PLASMA
CUTTING TORCH
• Model PCH-62 Hand Torch
• Model PCM-62 Machine Torch
Instruction Manual
January 28, 2004 Manual No. 0-2817
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.
Plasma Cutting T o rc h
Model PCH-62 & PCM-62
Instruction Manual Number 0-2817
Published by
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2000 by
Thermal Dynamics Corporation
All rights reserved
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by errors or omissions in this Manual, whether such errors r esult
from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: January 28, 2004
Record the following information for W arranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and W arnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications.................................................................................................. 1-2
1.07 Declaration of Conformity ............................................................................. 1-4
SECTION 2:
INTRODUCTION .............................................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications & Design Features................................................................. 2-1
2.04 Options And Accessories ............................................................................. 2-2
2.05 Introduction to Plasma.................................................................................. 2-2
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Location ................................................................................................ 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Setting Up Hand Torch ................................................................................. 3-1
3.05 Setting Up Machine Torch ............................................................................ 3-1
3.06 Connecting Torch ......................................................................................... 3-2
3.07 Gas Connection ........................................................................................... 3-4
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction .................................................................................................. 4-1
4.02 Functional Overview..................................................................................... 4-1
4.03 Getting Started............................................................................................. 4-1
4.04 Torch Parts Selection ................................................................................... 4-2
4.05 Cut Quality ................................................................................................... 4-2
4.06 General Cutting Information ......................................................................... 4-3
4.07 Hand Torch Operation .................................................................................. 4-4
4.08 Machine Torch Oper ation ............................................................................. 4-5
4.09 Recommended Cutting Speeds.................................................................... 4-6
4.10 Gouging ....................................................................................................... 4-7
TABLE OF CONTENTS (continued)
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 General Torch Maintenance ......................................................................... 5-1
5.03 Common Operating Faults ........................................................................... 5-2
5.04 Inspection and Replacement Consumable Torch Parts ................................ 5-2
5.05 Troubleshooting Guide ................................................................................. 5-3
5.06 T orch & Leads Troubleshooting .................................................................... 5-4
5.07 Servicing Hand Torch (PCH) Components ................................................... 5-6
5.08 Servicing Machine Torch (PCM) Components.............................................. 5-9
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 Replacement Hand Torch Parts (Ergonomic Handle) ................................... 6-2
6.04 Replacement Machine Torch Parts ............................................................... 6-4
6.05 Replacement Torch Lead Parts ................................................................... 6-6
6.06 Complete Torch & Leads Assembly Replacement ........................................ 6-7
6.07 Options and Accessories .............................................................................6-8
6.08 T orch Spare P a rts Kits ................................................................................. 6-9
APPENDIX 1: TYPICAL SYSTEM SEQ UENCE OF OPERATION BLOCK DIAGRAMS ...........A-1
For CutMaster 50 Applications .............................................................................A-1
For P akMaster 50XL Plus Applications.................................................................A-2
APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM
FOR MECHANIZED SYSTEMS........................................................................................ A-3
APPENDIX 3: GENERAL APPLICATION NOTES..................................................................... A-4
APPENDIX 4: CUTMASTER 50 APPLICATION........................................................................A-6
APPENDIX 5: PAKMASTER 50XL PLUS APPLICATION.......................................................... A-8
APPENDIX 6: CE PAKMASTER 50XL PLUS APPLICATION..................................................A-10
APPENDIX 7: HAND TORCH CONNECTION .........................................................................A-12
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 background 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
HEALTH.
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 1-603-2985711 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 processes. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• 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.”
May 14, 2002 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 ar ea where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut alu-
minum alloys underwater or on a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped 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 RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, 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 A TION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 May 14, 2002
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
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
May 14, 2002 1-3 GENERAL INFORMATION
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 repr esentative: Steve W ard
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley , Lancashire,
England PR6 7BX
GENERAL INFORMATION 1-4 May 14, 2002
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
PARTICULAR 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 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 To rch 1 Year 1 Year
SureLok Torches 1 Year 1 Year 1 Year
All Other To rches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective August 6, 2001
May 14, 2002 1-5 GENERAL INFORMATION
GENERAL INFORMATION 1-6 May 14, 2002
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the PCH/M-62 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 Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it
was designed.
2.02 General Description
NOTE
Refer to Section 2.05, Introduction to Plasma, for
a more detailed description on plasma theory.
The T orch provides cutting capacity of up to 1/2 inch (12.7
mm) at 60 amperes drawn at the power supply.
In the torch, a single torch lead provides compr essed air
from a single source to be used as both the plasma and
secondary gas. The air flow is divided inside the torch
head. Single - gas operation allows for a smaller sized
torch and inexpensive operation.
2.03 Specifications & Design Features
Refer to Appendix Pages for additional specifications as
related to the Power Supply used.
A. Torch Configurations and Dimensions
1. Hand Torch
Available with torch head at 70° and 90° to the
torch handle. The hand torches include an ergonomic torch handle and torch trigger assembly.
2. Machine Torch
The standard machine torch has a fiberglass posi-
tioning tube with rack & pinch block assembly.
A vailable options include a kit with metal mount-
ing tube with rack & pinion assembly or a kit with
the pinion assembly only.
10.5 in
(267 mm)
3.0 in
(76.2 mm)
1.1in
(28 mm)
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.
10.0 in
(254 mm)
3.4 in
(86.4 mm)
1.1in
(28 mm)
14.1 in
(358 mm)
1.4 in
(35.6 mm)
0.6 in
(15.2 mm)
13.5 in (343 mm) Max
3.7 in (94 mm) Min
0.8 in
(20.3 mm)
5.1 in
(129.5 mm)
1.1 in
(28 mm)
A-02813
Figure 2-1 Torch Configurations and Dimensions
Manual 0-2817 2-1 INTRODUCTION
B. Torch Leads Lengths
2.04 Options And Accessories
Hand Torch: 20 ft (6.1 m) or 50 ft (15.2 m)
Machine Torch: 25 ft (7.6 m) or 50 ft (15.2 m)
C. Torch Par ts
Gas Distributor , Electrode, Tip, Shield Cup
D. Par ts - In - Place (PIP)
Torch Head has built - in contacts
12vdc circuit rating.
E. Type of Cooling
Combination of ambient air and gas stream through
torch
F. Torch Ratings
Torch Ratings
Ambient
Temperature
Duty Cy cle
Maxi mu m C u r r e n t
Voltage (V
Arc Stri king Voltage
peak
)
100% @ 60 Amps @ 375 scfh
104° F
(40° C)
60 Amps
500V
12 kV
G. Plasma Power Supply Used With
• CutMaster 50
• PakMaster 50XL Plus
• CE CutMaster 50
• CE PakMaster 50XL Plus
H. Direct Contact Hazard
For exposed tip the recommended standoff is 1/8" 3/8" or 3.2 - 9.5 mm.
These items can be used to customize a standard system
for a particular application or to further enhance performance (refer to Section 6 for ordering information).
• Spare Parts Kits - V arious kits containing replace-
ment front - end torch parts for various applications.
• Circle Cutting Guide Kit - Easy add - on attach-
ments to allow for straight line, circle cutting, and
beveling with a hand torch. The guide fits both
the 70° and 90° hand torches.
• Standoff Cutting Guide - Simple push - on attach-
ment to allow for torch dragging without risk of
touching tip to workpiece.
• 1-3/8" Metal Mounting Tube with Rack & Pinion
Assembly
• Pinion Assembly - For machine torches.
• Computer Control (CNC) Cable 25 ft (7.6 m) or
50 ft (15.2 m)
• Hand Pendant Control Assembly - Used for ma-
chine applications. Hand Pendant Control has 20
ft. (6.1 m) cable which provides ON / OFF signals to the Power Supply.
• Extension Cable for Hand Pendant Control - 25 ft
(7.6 m) cable which can be added to the Hand
Pendant Control cable to provide a total control
cable length of 50 ft (15.2 m).
2.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting and gouging process use this plasma to transfer an electrical
arc to the workpiece. The metal to be cut or removed
is melted by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B
(refer to Figure 2-2), where a pilot arc between the
electrode and the torch tip heats and ionizes the gas.
The main cutting arc then transfers to the workpiece
through the column of plasma gas in Zone C.
INTRODUCTION 2-2 Manual 0-2817
_
Power
Supply
+
D. Capacitive Discharge (CD)
Because direct current (DC) alone is not sufficient to
strike and maintain the pilot arc, capacitive discharge
is also used. The high voltage jumps between the tip
and electrode with the DC following.
E. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con-
A
nected to the workpiece via the work cable and to
the torch through a pilot wir e.
F. Interlocks
Workpiece
C
Figure 2-2 Typical Torch Head Detail
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C. Direct current (DC) straight
polarity is used for plasma cutting, as shown in the
illustration.
Zone A is used as a secondary gas that cools the torch.
This gas assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a
fast, slag - free cut.
B. Gas Distribution
The single gas used is internally split into plasma and
secondary gases.
The plasma gas flows into the torch through the negative lead, through the gas distributor , around the electrode, and out through the tip orifice.
The secondary gas flows down around the outside
of the torch gas distributor, and out between the tip
and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot arc
creates a path for the main arc to transfer to the work.
A-00002
B
One pressure switch acts as an interlock for the gas
supply. If supply pressure falls below minimum requirements the pressure switch will open, shutting
off the DC power, and the GAS Indicator will go off.
When adequate gas supply pressure is available the
pressure switch will close, allowing power to be resumed for cutting.
G. Parts - In - Place (PIP)
The torch head has built - in contacts called Parts - In
- Place (PIP). These two contacts are made through
the ring inside the shield cup when the shield cup is
installed. The torch will fail to operate if these contacts are not made.
To Control
Cable Wiring
A-03540
Torch Switch
PIP Pins
Torch Trigger
Shield Cup
Figure 2-5 Parts - In - Place (PIP) Diagram (Hand
Torch)
Torch Switch
To Control
Cable Wiring
PIP Pin
Shield Cup
PIP Pin
A-00458
Figure 2-3 Parts - In - Place (PIP) Diagram (Machine
Torch)
Manual 0-2817 2-3 INTRODUCTION
INTRODUCTION 2-4 Manual 0-2817
SECTION 3:
INSTALLATION
3.01 Introduction
This section describes installation of the Torch. These
instructions apply to the T orch and Leads Assemblies only .
Installation procedures for the Power Supply , Options and
Accessories are provided in Manuals specifically provided for those products.
The complete installation consists of:
• Site Selection
• Unpacking
• Setting Up T or c h
• Connecting T orch
• Gas Connection
3.02 Site Location
3.05 Setting Up Machine Torch
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
The machine torch is factory assembled to the Power Supply. The standard machine torch includes a fiberglass
positioning tube with rack and pinch block assembly. A
metal mounting tube with rack & pinion assembly or the
pinion assembly only are available as options.
1. Mount the torch assembly on the cutting table.
2. T o obtain a clean vertical cut, use a squar e to align
the torch perpendicular to the surface of the workpiece.
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(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.
3.04 Setting Up Hand Torch
The hand torch is factory assembled to the Power Supply
and requires no special set up. The proper torch parts
(shield cup, tip, gas distributor, and electrode) must be
installed for the type of operation. Refer to Section 4.04,
Torch Parts Selection for more information.
Pinch Block
Assembly
Square
Workpiece
A-02591
Figure 3-1 Machine Torch Set - Up
3. The proper torch parts (shield cup, tip, gas distributor, and electrode) must be installed for the
type of operation. Refer to Section 4.04, Torch
Parts Selection for more information.
Manual 0-2817 3-1 INST ALLATION
3.06 Connecting T orc h
NOTE
4. Connect the torch Negative / Plasma Lead to the
bulkhead connection inside the Power Supply.
Equipment ordered as a system will have the T or ch
factory connected to the Power Supply.
The instructions for connecting the Torch Leads to the
Power Supply are different depending on the type of
leads. This sub - section covers connecting the T o r ch for
the following applications:
A. Hand Systems
B. Machine Systems (Unshielded Leads)
C. Remote Pendant Control (Optional)
The T orch Leads must be pr operly installed to the Power
Supply for proper operation. If the torch leads were not
factory - installed, make all torch connections to the T or ch
Bulkhead Panel for the desired application.
A. Hand Systems
WARNING
Disconnect primary power at the source before disassembling the torch or torch leads.
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Adapter
Control Circuit
Connectors
Negative/Plasma
Lead Connection
Torch Lead
Assembly
or ATC Adapter
Pilot Lead
Negative/Plasma
Lead
Connector
Pilot Lead Stud
A-03542
Figure 3-3 Torch Lead Connections For CutMaster
50 Power Supply
1. Remove the nut from the Through - hole protector .
Torch Leads
Assembly
Negative /
Plasma Lead
Thru-Hole Protector
Thru-Hole Protector Nut
Pilot Lead
Art # A-03852
Figure 3-2 Through - hole protectorNut Removal
2. Pass the torch lead ends and the Through - hole
protector into the hole in the unit.
3. Secure the Through - hole protector with the nut
removed earlier.
Note: Actual Bulkhead
configuration may
differ from that shown.
Adapter
Control Circuit
Connectors
Torch Leads
Assembly or
ATC Adapter
A-03527
Adapter
Connector
Plug
Negative/Plasma
Pilot Lead Stud
Negative/Plasma Lead
Connection
Pilot Lead
Lead
Figure 3-4 Torch Lead Connections For PakMaster
50XL Plus Power Supply
5. Connect the T orch Leads Cables to the mating connectors on the Adapter supplied on the Power
Supply.
6. Remove the top nut and washer from the Pilot
Stud.
INST ALLATION 3-2 Manual 0-2817
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