Tweco PCM-62 User Manual

0 (0)

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 Torch

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 result from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: January 28, 2004

Record the following information for Warranty 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

1.07

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 Operation .............................................................................

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

Torch & 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

Torch Spare Parts Kits .................................................................................

6-9

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAMS ...........

A-1

For CutMaster 50 Applications .............................................................................

A-1

For PakMaster 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 1-603-298- 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 processes. You 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 area where fire hazards may exist.

Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. 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 protective ear plugs and/or ear muffs. Protect others in the workplace.

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

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

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly 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 OCCUPATION 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 Standard 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 W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

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

14.American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

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

May 14, 2002

1-3

GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West 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 requirements. 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 boards used.

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

*Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

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

Manufacturers responsible representative: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

GENERAL INFORMATION

1-4

May 14, 2002

1.08Statement 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 stored, 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, correct such defects by suitable repair 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 Torch

 

 

 

1 Year

1 Year

 

SureLok Torches

1 Year

 

1 Year

1 Year

 

All Other Torches

180 Days

180 Days

180 Days

180 Days

Repair/Replacement Parts

90 Days

90 Days

90 Days

None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective 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 Torch 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 compressed air from a single source to be used as both the plasma and secondary gas. The air flow is divided inside the torch head. Single - gas operation allows for a smaller sized torch and inexpensive operation.

Plasma torches are similar in design to the common automotive spark plug. They consist of negative and positive sections which are separated by a center insulator. Inside the torch, the pilot arc is initiated in the gap between the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas flows through the small orifice in the torch tip, which is focused on the metal to be cut.

2.03Specifications & 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 positioning tube with rack & pinch block assembly.

Available options include a kit with metal mounting tube with rack & pinion assembly or a kit with the pinion assembly only.

10.5 in

(267 mm)

3.0 in

(76.2 mm)

1.1in (28 mm)

10.0 in

(254 mm)

3.4 in

(86.4 mm)

1.1in (28 mm)

14.1 in

(358 mm)

13.5in (343 mm) Max

3.7in (94 mm) Min

1.1in (28 mm)

1.4 in

0.8 in

5.1 in

(35.6 mm)

(129.5 mm)

(20.3 mm)

0.6 in

 

 

(15.2 mm)

 

A-02813

Figure 2-1 Torch Configurations and Dimensions

Manual 0-2817

2-1

INTRODUCTION

B.Torch Leads Lengths

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 Parts

Gas Distributor, Electrode, Tip, Shield Cup

D.Parts - 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

104° F

Temperature

(40° C)

Duty Cycle

100% @ 60 Amps @ 375 scfh

 

 

Maximum Current

60 Amps

 

 

Voltage (Vpeak)

500V

 

 

Arc Striking Voltage

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.

2.04 Options And Accessories

These items can be used to customize a standard system for a particular application or to further enhance performance (refer to Section 6 for ordering information).

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

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

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

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

Pinion Assembly - For machine torches.

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

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

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

2.05 Introduction to Plasma

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

 

A

Supply

 

+

 

 

 

 

B

 

 

Workpiece

 

C

A-00002

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.

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 connected to the workpiece via the work cable and to the torch through a pilot wire.

F.Interlocks

One pressure switch acts as an interlock for the gas supply. If supply pressure falls below minimum requirements the pressure switch will open, shutting 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.

Torch Switch

Torch Trigger

To Control

 

Cable Wiring

 

PIP Pins

Shield Cup

A-03540

 

Figure 2-5 Parts - In - Place (PIP) Diagram (Hand

Torch)

Torch Switch

PIP Pin

To Control

Cable Wiring

Shield Cup

PIP Pin

A-00458

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

Torch)

Manual 0-2817

2-3

INTRODUCTION

2-4

Manual 0-2817

SECTION 3:

INSTALLATION

3.01 Introduction

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

The complete installation consists of:

Site Selection

Unpacking

Setting Up Torch

Connecting Torch

Gas Connection

3.02 Site Location

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

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

3.03 Unpacking

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

1.Unpack each item and remove all packing material.

2.Locate the packing list(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.

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

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

INSTALLATION

Tweco PCM-62 User Manual

3.06 Connecting Torch

NOTE

Equipment ordered as a system will have the Torch 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 Torch for the following applications:

A.Hand Systems

B.Machine Systems (Unshielded Leads)

C.Remote Pendant Control (Optional)

The Torch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory - installed, make all torch connections to the Torch Bulkhead Panel for the desired application.

A. Hand Systems

WARNING

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

1.Remove the nut from the Through - hole protector.

Torch Leads

Thru-Hole Protector

 

Assembly

 

Negative /

Thru-Hole

Protector Nut

Plasma Lead

 

 

 

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.

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

Note: Actual Bulkhead configuration may differ from that shown.

Adapter Negative/Plasma Connector Lead Connection

Adapter

Control Circuit

Connectors

Pilot Lead Stud

Pilot Lead

Negative/Plasma

Lead

Torch Lead

Assembly

or ATC Adapter

A-03542

Figure 3-3 Torch Lead Connections For CutMaster

50 Power Supply

Note: Actual Bulkhead

Adapter

 

configuration may

Pilot Lead Stud

Connector

differ from that shown.

 

 

 

 

Adapter

Plug

Control Circuit

Connectors

Torch Leads

Negative/Plasma Lead

Connection

Assembly or

 

ATC Adapter

Pilot Lead

Negative/Plasma

Lead

A-03527

Figure 3-4 Torch Lead Connections For PakMaster

50XL Plus Power Supply

5.Connect the Torch 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.

INSTALLATION

3-2

Manual 0-2817

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