Page 1
REMOTE CONTROL
Model RC6010
ON
PLASMAPLASMA
ENABLEENABLE
START
REMOTE POWER SUPPLY CONTROL
OUTPUT AMPS
25 75
50
125+
IPM
0-125
SD
100
IPM
(%)
RUN
PURGE
TRAVELTRAVEL
SPEEDSPEED
SET
A-00668
Instruction Manual
December 10, 1997
Manual No. 0-2478
Page 2
Page 3
WARNING
WARNING
Read and understand this entire Instruction Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Thermal Dynamics Remote Control Model RC6010
Instruction Manual Number 0-2478
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1995
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
omission in the Thermal Dynamics Remote Control Instruction
Manual, whether such error results from negligence, accident, or
any other cause.
December 10, 1997
Page 4
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ..................................................................................... 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et A v ertissement ................................................................... 3
1.05 Precautions De Securite Importantes ............................................................ 3
1.06 Documents De Reference ............................................................................. 5
1.07 Declaration of Conformity .............................................................................. 6
1.08 Statement of W arr anty................................................................................... 7
SECTION 2: INTR ODUCTION & DESCRIPTION........................................................................ 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description....................................................................................... 9
2.03 Specifications & Design Features .................................................................. 9
SECTION 3: INSTALLATION PROCEDURES ........................................................................... 11
3.01 Introduction.................................................................................................. 11
3.02 Site Location................................................................................................ 11
3.03 Unpacking ................................................................................................... 11
3.04 Installation - General.................................................................................... 11
3.05 Remote Control Assembly Installation ......................................................... 11
3.06 Output Connector Installation With TD-750 Systems ................................... 13
3.07 Output Connector Installation With Merlin 3000 and 6000 Systems............. 14
3.08 Internal Switch and Jumper Selections........................................................ 14
3.09 External Cable Connections ........................................................................ 18
SECTION 4: OPERATION ......................................................................................................... 21
4.01 Introduction.................................................................................................. 21
4.02 Functional Overview .................................................................................... 21
4.03 Operating Controls ...................................................................................... 21
SECTION 5: CUST OMER/OPERATOR SERVICE..................................................................... 23
5.01 Introduction.................................................................................................. 23
5.02 Routine Maintenance................................................................................... 23
5.03 Troubleshooting Guide ................................................................................. 23
5.04 Troubleshooting Specific Problems .............................................................. 24
SECTION 6: PARTS LISTS........................................................................................................ 27
6.01 Introduction.................................................................................................. 27
6.02 Ordering Information.................................................................................... 27
6.03 Remote Control Assembly P arts.................................................................. 28
6.04 Replacement External Control Cables......................................................... 29
APPENDIX I: REMO TE CONTROL ACCESSORY - WIRING DIAGRAM .................................. 31
APPENDIX II: REMOTE CONTROL PC BOARD PARTS LOCATION ........................................ 32
APPENDIX III: CNC CABLE ...................................................................................................... 3 3
Page 5
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.
W ARNING
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.
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.
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.
Date: 6/22/99 1 GENERAL INFORMA TION
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.
ELECTRIC SHOCK
• Never touch any parts that are electrically “live” or
“hot.”
• W ear 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.
Page 6
• 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 hydr ogen 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.
• T o pr otect your hearing fr om loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC 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 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 HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, 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, W ashington, 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
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds 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
GENERAL INFORMATION 2 Date 6/22/99
Page 7
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. NFP A Standar d 70, NA TIONAL 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 W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARA TION 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
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 :
A VERTISSEMENT
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.
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
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant r ésulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
Date: 6/22/99 3 GENERAL INFORMA TION
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.
Page 8
• 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.
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
P AS 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.
RAYONS D’ARC DE PLASMA
CHOC ELECTRIQUE
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.
• 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.
• 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. (Voir 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.
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 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 oculaire.
• 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.
GENERAL INFORMATION 4 Date 6/22/99
Page 9
• 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.
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. Vous dú4ez vous protéger 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.
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 TRAVAIL 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 aupr ès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRA TIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, 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
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 York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (A WS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American W elding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFP A), 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, Batterymarch
Park, Quincy, MA 02269
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 W1 17.2, 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. ivret 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
Date: 6/22/99 5 GENERAL INFORMA TION
Page 10
14. Norme A WSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION 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, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION 6 Date 6/22/99
Page 11
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
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
manufacturing process. This is to ensure the product is safe, when used accor ding 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 pr oduct 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
Director of Operations
Thermadyne UK
Chorley England
Date: 6/22/99 7 GENERAL INFORMA TION
Page 12
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 prac tice,
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
PA R 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 80XL , 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 80XL 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 Series & Parts Parts
PAK Units, Power Supplies CutMaster 80XL 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
Consolles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 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 May 6, 1999
GENERAL INFORMATION 8 Date 6/22/99
Page 13
SECTION 2:
INTRODUCTION &
Standoff
Control Assembly
Power Base
Unit
DESCRIPTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and maintenance procedures for the RC6010 Remote
Control Accessory. Service of this equipment is restricted
to Thermal Dynamics 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
The RC6010 Remote Control Accessory extends the necessary system controls away from the power supply and
is provided with standard machine torch systems.
There are connections available at the Remote Control
Accessory for CNC control and Plasma Power Supply.
The inputs and outputs at these connections allow the
various parts of the system to be operated at one station.
Some of the functions of the Remote Control Accessory
may not operate depending on the Plasma Cutting System used.
All necessary cables are supplied for the type system ordered. If the RC6010 Remote Control Accessory is not
purchased as part of a system, the appropriate remote
control cable and a CNC cable (if required) must be ordered separately. Refer to Section 6, Parts Lists, for ordering information.
Internal Ribbon
Cable
Remote Control
Cable
Remote
Control Accessory
CNC
Control Cable
CNC Control
A-00670
Figure 2-2 TD-750 System Configuration
Standoff
Control Assembly
Internal Ribbon
Cable
Plasma
Power Supply
Remote Control
Cable
Remote
Control Accessory
CNC
Control Cable
CNC Control
A-01268
Figure 2-2 Merlin 3000 & 6000 System
Configurations
2.03 Specifications & Design Features
A. System Compatiblility
The RC6010 Remote Control Accessory was designed to
ON
PLASMAPLASMA
ENABLEENABLE
START
REMOTE POWER SUPPLY CONTROL
OUTPUT AMPS
25 75
50
125+
IPM
0-125
SD
100
IPM
(%)
RUN
PURGE
TRAVELTRAVEL
SPEEDSPEED
SET
A-00668
Figure 2-1 RC6010 Remote Control
Manual 0-2478 9 INTRODUCTION & DESCRIPTION
be used with the following:
• TD-750 Plasma Cutting System
• Merlin 3000 and 6000 Plasma Cutting Systems
Page 14
B. Input Power
TD-750 System
Supplied by the Power Base Unit
Merlin 3000 and 6000 Systems
Supplied by the Power Supply
C. Front Panel Controls
PLASMA Enable, RUN/PURGE/SET, Current Output, Corner Slowdown (CSD), and TRAVEL SPEED
D. Front Panel Indicators
Amperage Display , ON, ST AR T , 125+ IPM, 0-125 IPM,
RUN, PURGE, and SET indicators
E. Rear Panel Connections
The rear panel provides connections for CNC Control and the Plasma Power Supply
F. Dimensions (H xW xL)
2.62 x 12.12 x 10 inches (66 x 308 x 254 mm)
F. Weight
5 lbs (2.5 kg)
INTRODUCTION & DESCRIPTION 10 Manual 0-2478
Page 15
SECTION 3:
INSTALLATION
PROCEDURES
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.
3.01 Introduction
This Section describes installation of the RC6010 Remote
Control Accessory. These instructions apply to the Remote Control Accessory only; installation pr ocedures for
the Plasma Power Supply and T orches ar e given in Manuals specifically provided for those units.
The complete installation consists of:
1. Site Selection
2. Unpacking
3. Installing Remote Control Assembly
4. External Cable Connections
5. 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.
3.04 Installation - General
WARNING
Disconnect primary power to the plasma cutting
system before installating the Remote Control.
The installation of the Remote Control Accessory requir es
mounting the Remote Control and connecting all required
cables.
The installation instructions are divided into Sub-Sections
for the component to be installed. The Sub-Sections are
as follows:
Section 3.05 Remote Control Assembly Installation
Section 3.06 Installation With TD-750 Systems
Section 3.07 Installation With Merlin 3000 and 6000
Systems
Section 3.08 Internal Switch/Jumper Selections
3.03 Unpacking
Each component of the system is packaged separately and
protected with a carton and packing material to prevent
damage during shipping. Components are packaged as
follows:
A. Remote Control Components
Remote Control Accessory components are packaged
separately and include:
• Remote Control Assembly
• Instruction Manual
• Power Supply and CNC Control Cables
B. Other Equipment and Accessories
Items such as Standoff Control, Plasma Cutting Power
Supply and Torch are ordered and packaged separately
from the Remote Control components.
C. Unpacking Procedure
1. Unpack each item and remove all packing material.
Section 3.09 External Cable Connections
The Remote Control Assembly and external cable installation is the same for all systems.
3.05 Remote Control Assembly Installation
The Remote Control Assembly must be installed in a suitable location where it is easily accessable to the system
operator. The unit can be mounted on top of or underneath a mounting surface.
Mount the Remote Control Assembly per the following
procedure:
1. Select the mounting surface for the Mounting
Bracket.
2. Mount the bracket to the surface either on top of or
underneath the surface using four 1/4" bolts (not
supplied). It is recommended to use at least four
bolts to mount the bracket but a minimum of two
are required.
Manual 0-2478 11 INST ALLATION PROCEDURES
Page 16
NOTE
There are seven holes provided in the Mounting
Bracket. Use any four holes that are convenient
for the application.
1/4" Mounting Bolts
(Not Supplied)
A-00673
RUN
PURGE
SET
Hex Head Bolt
#10-32 x 3/8"
Slot
Knob
Figure 3-3 Bolt Installation
A-00671
Mounting Holes
(Seven Places)
Figure 3-1 Bracket Mounting On Top Of Surface
Mounting Holes
(Seven Places)
A-00672
1/4" Mounting Bolts
(Not Supplied)
Figure 3-2 Bracket Mounting Underneath Surface
3. Insert two of the #10-32 x 3/8" hex head bolts into
the slots on each side of the Remote Control unit.
The slot prevents the bolts from turning when the
knobs are installed.
4. Set the Remote Control unit into the Mounting
Bracket being sure the four bolts are in the mounting slots.
Mounting Bracket
Knob
Hex Head
Bolts
A-00674
Knob
Figure 3-4 Knob Installation
5. Place one knob on each of the bolts protruding from
the bracket slots.
6. The Remote Control unit can be adjusted for the
best viewing angle. The unit can be tilted up to
10°. Adjust the viewing angle per the following:
a. Loosen the four knobs sercuring the Remote
Control to the Mounting Bracket.
b. Adjust the Remote Control for the desir ed angle.
c. Tighten all four knobs.
d. If the angle is not correct, loosen knobs, read-
just until proper viewing angle is found, and
retighten all knobs.
INST ALLATION PROCEDURES 12 Manual 0-2478
Page 17
3.06 Output Connector Installation With TD-750 Systems
NOTE
The instructions in this Sub-Section are for TD750 Systems ordered without the Remote Control.
If the Remote Control was ordered as part of a system then the correct output connector was installed
at the factory. Proceed to the next Sub-Section.
This Sub-Section describes the two remote outputs that
are available with the TD-750 Power Base Unit. Depending on the remote control option to be used determines
the type of output connections that must be available at
the rear of the Power Base Unit.
The remote controls and connections available are as follows:
Cable Connector To
Control Module
J23
TO CONTROL
MODULE (J11)
Remote Control Panel
J27
CONTROL
TO REMOTE
A-00808
Cable Connector To Optional
Remote Control
• Remote Control RC6045 or Power Supply CNC
Cable (refer to paragraph 'A' below)
• Remote Control RC6010 (refer to paragraph 'B' below)
A. Used With RC6045 or CNC Cable
The output at the rear of the Power Base Unit has two
output connectors as shown in Figure 3-5. This output is factory installed and is used when the RC6045
Remote Control or connections to CNC equipment is
required.
Cable Connector To
Control Module
J23
TO CONTROL
MODULE (J11)
Cable Connector To
Remote Control/CNC
J25
TO REMOTE
CONTROL / CNC
A-00634
Remote Control Panel
Figure 3-5 Power Base Unit Remote Output
Accessory For RC6045 or CNC Cable
Figure 3-6 Power Base Unit Remote Output
Accessory For RC6010 Remote
Systems that already have the proper remote output accessory installed in the rear panel of the Power Base Unit
for the application proceed to the next Section 3.07.
WARNING
Disconnect primary power at the source before assembling or disassembling stacked modules, individual modules, torch parts, or torch and leads assemblies.
C. Removing Side Panel
The right side of the Power Base Unit must be removed
to install the remote output assembly.
1. Using a phillips head screwdriver remove the eight
screws securing the right side panel to the Power Base
Unit. The two screws in the slotted holes need only
be loosened for the panel to be removed.
B. Used With RC6010 Remote Control
The output at the rear of the Power Base Unit has two
output connectors as shown in Figure 3-6. This output is factory installed and is used with the RC6010
Remote Control.
Manual 0-2478 13 INST ALLATION PROCEDURES
Page 18
To check or change the switch selections use the following procedure:
1. Remove the two cover mounting screws on the top of
the Remote Control Accessory.
Right Side Panel
Screws, External Star Washers
A-00675
and Flat Washers (8-Places)
Figure 3-7 Screw Removal Details
2. Slide the right side panel forward and down to
disengage the two screws in the slotted holes.
3. Pull the right side panel from the Power Base Unit.
D. Installation Of Remote Output
Screw
Screw
Cover
ON
PLASMA
ENABLE
START
REMOTE POWER SUPPLY CONTROL
OUTPUT AMPS
25 75
50
125+
IPM
0-125
SD
100
IPM
(%)
RUN
PURGE
TRAVEL
SPEED
SET
A-00676
Figure 3-8 Cover Removal
2. Remove the enclosure cover by lifting straight up at
the rear of the cover and pulling it towards the r ear of
the unit. The front edge of the cover fits under a lip
on the front panel assembly.
Install the remote output assembly per the instructions
supplied with the Remote Output Accessory Kit.
3.07 Output Connector Installation With Merlin 3000 and 6000 Systems
The Merlin Systems come standard with the the remote
output connector. There are no internal Power Supply
parts to be installed.
3.08 Internal Switch and Jumper Selections
A. Switch Selections
The Remote Control Assembly has two internal switches
that have the following functions:
Switch Function
SW1 CNC Station Select and CSD Select
SW2 O K-To -Move Activat ion
3. Identify internal switches SW1 and SW2 and confirm
that each switch is set to the desired setting as follows:
a. Switch SW1 Selections
CNC Station Select/CSD Contact Switch (SW1) Selects normally open (NO) or normally closed
(NC) contacts for corner slowdown and station
select.
Station Select selection is an input normally used
when there are multiple plasma systems on a
single cutting machine. It allows the disabling of
one or more plasma cutting systems using a switch
or relay instead of turning OFF the system power .
The selection is factory set to activate with an open
contact but it can be set so a closed connection is
required to activate.
Corner Slowdown (CSD) selection is a signal from
the cutting machine controller used to deactive the
standoff control during speed changes or when
arc voltage changes would cause incorrect standoff distance. It may be used to reduce the cutting
current as the speed is reduced when cutting corners and sharp radiuses. The selection is factory
INST ALLATION PROCEDURES 14 Manual 0-2478
Page 19
set for closed contact which means that no connection equals standoff active and normal current.
It may be set so that an open connection activates
the CSD function.
OK-To-Move Activation SW2-1 SW2-2
Activate at Pilot Start ON ON
Activate CNC
Function with:
CSD
SW1 -1
St ation Sel e ct
Open Contact ON OFF *
Closed Contact OFF* ON
* = Factory Setting
Remote Control
PC Board Assembly
SW1 -2
Activate at Arc Transfer OFF * O FF*
* = F act ory Set ti ng
Remote Control
PC Board Assembly
A-00678
1
ON
2
ON
1
2
SW1
CNC Station Select/
CSD Contact Selection
Figure 3-9 Switch SW1 Location
B. Switch SW2 Selections
OK-To-Move Activation Switch (SW2) - The OKT o-Move signal may be set to activate either at pilot
start or arc transfer.
If the application requires starting the torch of f the
edge of the workpiece this selection should be set
to activate at pilot start.
A-00677
SW2
OK-To-Move
Activation Selection
Figure 3-10 Switch SW2 Location
C. OK-To-Move Jumper Selections
The OK-T o-Move signal may be selected by either a contact closure or 24 V AC switched thr ough the contact. The
Remote Control is factory-set for dry contacts. The purpose of selecting 24 VAC is to drive a relay coil whose
current must not exceed 150 ma or solid state relays in
cutting machine controllers.
Manual 0-2478 15 INST ALLATION PROCEDURES
Page 20
• ENABLE switch is ON
E1
J6
A-00679
Remote Control
PC Board Assembly
Figure 3-11 OK-To-Move Jumper Location
A jumper wire is connected between the terminal block
J6 and the lug connection E1 on the PC board. Select the
proper operation by moving the end of the wire connected
to the terminal block per the following chart:
• ST ATION SELECT switch is active
Contacts close when arc transfers to signal OK-T o-Move.
T o select contact closure connect the E1 jumper to termi-
nal block J6 position 14.
Jumper
Wire
13
A-00716
15
J6
16
E1
Contact Closure
J29-12
J6-13
NC
J6-16
J29-14
Wiring Diagram
Figure 3-12 Wiring Using Contact Closure
T o select 24 VAC connect the E1 jumper to terminal block
J6 position 15.
Jumper
Wire
E1
Contact Closure
O K-To -Move Sele ction J6
Dry Contacts 14*
24 VAC 15
* = Factory Setting
The Remote Control supplies an isolated OK-To-Move
signal. The signal may be selected to be a relay contact
closure that closes to signal motion start or a 24 VAC signal.
NOTE
When using the Remote Control the OK-To-Move
signal in the Control Module should be set for contacts. Refer to the Control and Power Components
Operating Manual supplied with the Control Module.
The OK-To-Move signal is available at the Remote Control rear panel CNC connector, J29 pins 12 and 14, or at
the internal CNC connection, J6 pins 13 and 16. The contacts are normally closed (NC) when power is OFF . When
power is turned ON the contacts open if the following
conditions are met:
13
A-00717
14
J6
16
J29-12
J6-13
J6-16
J29-14
Wiring Diagram
NC
24 VAC
Figure 3-13 Wiring Using 24 VAC
For cutting systems using two or more plasma supplies it
is neccessary to connect the OK-T o-Move in each Remote
Control to both turn ON to get the proper motion signal.
If the units turn ON at different times then motion may
start before the second plasma transfers. It is recommended that the OK-T o-Move contacts be connected per
the following:
Using Contact Closure Only
Connect the OK-To-Move contacts in series. Both contacts need to be closed, normal condition, to have a completed circuit. When one plasma supply is not being used,
either by the plasma power supply power, STATION
SELECT , or ENABLE are turned OFF, the contact closure
INST ALLATION PROCEDURES 16 Manual 0-2478
Page 21
for that system will be normally closed (NC). The system that is turned ON controls the OK-T o-Move signal to
the cutting equipment.
OK-To-Move
Contact Closure
(NC)
System #1
Remote Control
24
VAC
OK-To-Move
Contact Closure
(NC)
System #1
Remote Control
J29-14
J29-14
(NC)
J6-13 or
J6-13 or
J6-16 or
J6-16 or
OK-To-Move
Contact Closure
J29-12
J29-12
Cutting Equipment
Controls
System #2
Remote Control
A-00718
Figur 3-14 Wiring For Two Or More Sytems Using
Contact Closure
Using 24 VAC Signal
Connect the OK-To-Move contacts in one Remote Control for contacts and the second unit for 24 VAC.
NOTE
Do Not set both Remote Controls for 24VAC operation as the signals may be out of phase and cancel each other.
Cutting Equipment
J29-14
J6-16 or
J29-14
J6-16 or
OK-To-Move
Contact Closure
J6-13 or
(NC)
J29-12
J6-13 or
J29-12
Controls
System #2
Remote Control
A-00719
Figur 3-15 Wiring For Two Or More Sytems Using
24 VAC Signal
Using External AC or DC Voltage
An AC or DC voltage up to1 15 volts can be used for those
cutting systems that require an external AC or DC voltage.
NOTE
The Plasma power supply that is set for 24 VAC signal
must have power applied all the time. If the the unit is
not to be used then one of the following should be done:
• PLASMA ENABLE on the front panel of the Remote Control should be set to OFF
For systems using a single plasma power supply connect
the Remote Control OK-To-Move jumper for contacts.
Connect the external voltage between the cutting equipment and one side of the contact closure.
Do Not exceed 115 volts, AC or DC.
-or-
• Station Select (CNC Input) signal switched OFF
Manual 0-2478 17 INST ALLATION PROCEDURES
Page 22
OK-To-Move
Contact Closure
(NC)
J29-14
J6-16 or
J29-12
J6-13 or
System #1
Remote Control
Cutting Equipment
Controls
3.09 External Cable Connections
PS
J37
CNC
J29
Strain Relief
A-00680
Power Supply
Cable
External AC or DC Voltage
Maximum 115 Volts
A-00720
Figure 3-16 Wiring For One System Using External
Voltage
For systems using two or more plasma power supplies
connect the OK-To-Move contacts in series. Both contacts need to be closed, normal condition, to have a completed circuit. When one plasma supply is not being used,
either by the plasma power supply power, STATION
SELECT , or ENABLE are turned OFF, the contact closure
for that system will be normally closed (NC). The system that is turned ON controls the OK-T o-Move signal to
the cutting equipment. Connect the external voltage between one side of each contact closure.
OK-To-Move
Contact Closure
(NC)
J29-14
J6-16 or
J6-13 or
External AC or
DC Voltage
Maximum 115 Volts
J29-12
System #1
Remote Control
Cutting Equipment
Controls
CNC Control
Cable
Figure 3-18 Cable Connections
1. Power Supply Cable
Connect the Control Cable to the rear panel of the
Remote Control to the receptacle marked J37 (PS).
Connect the other end of the cable to the rear panel of
the Power Supply for the following systems:
• TD-750 System
Connect cable to the Power Base Unit at receptacle marked J27 (TO REMOTE CONTROL).
• Merlin 3000 and 6000 Systems
Connect cable to the Power Supply at receptacle
marked J15.
2. CNC Control Cable Using AMP Connector
NOTE
The supplied CNC cable is a shielded cable. Any
user supplied cable should also be of a shielded type.
The shields must be grounded only at the controller or cutting machine ground.
1. Connect the CNC Control Cable to the rear panel
of the Remote Control to the AMP receptacle
marked J29 (CNC).
J29-14
J6-16 or
OK-To-Move
Contact Closure
J6-13 or
(NC)
J29-12
System #2
Remote Control
A-00721
2. Connect the other end of the cable to the CNC Control Assembly per the following chart (r efer to Appendix III for more information).
Figure 3-17 Wiring For Two Or More Systems
Using External Voltage
INST ALLATION PROCEDURES 18 Manual 0-2478
Page 23
J29
Pin #
Polarity Description
10 + Corner Slowdown (CSD)
11 - Co rner Sl owdo wn (CSD) Return
3 + START /STO P
4 - ST ART/ST O P Re turn
5 + ST OP (Moment a ry)
6 - STOP (Moment ary) R et u rn
7 + Station Select
J6
8 - Stat ion Select Return
1 + START (Momentary)
2 - START (Momentary) Return
9 - E-ST O P (O n e si de O f Swit c h)
13 + E-STOP (Ot her Side Of Switch)
12 OK-To-Move (One Side Of Signal)
14 OK-To-Move (Other Side Of Signal)
3. CNC Control Cable - Hard Wired (Strain Relief)
NOTE
The supplied CNC cable is a shielded cable. Any
user supplied cable should also be of a shielded type.
The shields must be grounded only at the controller or cutting machine ground.
If the CNC cable from the CNC equipement cannot
be supplied with a mating AMP connector to J29
(CNC) the cable can be hard wired to the Remote
Control Accessory. To wire the cable to the unit use
the following procedure:
a. Remove the cover of the Remote Control to gain
access to the internal connection on the PC board.
b. Feed the control cable through the strain relief at
the rear panel of the Remote Control.
c. Locate the terminal block J6 on the PC board.
A-00681
Remote Control
PC Board Assembly
Figure 3-19 Terminal Block J6 Location
c. Connect the ends of the control cable to J6 on the
PC Board per the following chart:
NOTE
Pins 14 and 15 at J6 are used for OK-To-Move Selection only. Refer to Section 3.08-C for details.
J6
Pin #
Polarity Description
1 + Corner Slowdown (CSD)
2 - Corner Slow down (CSD) Re t urn
3 + START/STO P
4 - START /STOP R e t u rn
5 + STOP (Momentary)
6 - STOP (Momentary) Return
7 + St ation Select
8 - Station Select Return
9 + START (Momentary)
10 - START (Momentary) Return
11 - E- ST O P (O n e si d e O f Switch)
12 + E-STOP (Other Side Of Switch)
13 OK-To-Move (One Side Of Signal)
16 OK-To-Move (Other Side Of Signal)
d. Tighten the strain r elief to secure the contr ol cable.
e. Reinstall the cover to the Remote Control Acces-
sory.
Manual 0-2478 19 INST ALLATION PROCEDURES
Page 24
f. Connect the other end of the cable to the CNC Con-
trol Assembly (refer to Appendix III for more information).
INST ALLATION PROCEDURES 20 Manual 0-2478
Page 25
SECTION 4:
OPERATION
in preview mode. All thr ee decimal points r emain lit
when displaying corner slowdown output or operating in corner slowdown mode.
5. Current Control Adjustment
4.01 Introduction
This Section provides a description of the RC6010 Remote
Control Assembly followed by operating pr ocedures.
4.02 Functional Overview
The RC6010 Remote Control Accessory extends the necessary system controls away from the power supply and
is provided with standard machine torch systems.
There are connections available at the Remote Control
Accessory for CNC control, Standoff Control, and Plasma
Power Supply). The inputs and outputs at these connections allow the various parts of the system to be operated
at one station.
4.03 Operating Controls
1
PLASMA
ENABLE
2
ON
START
3
Figure 4-1 Front Panel Operating Controls
4
OUTPUT AMPS
56
REMOTE POWER SUPPLY CONTROL
50
25 75
0
CSD
(%)
100
7
125+
IPM
0-125
IPM
TRAVEL
SPEED
A-00682
RUN
PURGE
SET
8
Sets output current level.
6. CSD (%) Corner Slowdown Control Adjustment
Sets corner slowdown (CSD) output as a percentage
of main output.
7. TRAVEL SPEED Switch and Indicators
NOTE
This function used with TD-750 Systems Only.
Pushbutton used to select the pilot pulse rate and restart delay for the range of travel speed desired for
the operation. Each time the pushbutton is pressed
the travel speed indicators will toggle between 125+
IPM and 0-125 IPM speeds. The travel speed currently
selected is indicated by the indicator being turned ON.
8. Mode Selection Switch and Indicators
Pushbutton used to select the operating mode of the
system. Each time the pushbutton is pressed the mode
indicators will sequence through RUN, PURGE, and
SET . RUN mode is used for tor ch operation; PURGE
mode is used for purging the plasma gas line only;
SET mode is used to set the plasma and secondary
gas pressures and flows with Optional Gas Flow Control. The mode currently selected is indicated by the
indicator being turned ON.
1. PLASMA ENABLE (On/Off) Switch
Turns on contactor(s) in the Plasma Power Supply to
apply power to the Plasma Power Supply power and
control circuits when in the on (|) position. When the
switch is in the off (0) position the display will be blank
but some indicators may be ON.
2. ON Indicator
Yellow light indicates Plasma Power Supply is enabled.
3. START Indicator
Yellow light indicates Plasma Power Supply has received start signal from Remote Control.
4. OUTPUT AMPS Meter
Displays actual output during cutting operation. Preview mode displays expected output before starting
a cut according to the current setting. A decimal point
to the right of the display is lit whenever the meter is
NOTE
Mode cannot be switched from RUN mode during
cut operation.
Manual 0-2478 21 OPERA TION
Page 26
OPERA TION 22 Manual 0-2478
Page 27
SECTION 5:
5.03 Troubleshooting Guide
CUSTOMER/OPERATOR
SERVICE
5.01 Introduction
This Section describes basic maintenance procedures performable by operating personnel. No other adjustments
or repairs are to be attempted by other than Thermal
Dynamics T rained personnel.
W ARNINGS
Disconnect primary power at the source before disassembling any part of the cutting system.
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 cutting system is activated.
A. General
This manual covers a level of troubleshooting that requires
limited dissasembly and measurements. It is helpful for
solving many of the common problems that can arise with
the Remote Control System.
Troubleshooting and repairing the this unit is a process
which should be undertaken only by those familiar with
high voltage, high power electronic equipment.
W ARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
The troubleshooting guide consists of the following sections:
Section 5.04 Troubleshooting Specific Problems
Section 5.05 Test Procedures
CAUTION
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
5.02 Routine Maintenance
The only routine maintenance required for the RC6010
Remote Control components is a thorough cleaning and
inspection, with the frequency depending on the usage
and the operating environment.
To clean the Remote Control, first make sure that the
power is disconnected. Open the Remote Control enclosure and blow out any accumulated dirt and dust with
compressed air. The unit should also be wiped clean. If
necessary, solvents that are recommended for cleaning
electrical apparatus may be used.
While the enclosures are open, inspect the wiring in the
unit. Look for any frayed wires or loose connections that
should be corrected.
Follow all instructions as listed and complete each section of the troubleshooting guide in the order presented.
Specific test procedures have been grouped together and
are referenced by the troubleshooting guide.
B. How to use this Guide
The following information is a guide to help determine
the most likely causes for various symptoms.
This guide is set up in the following manner:
A. Symptom (Bold Type)
Any Special Instructions (Text Type)
1. Cause (Italic Type)
a. Check/Remedy (Text T ype)
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.
NOTE
Many signals are transfered between various assemblies on interconnecting cables. If these cables
become faulty they can then cause various problems. Do not forget about these cables when
troubleshooting.
Manual 0-2478 23 SERVICE
Page 28
5.04 Troubleshooting Specific Problems
Most of the RC 6010 circuits such as ST ART , OK TO MOVE
and CURRENT CONTROL are critical to the system operation and troubleshooting of them is intergrated into
the Power Supply troubleshooting section. This section
is for circuits not covered there.
NOTE
Any voltage measurements in this section are with
respect to TP1, the Remote Control PC Board common.
A. Front panel switch for TRAVEL SPEED or RUN/
PURGE/SET doesn’t work
The front panel momentary switches are part of a
membrane panel which connects to the Remote Control PC Board at J1.
1. Improper connection to PC Board
a. Check J1 for loose connection.
b. Check that connection is not plugged in with
one (or more) pins offset.
2. Faulty Remote Control PC Board
C. More than one of the RUN, PURGE, SET indica-
tors are ON
1. Improper connection to PC Board
a. Check J1 for loose connection.
b. Check that connection is not plugged in with
one (or more) pins offset.
2. Faulty indicator or Remote Control PC Board
Test the indicators per the following:
With one indicator ON, the anodes of each indicator is at 3.5 V. The cathode of the one indicator
that is ON is 1.2 V and the two indicators that are
OFF are 2 V.
a. Check J1 for loose connection.
b. Check that connection is not plugged in with
one (or more) pins offset.
2. Normal operation
It is normal that RUN/PURGE/SET can’t be switched
during the pilot or cut sequence.
3. Faulty RUN/PURGE/SET Switch
Measure continuity from Remote Control PC Board
common, TP1, to J1-7 while pressing the switch. It
should be less than 300 ohms.
a. Replace the Front Panel Assembly.
4. Faulty TRA VEL SPEED Switch (See Note)
NOTE
The TRAVEL SPEED circuit isn’t used with the
Merlin Systems.
Measure continuity from Remote Control PC Board
common, TP1, to J1-9 while pressing the switch. It
should be less than 300 ohms.
a. Replace the Front Panel Assembly.
B. One or more front panel indicators will not come
ON
Anode
Connection
J1-11 SET J1 -10
J1-13 PURGE J1-12
J1-18 RU N J1-17
Indicator
Cathode
Connection
If none of the three indicators are ON the anodes
would go to 5 V and the cathodes of the good ones
would be about 3.5V. The bad indicator would be
near 0 V if open, or 5 V if shorted.
a. If all the cathodes are at 3.5 V then replace the
Remote Control PC Board.
b. If one or more of the cathodes are near 0 V or 5
V, then replace the Front Panel Assembly.
D. START indicator OFF
Normal conditions of the ST ART indicator:
Anode Cathode
Indicato r
Condition
ON J1-3 About 3.5 V J1-2 About 1.4 V
OFF J1 -3 5 V J1-2 4.2 V
Connection Voltage Connection Voltage
The front panel indicators are part of a membrane
panel which connects to the Remote Control PC Board
at J1. One indicator ON at a time is normal.
1. Improper connection to PC Board
1. Faulty Remote Control PC Board
Measure the voltage at J1-3
a. Replace Remote Control PC Board if less than
5V.
SERVICE 24 Manual 0-2478
Page 29
2. Faulty Front Panel Assembly or Remote Control PC
Board
TRAVEL SPEED
Measure the voltage at JI-2
a. If 0 V (open) or 5 V (shorted) then replace Front
Panel Assembly .
b. If voltage is about 4.2 V then replace Remote
Control PC Board.
E. ON indicator OFF
The ON indicator should be ON whenever the
PLASMA ENABLE switch is ON.
PLASMA
ENABLE
Switch Connection Voltage Conne ction Voltage
ON J1-5 About 3.5 V J1-4 About 1.2 V
OFF J1-5 0.8 V J1-4 0 V
Anode Catho d e
1. Faulty connection btween the Remote Control and the
Power Supply
With the PLASMA ENABLE switch to ON, measure
the voltage at J1-4. If it is greater than 3 volts, then
the connection between J1-4 and J50-10 on the Merlin
Switching Control PC Board is faulty.
RUN / PURGE / SET
HI
LOW
RUN
PURGE
SET
ON
a. Check and repair connection
2. Faulty Front Panel Assembly
Measure the voltage at J1-4
a. If the voltage at J1-4 is between 1 and 5 volts,
then measure J1-5. If J1-5 is less than 1 volt
higher then J1-4 the ON indicator is shorted,
replace the Front Panel Assembly.
b. If the voltage at J1-4 is 0 volts, then check J1-5.
If J1-5 is high, greater than 12 volts, the ON indicator is open, replace the Front Panel Assembly .
c. If the voltage at J1-5 is less than 1 volt there is a
bad connection between J1-5 and J50-12 on the
Merlin Switching Control PC Board or the
Switching Control PC Board is defective.
START
A-01246
Figure 5-1 Indicator Circuit Diagram
Manual 0-2478 25 SERVICE
Page 30
SERVICE 26 Manual 0-2478
Page 31
SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provides a breakdown of all replaceable
components. The parts lists are arranged as follows:
Section 6.03: Remote Control Assembly Parts
Section 6.04: Replacement External Control Cables
NOTE
Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers
shown.
B. Returns
If a Thermal Dynamics product must be returned for service, contact your Thermal Dynamics distributor. Materials returned to Thermal Dynamics 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 Thermal Dynamics distributor .
Manual 0-2478 27 P A RTS LISTS
Page 32
6.03 Remote Control Assembly Parts
The replacement parts are limited as the Remote Control Accessory is designed as a complete replacement if failures
occur.
Item # Qty Description Catalog #
1 1 Remote Control Assembly (Includes items #5, 6, and 7) 3-6106
2 1 Mounting Bracket 8-3483
3 4 Clamping Knob 9-4488
4 4 Machine Screw, #10-32 x 3/8", Plain Hex Head See Note
5 1 Switch, SPST Rocker, 4A/2A, 125V/250V, Panel Mount 9-6690
6 1 Knob, With Pointer and Skirt, Gray, 1/8" Shaft - Current Control 8-3284
7 1 Knob, With Pointer, Gray, 1/8" Shaft - CSD (%) Adjustment 8-3286
NOTE: Item can be purchased locally.
1
ON
PLASMA
ENABLE
START
5
OUTPUT AMPS
REMOTE POWER SUPPLY CONTROL
25 75
50
CSD
100
(%)
TRAVEL
SPEED
125+
IPM
0-125
IPM
RUN
PURGE
SET
4
4
3
6
7
3
2
A-00683
PARTS LISTS 28 Manual 0-2478
Page 33
6.04 Replacement External Control Cables
Qty Description Catalog #
Remote Control Cable (TD-750 Power Base Unit to RC6010 Remote Control)
1 25 ft (7.6 m) 8-3466
1 50 ft (15.2 m) 8-3467
1 75 ft (22.8 m) 8-3468
1 100 ft (30.4 m) 8-3469
Remote Control Cable (Merlin Power Supply to RC6010 Remote Control)
1 25 ft (7.6 m) 9-5961
1 50 ft (15.2 m) 9-5962
1 75 ft (22.8 m) 9-5963
1 100 ft (30.4 m) 9-5964
CNC Interface Cable
1 5 ft (1.5 m) 9-4483
1 10 ft (3.0 m) 9-4484
1 15 ft (4.6 m) 9-4485
1 20 ft (6.1 m) 9-4486
Manual 0-2478 29 P A RTS LISTS
Page 34
PARTS LISTS 30 Manual 0-2478
Page 35
APPENDIX I: REMOTE CONTROL ACCESSORY -
WIRING DIAGRAM
Power Supply Cable To
Power Base Unit
Display Signal (+)
Display Signal (-)
START LED
PS ENABLE OFF
POT HI
POT HI Return
HI/LOW
HI/LOW Return
PLASMA START
Remote Installed
PURGE
PURGE Return
+48 V Return
+48 V
ON LED
DEMAND
DEMAND Return
SET Return
SET
POT LOW Return
POT LOW
ENABLE
E-STOP
OK-To-Move
ARC Volt Signal (-)
ARC Volt Signal (+)
+48 V Return
+48 V
+15 V
ARC ON
Cable To Optional
Arc Hour and
ArcStarts Counters
PS
J37
J37
Remote Control
PC Board
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
J4
1
2
Ribbon Cable Installed Between J5 and Standoff
Control PCB J7 When Standoff Control Is Used
J5
1234789
10111213141516171819222324
OK-To-Move Select
Jumper Wire
E1
Contacts
or
24 VAC
J9
J6
10
11
12
14
16
10
11
12
13
16
14
15
CNC Cable With
CNC
1
2
3
4
5
6
7
8
9
AMP Connector To
J29
10
11
13
12
14
CNC Equipment
START (Momentary)
1
START (Momentary) Return
2
START/STOP
3
START/STOP Return
4
STOP (Momentary)
5
STOP (Momentary) Return
6
Station Select
7
Station Select Return
8
Corner Slowdown (CSD)
Corner Slowdown (CSD) Return
9
E-STOP
OK-To-Move
CNC Cable Hard Wired
1
2
3
4
5
6
7
8
9
Corner Slowdown (CSD)
Corner Slowdown (CSD) Return
START/STOP
START/STOP Return
STOP (Momentary)
STOP (Momentary) Return
Station Select
Station Select Return
START (Momentary)
START (Momentary) Return
E-STOP
OK-To-Move
+48 V
+48 V
Ground
PS ENABLE
A-00684
ARC Volt Signal (-)
ARC Volt Signal (+)
HI LIFTER Speed
1234789
J7
Ground
Ground
Ground
Ground
START
Ground
Station Select
Delayed OK-To-Move
10111213141516171819222324
Standoff Control PC Board
Ground
Ground
OK From PS
Ground
START From SC
Manual 0-2478 31 APPENDIX
Page 36
PC Board
(See Note 3)
APPENDIX II: REMOTE CONTROL PC BOARD
PARTS LOCATION
J37 (See Note 1)
NOTES:
1. Connector J37 was J4 on earlier versions of the PC Board.
2. New version PC Board has new J4 connector.
3. Componet layout may be different from PC Board shown.
J4
(See Note 2)
J9
J5
J6
E1
J1
A-00685
SW1
SW2
APPENDIX 32 Manual 0-2478
Page 37
APPENDIX III: CNC CABLE
Signal inputs can be activated by one of the following:
Switches
Relay Closures
Solid State AC or DC Relays (40 VDC, 50ma rating)
Applying AC or DC Voltage (12-120V)
NPN or PNP Transistor Drivers (40 VDC, 50ma rating)
For DC voltage, DC solid state relays, or transistor drivers use the following polarities
as shown:
+
DC Voltage
See Note 1
+
Solid State
DC Relay
+
+
NPN Transistor Driver
PNP Transistor Driver
NOTES
1. When using a DC voltage the source plus (+) should be connected to the negative (-) line.
2. When using AC inputs the phase should be the same on each connection.
START
START RETURN
START/STOP
START/STOP RETURN
STOP
STOP RETURN
STATION SELECT
STATION SELECT RETURN
+
-
+
-
+
-
+
-
BLACK
RED
SHIELD
RED
GREEN
SHIELD
BLACK
BLUE
SHIELD
RED
WHITE
SHIELD
BLACK
YELLOW
E-STOP
-
+
SHIELD
J29
1
2
3
4
5
6
7
8
9
13
J6
or
9
10
3
4
5
6
7
8
11
12
CORNER SLOW DOWN
CORNER SLOW DOWN RETURN
OK-TO-MOVE
+
-
BLACK
GREEN
SHIELD
BLACK
WHITE
SHIELD
10
11
12
14
1
2
13
16
BLACK
ORANGE
SHIELD
BLACK
BROWN
SHIELD
A-00811
All Shields must be grounded at
the CNC Controller or Cutting
Machine.
Spare
Spare
Manual 0-2478 33 APPENDIX
Page 38
Loading...