Tweco SC-3000 User Manual
SC-3000
PRECISION TORCH
HEIGHT CONTROL
Operating Manual
Rev. AC Date: February 4, 2010 Manual # 0-5100
Operating Features:
PRECISION
PLASMA
12kg
26.4 lb.
CAPACITY
220mm
8.66in
STROKE
Art # A-08652
TACTILE
IHS
115230
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-4261888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators
Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within
the welding industry.
!
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Precision Torch Height Control
SC-3000™
Operating Manual Number 0-5100
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 2009, 2010 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
Original Publication Date: January 9, 2009
Revision Date: February 4, 2010
Record the following information for Warranty purposes:
Where Purchased:_______________________________ ________________
Purchase Date:__________________________________ ________________
Power Supply Serial #:___________________________ ________________
Torch Serial #:___________________________________ ________________
i
This Page Intentionally Blank
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 ...........................................................................1-6
1.08 Statement of Warranty ................................................................................1-7
SECTION 2 SYSTEM:INTRODUCTION .................................................................................2-1
2.01 How To Use This Manual ............................................................................2-1
2.02 Equipment Identification .............................................................................2-1
2.03 Receipt Of Equipment .................................................................................2-1
2.04 System Specifications .................................................................................2-2
2.05 System Componants ..................................................................................2-3
2.06 Application and System Description ...........................................................2-7
SECTION 3 SYSTEM: INSTALLATION ...................................................................................3-1
3.01 Unpacking ................................................................................................... 3-1
3.02 Handling Options ........................................................................................3-1
3.03 System Layout ............................................................................................3-2
3.04 Installation ...................................................................................................3-4
3.05 Checking of Grounding .............................................................................3-18
SECTION 4 SYSTEM: OPERATION ........................................................................................ 4-1
4.01 Requirements and Check List for first Start-up ........................................... 4-1
4.02 Power Up ....................................................................................................4-1
4.03 OPERATOR TERMINAL Menu-Overview ...................................................4-3
4.04 OPERATOR TERMINAL SETTINGS ..........................................................4-4
4.05 SIGNAL FLOW DURING PLASMA CUTTING ............................................4-9
4.06 SC 3000 Operation Sequence .................................................................... 4-9
4.07 LOSS OF PLASMA ARC ..........................................................................4-12
4.08 DETECTION OF KERFS AND EDGES DURING CUTTING ....................4-12
4.09 SCRAP CUTTING ....................................................................................4-14
4.10 PROCEDURE WITH GAS PRE-FLOW ....................................................4-16
4.11 SC 3000 Torch Height Control (THC) Modes of Operation .......................4-18
4.12 Parameter Setting ..................................................................................... 4-19
SECTION 5 SYSTEM:SERVICE ..............................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Troubleshooting ...........................................................................................5-2
SECTION 6:PARTS LISTS ....................................................................................................... 6-1
6.01 Introduction .................................................................................................6-1
6.02 Ordering Information ................................................................................... 6-1
6.03 Replacement Parts ....................................................................................6-2
TABLE OF CONTENTS
APPENDIX 1: DEFINITIONS .................................................................................................. A-1
APPENDIX 2: GROUNDING A CUTTING MACHINE ............................................................ A-2
APPENDIX 3: POWER SUPPLY ............................................................................................ A-4
APPENDIX 4: INTERFACE .................................................................................................... A-5
APPENDIX 5: OPERATOR TERMINAL-REMOTE ................................................................. A-7
APPENDIX 6: CNC CONNECTIONS TO OTHER CONTROLLERS ..................................... A-8
APPENDIX 7: CONTROLLER SCHEMATIC ........................................................................ A-12
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION ......................... Inside Rear Cover
SC 3000
!
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:
NOTE
An operation, procedure, or background information
which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause
damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause
injury to the operator or others in the operating area.
1.02 Important Safety Precautions
• The kinds of fumes and gases from the plasma arc depend on
the kind of metal being used, coatings on the metal, and the
different processes. You must be very careful when cutting
or welding any metals which may contain one or more of the
following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs
will give you the information regarding the kind and amount of
fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
this manual.
• Use special equipment, such as water or down draft cutting
tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these
vapors.
• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code Sec. 25249.5 et seq.)
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other
electronic health equipment. Persons who work near
plasma arc cutting applications should consult their
medical health professional and the manufacturer of
the health equipment to determine whether a hazard
exists.
To prevent possible injury, read, understand and follow
all warnings, safety precautions and instructions before
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your
head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
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.”
• 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.
Manual 0-5100 1-1 GENERAL INFORMATION
SC 3000
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards
may exist.
• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.
1.03 Publications
Refer to the following standards or their latest revisions for more
information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superintendent
of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
• To protect your hearing from loud noise, wear protective ear
plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels (sound)
do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma
arc process produces very bright ultra violet and infra red light. These
arc rays will damage your eyes and burn your skin if you are not
properly protected.
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or
other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective
booths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly seen.
Experience has shown that lighter filters may be used
when the arc is hidden by the workpiece.
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable
from American National Standards Institute, 1430 Broadway,
New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUT-
TING AND WELDING PROCESSES, obtainable from American
National Standards Institute, 1430 Broadway, New York, NY
10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces
chemicals known to the State of California to cause cancer, birth defects
and other reproductive harm. Wash hands after handling. (California
Health & Safety Code § 25249.5 et seq.)
GENERAL INFORMATION 1-2 Manual 0-5100
from the National Welding Supply Association, 1900 Arch
Street, Philadelphia, PA 19103
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable
14. American Welding Society Standard AWSF4.1, RECOM-
!
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018
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.
ATTENTION
Toute procédure pouvant résulter l’endommagement
du matériel en cas de non-respect de la procédure 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
SC 3000
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.
• 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 différents 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
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT
PRÉSENTER DES RISQUES ET DES DANGERS DE
SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé
electronique. Ceux qui travail près d’une application à
l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de
santé pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les blessures
possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le +
603-298-5711 ou votre distributeur local si vous avez
des questions.
Manual 0-5100 1-3 GENERAL INFORMATION
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
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet
de plasma requiert et produit de l’énergie électrique haute tension. Cette
énergie électrique peut produire des chocs graves, voire mortels, pour
l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
gants et des vêtements secs. Isolez-vous de la pièce de travail ou
des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.
SC 3000
• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de consignes.
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.
• 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.
• 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.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc
nuiront à vos yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran
de soudeur. Portez toujours des lunettes de sécurité munies de
parois latérales ou des lunettes de protection ou une autre sorte
de protection oculaire.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb,
ou engendre des produits chimiques, reconnus par l’état de
Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction.
Il f a u t s e laver l e s mains a p r è s toute ma n i p u l a t i o n .
(Code de Californie de la sécurité et santé, paragraphe 25249.5 et
suivants)
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de
l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.
GENERAL INFORMATION 1-4 Manual 0-5100
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd.,
Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible 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 TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY
10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards
Institute, 1430 Broadway, New York, NY 10018
SC 3000
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
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT 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, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA 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
Manual 0-5100 1-5 GENERAL INFORMATION
SC 3000
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive
73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/
EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used in conjunction with
hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to
ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous
testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Operations Director
GENERAL INFORMATION 1-6 Manual 0-5100
SC 3000
1.08 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermal Dynamics® Corporation warrants to the original retail purchaser
that new Thermal Dynamics SC-3000™ Precision Height Control systems sold after the effective date of this warranty are free of defects in material
and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermal Dynamics Corporation
shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics’
specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermal Dynamics will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the
time periods set out below. Thermal Dynamics Corporation must be notified within 30 days of any failure, at which time Thermal Dynamics Corporation
will provide instructions on the warranty procedures to be implemented.
Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date
of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor.
LIMITED WARRANTY PERIOD
Product
SC-3000™
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon industry
standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermal Dynamics Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned
for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermal Dynamics Corporation 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 customer of distributors (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 the goods covered
by or furnished by Thermal Dynamics 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 liability is based.
Control Interface and Terminal
(Parts and Labor)
1 Years 1 Year
Linear Drive
(Parts and Labor)
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics
product.
This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.
Effective January 5, 2009
Manual 0-5100 1-7 GENERAL INFORMATION
SC 3000
This Page Intentionally Blank
GENERAL INFORMATION 1-8 Manual 0-5100
SC-3000
!
SECTION 2 SYSTEM:
INTRODUCTION
2.01 How To Use This Manual
This Owner’s Manual applies to just specication
or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay
particular attention to the information provided
under these headings. These special annotations
are easily recognized as
follows:
WARNING
A WARNING gives information regarding
possible personal injury.
CAUTION
A CAUTION refers to possible equipment damage.
NOTE
2.02 Equipment Identification
The unit’s identication number (specication or
part number), model, and serial number usually
appear on a data tag attached to the rear panel.
Equipment which does not have a data tag such
as torch and cable assemblies are identied
only by the specication or part number
printed on loosely attached card or the shipping
container. Record these numbers on the bottom of
page 1 for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it against
the invoice to make sure it is complete and inspect the equipment for possible damage due to
shipping. If there is any damage, notify the car-
rier immediately to le a claim. Furnish complete
information concerning damage claims or shipping errors to the location in your area listed in
the inside back cover of this manual.
Include all equipment identication numbers as
described above along with a full description of
the parts in error.
Move the equipment to the installation site before
un-crating the unit. Use care to avoid damaging
the equipment when using bars, hammers, etc., to
un-crate the unit.
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be
purchased by contacting Thermadyne at the
address and phone number in your area listed
in the inside back cover of this manual. Include
the Owner’s Manual number and equipment
identication numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermal Dynamics web site listed below and
clicking on Thermal Dynamics and then on the
Literature link:
http://www.thermal-dynamics.com
Manual 0-5100 2-1 INTRODUCTION
SC-3000
2.04 System Specifications
Power supply 115/230 VAC ±10%
Current 2A/1A max.
Initial Position Finding -tactile
Clearance control in plasma mode by plasma arc voltage
Accuracy appr. ± 0.012" (± 0.3 mm)
Linear Drive Stroke = 8.3" (210 mm)
Speed = 3.1" / sec (80 mm / sec)
Load = 26.45 lbs (12 kg)
Collision protection built in.
INTRODUCTION 2-2 Manual 0-5100
2.05 System Componants
Linear Drive
Operator
Terminal
SC-300 Interface
Enclosure
Linear Drive
Cable
Linear Drive
Power Cable
Operator Terminal
Cable
Power
Supply
CNC Cable
Art # A-08798_AB
OVERVIEW
SC-3000
Linear Drive contains the motor and control electronics for positioning the torch and controlling its
height.
Interface Enclosure provides the system power and the common connection point for all the systems
cables.
Remote Operator Terminal allow the operator to set and monitor all the parameters used to position and
control torch height.
Manual 0-5100 2-3 INTRODUCTION
SC-3000
Art # A-08800
LINEAR DRIVE
Features
• Fast vertical drive for precise clearance control of plasma torches to metal sheets
• Integrated control
• Dust proof chamber protects rail and gear
• Built-in vertical collision protection
• 3-dimensional collision protection at the torch clamp
• Clamp for torch and leads
• High temperature proof bellows made of silicone rubber
• US Patent No. US 6,239,573 B1 / Euro Patent No. 0997801
General technical data
Motor 24 VDC / max. 6.5A
Power 100 W
Stroke 8.3" (210 mm)
Torch Clamp
for Torch Diameter 1.4"-2.1" (35-53 mm ) standard or
1.2"-1.4" (30-35 mm ) optional
Protective Earth Connector Screw M4
Weight 26.45 lbs. (12 kg )
Dimension of Housing approx. 4.5"x8.9"x6.3" (WxHxD)
(115x226x160 mm)
Dimensions overall 4.7"x2.8"x9.8" (WxHxD)
(approx.120x730x250 mm)
Features of versions
LINEAR DRIVE
Model SC-3000
TDC part no. 9-0404
Stroke 8.3" (210 mm)
Speed 3.1"/s (80 mm/s)
Load 26.45 lbs (12 kg)
Note:
The LINEAR DRIVE can only be used for vertical operation!
INTRODUCTION 2-4 Manual 0-5100
SC 3000 Interface Enclosure
Art # A-09098
Art # A-8938_AB
SC-3000
The Interface Enclosure is the central connection point for all the cables of the SC 3000 system. It contains:
• System power supply, 120 / 240 VAC to 24 VDC @ 6.5A (Appendix 4).
• Interface IHT 7250 Module providing communication between the Operator Terminal, the Plasma
Supply and the Linear Drive (Appendix 5).
• 9-0433 Control PCB providing system fuses, relays, selection switches for OK to Move and some
LEDs to assist troubleshooting.
Manual 0-5100 2-5 INTRODUCTION
SC-3000
Art # A-08948_AB
Information menu
Fast settings
ESCAPE
Back to menu
Manual UP/Clear Error
Manual DOWN
Menu upwards
Help Menu
Me
nu downwards
Ready
Communication
Error
Display
OK
ENTER
Control Panel
Technical Information
Power 24 VDC ±10%, with integrated reverse voltage protection
Consumption 60 mA
Over Voltage protection 30 V
Graphic Display 128x64 pixel blue/white with LED backlight
Serial Interface RS485
Environment temperature 32°-122°F (0 to +50°C)
Relative Humidity 98% (non condensing)
Protection class IP10 EN60529/IEC529 for assembly into operator console
Dimensions 6.3"x4.8"x1.4" (160x120x35 mm)
Weight approx. 0.4 kg
SC-3000 part no. 9-0427
Connecting cables can be found in table / chapter Devices and spare parts.
INTRODUCTION 2-6 Manual 0-5100
SC-3000
Art # A-8938_AB
2.06 Application and System Description
The SC-3000 height control system enables a precise clearance control of plasma and oxyfuel torches
on cutting machines.
Using this height control system leads to high quality results when cutting with or without the inuence
of water.
The SC-3000 system automatically controls the distance between the plasma torch and the metal sheet.
Initial position finding of the work piece
Before the system starts cutting SC-3000 precisely detects the position of the work piece and nds the
pre-selected PIERCE HEIGHT (ignition height). This process is called initial position nding.
When cutting with plasma
• tactile, by softly touching the work piece
Explanation of the system and using the Interface Enclosure
SC3000 Torch Height Control system consists of a Linear Drive (Torch Lifter Station), a Remote
Operator Terminal and an Interface Enclosure plus various cables. The Interface Enclosure contains a
115V/230V to 24VDC power supply, an interface module and a PCB with fuses, relays, LEDs and set
up switches.
Inside the SC 3000 Enclosure 9-8145
Power Supply provides 24 VDC to operate the SC 3000. It is switch selectable for either 115 VAC or
230 VAC 50-60 Hz but failure to put the switch in the correct position can cause failure of the power
supply.
Interface Module
Interface Module is the green box next to the PCB. It has 3 rotary switches which allow selecting the
Address of the unit, The Baud Rate and the arc voltage input ratio. The Address and Baud Rate are used
for communication over the serial Cutbus. For now they should remain at their factory settings.
The Arc voltage may be set to accommodate different divided arc voltage ratios.
Manual 0-5100 2-7 INTRODUCTION
SC-3000
ARC voltage
from
plasma-source
OPERATOR
TERMINAL
Art # A-08799_AB
CNC
Movement of Torch
The vertical torch movement for initial position nding and clearance control is handled using the SC-
3000- LINEAR DRIVE.
The built in electronics in this LINEAR DRIVE processes all control signals from the CNC and the
plasma arc voltage for height control.
The Electronic Enclosure connects to the CNC-machine control, to the plasma sources for receiving the
plasma arc voltage and connects to the OPERATOR TERMINAL.
System overview
INTRODUCTION 2-8 Manual 0-5100
SECTION 3 SYSTEM:
!
INSTALLATION
3.01 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor
and / or shipping company before proceeding with the installation.
3. Record each componant's model and serial numbers, purchase date and vendor name, in the information block at the front of this manual.
3.02 Handling Options
Be sure unit is lifted and transported safely and securely.
WARNING
Do not touch live electrical parts.
Disconnect input power cord before moving unit.
SC-3000
FALLING EQUIPMENT can cause serious personal injury and can damage equipment.
• Only persons of adequate physical strength should lift the unit.
• Lift unit using two hands. Do not use straps for lifting.
• Use optional cart or similar device of adequate capacity to move unit.
• Place unit on a proper skid and secure in place before transporting with a fork lift or other vehicle.
• Do not grip or lift the Linear Drive by the belows.
Manual 0-5100 3-1 INSTALLATION
SC-3000
Art # A-08904
3.03 System Layout
CONNECTING CABLES
INSTALLATION 3-2 Manual 0-5100
SC-3000
KEY DESCRIPTION 15’ (5m) 25’
(7.62m)
Linear Drive Control 9-0406 9-0407
A
B
C
D
E
Linear Drive Power 9-0408 9-0409
* CNC Control 9-8312 9-8313 9-8315 9-8316
Preflow Control 9-0430 9-0431 9-0432 9-0433
Plasma Control 9-0426 9-0427 9-0428 9-0429
F
Operator Terminal 9-0416 9-0417
* CNC Control also available in 125’ (38m) -- 9-8317
Table 3-1 SC3000 Cables
30’ (10m) 50’
(15.24M)
65’ (20m) 75’
(22.86m)
100’
(30.48m)
User supplied ground cables required for Linear Drive and Interface Enclosure must be minimum of 8
AWG (8qmm). Larger is better.
Manual 0-5100 3-3 INSTALLATION
3.04 Installation
22 6mm - 8.9”
max. 360 / min.14 0mm
14.2” / 5.5”
min. 90 /max. 31 0mm
3.5” / 12.2”
160mm - 6.3”
120,4mm - 4.7”
76 mm
3”
Torch
Rear Mounting Plate
Cutting Machine
Linear Drive SC-3000
Hose Clamp
Art # A-08842
SIDE VIEW OF LINEAR DRIVE
View with plasma torch.
Dimensions in inches and milimeters
SC-3000
INSTALLATION 3-4 Manual 0-5100
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