Tweco SC10 User Manual

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A-00686

Instruction Manual

February 11, 2004 Manual No. 0-2479

W ARNINGS

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

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

Standoff Control
Model SC10
Instruction Manual No. 0-2479

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

Copyright 1996 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written permis­sion of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in this
Manual, whether such error results from negligence, accident, or any
other cause.

Printed in the United States of America

Publication Date: February 1 1, 2004

Record the following information for W arranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

T or ch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1:

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

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.0 2 Important Safety Precautions....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.0 4 Note, Attention et Avertissement.................................................................. 1-3

1.0 5 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty .................................................................................. 1-8

SECTION 2:

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

2.0 1 Scope of Manual .......................................................................................... 2-1

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

2.0 3 Specifications & Design Features................................................................. 2-1

SECTION 3:

INST ALLA TION PR OCEDURES ........................................................................................ 3-1

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

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

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

3.04 Installation - General..................................................................................... 3-1

3.0 5 Mounting Bracket Assembly Installation....................................................... 3-2

3.0 6 Standoff Control Assembly Installation ......................................................... 3-2

3.0 7 Installation With TD-750 Systems ................................................................. 3- 4

3.0 8 Installation With Merlin 3000 Systems .......................................................... 3-7

3.09 Internal Selections........................................................................................ 3-8

3.10 External Cable Connections.......................................................................... 3-8

3.1 1 Lifter Motor Installation ................................................................................. 3-9

SECTION 4:

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

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

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

4.03 Operating Controls........................................................................................ 4-1

4.04 Sequence Of Operations .............................................................................. 4-2

SECTION 5:

CUSTOMER/OPERA T OR SERVICE.................................................................................. 5-1

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

5.02 Routine Maintenance .................................................................................... 5-1

5.03 T roubleshooting Guide .................................................................................. 5-1

5.04 Troubleshooting Specific Problems ............................................................... 5-2

5.05 Test Procedures............................................................................................ 5-3

TABLE OF CONTENTS (continued)

SECTION 6:

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

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

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

6.0 3 Standoff Control Assembly Parts.................................................................. 6-2

6.04 Replacement External Control Cables........................................................... 6-3

6.0 5 Lifter Motor Assembly Parts ......................................................................... 6-4

APPENDIX 1: STANDOFF CONTROL ACCESSOR Y - WIRING DIAGRAM ..............................A-1

APPENDIX 2: STANDOFF CONTROL PC BOARD PARTS LOCATION.................................... A-2

APPENDIX 3: START CIRCUIT SCHEMATIC ...........................................................................A-3

APPENDIX 4: OK-T O-MOVE CIRCUIT SCHEMATIC ................................................................ A-4

APPENDIX 5: LIFTER MO T OR ASSEMBLY DET AILED DIMENSIONS ....................................A-5

MOUNTING HOLE TEMPLATE ..................................................................................................A-7

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

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

To prevent possible injury, read, understand and
follow all warnings, safety precautions and in­structions before using the equipment. Call 1-603­298-5711 or your local distributor if you have any
questions.

GASES AND FUMES

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

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

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

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

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

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

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

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

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

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

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

ELECTRIC SHOCK

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

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

Date: J a nuary 27, 2004 1-1 GENERAL INFORMATION

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any
service or repairs.

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

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from
the workplace.

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

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

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

NOISE

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

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

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

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

PLASMA ARC RA YS

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

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

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

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

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

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

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

1.03 Publications

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

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

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

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

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU­P ATION AND EDUCA TIONAL EYE AND F ACE PRO­TECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the Ameri­can National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-2 Date: J anuary 27, 2004

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

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

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

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

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

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

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

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

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

ATTENTION

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

AVERTISSEMENT

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

1.05 Precautions De Securite
Importantes

AVERTISSEMENTS

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

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

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

1.04 Note, Attention et

Avertissement

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

NOTE

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

Date: J a nuary 27, 2004 1-3 GENERAL INFORMATION

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

FUMÉE et GAZ

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

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

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

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

• Réparez ou remplacez toute pièce usée ou
endommagée.

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

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

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

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

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

INCENDIE ET EXPLOSION

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

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

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

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

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

• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper . Le gas hydrogène accumulé
explosera si enflammé.

Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.

GENERAL INFORMATION 1-4 Date: J anuary 27, 2004

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

RAYONS D’ARC DE PLASMA

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

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

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

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

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

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

1.06 Documents De Reference

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

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

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

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

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

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

BRUIT

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

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

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

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

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

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

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

Date: J a nuary 27, 2004 1-5 GENERAL INFORMATION

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

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

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

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

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

14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 Date: J anuary 27, 2004

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

W est Lebanon, New Hampshire 03784
USA

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

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

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

National Standard and Technical Specifications

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

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

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

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

associated accessories.

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

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

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

Manufacturers responsible repr esentative: Steve W ard

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

Date: J a nuary 27, 2004 1-7 GENERAL INFORMATION

1.08 Statement of Warranty

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

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

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

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

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

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

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

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

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

Parts

XL Plus & Parts Parts

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

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Y ear 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

Effective: November 15, 2001

GENERAL INFORMATION 1-8 Date: J anuary 27, 2004

SECTION 2:

TORCH

MODE

LIFTER
SPEED

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions
and maintenance procedures for the SC10 Standoff Con­trol Accessory. 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

The SC10 Standoff Control Accessory extends the neces­sary system controls away from the power supply and is
an accessory for use with standard machine torch sys­tems.

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A-00686

Figure 2-1 SC10 Standoff Control

The SC10 Standoff Control must be connected to the Re­mote Control Accessory RC6010.

There is a connection available at the rear panel for con­nection to the lifter motor. An internal jumper ribbon
cable also interfaces the unit to the Remote Control. The
inputs and outputs at these connections allow the vari­ous parts of the system to be operated at one station.

Remote

Control Assembly

Remote

Control Cable

The SC10 Standoff Control is designed to be used with
the RC6010 Remote Control. The Standoff Control is me­chanically mated with the Remote Control, either top or
bottom, and electrically connects to the Remote Control
through a 34 circuit ribbon cable from which it receives
bias power (+48 vdc), torch voltage signal (0-12 vdc = 0­200 arc volts) and sends and receives power supply and
CNC control signals such as start, arc transfer (OK-To­Move) and standoff inhibit (CSD).

The Standoff Control operates the torch lifter motor as­sembly to find height, regulate height and retract at end
of cut. Height is regulated by comparing the torch arc
voltage with a preset reference voltage (ARC VOLTS con­trol) and using the resulting error voltage to raise and
lower the torch lifter motor.

Internal Jumper

Ribbon Cable

Power Supply

Assembly

Standoff

Control Accessory

Lifter Motor

Control Cable

Lifter Motor

A-00699

Figure 2-2 Modular Remote System Configuration

2.03 Specifications & Design
Features

A. Standoff Control

The following applies to the Standoff Control Assembly
only.

1. System Compatiblility

The Standoff Control Accessory was designed to be
used with various Plasma Cutting Systems

Manual 0-2479 2-1 INTRODUCTION & DESCRIPTION