Tweco SC11 User Manual

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A-00686

Instruction Manual

November 30, 2001 Manual No. 0-2556

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 SC11 Instruction Manual No. 0-2556

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

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: November 30, 2001

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

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

1.02 Important Safety Precautions ....................................................................... 1-1

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

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

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

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

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

SECTION 2:

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

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

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

2.03 Specifications & Design Features................................................................. 2-1

SECTION 3:

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

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

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

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

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

3.05 Mounting Bracket Assembly Installation ....................................................... 3-2

3.06 Standoff Control Assembly Installation ......................................................... 3-2

3.07 Installation With Automated Systems ........................................................... 3-3

3.08 Internal Selections........................................................................................ 3-3

3.09 External Cable Connections......................................................................... 3-5

3.10 Lifter Motor Installation ................................................................................. 3-6

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 .............................................................................. 4-3

SECTION 5:

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

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

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

5.03 Troubleshooting Guide ................................................................................. 5-1

5.04 T roubleshooting 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

6.03 Standoff Control Assembly Parts.................................................................. 6-2

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

6.05 Lifter Motor Assembly Parts ......................................................................... 6-4

APPENDIX 1: STANDOFF CONTROL ACCESSORY - WIRING DIAGRAM............................. A-1

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

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

APPENDIX 4: MO TION (OK-TO-MOVE) CIRCUIT SCHEMATICS ...........................................A-4

APPENDIX 5: CNC CONTR OL CABLE INTERFACE DIAGRAM.............................................. A-5

APPENDIX 6: SYSTEM INTERCONNECTION DIA GRAM.......................................................A-6

APPENDIX 7: LIFTER MO TOR ASSEMBLY DETAILED DIMENSIONS ...................................A-7

MOUNTING HOLE TEMPLATE .................................................................................................A-9

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

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

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

GASES AND FUMES

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

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

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

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

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

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

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

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

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

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

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

ELECTRIC SHOCK

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

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

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

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any service or repairs.

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

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from the workplace.

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

• Provide a fire watch when working in an area 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 FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

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

GENERAL INFORMATION 1-2 Date: Nov ember 15, 2001

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

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

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

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

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

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

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

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

14. American W elding Society Standard AWSF4.1, 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 procédur e pouvant r ésulter l’endommagement du matériel en cas de nonrespect de la procédur e en question.

AVERTISSEMENT

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

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

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

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

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

1.04 Note, Attention et

Avertissement

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

NOTE

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

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

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

FUMÉE et GAZ

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

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

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

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

• Réparez ou remplacez toute pièce usée ou endommagée.

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

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

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

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

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

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

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

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

CHOC ELECTRIQUE

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

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

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

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

INCENDIE ET EXPLOSION

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

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

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

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

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

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

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

GENERAL INFORMATION 1-4 Date: Nov ember 15, 2001

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

RAYONS D’ARC DE PLASMA

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

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

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

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

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

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

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

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

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

1.06 Documents De Reference

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

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

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

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

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

BRUIT

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

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

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

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

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

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

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

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

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

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

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

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

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

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA 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 1-6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

W est Lebanon, New Hampshire 03784 USA

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

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

National Standard and Technical Specifications

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

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

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

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

ated accessories.

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

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

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

Manufacturers responsible representative: Giorgio Bassi

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

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

1.08 Statement of Warranty

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

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

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

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

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

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

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

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

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

Parts

XL Plus & Parts Parts

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

Main Power Magnetics 3 Y ears 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year Control PC Board 3 Y ears 1 Year 2 Years 1 Year All Other Circuits And Components Including, 1 Year 1 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 August 6, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

TORCH

MODE

LIFTER SPEED

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions and maintenance procedures for the SC11 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 SC11 Standoff Control Accessory extends the necessary system controls away from the power supply and is an accessory for use with standard machine torch systems.

AUTO

FIND HT

P L

A S

ARC VOLTS

0 . 2

. 1

0 . 4

. 5

. 7

0 .

5 P I E R

( i n

. H

c h

. C

)

I V

I E

E A Y

7 ( s

)

T C T

(

)

A-00686

Figure 2-1 SC11 Standoff Control

All necessary cables are supplied for the type system ordered. If the SC1 1 Standoff Control Accessory is not purchased as part of a system, the appropriate remote control cable and a CNC cable (if required) must be or der ed separately . Some systems may requir e an external 48 volt power source. Refer to Section 6, Parts Lists, for ordering information.

Plasma Power

Supply

NOTE

The SC11 Standoff Contr ol functions without connection to the Remote Control Accessory RC6010.

The SC11 Standoff Control has all the connections required at the rear panel. The connections are for CNC Control, External Power , Lifter Motor , and Plasma Power Supply. The inputs and outputs at these connections allow the various parts of the system to be operated at one station.

The Standoff Control receives bias power (+48 vdc), tor ch voltage signal (0-12 vdc = 0-200 arc volts) and sends and receives power supply and CNC control signals such as start, arc transfer (OK-To-Move) 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.

Power Supply Control Cable

A-00700

Standoff

Control Accessory

CNC

Control Cable

CNC

Input Power

Lifter Motor

Control Cable

Lifter Motor

Figure 2-2 System Configuration With SC11

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

Manual 0-2556 2-1 INTRODUCTION & DESCRIPTION

used with various Plasma Cutting Systems

2. Input Power

48 vdc supplied from the Plasma Cutting Power Supply or an external 48 volt power source

3. Front Panel Controls

MODE, LIFTER SPEED, TORCH, ARC VOLTS, PIERCE HT , PIERCE DELAY , and END OF CUT RETRACT

4. Front Panel Indicators

Arc Volts Display, PLASMA ON, AUTO HT, FIND HT , HI, LO, T.H.C. ACTIVE, UP, and DN indicators

5. Rear Panel Connections

Connections for MOTOR, PLASMA, EXTERNAL POWER, CNC, and CNC Cable Strain Relief

6. Dimensions (H x W x L)

2.62 x 12.12 x 10 inches (66 x 308 x 254 mm)

7. Weight

5 lbs (2.5 kg)

B. Lifter Motor

The following applies to the Lifter Motor Assembly only.

1. Dimensions (H x W x D)

29 x 10 x 8 inches (737 x 254 x 203 mm) Refer to Appendix 7 for detailed dimensions.

2. Weight (Approximately)

20 lbs (9.07 kg)

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2556

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

This Section describes installation of the Standoff Control Accessory. These instructions apply to the Standoff Control Accessory only; installation procedures for the Plasma Power Supply and T o rches ar e given in Manuals specifically provided for those units.

For Other Cutting Systems:

• Standoff Control Assembly

• Lifter Motor Assembly

• Voltage Divider PC Board, Ribbon Cable, and Wire Harness Assembly

• Instruction Manual

NOTE

The V oltage Divider PC Board, Ribbon Cable and Wire Harness Assembly will be factory installed if ordered as part of a Plasma Cutting System.

B. Other Equipment and Accessories

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Installing Standoff Control Assembly

4. External Cable Connections

5. Lifter Motor Installation

6. Operator Training

3.02 Site Location

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

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

3.03 Unpacking

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. Standoff Control Components

The components supplied with the Standoff Control Accessory depends on the Cutting System. The Standoff Control Accessory components ar e packaged separately and include:

Items such as Lifter Motor Control Cable, CNC Cable, Remote Cable, Plasma Cutting Power Supply and Torch are ordered and packaged separately from the Standoff Control components.

C. Unpacking Procedure

1. Unpack each item and remove all packing material.

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

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

3.04 Installation - General

WARNING

Disconnect primary power to the plasma cutting system before installating the Standoff Control.

The installation of the Standoff Control Accessory requires mounting the Standoff 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:

For Automated Cutting Systems:

• Standoff Control Assembly

• Lifter Motor Assembly

• External Power Supply and Cables

• Instruction Manual

Manual 0-2556 3-1 INST ALLATION PROCEDURES

Section 3.05 Mounting Bracket Assembly Installa-

tion

Section 3.06 Standoff Control Assembly Installa-

tion

Section 3.07 Installation With Automated Systems Section 3.08 Internal Switch/Jumper Selections Section 3.09 External Cable Connection Section 3.10 Lifter Motor Installation

The Standoff Control Assembly and external cable instal-

TORCH

lation is the same for all systems.

3.05 Mounting Bracket Assembly Installation

The Mounting Bracket Assembly is used to mount the Standoff Control Assembly and 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.

Install the Mounting Bracket 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.

Mounting Holes

(Seven Places)

A-00672

1/4" Mounting Bolts

(Not Supplied)

Figure 3-2 Bracket Mounting Underneath Surface

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-00671

Mounting Holes

(Seven Places)

Figure 3-1 Bracket Mounting On Top Of Surface

3.06 Standoff Control Assembly Installation

Mount the Standoff Control Assembly per the following procedure:

1. Install the Mounting Bracket per Section 3.05.

2. Insert two of the #10-32 x 3/8" hex head bolts into the

slots on each side of the Standoff Control unit. The slot prevents the bolts from turning when the knobs are installed.

A-00688

TORCH

Hex Head Bolt

#10-32 x 3/8"

Slot

Knob

Figure 3-3 Bolt Installation

3. Set the Standoff Control unit into the Mounting

Bracket being sure the four bolts are in the mounting slots.

INST ALLATION PROCEDURES 3-2 Manual 0-2556

Mounting Bracket

A-00674

Knob

Figure 3-4 Knob Installation

Hex Head

Bolts

Knob

Customer's

Power Source

(120/240 VAC)

External Power

Supply

Standoff Control

SC11

Supplied Input Power Cable

With 120 VAC Plug

Supplied Output Power Cable

Attached to External

Power Supply

A-01428

4. Place one knob on each of the bolts protruding from the bracket slots.

5. The Standoff Control unit can be adjusted for the best viewing angle. Adjust the viewing angle per the following:

a. Loosen the four knobs sercuring the Standoff Con-

trol to the Mounting Bracket. b. Adjust the Standoff Control for the desired angle. c. Tighten all four knobs. d. If the angle is not correct, loosen knobs, adjust the

unit until the proper viewing angle is found, and

retighten all knobs.

3.07 Installation With Automated Systems

This Section describes the installation of an external power supply components to allow use of the Standoff Control with an Automated Cutting System.

WARNING

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

Figure 3-5 External Power Supply

3. Connect the end of the output power cable from the external power supply , to the r ear panel of the Standoff Control (SC11). Make the connection to the EXTERNAL POWER connector (J41).

4. Plug the input power cable into a mating connector from the customer's power source. If a differ ent type plug is required do the following:

a. Cut off the 120 VAC plug. b. Install the correct type plug (customer supplied)

onto the end of the input power cable.

This completes the installation of the external power supply for the Automated System.

3.08 Internal Selections

A. Switch (SW1) Selection

The Standoff Control Assembly has one internal switch (SW1) that is used for some plasma cutting systems without an arc transfer or motion signal. Turning ON SW1-1 and SW1-2 will generate the signal as soon as the pilot arc voltage drops from open circuit to under 195v. This occurs as soon as pilot is initiated so the PIERCE DELAY should be used to delay the motion signal. This will allow time for arc transfer and piercing.

1. Locate the external power supply assembly and cables

NOTE

shipped with the Standoff control.

Switch SW1 is not needed for Automated Systems (Merlin 1000, PakMaster XL Plus or Pak Master

2. Connect the supplied input power cable , with 120 VAC plug, to the input of the external power supply.

150XL) and both positions should be in the OFF position.

T o check or change the switch selection use the following procedure:

1. Remove the two cover mounting screws on the top of the Standoff Accessory.

Manual 0-2556 3-3 INST ALLATION PROCEDURES

TORCH

MODE

LIFTER SPEED

L I F S P E

D E

T E

A U

T O

I N D H T

H I

L O

Cover

L A

S M

0 .2

0.1

Screw

E M

S T

A N

F F

0 .4

0.75

T R

.25 PIE RC

(in

che

0.1

PIE

(s ec)

T .

H .

C . A

I V

E ND

OF R E

T (%

)

Screw

Standoff Control

PC Board Assembly

A-00689

U P

T O R

C H

D N

A-00861

ON 1

Figure 3-6 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.

3. Identify internal switch SW1 and confirm that the switch is set for the desired system as follows:

System

SW1-1SW1-

Without Motion Signal (OK-To-Move) ON ON

With Moti on Signal (OK-To-Move) OFF* OFF*

* = Fa ct o ry Setting

NOTE

Refer to Section 4.04-E for operation when starting the the cutting operation off the plate (workpiece).

SW1

Type System

Selection

Figure 3-7 Switch SW1 Location

B. CNC Interface

Isolated START, standoff inhibit (CSD) and motion (OK-T o-Move) signals are available at the Rear Panel CNC (J40) connector or an internal terminal strip (J11).

The motion signal (OK-T o-Move) may be selected to be either a contact closure or 24 VAC switched through the contact. The Standoff Control is factoryset for 24 VAC operation. The purpose of selecting 24 VAC is to drive a relay coil whose current must not exceed 150 ma.

NOTE

The 24 VAC may be required by some cutting machine controllers.

INST ALLATION PROCEDURES 3-4 Manual 0-2556

Standoff Control

PC Board Assembly

EXTERNAL

CNC

J40

A-00693

POWER

J41

PLASMA

J42

MOTOR

J43

Lifter Motor

Control Cable

A-01424

J11

Pin 6

Figure 3-8 Motion (OK-To-Move) Jumper Location

A jumper wire is connected between the terminal block J11 pin 7 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:

Pin 7

CNC

Strain Relief

CNC Control

Cable

External Input

Power Cable

Plasma Power Supply Control

Cable

Figure 3-9 Cable Connections

1. Lifter Motor Cable Connect the Lifter Motor Control Cable to the rear

panel of the Standoff Control to the receptacle marked J43 (MOTOR). The other end of the cable is connected to the lifter motor equipment.

2. Power Supply Control Cable Connect the Power Supply Control Cable to the rear

panel of the Standoff Control to the receptacle marked J42 (PLASMA). Connect the other end of the cable to the Power Supply receptacle marked TO REMOTE CONTROL. Power Supply connector is J22 on Merlin 1000 Systems.

NOTE

Motion (OK-To-Move) Selection J11

Some systems may supply the +48 volts external power from the Plasma Power Supply via the Con-

Contacts or External 115V 6

24 VAC 7*

* = Factory Setting

3.09 External Cable Connections

There are four standard output connectors and one strain relief at the rear panel of the unit. Connect the required control cables per the following:

trol Cable. These Remote Cables have two connectors for PLASMA (J42) and EXTERNAL POWER (J41).

3. External +48 Volt Power Source Connect the External Power Source Cable to the rear

panel of the Standoff Control to the receptacle marked J41 (EXTERNAL POWER). The other end of the cable is connected to the external +48 volt power source. The factory supplied external power source can be connected to 115 or 220 VAC, 50/60Hz.

NOTE

Plasma Power Supplies that do not have a +48 volt output require a seperate external power source.

Manual 0-2556 3-5 INST ALLATION PROCEDURES

4. CNC Control Cable Using AMP Connector Connect the CNC Control Cable to the rear panel of

the Standoff Control to the AMP receptacle marked J40 (CNC). Connect the other end of the cable to the CNC Control Assembly. Terminate the shield(s) of the cable to earth or chassis ground at the cutting machine.

Pin # Descripti on

1 Standoff Inhibi t /Corner Slowdown (CSD) 2 Standoff Inhibi t /Corner S lowdown (CSD) Return 3 START/STOP 4 START/STOP Return

5. CNC Control Cable - Hard Wired If the CNC cable from the CNC equipment cannot be

supplied with a mating AMP connector to J40 (CNC) the cable can be hard wired to the Standoff Control Accessory. To wire the cable to the unit use the following procedure:

a. Remove the cover of the Standoff 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 Standoff Control.

c. Locate the terminal block J11 on the PC board.

Standoff Control

PC Board Assembly

5 Motion (OK-To-Move) 8 Motion (OK-To-Move)

e. Tighten the strain relief to secur e the control cable. f. Reinstall the cover to the Standoff Control Acces-

sory.

g. Connect the other end of the cable to the CNC

Control Assembly .

3.10 Lifter Motor Installation

A. Mounting Holes

NOTE

Refer to the exploded view of the Lifter Motor Assembly for parts location and assembly.

The Lifter Motor Assembly must be mounted to the Cutting T able. Mount the assembly per the following procedure:

1. Lossen the four screws securing the Front Cover to the assembly.

A-01425

J11

Figure 3-10 Terminal Block J11 Location

d. Connect the ends of the CNC control cable to J11

on the PC Board per the following chart:

2. Remove the Torch Holder and Front Cover from the assembly.

3. Use the template at the end of this Manual to locate the four mounting holes noting the following:

• The bottom edge of the Lifter Motor Assembly must be able to clear any obstructions in the cutting path.

• The assembly must be mounted low enough to allow proper operation of the Torch Assembly.

4. Drill and tap four holes for 1/4-20 bolts.

5. Mount the Lifter Motor Assembly to the four tapped holes using the four bolts and washers supplied.

6. Install the Hose Holder (T orch Leads Support Bracket) to the Gear Rack using the two bolts provided.

7. Reinstall the Front Cover and Torch Holder.

8. Tighten the four cover screws.

INST ALLATION PROCEDURES 3-6 Manual 0-2556

B. Torch Assembly Installation

1. Place the end of the mounting pin on the T orch Mounting Tube Assembly into the Torch Holder Pivot.

2. Tighten the wing nut and washer to secure the Torch Mounting T ube Assembly to the Lifter Motor Assembly.

3. Route the Torch Leads up and over the Hose Holder (Torch Leads Support Bracket). Leave some slack in the Torch Leads between the Mounting Tube and the Hose Holder .

Shown with

Rack and Pinion

Mounting Assembly

Direction of Torch Travel

Standoff Distance

Straight Arc

Trailing Arc

A-01556

Leading Arc

Figure 3-11 Lifter Motor and Torch Mounting

4. Connect the end of the Torch Leads per the appropriate Torch Manual.

Manual 0-2556 3-7 INST ALLATION PROCEDURES

INST ALLATION PROCEDURES 3-8 Manual 0-2556

SECTION 4:

TORCH

MODE

LIFTER SPEED

OPERATION

Pressing MODE a third time turns both indicators OFF for fully manual mode. Pressing MODE the forth time returns to fully automatic operation.

2. LIFTER SPEED Pushbutton and Indicators

4.01 Introduction

This Section provides a description of the Standoff Control Accessory followed by operating pr ocedur es.

4.02 Functional Overview

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

There is are various connections available at the Rear Panel of the Standoff Control Accessory. These connections provide inputs and outputs to allow various parts of the system to be operated from one station.

4.03 Operating Controls

A. Front Panel

AUTO

MODE

FIND HT

LIFTER SPEED

Figure 4-1 Front Panel Operating Controls

1. MODE Pushbutton and Indicators

The momentary MODE pushbutton switch selects one of four modes of operation.

• Fully automatic - AUTO HT and FIND HT in-

• Automatic height - AUTO HT indicator ON

• Find height - AUTO HT indicator OFF and

• Fully Manual - AUTO HT and FIND HT indi-

PLASMA ON

ARC VOLTS

REMOTE STANDOFF CONTROL

0.3

0.2

0.4

0.1

0.5

PIERCE

HT (inches)

0.75

0.5

0.25

0.1 PIERCE

DELAY (sec)

dicators ON

and FIND HT indicator OFF

FIND HT indicators ON

cators OFF

25 75

T.H.C. ACTIVE

END OF CUT

RETRACT (%)

100

A-00691

TORCH

The momentary LIFTER SPEED pushbutton switch selects one of two torch lifter speeds.

• High speed - HI indicator ON and LO indicator OFF

• Low speed - LO indicator ON and HI indicator OFF Pressing the LIFTER SPEED switch toggles between

HI and LO. When power is supplied the Standoff Control auto-

matically selects the HI Lifter Speed mode. The HI indicator will be ON. Pressing LIFTER SPEED once turns HI indicator OFF and LO indicator ON. Pressing LIFTER SPEED the thrid time returns to the HI Lifter Speed mode.

At lower cutting speeds the HI mode may cause oscillation or diving toward the work during the cut. If this happens it is recommended that the operator select the LO lifter speed.

3. PLASMA ON Indicator

When the Standoff Control sends a start signal to the Plasma Power Supply the PLASMA ON indicator turns ON. The start signal is sent automatically after finding height.

4. ARC VOLTS Control and Display

The ARC VOLTS control allows the operator to select the desired arc voltage from 65 to 195, as indicated at the ARC VOLTS Display. Volts above 199 will cause the display to indicate over range (left display digit is "1"). The standoff, distance from torch to work, may be changed during cutting by changing the ARC VOLTS setting.

Prior to enabling the PLASMA ON indicator a decimal point will be displayed on the right hand side of the ARC VOLTS Display indicating preview mode. After the PLASMA ON indicator is turned ON the ARC VOLTS Display indicates the actual arc volts from 0 to 199.

Three decimal points displayed in the ARC VOLTS Display indicate the Standoff Control is receiving a standoff inhibit (corner slowdown - CSD) signal.

When power is supplied the Standoff Control enters

5. PIERCE HT (inches) Control

the fully automatic mode. The AUTO HT and FIND HT indicators will be ON. Pressing MODE once turns FIND HT indicator OFF . Pressing MODE again turns AUTO HT indicator OFF and FIND HT indicator ON.

The PIERCE HT (height) controls the starting distance from torch to workpiece from nearly zero to 1/2 inches.

Manual 0-2556 4-1 OPERA TION

After receiving a start signal with one of the FIND HT modes selected, FIND HT indicator ON, the standoff control equipment lowers the torch fr om the retracted position until it contacts the metal to be cut. The standoff equipment then lifts the torch back up the distance above the plate set by the adjustable PIERCE HT control from nearly zero to over 1/2".

When doing a piercing operation it is best to start from the highest possible position to minimize splatter onto the end of the torch. Splatter onto the torch shield and tip can block the cutting tip orifice.

6. PIERCE DELAY (sec) Control

The PIERCE DELAY contr ols the arc transfer or motion (OK-To-Move) start signals to the cutting machine. This delay allows time for the arc to pierce through the material. The delay time is adjustable from zero to over thr ee seconds.

NOTE

The cutting machine controller may also have a motion delay which will add to the total delay, if so it should be set to zero.

9. TORCH UP/DN Pushbuttons and Indicators

The momentary TORCH UP/DN pushbutton switches allow setting the torch position manually. Pressing the TORCH UP switch will cause the UP indicator to turn ON. The DN (Down) indicator turns ON if the TORCH DN pushbutton is pressed.

The manual control may be used to set initial height when the FIND HT indicator is OFF. The controls can also be used to adjust the standoff when the AUTO HT indicator is OFF.

The manual controls should not be used while cutting if the AUTO HT indicator is ON (see ARC VOL TS Control).

B. Rear Panel

Height regulation will be inhibited during the delay time selected.

7. END OF CUT RETRACT (%) Control

The END OF CUT RETRACT controls the raising (retracting) of the torch from zero to 100% of the selected setting of the END OF CUT RETRACT (%) Control.

With one of the FIND HT modes selected, FIND HT indicator ON, the torch is raised at the end of a cut operation when the start signal is removed. The amount of time that it takes to raise the torch can be reduced by not retracting the torch fully, if not required.

8. T.H.C. ACTIVE Indicator

The T.H.C. (Torch Height Control) ACTIVE indicator turns ON when the height is under active control. The T.H.C. ACTIVE indicator turns OFF when no initial arc transfer signal is received, standoff inhibit (corner slowdown - CSD) signal is on, an arc voltage outside the regulation limits of 65 to 195 volts, or the voltage is rising rapidly.

The voltage rising rapidly can be caused by cutting over a kerf, other hole, or the edge of the plate being cut.

A-01426

Figure 4-2 Rear Panel Connectors

1. MOTOR (J43) Connector

Connector to interface the Standoff Control to the lifter motor assembly. Signals include drive (up to +/-20 vdc), tachometer (0 to +/- 15 vdc) and TORCH ON WORK switch (NC).

2. PLASMA (J42) Connector

Connector to interface the Standoff Control to the Plasma Power Supply.

3. EXTERNAL POWER (J41) Connector

Connector to interface the Standoff Control to a remote 48 vdc bias supply.

4. CNC (J40) Connector

Connector to interface the Standoff Control to the CNC equipment when the interface cable has a mating connector .

5. Strain Relief

When the T .H.C. ACTIVE indicator is OFF the standoff is not being regulated during that time.

Connection to interface the Standoff Control to the CNC equipment when there is no mating connector . The CNC cable is fed through the strain relief and connected to an internal terminal strip (J11).

OPERA TION 4-2 Manual 0-2556

4.04 Sequence Of Operations

This Section describes the typical sequences for various operations. The information is suppied to give the operator an understanding of what is occuring during the cutting cycle. Each of the following paragraphs describe a different operation as follows:

• Paragraph ‘A ’ - Fully Automatic Mode With Pierce

Start

• Paragraph ‘B’ - AUTO HT ON and FIND HT indi-

cators OFF

• Paragraph ‘C’ - AUTO HT Indicator OFF and FIND

HT Indicator ON

• Paragraph ‘D’ - Fully Manual Mode

• Paragraph ‘E’ - Starting Off The Plate

A. Fully Automatic Mode (AUTO HT and FIND

HT Indicators ON) With Pierce Start

1. The cutting machine controller sends a start signal to the Standoff Control.

2. The Standoff Control starts to find height by rapidly lowering the torch from the retracted position towar ds the work. When the torch contacts the work or the bottom of torch travel if not over the work, it opens the normally closed (NC) torch on work (T.O.W.) switch in the Lifter Motor Assembly.

3. When the T.O.W. switch opens the torch downward motion is reversed and it slowly rises until the T .O.W . switch closes which starts the PIERCE HT timer . The torch continues upward for the time requir ed to reach the selected pierce height setting.

4. A start signal is sent to the Plasma Power Supply and the Standoff Control PLASMA ON indicator turns ON. The pilot starts after pre-flow and immediately, if the initial height is correct, the cutting arc is established at which time the Plasma Power Supply sends a motion (OK-To-Move) signal to the Standoff Control through the Remote Control.

5. Receiving the motion (OK-To-Move) signal from the Plasma Power Supply starts the PIERCE DELAY. As the PIERCE DELAY ends the motion (OK-To-Move) signal is sent to the cutting machine controller through the Remote Control starting the horizontal travel.

6. At the same time, the T.H.C. ACTIVE indicator turns ON and the torch moves to the desired cutting standoff as determined by the pre-selected ARC VOLTS Control, unless the cutting machine standoff inhibit (corner slowdown - CSD) is ON, or the arc voltage is outside the range of 65 to 195V inhibiting it. Even if the standoff is inhibited, because the cut is starting in a corner, the controller is enabled for 1/2 second to

position the torch down to the proper cutting height. Without this feature the first few inches could be cut at excessive standoff adversely affecting the quality.

7. The piece is cut then the cutting machine removes the start signal. The arc goes out removing the motion (OK-T o-Move) signal from the Plasma Power Supply.

8. When both the start and motion (OK-To-Move) signals are removed (allows for current ramp down for systems that have that feature) the retract timer is activated to rapidly raise the torch up to clear obstructions, such as cut out pieces that tilt up, while traversing to the next piece to be cut. The amount of retract is set from zero to 100% by the END OF CUT RETRACT Control. The torch remains r etracted until the sequence repeats with the next start signal.

B. AUTO HT ON and FIND HT indicators OFF

The operator sets the torch height manually. Refer to paragraph 'D' for "Starting Off The Plate (Workpiece)".

1. The cutting machine controller sends a start signal to the Standoff Control.

2. A start signal is sent to the Plasma Power Supply and the Standoff Control PLASMA ON indicator turns ON. The pilot starts after pre-flow and immediately, if the initial height is correct, the cutting arc is established at which time the Plasma Power Supply sends a motion (OK-To-Move) signal to the Standoff Control.

3. Receiving the motion (OK-To-Move) signal from the Plasma Power Supply starts the PIERCE DELAY. As the PIERCE DELAY ends the motion (OK-To-Move) signal is sent to the cutting machine controller, starting the horizontal travel.

4. At the same time, the T.H.C. ACTIVE indicator turns ON and the torch moves to the desired cutting standoff as determined by the pre-selected ARC VOLTS Control, unless the cutting machine standoff inhibit (corner slowdown - CSD) or the arc voltage is outside the range of 65 to 195v inhibiting it. Even if the standoff is inhibited, because the cut is starting in a corner , the controller is enabled for 1/2 second to position the torch down to the proper cutting height. W ithout this feature the first few inches could be cut at excessive standoff adversely affecting the quality.

5. The piece is cut then the cutting machine removes the start signal. The arc goes out removing the motion (OK-T o-Move) signal from the Plasma Power Supply.

6. The torch does not retract.

Manual 0-2556 4-3 OPERA TION

C. AUTO HT Indicator OFF and FIND HT

Indicator ON

D. Fully Manual Mode (AUTO HT and FIND HT

Indicators OFF)

NOTE

The standoff height is not controlled during the cut except manually by the operator using the TORCH UP/DN switches.

1. The cutting machine controller sends a start signal to the Standoff Control.

NOTE

Torch height is not controlled automatically.

6. The piece is cut then the cutting machine removes the start signal. The arc goes out removing the Motion (OK-T o-Move) signal from the Plasma Power Supply.

7. When both the start and motion (OK-To-Move) signals are removed (allows for current ramp down for systems that have that feature) the retract timer is activated to rapidly raise the torch up to clear obstructions, such as cut out pieces that tilt up, while traversing to the next piece to be cut. The amount of retract is set from zero to 100% by the END OF CUT RETRACT Control. The torch remains r etracted until the sequence repeats with the next start signal.

NOTE

Initial height is set manually and controlled manually during cutting. PIERCE DELAY is still active and the arc volts display indicates actual arc volts but the ARC VOL TS control will not change the standoff.

1. The cutting machine controller sends a start signal to the Standoff Control.

4. The piece is cut then the cutting machine removes the start signal. The arc goes out removing the Motion (OK-T o-Move) signal from the Plasma Power Supply.

E. Starting Off The Plate (Workpiece)

When starting off the plate (running edge start) FIND HT indicator should be OFF and height set manually . AUTO HT indicator is normally ON to control height after the cut starts.

When starting off the plate there is no start motion (OKTo-Move) signal as there has been no arc transfer. For systems with normally open PSR contacts, Merlin 3000 for example, wiring the contacts in parallel with the motion (OK-To-Move) signal contacts supplies the motion start signal as soon as the pilot starts. Use the PIERCE DELAY to supply time for the torch to move over the workpiece before the Standoff Control starts controlling the height.

For systems where the output voltage drops below 195 volts during piloting, SW1 turned ON, will start motion when the pilot starts (refer to Section 3.08, Internal Selections). Use PIERCE DELA Y to allow time for arc transfer before the Standoff Control starts contr olling height.

For those systems where neither of the above applies then some external means of detecting pilot (PSR) will have to be added and connected to the motion (OK-T o-Move) signal contacts as explained above.

OPERA TION 4-4 Manual 0-2556

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.

WARNINGS

Disconnect primary power at the source before disassembling any part of the cutting system.

Frequently review the Important Safety Precautions in Section 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.

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

A. Troubleshooting

This Sub-Section covers troubleshooting that requires dissasembly and electronic measurements. It is helpful for solving many of the common problems that can arise with the Standoff Control Assembly.

WARNING

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.

Specific test procedures are referenced by the troubleshooting guide.

The guide has two sections as follows:

Section 5.04 - Troubleshooting Specific Problems Section 5.05 - Test Procedures

B. How to use this Guide

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

5.02 Routine Maintenance

A. Standoff Control

The only routine maintenance required for the Standoff Control components is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment.

To clean the Standoff Control, first make sure that the power is disconnected. Open the Standoff 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.

B. Lifter Moter assembly

The Rollers and Slides on the Lifter Motor Assembly should be checked, cleaned and adjusted required.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your symptom, check the causes (easiest listed first) then remedies. Repair as needed being sure to verify that unit is fully operational after any repairs.

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 0-2556 5-1 CUSTOMER/OPERATOR SER VICE

5.04 Troubleshooting Specific Problems

A. Front panel switch for MODE, LIFTER

SPEED, TORCH UP or TORCH DOWN will not function

1. Connector J3 on the Standoff Control PC Board is connected one pin off

a. Make sure connector is plugged in correctly.

2. Faulty front panel switch or Standoff Contr ol PC Board

a. Test per Section 5.05-B and replace faulty as-

sembly as required

3. External power source not connected or turned ON

a. Verify +48 volt external power source is con-

nected and turned ON

B. One or more, not all, front panel indicators will

not turn ON when expected

1. Faulty indicator or Standoff Control PC Board

a. Test per Section 5.05-C and replace fr ont panel

assembly if necessary

C. Torch will not move up or down manually using

TORCH UP and TORCH DOWN switches; TORCH UP and TORCH DOWN indicators come ON

1. Torch Lifter Assembly rack and pinion gear misaligned or not meshing

a. Lift up on the torch while pressing the T ORCH

UP arrow to remesh the gears.

2. Dirty Lifter Slide or Rollers

a. Remove cover and clean Slide and Rollers

3. Mounting screw of T or ch Lead Support Bracket too long

a. Replace with shorter screw

NOTE

The mounting bolts attaching the torch lead support bracket to the Torch Lifter Assembly can bind if the mounting bolts are too long.

NOTE

The mounting bolts attaching the torch lead support bracket to the Tor ch Lifter Assembly can bind if the mounting bolts are too long.

2. Faulty torch lifter motor, cable or start circuit

a. Check the motor and cable per Section 5.05-D,

repair as necessary

E. Torch moves down to work but does not retract to

PIERCE HT setting

1. PIERCE HT control is set fully counterclockwise (CCW), minimum standoff

a. Adjust for higher standoff

2. Tip-On-Work micro-switch faulty, out of adjustment or slide frozen so switch cannot be activated

a. Check the Tip-On-W ork micro-switch per Sec-

tion 5.05-E, repair as necessary

F. Torch moves down to the work and retracts, but

stops at a point higher than the PIERCE HT setting or continues to a point at the top of travel; Pilot may activate when the travel stops

1. Tip-On-Work micro-switch circuit is faulty or have dirty contacts

a. Check the Tip-On-W ork micro-switch per Sec-

tion 5.05-E, repair as necessary

G. Torch moves up instead of down when it should

be finding height

1. Tip-On-Work micro-switch cir cuit is open

a. Check the Tip-On-W ork micro-switch per Sec-

tion 5.05-E, repair as necessary

H. Torch finds height and starts cutting but cutting

machine doesn’t move

1. Motion (OK-To-Move) signal not compatible with cutting machine controller. Signal set for contacts, but controller needs AC volts or vice versa.

a. Change setting per Section 3.09-B.

2. Faulty motion (OK-To-Move) signal from Plasma Power Supply

D. Torch will not move or no pilot arc when START is

pressed

Push front panel TORCH UP or TORCH DOWN switch to see if torch will move manually. If torch will move in either direction, then torch lifter motor and cable are okay.

1. Check for binding of the torch lifter assembly slide.

a. Repair as required

CUSTOMER/OPERATOR SER VICE 5-2 Manual 0-2556

a. Check for proper motion (OK-To-Move) signal

per Section 5.05-F, repair as necessary

I. After cutting starts torch remains at initial height;

THC ACTIVE indicator is OFF

1. Automatic find height not activated, AUTO HT indicator OFF

a. Press MODE control switch until AUTO HT in-

dicator comes ON

2. Faulty Arc voltage input to Standoff Control

a. Check for proper arc voltage input per Section

5.05-G, repair as necessary

J. Torch dives or oscillates while cutting instead of

maintaining constant height

1. Lifter speed set too high

a. For travel speeds under150 inches per minute

select low speed

2. Faulty motor tachometer

a. Check the motor/tachometer per Section 5.05-

H, repair as necessary

5.05 Test Procedures

This section describes the tests required to isolate problems or faulty assemblies in the Standoff Control Assembly. The section contains a functional description of the Standoff Control followed by individual test pr ocedures. Each procedure is referenced in Section 5.04, Troubleshooting Specific Problems.

A. Functional description

The Standoff Control controls the operation of the torch lifter motor assembly to find height, regulate height and retract at the end of cut per the following sequence:

1. Standoff Control receives a START signal.

2. Torch moves down at high speed until the torch tip contacts the workpiece.

3. T or ch retracts at slow speed to the setting selected by the PIERCE HT control.

down - CSD) signal. When this occurs all three decimals in the ARC VOL TS display turn ON and the THC ACTIVE indicator will turn OFF.

10. At the end of the cut program the ST ART signal is removed.

11. The torch retracts at high speed to the setting of the END OF CUT RETRACT (%) control . This setting is a percentage (%) of the full lifter travel.

If the FIND HT indicator is OFF, the system will skip the find height sequence and the retract at the end of the cut. The desired pierce height is set manually.

If the AUTO HT indicator is OFF, height is not controlled during the cut.

The T orch Lifter Assembly uses a dc motor with a tachometer for speed and direction feedback. The motor pinion gear mates with a rack on the up/down slide to move the torch. A second small vertical slide allows about 1/2 inch of free movement. Held down by the weight of the torch it keeps the Tip-On-Work micro-switch (mounted above the small slide) closed. When finding height, as the torch moves downward and makes contact with the the work, the small slide moves up, opening the microswitch to signal that the torch has made contact with the work.

B. Front Panel Switch Tests

The four switches have a common connection to J3-

13. T o check the operation of the switch measur e for

continuity from the PC Board common (TP1) to the other side of the switch at J3 per the following:

4. Upon finding height as set by the PIERCE HT control a START signal is sent to the plasma power supply and the PLASMA ON indicator turns ON.

5. The power supply starts the arc which pierces the metal.

6. After the time delay as set at the PIERCE DELAY ends, a motion (OK-T o-Move) signal is sent to the cutting machine to start the cutting motion.

7. As the cutting machine accelerates the standoff inhibit (corner slowdown - CSD) signal is removed.

8. The THC ACTIVE indicator turns ON and the Standoff Control regulates height to maintain the selected standoff.

9. At times during the cutting operation the controllor program may disable the Standoff Control by applying the standoff inhibit (corner slow-

Manual 0-2556 5-3 CUSTOMER/OPERATOR SER VICE

Sw itch J3 Pin # MODE 8

LIFT ER SP EED 12

TORCH UP 17

TORCH DO WN 14

MODE

LIFTER SPEED

J3-8

J3-12

AUTO HT

FIND HT

+V1

J3-4

J3-7

J3-5

J3-17

DOWN

J3-14 J3-13

A-01076

The measurement should be less than 200 to 300 ohms when the switch is pushed.

If the measurement is not correct the switch is faulty; replace front panel assembly.

If the measurement is correct then the Standoff Control PC Board is faulty; replace the complete Standoff Control Assembly.

C. Front Panel Indicator Tests

For all indicators, except TORCH UP and TORCH DOWN, measure the dc voltage from PC Board common (TP1) to the J3 pin for the indicator cathode per the following:

J3-6

LOW

PLASMA ON

THC ACTIVE

J3-10

J3-11

J3-9

J3-2

J3-3

J3-18

J3-19

A-01077

If the voltage is near 15 vdc momentarily jumper the cathode to TP1. If the indicator does not come ON momentarily the indicator is faulty . Replace the front panel assembly.

Indicator C athode Pin #

PLASMA ON J3-3

FIND HT J3-6

AUT O HT J3-7

HI J3-9

LOW J3-11

T.H.C. ACTIVE J3-19

If the indicator comes ON the Standoff Control PC Board is faulty, assuming the system is working normally.

For the UP and DOWN indicators, if the motor moves up and down manually and if one indicator works normally but not the other , it is faulty and front panel assembly should be replaced. If neither works measure from TP1 to J3-15 while moving the motor up and down. If the voltage is zero the Standoff Contr ol PC Board is faulty. If it is higher, can be as high as +/

-20v, the front panel assembly is faulty.

DOWN

A-01078

J3-15

CUSTOMER/OPERATOR SER VICE 5-4 Manual 0-2556

D. Lifter Motor and Cable Tests

1. Remove cable from torch lifter assembly. Measure for + (up) or - (down) about 20v with meter (+) on pin 1 and negative (-) on pin 2 of the cable when TORCH UP or TORCH DOWN is pr essed. TORCH UP or TORCH DOWN indicator not ON may indicate no output to motor however a shorted motor or cable can prevent the indicator from coming ON. If indicators are corr ect, remove lifter assembly cover and check wiring to motor. Also check for binding of the torch lifter assembly slide.

NOTE

The mounting bolts attaching the torch lead support bracket to the Torch Lifter Assembly can bind if the mounting bolts are too long.

2. If no voltage is seen in above step 1 repeat the measurement at pins J43-1 and J43-2, if no voltage at J43 check at J10-1 and J10-2. If no voltage at J10, Standoff Control PC Board is faulty otherwise the J10 harness or motor cable is open.

If T orch moves up but not down. TORCH DOWN indicator will not come ON.

a. Remove motor cable from J43 and check for

continuity between pins J43-7 and J43-8. If correct (less than 500 ohms) Standoff Control Assembly is faulty. If over 500 ohms possible causes are:

• Open motor cable (pins J43-7 or J43-8)

• Open connection between motor cable connector and micro-switch in the torch lifter assembly

• Faulty microswitch

• Switch being held open, possible sticking slide.

Torch moves up and down manually.

Check for proper START signal to Standoff Control Assembly PC Board. If ST ART indicator, D79, comes ON, START signal is present, Standoff Control Assembly is faulty. START signal is from the CNC input at J40-3 and J40-4 or J11-3 and J11-4.

NOTE

Refer to Appendix 3 for schematic of STAR T signal circuit.

If ST ART indicator , D79, does not come ON, jumper J11-3 to J11-4.

CAUTION

Torch may start.

If ST ART indicator , D79, comes ON and torch finds height and pilot starts then problem is in the START signal input to the Standoff Control Assembly. Check the CNC cable input or the internal ribbon cable between the Standoff Control Assembly and the Remote Control Assembly (RC6010) if used.

E. Tip-On-Work Micro-Switch Tests

T o test the micro-switch, remove the motor cable from J43 on the back of the Standoff Control Assembly and with the torch not on the work measure continuity between pins J43-7 and J43-8 of the cable. Then lift up on the torch. The small slide should move freely and come up about 1/2 inch and pins J43-7 and J438 should measure open circuit. If correct then the Standoff Control Assembly is faulty.

F. Motion (OK-To-Move) Signal Tests

Check for internal indicator, OK PS indicator D82 comes ON when arc starts.

If indicator is OFF , jumper J8-5 to J8-6. If OK PS indicator comes ON then the motion (OK-To-Move) signal is missing to the Standoff Control Assembly.

NOTE

Refer to Appendix 4 for schematic of motion (OKTo-Move) circuit.

If indicator is still OFF , then the Standof f Control Assembly is faulty.

If indicator OK PS comes ON when arc starts, set PIERCE DELAY to minimum and check for D37 PS OUT indicator for an ON condition.

If Indicator D37 does not come ON the Standoff Control Assembly is faulty. Check for the motion (OKTo-Move) signal between J8-22 to J8-24 or J11-5 and J11-8. Should be contact closure if E1 jumper is in J11-6, or 24 vac if jumper is in J11-7. If okay problem is in CNC connections or cutting machine.

If indicator D37 comes ON, then the Standoff Control Assembly is okay, go to System T roubleshooting Section in the Power Supply Service Manual for the Motion (OK-T o-Move) Test Procedure.

G. Arc V oltage Tests

If Arc Voltage display reads near zero, voltage signal is not present to the Standoff Control Assembly. Measure voltage at J8-3(negative) and J8-4(positive). Should be between 6 to 12 vdc when cutting (9 volts when cutting equals minus 150 arc volts).

Manual 0-2556 5-5 CUSTOMER/OPERATOR SER VICE

• If correct, the Standoff Control is faulty.

• If voltage is not correct, check the voltage from the type plasma power supply per one of the following:

Merlin 1000 Systems

This check is for Merlin 1000power Supplies without the Filter/Voltage Divider PC Board. If the Mer lin 1000 has the Filter/V oltage Divider PC Board, then refer to Automated Systems.

WARNING

Use extreme caution as high voltage is present.

J23-4 (+). It is converted to a positive 6 to 12 vdc between J24-12 (+) and J24-14 (-). The wires from J24 go to J22, CNC Interface Connector , on the power supply rear panel. Connection J24-12 goes to J22-6 (wire #69) and connector J24-14 goes to J22-5 (wire #68). Measure for 6 to 12 vdc between J24-12 (+) to J24-14 (-).

• If voltage is not correct then the Filter/V oltage Divider PC Board may be faulty. Make the following checks:

a. Check for 20 to 30 vdc (power for the voltage

circuit) between J23-7 (+) to J23-4 (-).

• If voltage is correct, check for minus 100 to 200 vdc arc voltage (while cutting) between J23-1 (-) to J23-4 (+).

Main arc voltage, typically minus 100 to 200 vdc is present on the Pilot/Output PCB at E3 (-) and E8(+). It is converted to a positive 6 to 12 vdc between J12 pin 15 (+) and J12 pin 16 (-). Measure for 6 to 12 vdc between J12-15 (+) to J12-16 (-).

• If voltage is not correct then the Pilot/Output PC Board is faulty.

• If voltage is correct, check the following: a. Open connection between J12-15 and J22-6

(wire #91).

b. Open connection between J12-16 and J22-5

(wire #92).

c. Open in the Power Supply Torch Contr ol Cable

between J22-5 and J22-6.

NOTE

To rch Control Connector, J22, is located on the Plasma Power Supply internal torch connection bulkhead.

Automated Sytems

This check is for Merlin 1000 Systems With Filter/ Voltage Divider PC Board, Automated Pak Master 75XL Plus, Automated Pak MAster 100XL Plus and Automated Pak Master 150XL Power Supplies.

WARNING

• If both the 20 to 30 vdc and minus 100 to 200 vdc are correct, then the Fiter/Voltage Divider PC Board is faulty.

• If voltage is correct, check the following: a. Check connections to Power Supply CNC In-

terface Control Connector J22, pins 5 and 6.

b. Open in Power Supply CNC Interface Con-

trol Cable pin 5 or 6.

NOTE

CNC Interface Control Connector, J22, is located on the Plasma Power Supply Rear Panel.

H. Motor/Tac hometer Tests

Move torch up and down manually in both high and low speed. If lifter operates at high speed in both cases either the motor tachometer or connections from it may be open. Measure voltage between J10-4 and J10-5. If voltage is approximately 10 to 15 vdc either plus or minus the motor is okay , replace the Standof f Control Assembly. If near zero, repeat the measurement at the motor .

The motor has two sets of brushes, the set to the rear is for the tachometer . If this also is near zero with the motor moving replace the motor/tachometer. Otherwise check for faulty connections between the motor and J10 (lifter assembly connector, motor cable, J43 to J10 harness).

Use extreme caution as high voltage is present.

Automated power supplies generate the arc voltage signal on the Filter/V oltage Divider PC Board. Main arc voltage, typically minus 100 to 200 vdc is present on the Filter/Voltage Divider PCB at J23-1 (-) and

CUSTOMER/OPERATOR SER VICE 5-6 Manual 0-2556

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 Standoff Control Assembly Parts Section 6.04 Replacement External Control Cables Section 6.05 Lifter Motor Assembly Parts

NOTE

Parts listed without item numbers are not illustrated, but may be ordered by the catalog numbers shown.

B. Returns

If a product must be returned for service, contact your authorized distributor . Materials returned without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description column of the Parts List. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor .

Manual 0-2556 6-1 P A RTS LISTS

6.03 Standoff Control Assembly Parts

TORCH

MODE

LIFTER SPEED

The replacement parts are limited as the SC11 Standoff Control Accessory is designed as a complete replacement if failures occur.

Item # Qty Description Catalog #

1 1 Standoff Control Assembly (includes items #2 - 5) 7-3900 2 1 Mounting Bracket 8-3483 3 4 Clamping Knob 8-3480 4 4 Machine Screw, #10-32 x 3/8", Plain Hex Head See Note 5 4 Knob, With Pointer and Skirt, Gray, 1/8" Shaft 8-3284 6 1 Front Panel Assembly includes Front Panel Bezel and Keypad 9-8604

The followingparts are not shown:

1 Lifter Motor Assembly (Only) 7-3509

NOTE: Item can be purchased locally.

REMOTE STANDOFF CONTROL

(

)

. A

(

)

(

)

A-00692

PARTS LISTS 6-2 Manual 0-2556

6.04 Replacement External Control Cables

Qty Description Catalog #

Motor Control Cable (Standoff Control to Lifter Motor) 1 10 ft (3.05 m) 9-4535 1 15 ft (4.57 m) 9-4536 1 20 ft (6.1 m) 9-4537 1 25 ft (7.62 m) 9-4538 1 50 ft (17.2 m) 9-4539

CNC Control Cables for Automated Systems 1 5 ft (1.5 m) 9-4483 1 10 ft (3 m) 9-4484 1 15 ft (4.6 m) 9-4485 1 20 ft (6.1 m) 9-4486 1 25 ft (7.6 m) 9-4486-25 1 30 ft (9.1 m) 9-4486-30 1 50 ft (15.2 m) 9-4486-50

Power Supply Control Cable for Automated Systems 1 25 ft (7.6 m) 9-9020 1 50 ft (15.2 m) 9-9021 1 75 ft (22.9 m) 9-9022 1 100 ft (30.5 m) 9-9023

1 External +48 vdc Power Source 9-9024 1 Input Power Cord with 120 VAC Plug (for External +48 vdc Power Supply) 9-9025

Manual 0-2556 6-3 P A RTS LISTS

6.05 Lifter Motor Assembly Parts

Item # Qty Description Catalog #

1 Complete Lifter Motor Assembly Includes the following: 7-3509 1 1 Torch Lifter Motor 9-4560 2 1 Pinion 18T 9-4561 3 6 'V' Wheel 9-4562 4 3 Concentric Bushing 9-4563 5 3 Eccentric Bushing 9-4564 6 2 'V' Rail 9-4565 7 1 Gear Rack 9-4566 8 1 Micro Switch 9-4567 9 1 Hose Holder 9-4568

10 1 T op Cover 9-4569 11 1 Front Cover 9-4570 12 1 Torch Mount Pivot 9-4571 13 2 1/4 - 20 x 1" SHCS 9-4572 14 1 Torch Holder Pivot 9-4573 15 1 3/8 - 24 x 1-1/2" HHCS 9-4574 16 1 5/16 - 18 x 1" Wing Nut 9-4575 17 1 5/16" Flat Washer See Note 18 2 3/8" Wave Washer See Note 19 1 3/8" Nylock Hex Nut See Note

NOTE: Item can be purchased locally.

PARTS LISTS 6-4 Manual 0-2556

A-01134

Manual 0-2556 6-5 P A RTS LISTS

PARTS LISTS 6-6 Manual 0-2556

APPENDIX 1: STANDOFF CONTROL ACCESSORY -

WIRING DIAGRAM

Plasma Control Cable To

Plasma Power Supply

ARC Volt Signal (-)

ARC Volt Signal (+)

Corner Slowdown (CSD)

N/O N/C

Corner Slowdown (CSD)

CSD Return

START/STOP

START/STOP Return

Chassis Ground

External Input

Power

+48 vdc Return

CNC Cable To

Cutting Machine

START/STOP

START/STOP Return

Corner Slowdown (CSD)

CSD Return

OK-To-Move

OK-To-Move Return

GND

+20V

OK PS

Common

+48 vdc +48 vdc

PLASMA

J42

1 2 5

6 12 14

9 10 11

3 13

EXTERNAL

POWER

J41

1 2 4 3

CNC

J40

4 10 11 12 14

10 11

12 13 14 15

1 2 3 4 5 6 7 8 9

17 18 19 20 22 24

Cable to Front Panel Keypad

Standoff Control

PC Board

1 2 3 4 7 5 6

8 13 10 12

9 11 14 15 16 17 18 19 20

Common

PLASMA ON LED PLASMA ON LED Return AUTO HT LED AUTO HT LED Return FIND HT LED FIND HT LED Return

MODE Switch MODE Switch Return LIFTER SPEED Switch Return LIFTER SPEED Switch

HI LED LOW LED

DN (Down) Switch UP and DN (Down) LED Return

Common UP Switch

THC ACTIVE LED

THC ACTIVE LED Return Common

Torch Lifter Motor Control Cable

Motor (+)

Motor Common (-)

TACH (+)

TACH Common(-)

Torch Tip On Work

Torch Tip On Work Return

Cable Shield

MOTOR

J43

1 2 4 5 7 8

J10

1 2 4 5 7 8

OK-To-Move Jumper Wire

Contacts

24 VAC

J11

CNC Cable Hard Wired

Corner Slowdown (CSD)

Corner Slowdown (CSD) Return

START/STOP

START/STOP Return

OK-To-Move

OK-To-Move Return

6 7

A-01427

Manual 0-2556 A-1 APPENDIX

APPENDIX 2: STANDOFF CONTROL PC BOARD

PARTS LOCATION

TP4

D37

J10

J11

D79

TP1

D105

D82

TP6

A-00701

Indicator LED Function

D37 ON= OK-To-Move (OK OUT) from Standoff Contr ol D82 ON = OK-To-Move (OK PS) received from Power Supply D79 ON = ST ART signal received from CNC Control D105 OFF = Voltage in range to regulate

ON = 0 volts, No Arc or 220 </<65 vdc

SW1

TP3

TP2

TP5

TP7

APPENDIX A-2 Man ual 0-2556

APPENDIX 3: START CIRCUIT SCHEMATICS

Standoff Control SC11

START

D79

PLASMA

CNC

START

J40-3

J40-4

J8-18

J11-3 J11-4

J8-17

OPTO-

Isolator

FIND HT

OFF

FIND

K10

START

J8-10

J8-11

J42-3

J42-4

K10

START

A-02934

J22-3

Automated System

Power Supply

J22-4

Manual 0-2556 A-3 APPENDIX

APPENDIX 4: MOTION (OK-TO-MOVE) CIRCUIT

SCHEMATICS

Merlin 1000 Without Filter/Voltage

Divider PC Board

Logic PCB

Pilot/Output

PCB

J17-11

J13-3

J12-7

J17-12

A-01430

Automated Pak Master 150XL &

Merlin 1000 With Filter/Voltage Divider PC Board

Logic PCB

J17-11

J17-12

J13-4

Pilot/Output

PCB

J13-3

J13-4

J12-7

J12-8

Filter/Voltage

Divider PCB

J23-14

J23-16

J22-12 J42-12

J22-14

J24-3

J24-1

J42-14

J22-12 J42-12

J22-14

J42-14

Standoff Control SC11

OK PS

D82

Pierce Delay

0 - 3 Seconds

24VAC Source

OK PS

D82

Pierce Delay

0 - 3 Seconds

24VAC Source

OK OUT

D37

K12 Energized prior to

and during pierce delay

J11-7

J11-6

Standoff Control SC11

OK OUT

D37

K12 Energized prior to

and during pierce delay

J11-7

K12

J8-24

J40-14

J11-5

J8-22

J40-12

J11-8

K12

A-02935

Automated Pak Master 75XL Plus

and Pak Master 100XL Plus

Pilot/Output

PCB

J12-8

Filter/Voltage

Divider PCB

J23-14

J24-3

J12-10

A-02939

J23-16

J24-1

J22-12 J42-12

J22-14

J42-14

OK PS

D82

Pierce Delay

0 - 3 Seconds

Standoff Control SC11

OK OUT

D37

24VAC Source

J11-7

J11-6

J8-24

J11-5

J8-22

J11-8

K12

K12 Energized prior to

and during pierce delay

J8-24

J11-5

J8-22

J11-8

J40-14

J40-12

J40-14

J40-12

APPENDIX A-4 Man ual 0-2556

APPENDIX 5: CNC CONTROL CABLE INTERFACE

DIAGRAM

NOTE

Control Cable connects the Cutting Machine Controller (CNC) to Standoff Control SC11.

Cutting Machine

(Corner Height Freeze or Hold)

CNC Cable

Red Green

Shield

Black Green

Shield

Black White

Shield

J40

Standoff Control

SC11

A-01432

Manual 0-2556 A-5 APPENDIX

APPENDIX 6: SYSTEM INTERCONNECTION DIAGRAM

120/220 V AC

Input

Cutting Machine

Controller (CNC)

External +48 v

Power Supply

Plasma

Power

Supply

CNC Control

Cable

J22

J40

Standoff Control

SC11

J41

Plasma Power Supply

Control Cable

Motor Control

Cable

J43

J42

Torch Lifter

Motor

A-02254

APPENDIX A-6 Man ual 0-2556

APPENDIX 7: LIFTER MOTOR ASSEMBLY DETAILED

DIMENSIONS

34 in Max

(863.6 mm)

(482.6 mm)

19 in

12 5/8 in

(320.7 mm)

3 5/8 in

(92.1 mm)

(146.1 mm)

11 in

(279.4 mm)

5 3/4 in

8 in Travel

(203.2 mm)

6 1/4 in

(158.8 mm)

A-02537

Manual 0-2556 A-7 APPENDIX

APPENDIX A-8 Man ual 0-2556

4 3/4"

5/8"

MOUNTING HOLE TEMPLATE

Drill and Tap Holes for

1/4-20 Bolts (4 - Required)

A-01135

Manual 0-2556 A-9 APPENDIX

Bottom of Torch Lifter Channel

Must clear any obstructions in the

cutting path (example: Edge of Table)

Tweco SC11 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.05 Precautions De Securite Importantes

1.06 Documents De Reference

1.07 Declaration of Conformity

1.08 Statement of Warranty

2.01 Scope of Manual

2.02 General Description

2.03 Specifications & Design Features

3.01 Introduction

3.02 Site Location

3.03 Unpacking

3.04 Installation - General

3.05 Mounting Bracket Assembly Installation

3.06 Standoff Control Assembly Installation

3.07 Installation With Automated Systems

3.08 Internal Selections

3.09 External Cable Connections

3.10 Lifter Motor Installation

4.01 Introduction

4.02 Functional Overview

4.03 Operating Controls

4.04 Sequence Of Operations

5.03 Troubleshooting Guide

5.01 Introduction

5.02 Routine Maintenance

5.04 Troubleshooting Specific Problems

5.05 Test Procedures

6.01 Introduction

6.02 Ordering Information

6.03 Standoff Control Assembly Parts

6.04 Replacement External Control Cables

6.05 Lifter Motor Assembly Parts

APPENDIX 3: START CIRCUIT SCHEMATICS

APPENDIX 6: SYSTEM INTERCONNECTION DIAGRAM

MOUNTING HOLE TEMPLATE