrous materials because less expensive gases can achieve similar cut quality.

• Poor cut quality on ferrous materials.

• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher cost.

• A 65% argon/35% hydrogen mixture should be used.

B. Secondary Gases

NOTE

Refer to Section 2.03, Specifications & Design Features, for proper gas pressure and flow rate.

1. Compressed Air Secondary

• Nitrogen secondary is used with Ar/H2 plasma.

• Provides smooth finishes on non-ferrous materials.

• May be used with nitrogen plasma in order to operate from one compressed gas cylinder - but torch parts life may be shorter than with CO2 secondary.

• May reduce smoke when used with Ar/H2 plasma.

3.08 Gas Connections

A. Connecting to Power Supply

Connect the gases to the power supply as described in the power supply operating manual supplied with the power supply.

CAUTION

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 for 2-3 minutes. Any oil or moisture in the air will be visible on the lens. Do not initiate an arc!

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

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.

2. Carbon Dioxide (CO2) Secondary

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

• Provides good cooling and maximizes torch parts life.

• Provides good cut quality on ferrous or non-ferrous material.

• May reduce smoke when used with Ar/H2 plasma.

NOTE

When CO2 is used as the secondary gas, twenty (50 lb) cylinders must be manifolded together or a bulk CO2 system used to get the required flow rate of 340 scfh. Shop compressed air is a good alternative if providing the required CO2 flow rate is not feasible.

C. Filtering

An inline 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 contminants from the supply hose do not enter the torch. For highly automated applications,

a refrigerated drier may be used.

NOTE

Do not use an air line filter with high pressure gas cylinders.

Manual 0-2698 3-3 INST ALLATION PR OCEDURES

INST ALLATION PROCEDURES 3-4 Manual 0-2698

SECTION 4:

OPERATION

4.01 Introduction

This section provides a description of the Torch Assembly followed by operating procedures.

4.02 Functional Overview

The Torch is designed to operate with the PakMaster 150XL Plasma Power Supply to provide a cutting system which can cut most metals from gauge thickness up to 1-1/2 inches (38.1 mm). With a quick change of torch parts the torch can be used for plasma arc gouging.

4.03 Getting Started

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

E. Purge System

Place the Power Supply ON/OFF switch to the ON position. An automatic gas purge (pr e-flow) will remove any condensation that may have accumulated in the torch and leads while the system was shut down. The torch cannot be activated during the purge cycle (pre-flow). After the purge is complete, if the RUN/SET switch is in SET position, gas will flow . If the switch is in RUN position there will be no gas flow.

F. Current Output Level

At the Power Supply set the desired current output level to a maximum of 120 amperes.

G. Pressure Settings

Place the RUN/SET switch to the SET position. Adjust PLASMA gas pr essur e control to 65 psi (4.5 bar) and SECONDARY gas pr essure controls to 60 psi (4.1 bar).

H. Ready for Operation

WARNING

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

A. T or ch Parts

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

1. Check the power source for proper input voltage.

2. Make sure that the Power Supply is set for the proper input voltage (refer to Power Supply Operating Manual for connections).

3. Close main disconnect switch or plug unit in to supply primary power to the system.

C. Work Cable

Check for a solid work cable connection to the workpiece.

Return the RUN/SET switch to RUN position. The system is now ready for operation.

NOTE

Refer to Appendix 2 for a detailed block diagram of the Sequence of Operation.

4.04 Torch Parts Selection

Depending on the type of operation to be done (standoff cutting, drag cutting or gouging) determines the torch parts to be used.

Torch parts:

Shield Cup, Cutting Tip, Electrode, Gas Distributor, and Cooling T ube (Cooling Tube for Gouging Only).

Refer to Figure 4-1 for the various torch parts.

CAUTION

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma and secondary in use and the type of operation (cutting or gouging).

D. Gas Supplies

Select desired gas supplies. Make sure gas sources meet requirements (refer to Section 2.03, Specifications & Design Features and 3.07, Gas Selection). Check connections and turn gas supplies on.

Manual 0-2698 4-1 OPERA TION

Short Shield Cup

Standoff Cutting Only

Catalog No. 20-1225

Crown Shield Cup Standoff Cutting Only Catalog No. 20-1226

Gouging Shield Cup

Gouging Only

Catalog No. 20-1227

Cutting Tip Air/N2/AR-H2

0.031" Orifice, 35 amps Catalog No. 20-1220

Gouging Tip Air/N2/Ar-H2

0.110" Orifice

Catalog No. 20-1412

Cutting Electrode Air/N2

Catalog No. 20-1210

Gouging Electrode

Air/N2

Catalog No. 20-1404

Water Tube Extension

(Gouging)

3.35" (85 mm) Length

Cat No. 20-1402

Cutting Tip Air/N2/AR-H2

0.047" Orifice, 70 amps Catalog No. 20-1221

Gouging Tip Air/N2/Ar-H2

0.125" Orifice

Catalog No. 20-1413

Cutting Electrode N2, Ar-H2

Catalog No. 20-1211

Gouging Electrode,

N2/Ar-H2

Catalog No. 20-1405

Cutting Tip Air/N2/AR-H2

0.063" Orifice, 120 amps Catalog No. 20-1222

Gouging Tip Air/N2/Ar-H2

0.156" Orifice

Catalog No. 20-1414

Gas Distributor - Cutting

0.712" (18 mm) Length Cat. No. 20-1215

Figure 4-1 Various Torch Parts Selection

Gouging Tip Air/N2/Ar-H2

0.171" Orifice

Catalog No. 20-1415

Gas Distributor - Gouging

0.912" (23 mm) Length Cat. No. 20-1409

A-02187

T o change the torch parts for a differ ent operation use the following procedure:

NOTE

A multi-purpose wrench is supplied for changing the tip, electrode and gas distributor in the torch head.

When installing gouging parts, the gouging electrode requires the use of a water extension tube. Refer to Figure 4-3 for parts location.

Used for 11/16" ( 17.5 mm)

Across Tip Flats

This Side

T o wards Torch

Gas Distributor Notch

Used with 5/8" (15.9 mm)Tip

Multi-Purpose Wrench

(Catalog Number 20-0001)

Gas Distributor Notch

Used with 11/16" (17.5 mm)Tip

Used for Electrodes

Used for 5/8" (15.9 mm)

Across Tip Flats

A-01639

Figure 4-2 Multi-Purpose Wrench

OPERATION 4-2 Manual 0-2698

1. Unscrew and remove the shield cup from the torch head.

2. Using the multi-purpose wrench (5/8 inch slot) remove the tip.

Torch Head

Water Tube Extension

(Gouging Only)

Electrode

Distributor

Tip

Gas

Shield Cup

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

A-02188

Figure 4-3 Torch Parts

3. Tilt the torch head to remove the gas distributor. The end of the multi-purpose wrench can be used to help remove the gas distributor.

4. Using the multi-purpose wrench (electrode area) remove the electrode.

5. Remove gouging water extension tube, if used.

6. Install the desired electrode for the operation into the

torch head. The circular area ar ound the wrench used for electrodes will also align the electrode in the torch head. This will prevent installing the electrode on an angle and cross threading the electrode in the torch head.

7. Install gouging water extension tube if required.

8. Install the desired gas distributor and tip for the operation into the torch head.

NOTE

Top Edge Rounding

Dross

Build-Up

Cut Surface

Drag Lines

Figure 4-4 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.

A-00007

Be careful not to overtighten the electrode and tip

D. Top-Edge Rounding

when reinstalling.

Rounding on the top edge of a cut due to wearing

9. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the

from the initial contact of the plasma arc on the workpiece.

cup, check the threads before proceeding.

E. Bottom Dross Build-up

4.05 Cut Quality

NOTE

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

Manual 0-2698 4-3 OPERA TION

Molten material which is not blown out of the cut area and re-solidifies on the plate. Excessive dross may require secondary clean-up operations after cutting.

F . K erf 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.

H. Various Materials and Thicknesses

Chart in Figure 4-5 defines the cut quality on various materials and thicknesses:

Cut Qua lity on Various Materials

Type of Gases Material Thickness Carbon Stee l S ta i nl ess Aluminum

Ai r P l asma and Gage Excel l ent Good-E xcel l ent Good-E x cell ent

Ai r Secondary Gage t o 1 inch Excel lent Good Good

1 to 1-1/2 inc h Excel l ent Good Good

Nit rogen P lasm a Gage NR Good-Excellent G ood-E xcellent

and Air or CO2 Gage to 1 /2 inch NR G ood-Excellent Good-E xcellent

Secondary 1/2 to 1-1/2 inc h NR Good-Exc el l ent Good-Excellent

Ar/H2 Plasma and Gage t o 1 /4 inc h NR NR NR

N2 or CO2 1/4 to 1-1/ 4 inch NR Good Excel l ent

Secondary 1/2 to 1-1/2 inc h NR Good E xcel l ent

Types of Materi al

Figure 4-5 Cut Quality

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

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

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

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

Fair - Excessive bevel (over 10°), wide kerf (over 2-1/2 x

tip orifice diameter), medium to heavy dross, rough cut surface, top edge rounding.

NR - Not Recommended.

NOTE

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

4.06 Operating the System

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.

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

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

OPERATION 4-4 Manual 0-2698

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. Tor c h 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.

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.

4.07 Hand T orch Operation

A. Drag or Standoff Cutting With Hand Torch

C. Edge Star ting

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 torch, 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 . V iewed along the dir ection of travel, the right side of the cut is more square than the left (Refer to Figure 4-6). T o make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Left Side

Cut Angle

Right Side

Cut Angle

1. The torch can be comfortably held in one hand or steadied with two hands. Choose the technique that feels most comfortable and allows good control and movement. Position the index finger or thumb to press the control switch on the torch handle.

NOTE

The tip should never come in contact with the workpiece during operation except if drag cutting. Amperage is limited to 35 Amps when drag cutting.

2. Depending on the type of 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.

b. For drag cuts keep the torch in contact with

the workpiece. Output current is automatically limited to 35 amps.

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

in (3 - 9 mm) from the work .

A-00512

Figure 4-6 Side Characteristics of Cut

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

Manual 0-2698 4-5 OPERA TION

Torch

Shield Cup

A-02202

4. 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.

C. Standoff Shield Cup With Straight Edge

The standoff shield cup can be used with a non-conductive straight edge to make straight cuts by hand. The standoff shield cup functions best when cutting relatively smooth metal surfaces that are solid.

Standoff

Distance 1/8" - 3/8"

WARNING

The straight edge must be non-conductive.

Figure 4-7 Standoff Distance

3. With the tor ch in starting position, lower the welding helmet, then press and hold the control switch. After an initial gas purge, the pilot arc will come on and remain on until the cutting arc starts.

4. Once on, the main arc remains on as long as the control switch 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.

5. T o shut off the torch simply r elease the thumb control switch. When the switch is released a ten second post-flow will occur. If the torch switch is closed during the post-flow, the cutting arc will restart immediately when the torch is brought within range of the workpiece.

B. Piercing With Hand T orc h

Torch

Crown Shield

Cup

Non-Conductive

Straight Edge Cutting Guide

A-02203

Standoff

Distance 1/8"

Figure 4-8 Using Standoff Shield Cup With Straight

Edge

4.08 Machine T orch Operation

A. Cutting With Machine T orch

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

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 com-

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

plete.

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.

OPERATION 4-6 Manual 0-2698

1. Straight Arc

Rack and

Pinion Mounting

Assembly

Square

A-00660

Workpiece

Figure 4-9 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 4-10).

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.

2. Leading Arc

The leading arc is directed in the same direction as torch travel. A five degr ee leading arc is gener ally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direction as torch travel.

Shown with

Rack and Pinion

Mounting Assembly

Direction of Torch Travel

3. The machine torch can be activated by the remote operator control panel, remote control pendant, or by remote interface device such as CNC. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch is activated.

4. With the pilot arc on, the main cutting arc will be established when the torch is brought within 1/8

- 3/8 in (3 - 10 mm) of the workpiece. If the cutting arc is interrupted and the torch is still activated, as when cutting expanded metal, the pilot arc will automatically restart (see Delayed AutoRestart Options in the Power Supply Operating Manual).

5. Cut with a standoff of 1/8 - 3/8 inch (3 - 10 mm) from the work. The torch should be held perpendicular to the workpiece while cutting. Start cutting slowly and adjust cutting speed for optimum cutting performance. Refer to Section 4.09, Recommended Cutting Speeds, for typical cutting speeds for various materials and material thicknesses.

B. Travel Speed

Proper travel speed is indicated by the trail of the arc which is seen below the plate ( Figure 4-10). The arc can be one of the following:

Standoff

Distance

Straight Arc

Trailing Arc

A-00662

Leading Arc

Figure 4-10 Machine Torch Operation

The arc characteristics vary with gases used, cutting speed, material, and thickness. Air plasma normally produces a straight arc (on stainless or aluminum), while nitrogen plasma generally creates a 5° trailing arc.

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.

Manual 0-2698 4-7 OPERA TION

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.

C. Piercing With Machine T or ch

To 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. Torch 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 - 3/8 inch (3 - 9 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.

A standar d shield cup is recommended for most machine cutting applications. Do not allow an exposed torch tip to contact the workpiece or output current will fold back to 35 amps..

A method called “running start” is recommended when piercing with a machine mounted torch. The torch should be positioned far enough off the cutting line to allow the pierce to be complete before the cutting line is reached. This allowance depends on the thickness of the material and the torch travel speed.

Piercing the plate is not recommended on plates having a thickness greater than 3/4 inch (19 mm). Blowback from the piercing operation can shorten the life of torch parts. All piercing should therefore be done as quickly as possible and at maximum amperage (120 amps) and maximum standoff.

Pierce off the cutting line and then continue the cut as needed. 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.

4.09 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:

• Tor ch parts wear

• Air quality

• Operator experience

• Tor ch standoff height

• Proper work cable connection

• Alloy content of material

NOTE

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

Refer to Appendix 1, Cutting Speed Charts, for complete chart data.

4.10 Gouging

WARNINGS

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

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.

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. Recommended Gases

Refer to the following table for characteristics of recommended gases when gouging with the Torch:

OPERATION 4-8 Manual 0-2698

B. 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).

Torch Head

Characteristics of Recommended

Gases for Plasma Arc Gouging

Type of Ga s Type of Material

Plasma Secondary

Air Air Excellent Good Fair

Nitrogen Air Good Good Fair Nitrogen CO2 Good Good Good

Ar/H2 Nitrogen Good Ar/H2 Argon Good Excellent Excellent

Carbon

Steel

Stainless

Steel

Excellent

(Ove r 3/4 in)

Aluminum

Excellent

Figure 4-11 Gas Characteristics

C. Tor ch Tra vel Speed

Optimum torch travel speed for gouging is between 20 and 120 inches per minute (0.5 and 3.0 meters per minute). Travel speed is dependent on current setting, lead angle, and mode of operation (hand or machine torch).

D. Current Setting

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

E. Lead Angle

The angle between the torch and workpiece depends on the output current setting and torch travel speed. At 35 amps, the recommended lead angle is 35°. 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.

35˚

Standoff Height

1/4 - 3/8"

Workpiece

A-00280

Figure 4-12 Gouging Angle and Standoff Distance

F. Standoff Distance

The tip to work distance affects gouge quality and depth. A standoff of 1/4 - 3/8 inch (6.3 - 9.5 mm) allows smooth, consistent metal removal. A smaller standoff may result in a severance cut rather than a gouge. A standoff greater than 3/8 inch (9.5 mm) may result in minimal metal removal or loss of transferred main arc.

G. Slag Build-up

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.

Manual 0-2698 4-9 OPERA TION

OPERATION 4-10 Manual 0-2698

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

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 (refer to Section 5.07, Servicing Machine Torch Components, or Section 5.06, Servicing Hand T orch Components) and cleaned more thor oughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.

This section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by other than properly per sonnel.

WARNINGS

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

Frequently review the Important Safety Precautions (page 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protection. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.

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

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

5.02 General T orch Maintenance

CAUTION

Dry the torch thoroughly before r einstalling.

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 on the front panel 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.

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 on the front panel of the power supply is ON.

Manual 0-2698 5-1 CUSTOMER/OPERATOR SER VICE

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 5.08, T o r ch and Leads Troubleshooting.

C. Torch O-ring Lubrication

The internal o-rings on the torch head assembly (electrode, gas distributor and tip) require lubrication on a scheduled basis. This will allow the o-rings to remain pliable and provide a proper seal. The o-rings 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 internally and externally. Failure of o-rings that seal against outside “air” entering the torch assembly can cause severe contamination. These contaminants can destroy or shorten the parts life of tips, electrodes, and internal torch parts.

It is recommended to apply a very light film of oring lubricant, (Catalog Number 8-4025), to the internal torch head assembly o-rings on a weekly basis.

4. Short Torch Parts Life

a. Oil or moisture in air source b. Exceeding system capability (material too thick)

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 what is the possible cause:

1. Insufficient Penetration

a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts e. Cutting current too low f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow b. Torch standoff too high from workpiece c. Cutting current too high

c. Excessive pilot arc time d. Air flow too low (incorrect pressure) e. Improperly assembled torch f. Output current too high g. Torch tip contacting workpiece h. Damaged or loose torch head components i. Non-Genuine Thermal Dynamics Parts

5. Poor Pilot Starting

a. High coolant conductivity (Refer to Power Supply

Manual)

b. Non-Genuine Thermal Dynamics Parts

5.04 Inspection and Replacement Consumable T orch P arts

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 on the front panel of the Power Supply is ON.

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

CUSTOMER/OPERATOR SER VICE 5-2 Manual 0-2698

Remove the consumable torch parts per the following procedure (See Note):

NOTE

A multipurpose wrench is supplied for changing the tip, electrode and gas distributor in the torch head.

Multi-Purpose Wrench

(Catalog Number 20-0001)

Gas Distributor Notch

Used with 11/16" (17.5 mm)Tip

Used for 11/16" ( 17.5 mm)

Across Tip Flats

This Side

T o wards Torch

Used for Electrodes

Used for 5/8" (15.9 mm)

Gas Distributor Notch

Used with 5/8" (15.9 mm)Tip

Across Tip Flats

A-01639

Figure 5-1 Multi-Purpose Wrench

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.

3. Using the multipurpose wrench (5/8 inch slot) remove

the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Replace the tip if necessary.

NOTE

The tip, electrode and gas distributor have o-rings on each part. The o-rings should be removed and a light coating of o-ring lubricant (catalog number 8-4025) applied.

Good Tip

Worn Tip

A-02195

Figure 5-3 Tip Wear

4. Tilt the torch head to remove the gas distributor. The

end of the multipurpose wrench can be used to help remove the gas distributor . Check for excessive wear , plugged gas holes, or discoloration. Replace if necessary.

Torch Head

Water Tube Extension

(Gouging Only)

Electrode

Distributor

Tip

Gas

Shield Cup

A-02188

Figure 5-2 Torch Consumable Parts

2. Inspect the cup for damage. Wipe it clean or replace if damaged.

5. Using the multipurpose wrench (electrode area) remove the electrode. Refer to Figure 5-4 and check the face of the electrode for excessive wear.

New Electrode

Worn Electrode

A-02208

Figure 5-4 Electrode Wear

6. Install the electrode and tighten with multipurpose wrench. Do not over tighten the electrode. The circular area around the wrench used for electr odes will also align the electrode in the torch head. This will prevent installing electrodes on an angle and cross threading the electrode in the torch head.

7. Install the gas distributor.

Manual 0-2698 5-3 CUSTOMER/OPERATOR SER VICE

8. Install the tip and tighten with the multipurpose

wrench. Do not over tighten the tip.

5. Plasma gas pressure too high.

a. Set pressure to 65 psi (4.5 bar).

CAUTION

Make sure both the tip and electrode correspond with the plasma and secondary gases being used, the current range, and the type of operation. Refer to Section 4.04, Torch Parts Selection.

9. 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.

5.05 Troubleshooting Guide

A. Troubleshooting

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

B. How to Use This Guide

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

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

7. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached

to power supply.

2. Poor Work Cable Connection.

a. Inspect work cable connection and adjust if nec-

essary.

3. Faulty components in torch and leads assembly a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

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.

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN/SET switch in SET position

a. Place RUN/SET switch to RUN position.

2. Torch switch activated during 20 second pre-flow

a. Release torch switch and wait at least 20 sec-

onds before activating switch again.

3. Coolant return lead clogged or plugged.

a. Check coolant return into unit reservoir. In-

spect torch assembly and replace if necessary.

4. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

C. Low cutting output with no control

1. Incorrect setting of AMPERAGE control on power supply.

a. Check and adjust to proper setting.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

4. Faulty torch parts.

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

fer to Section 5.04, Inspection and Replacement Consumable T o rch Parts

CUSTOMER/OPERATOR SER VICE 5-4 Manual 0-2698

D. Limited output with no control

G. Torch cuts but not adequately

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 5.08, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

E. Improper cutting output

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 1, Cut-

ting Speed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

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

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 1, Cut-

ting Speed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface

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

4. Poor input or output connections to power supply

a. Check all input and output connections.

F. No gas flow

1. Gas not connected or pressure too low

a. Check source for at least 100-125 psi (6.9- 8.6

bar) maximum pressure.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.09, Torch and Leads Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

Manual 0-2698 5-5 CUSTOMER/OPERATOR SER VICE

5.06 Servicing Hand Torch Components

Coolant Return Lead

A. Removing T orch Switch and T orch Head

Assembly

Removing the torch control switch assembly requir es gaining access to the switch wiring and partially disassembling the torch handle, per the following procedure:

1. Remove the shield cup, tip, gas distributor and electrode from the torch head assembly.

2. Roll the torch switch sheath back over the handle to expose the tape covering the torch switch connectors.

NOTE

Use a soap and water solution on the sheath to assist in rolling.

Sheath

Connectors From

Torch Switch

Torch Control

Switch

Coolant (-) Supply Lead

Plasma (+) Lead

Secondary Lead

A-02197

Figure 5-6 Torch Head Removal (PCH-120)

8. Disconnect all four leads to disconnect the torch head.

9. Remove torch head assembly .

10. Remove the torch handle and switch from the leads.

11. If the torch switch is defective, remove the switch from the torch handle.

B. Reassembling Tor ch Switch and Tor ch

Head Assembly

Torch Handle

A-02196

Threaded Locking Nut

Figure 5-5 Torch Control Switch Wiring

3. Carefully cut and remove the tape from the leads and the end of the leads sheathing.

4. Slide the sheathing back to expose the torch switch connectors.

5. Remove the tape securing the two connectors together.

6. Disconnect the torch switch leads.

NOTE

The torch switch connectors are made to fit into the matching connectors.

7. Remove torch from handle.

NOTE

NOTE:

Verify that small rubber duck valve is in torch plasma fitting.

T o install the torch switch or torch head assembly use the following procedure:

1. Slide the torch handle with torch switch and sheathing over the torch leads.

2. Connect all four leads to connect to the replacement torch head assembly.

3. Remove the rigid insulator from the old Torch Head Assembly from between the layers of Estermat paper and install replacement insulator . Refer to Figure 5-9 for location and orientation of rigid insulator .

NOTE

Over a period of time there may be a breakdown of the estermat paper causing the T orch Head to short out if the rigid insulator is not installed.

4. Secure the rigid insulator in place with electrical tape.

Keep the lock nut threaded on the torch head.

CUSTOMER/OPERATOR SER VICE 5-6 Manual 0-2698

5. Tighten the threaded locking nut with the flat (non-chamfered) edge against the torch head, then loosen the nut slightly by turning it back approximately one-half turn.

6. Install the torch head on the handle.

NOTE

The torch switch connectors are made to fit into the matching connectors.

A. Removing Machine Torch Head

1. Remove the shield cup, tip, gas distributor and electrode from the torch head assembly.

2. Remove shrink on tubing.

3. Locate the tape at the back end of the torch positioning tube. Remove the tape from the torch lead sleeving and slide the sleeving back (see NOTE).

7. Connect the two torch switch leads.

8. Tape the two control cable connector leads together.

9. Pull the leads sheathing over the connectors and secure with electrical tape to the torch leads.

10. Roll the torch switch sheath back over the handle.

11. Install torch parts in torch.

12. Align the Torch Control Switch on the handle in the desired position for cutting, position the torch head then tighten the threaded locking nut against the torch handle.

NOTE

There will be a slight gap between the torch head and the lock nut.

5.07 Servicing Machine Torch Components

WARNINGS

NOTE

The positioning tube will not slide over the torch lead sleeving.

4. Unscrew the positioning tube from the tor ch adaptor on the torch head assembly and slide the positioning tube back over the leads.

5. Unscrew the torch adaptor from the torch head assembly. Slide the torch adaptor back over the leads to expose the plasma (+), secondary, coolant supply (-), and coolant return connectors.

Pinion Assembly

Machine

Torch Head

Positioning Tube

Lead Connections

Bushing

Torch Adaptor

A-00663

Figure 5-7 Torch Mounting Assembly

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 on the front panel of the Power Supply is ON.

6. Disconnect the plasma (+), secondary , coolant supply (-), and coolant return connectors to allow removal of the torch head. Note the location of the torch leads insulator which separates the negative and positive leads.

Coolant Return Lead

(LH Threads)

Coolant (-)

Supply Lead

Secondary Lead

Plasma Lead (+)

A-02198

Figure 5-8 Torch Head Removal

Manual 0-2698 5-7 CUSTOMER/OPERATOR SER VICE

B. Reassembling Machine Torch Assembly

NOTE

5.08 Torch And Leads Troubleshooting

Verify that the small rubber duck valve is in torch plasma fitting.

1. Remove the rigid insulator from the old Torch Head Assembly from between the layers of estermat paper .

2. Slide the rigid insulator between the layers of estermat paper on the replacement Torch Head Assembly (see note).

NOTE

Over a period of time there may be a breakdown of the estermat paper causing the T orch Head to short out if the rigid insulator is not installed.

Two Layers Of

Estermat Paper

Rigid Torch

Leads Insulator

A-01577

Figure 5-9 Rigid Insulator Installation

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

The use of a Hi-Pot T ester 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.

3. Secure the rigid insulator in place with electrical tape.

4. Slide replacement shrink on tubing on leads.

5. Connect the plasma (+), secondary, coolant supply, (-) and coolant return connectors.

6. Secure leads and tubing with single layer of electrical tape.

7. Slide the torch adapter down over the leads and screw the adaptor securely onto the back of the torch head assembly.

8. Slide the positioning tube down over the leads and thread it into the torch adaptor on the torch head assembly .

9. Apply tape to the torch leads sleeving at the back end of the positioning tube.

10. Position shrink on tubing over the tape and shrink.

11. Install the front end torch parts.

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 per the following 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.

CUSTOMER/OPERATOR SER VICE 5-8 Manual 0-2698

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.

C. Checking Proper Isolation Resistance

Procedure

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

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.

• If there is continuity, torch head must be re-

placed.

• 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 re-

placed.

• 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.

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

maximum of 2500 VAC.

• If the voltage drops to 0 VAC or leakage cur-

rent is detected, then the Torch Head center insulator is breaking down and the T orch 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 cur rent 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.

Manual 0-2698 5-9 CUSTOMER/OPERATOR SER VICE

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

• If problems are evident, repair or replace as

required.

• If there are no visual problems, then proceed

to Step 4.

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 T o rch 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 Tor ch Leads.

CUSTOMER/OPERATOR SER VICE 5-10 Manual 0-2698

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 Torch Parts Section 6.04: Replacement Machine Tor ch Parts Section 6.05: Torch Lead Component Replacement

Parts Section 6.06: Complete Assembly Replacements Section 6.07: Spare Parts Kits

NOTE

Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers 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 description column of the Parts List. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor .

Manual 0-2698 6-1 P A RTS LISTS

6.03 Replacement Hand Torch Parts

Item # Qty Description Catalog #

1 1 Insulator, Torch Leads, Rigid 9-7828 2 2 O-Ring 8-0538 3 1 Assembly, Basic Head, PCH-120 70° 9-7830

1 Assembly , Basic Head, PCH-120 90° 9-7831

4 1 Distributor, Gas - Cutting 20-1215

1 Distributor, Gas - Gouging 20-1409

5 1 Tip, Cutting, Air/N2/Ar-H2, 0.031" Orifice, 35 Amps 20-1220

1 Tip, Cutting, Air/N2/Ar-H2, 0.047" Orifice, 70 Amps 20-1221 1 Tip, Cutting, Air/N2/Ar-H2, 0.063" Orifice, 120 Amps 20-1222 1 Tip, Gouging, Air/N2/Ar-H2, 0.110" Orifice 20-1412 1 Tip, Gouging, Air/N2/Ar -H2, 0.125" Orifice 20-1413 1 Tip, Gouging, Air/N2/Ar -H2, 0.156" Orifice 20-1414 1 Tip, Gouging, Air/N2/Ar -H2, 0.171" Orifice 20-1415

6 1 Electrode, Cutting Air/N2 20-1210

1 Electrode, Cutting N2/Ar-H2 20-1211 1 Electrode, Gouging, Air/N2 20-1404 1 Electrode, Gouging, N2/Ar-H2 20-1405

7 1 Shield Cup, Short 20-1225

1 Shield Cup, Crown 20-1226

1 Shield Cup, Gouging 20-1227 8 1 Handle Sheath, 1-3/8 O.D. 8-4216 9 1 Leads Assembly (Refer to Section 6.05 for Leads Component Parts)

With Nylon Leads Sleeving

25 ft (7.6 m) Length 4-6092 50 ft (15.2 m) Length 4-6093

With Kevlar Leads Sleeving

25 ft (7.6 m) Length 4-6192

50 ft (15.2 m) Length 4-6193 10 1 Assembly, Torch Switch 9-1246 11 1 Torch Handle 9-7833 12 1 Water Tube Extension (Gouging Only) 20-1402 13 1 Locking Nut 9-7902

P AR TS LISTS 6-2 Manual 0-2698

A-02200

Manual 0-2698 6-3 P A RTS LISTS

6.04 Replacement Machine Torch Parts

Item # Qty Description Catalog #

1 1 Insulator, Torch Leads 9-7828 2 1 Assembly, Basic Head, PCM-120 180° (See Note 2) 9-6410 3 1 Distributor, Gas - Cutting 20-1215

1 Distributor, Gas - Gouging 20-1409

4 1 Tip, Cutting, Air/N2/Ar-H2, 0.031" Orifice, 35 Amps 20-1220

1 Tip, Cutting, Air/N2/Ar-H2, 0.047" Orifice, 70 Amps 20-1221 1 Tip, Cutting, Air/N2/Ar-H2, 0.063" Orifice, 120 Amps 20-1222 1 Tip, Gouging, Air/N2/ArH2, 0.110" Orifice 20-1412 1 Tip, Gouging, Air/N2/ArH2, 0.125" Orifice 20-1413 1 Tip, Gouging, Air/N2/ArH2, 0.156" Orifice 20-1414 1 Tip, Gouging, Air/N2/ArH2, 0.171" Orifice 20-1415

5 1 Electrode, Cutting Air/N2 20-1210

1 Electrode, Cutting N2/Ar-H2 20-1211 1 Electrode, Gouging, Air/N2 20-1404 1 Electrode, Gouging, N2/Ar-H2 20-1405

6 1 Shield Cup, Short 20-1225

1 Shield Cup, Crown 20-1226

1 Shield Cup, Gouging 20-1227 7 1 Water Tube Extension (Gouging Only) 20-1402 8 1 Leads Assembly

Unshielded (Refer to Section 6.05 for Leads Component Parts)

25 ft (7.6 m) Length 4-6090 50 ft (15.2 m) Length 4-6091

Shielded

25 ft (7.6 m) Length 4-9026 50 ft (15.2 m) Length 4-9051

9 1 Adapter, 1-3/8 O.D. Torch to 1-3/8 Positioning Tube 8-2158

10 1 Tube, Positioning, 1-3/8, W ith Rack 7-3207 11 1 Positioning Tube End Cap (Molded) 8-4204

1 Pinion Assembly includes: 7-2827

12 1 Torch Holder Sleeve 7-2896 13 1 Pinion Gear-Short 8-6074 14 1 Handwheel (Torch Holder) 9-4514 15 1 Low Profile Torch Holder (1 3/8 Dia) w/o Hardware 9-4515 16 1 Calibrated Torch Holder Bushing 9-4366 17 1 5/32 Dia x 5/8 Lg Slotted Spring Pin See Note 1 18 1 3/8-24 x 3/8 Soc Hd Set Screw, Cup Point See Note 1 19 2 1/4-20 x 5/8 Hex Socket Head Screw See Note 1 20 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point See Note 1

21 1 Shrink On Tubing (Refer to Note 2) 9-9092

Note 1 Item may be purchased locally.

Note 2 Shrink On Tubing for the Torch Leads is r equired when replacing the Torch Head or Leads

P AR TS LISTS 6-4 Manual 0-2698

5 3

Shielded Leads

A-02199

Manual 0-2698 6-5 P A RTS LISTS

6.05 Torch Lead Component Replacement Parts (Unshielded Leads Only)

Item # Qty Description Catalog #

1 1 Negative/Coolant Supply Lead

25 ft (7.6 m) 9-6496 50 ft (15.2 m) 8-3283

2 1 Secondary Gas Hose

25 ft (7.6 m) 8-5135 50 ft (15.2 m) 8-5136

3 1 Positive/Plasma Gas Lead

25 ft (7.6 m) 8-5565 50 ft (15.2 m) 8-5566

4 1 Coolant Return Hose

25 ft (7.6 m) 8-6305 50 ft (15.2 m) 8-6306

5 1 Lead Sleeving

Nylon Sleeving

25 ft (7.6 m) 9-7898 50 ft (15.2 m) 9-7899

Kevlar Sleeving

25 ft (7.6 m) 9-7910 50 ft (15.2 m) 9-7911

6 1 Control Cable

25 ft (7.6 m) 9-7581 50 ft (15.2 m) 9-7582

P AR TS LISTS 6-6 Manual 0-2698

Hand T orch Leads

Machine T orch Leads

A-02654

A-02887

Manual 0-2698 6-7 P A RTS LISTS

6.06 Complete Assembly Replacements

Qty. Description Catalog #

Hand Torches w/Leads & Nylon Leads Sleeving:

PCH-120 With 70° Torch Head 1 25 ft (7.6 m) Leads 2-1270 1 50 ft (15.2 m) Leads 2-1271

PCH-120 With 90° Torch Head 1 25 ft (7.6 m) Leads 2-1290 1 50 ft (15.2 m) Leads 2-1291

Hand Torches w/Leads & Kevlar Leads Sleeving:

PCH-120 With 70° Torch Head 1 25 ft (7.6 m) Leads 2-1370 1 50 ft (15.2 m) Leads 2-1371

PCH-120 With 90° Torch Head 1 25 ft (7.6 m) Leads 2-1390 1 50 ft (15.2 m) Leads 2-1391

Machine Torches w/Leads and Rack & Pinion Mounting Assembly:

PCM-120 With Unshielded Leads 1 25 ft (7.6 m) 2-1280 1 50 ft (15.2 m) 2-1281

PCM-120 With Shielded Leads 1 25 ft (7.6 m) 2-1282 1 50 ft (15.2 m) 2-1283

P AR TS LISTS 6-8 Manual 0-2698

6.07 Spare Parts Kits

Qty Description Catalog #

Cutting, Spare Parts Kit (Air)- Includes: 5-1500 1 Adapter Fitting 1/4" Hose to 1/4" NPT 8-4264 1 Lubricant 8-4025 1 Multi-Purpose W rench 20-0001 2 Tip - Cutting (Air) - Orifice 0.031, 35 Amp 20-1220 2 Tip - Cutting (Air) - Orifice 0.047, 70 Amp 20-1221 5 Tip - Cutting (Air) - Orifice 0.063, 120 Amp 20-1222 1 Shield Cup - Short 20-1225 2 Electrode - Cutting (Air) 20-1210 2 Electrode, Multi-Gas 20-1211 1 Gas Distributor - Cutting 20-1215 1 Box, Utility 9-4173

Gouging, Spare Parts Kit - Includes: 5-1505 1 Lubricant 8-4025 1 Multi-Purpose W rench 20-0001 2 Tip - Gouging (Air) - Orifice 0.171 20-1415 2 Tip - Gouging (Air) - Orifice 0.156 20-1414 2 Tip - Gouging (Air) - Orifice 0.125 20-1413 3 Tip - Gouging (Air) - Orifice 0.110 20-1412 2 Shield Cup - Gouging 20-1227 3 Electrode - Gouging (Multi-gas) 20-1405 3 Electrode - Gouging (Air) 20-1404 2 Gas Distributor - Gouging 20-1409 1 Extension, Water Tube - Gouging 20-1402 1 Box, Utility 9-4173

Manual 0-2698 6-9 P A RTS LISTS

6.08 Options and Accessories

Qty Description Catalog #

1 Protector, Torch Head, PCH-120, 70 Degree 9-8135 1 Protector, Torch Head, PCH-120, 90 Degree 9-8136 1 Torch Guide/Circle Cutting Attachment 7-7505

P AR TS LISTS 6-10 Manual 0-2698

Manual 0-2698 A-1 APPENDIX

Air P lasma Cutt ing S p eed Data Chart Type Torch: PCM-120 Type Material: Aluminum Type Plasma Gas: Air Type Secondary Gas: Air

Thickness Tip Output Volts Amperage Speed (Per M inute) Standoff Plasma Gas Press Sec Gas Press Total Flow (SCFH) Pierce Height

Inches

0.032

0.05

1/16 1.6 1/11 2.3 1/8 3.2 20-1220 115 35 60 1.5 0.13 3.3 63 4.3 60 4.1 50 340 0.13 3.3 1/16 1.6 20-1221 118 70 200 5.1 0.13 3.3 50 3.4 60 4.1 60 332 0.13 3.3 1/8 3.2 20-1221 125 70 125 3.2 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3 3/16 4.8 20-1221 125 70 85 2.2 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3 1/4 6.4 20-1221 130 70 65 1.7 0.13 3.3 70 4.8 60 4.1 82 332 0.13 3.3 3/8 9.5 20-1221 140 70 25 0.6 0.13 3.3 70 4.8 60 4.1 82 332 0.25 6.4 1/2 12.7 20-1221 145 70 15 0.4 0.13 3.3 70 4.8 60 4.1 82 332 0.25 6.4 1/4 6.4 20-1222 125 120 125 3.2 0.19 4.7 60 4.1 60 4.1 78 340 0.25 6.4 3/8 9.5 20-1222 130 120 70 1.8 0.19 4.8 60 4.1 60 4.1 78 340 0.25 6.4 1/2 12.7 20-1222 145 120 35 0.9 0.19 4.8 60 4.1 60 4.1 78 340 0.25 6.4 5/8 15.9 20-1222 150 120 30 0.8 0.19 4.8 60 4.1 60 4.1 78 340 0.38 9.7 3/4 19.1 20-1222 160 120 20 0.5 0.19 4.8 60 4.1 60 4.1 78 340 0.38 9.7

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches m m

0.8

1.3

20-1220 20-1220 20-1220 20-1220

100 35 400 100 35 250

100 35 125 3.2 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.3 110 35 90 2.3 0.13 3.2 63 4.3 60 4.1 50 340 0.13 3.3

10.2

6.4

0.125

3.2

63 63

4.3

60 60

4.1

50 340 0.125 50 340 0.125

APPENDIX 1: CUTTING SPEED CHARTS

3.2

APPENDIX A-2 Man ual 0-2698

Ar-H2/N2 Cuttin g Speed Data Chart Type Torch: PCM-120 Type Material: Aluminum Typ e Plasma Gas: A r - 35H

Thickness Tip O utput V olts Ampera ge S peed (P er Minute) Standoff Plasma Gas Press Se c Gas Press Total Flow (S C FH ) Pierce Height

Inches

1/4 6.4 1/2 12.7 3/4 19.1 1 25.4

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar pasi bar Plasm a Secondary Inches mm

20-1222 20-1222 20-1222 20-1222 140 120 20 0.5 0.25 6.4 65 4.5 60 4.1 75 340 N/R N/R

130 120 100 2.5 0.25 6.4 65 4.5 60 4.1 75 340 0.25 6.4 135 120 60 1.5 0.25 6.4 65 4.5 60 4.1 75 340 0.38 9.7 135 120 30 0.8 0.25 6.4 65 4.5 60 4.1 75 340 0.38 9.7

Type Secondary Gas: Nitrogen

APPENDIX 1: CUTTING SPEED CHARTS (continued)

N/R = No t Recommended

Manual 0-2698 A-3 APPENDIX

Air P l asma C u tt i n g Speed D at a Chart Type Torch: PCM-120 Type Material: Mild Steel Typ e P l asm a G as: Air T ype Secondary Gas: A i r

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

Inches

21 ga 0.8 20-1220 95 35 400 10.2 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

18 ga 1.2 20-1220 100 35 300 7.6 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 16 ga 1.5 20-1220 100 35 275 7.0 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 13 ga 2.2 20-1220 105 35 150 3.8 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 11 ga 2.9 20-1220 110 35 90 2.3 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

7 ga 4.8 20-1220 110 35 60 1.5 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

1/8 3.2 20-1221 120 70 180 4.6 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4 3/16 4.8 20-1221 120 70 140 3.6 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4 1/4 6.4 20-1221 122 70 75 1.9 0.19 4.7 70 4.8 60 4.1 77 340 0.25 6.4 3/8 9.5 20-1221 125 70 55 1.4 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4 1/2 12.7 20-1221 132 70 35 9.0 0.19 4.8 70 4.8 60 4.1 77 340 0.25 6.4 1/4 6.4 20-1222 125 120 125 3.2 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7 3/8 9.5 20-1222 130 120 80 2.0 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7 1/2 12.7 20-1222 135 120 55 1.4 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7 5/8 15.9 20-1222 140 120 40 1.0 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7 3/4 19.1 20-1222

1 25.4 20-1222 1 1/4 31.8 20-1222 1 1/2 38.1 20-1222

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

145 160 165

180

120 30 0.8 0.25 6.4 65 4.5 60 4.1 78 340 0.38 9.7 120 15 0.4 0.25 6.4 65 4.5 60 4.1 78 340 N/R N/R 120 12 0.3 0.25 6.4 65 4.5 60 4.1 78 340 N/R N/R 120 5 0.1 0.25 6.4 62 4.3 60 4.1 78 340 N/R N/R

APPENDIX 1: CUTTING SPEED CHARTS (continued)

N/R = Not Recomm en d ed

NOTE

N2/CO2 speeds are typically 10% slower than air/air cuts. The quality of cut will be reduced on carbon steel with N2/CO2 when compared to air/air cutting.

APPENDIX A-4 Man ual 0-2698

Air Plasma Cutting Speed Data Chart Type Tor ch: PC M - 120 Type Mate r i al : Stainl e ss Steel Type Plasm a G as: Air Typ e Secon dary Gas: A ir

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plas ma Gas Press Sec Gas Press Total Flow (SCFH) Pierce Height

Inches

20 ga. 0.9 20-1220 110 35 100 2.5 0.13 3.2 65 4.5 60 4.1 50 340 0.13 3.3 18 ga. 1.2 20-1220 110 35 50 1.3 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3

1/16 1.6 20-1220 110 35 40 1.0 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 1/8 3.2 20-1220 110 35 30 0.8 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 3/16 4.8 20-1220 110 35 20 0.5 0.13 3.3 65 4.5 60 4.1 50 340 0.13 3.3 1/16 1.6 20-1221 120 70 225 5.7 0.13 3.2 70 4.8 60 4.1 80 340 0.13 3.3 1/8 3.2 20-1221 120 70 135 3.4 0.13 3.2 70 4.8 60 4.1 80 340 0.13 3.3 3/16 4.8 20-1221 120 70 100 2.5 0.13 3.3 70 4.8 60 4.1 80 340 0.13 3.3 1/4 6.4 20-1221 125 70 65 1.7 0.13 3.3 70 4.8 60 4.1 80 340 0.13 3.3 3/8 9.5 20-1221 130 70 30 0.8 0.13 3.3 70 4.8 60 4.1 80 340 0.25 6.4 1/2 12.7 20-1221 140 70 20 0.5 0.19 4.7 70 4.8 60 4.1 80 340 0.25 6.4 1/4 6.4 20-1222 130 120 135 3.4 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4 3/8 9.5 20-1222 130 120 80 2.0 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4 1/2 12.7 20-1222 135 120 40 1.0 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4 5/8 15.9 20-1222 140 120 30 0.8 0.19 4.8 75 5.2 60 4.1 90 340 0.25 6.4 3/4 19.1 20-1222 145 120 25 0.6 0.19 4.8 75 5.2 60 4.1 90 340 N/R N/R

1 1/4 31.8 20-1222 160 120 10 0.3 0.19 4.8 75 5.2 60 4.1 90 340 N/R N/R

(Cat. No.) (VDC) (Amps) Inches Meters Inches mm psi bar psi bar Plasma Secondary Inches mm

APPENDIX 1: CUTTING SPEED CHARTS (continued)

N/R= Not Rec om m end ed

Manual 0-2698 A-5 APPENDIX

Ar-H2/N2 Cutting Speed Dat a C hart

Typ e Torch: PCM-120 Type Mater i al: Stain less Steel -A bove Water Typ e Plasma Gas: Ar-35H

Thickne ss Tip Output V olts Ampera ge Speed (Per Minute) Standoff Plasma Gas Press Sec Gas Pres s Total Flow (SCFH) Pierce Pierce Height

Inches

3/4 19.1 20-1222 140 120 20 0.5 0.19 4.8 62 4.3 60 4.1 78 340 0.4 0.50 1 25.4 20-1222 145 120 15 0.4 0.19 4.8 62 4.3 60 4.1 78 340 N/R N/R 1 1/4 31.8 20-1222 150 120 10 0.3 0.19 4.8 62 4.3 60 4.1 78 340 N/R N/R 1 1/2 38.1 20-1222 155 120 7 0.2 1.90 48.3 62 4.3 60 4.1 78 340 N/R N/R

N/R = Not Recommended

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

Type Secondary Gas: Nitrogen

APPENDIX 1: CUTTING SPEED CHARTS (continued)

APPENDIX 2: SEQUENCE OF OPERATION BLOCK

DIAGRAM

ACTION

Close external

disconnect switch.

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Gas flows

GAS indicator on

After gas pre-flow:

DC indicator on.

Power supply enabled.

HF enabled.

Pilot arc established.

ACTION

ON/OFF switch

to ON.

RESULT

AC indicator on.

Pilot disabled during

pre-flow.

Fan on.

PILOT ARC

ACTION

RUN/SET switch

to SET.

RESULT

Gas solenoids open,

gas flows to set pressure.

GAS indicator on.

ACTION

RUN/SET switch

to RUN.

RESULT

Gas flow stops.

GAS indicator off.

Power circuit ready.

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc auto-

matically restarts.

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 solenoids close, gas flow stops.

Main arc stops.

DC indicator off.

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.

Fans off.

ACTION

Torch moved within

transfer distance of workpiece.

RESULT

Main arc transfer.

Pilot arc off.

DC indicator still on.

ACTION

Open external

disconnect.

RESULT

No power to system.

A-02194

APPENDIX A-6 Man ual 0-2698

Tweco PCM-120 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.03 Specifications & Design Features

2.01 Scope of Manual

2.02 General Description

2.05 Introduction to Plasma

3.01 Introduction

3.05 Connecting T orch

3.02 Site Location

3.03 Unpacking

3.06 Setting Up Machine Torch

3.07 Gas Selection

3.08 Gas Connections

4.01 Introduction

4.02 Functional Overview

4.03 Getting Started

4.04 Torch Parts Selection

4.05 Cut Quality

4.06 Operating the System

4.07 Hand T orch Operation

4.08 Machine T orch Operation

4.09 Recommended Cutting Speeds

4.10 Gouging

5.01 Introduction

5.02 General T orch Maintenance

5.03 Common Operating Faults

5.04 Inspection and Replacement Consumable T orch P arts

5.05 Troubleshooting Guide

5.06 Servicing Hand Torch Components

5.07 Servicing Machine Torch Components

5.08 Torch And Leads Troubleshooting

6.01 Introduction

6.02 Ordering Information

6.03 Replacement Hand Torch Parts

6.04 Replacement Machine Torch Parts

6.05 Torch Lead Component Replacement Parts (Unshielded Leads Only)

6.06 Complete Assembly Replacements

6.07 Spare Parts Kits

6.08 Options and Accessories

APPENDIX 1: CUTTING SPEED CHARTS