Tweco TA 500 User Manual

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Plasma Cutting

System

Thermal Arc T A 500

Instruction Manual

August 7, 2001 Manual No. 0-0470

WARNINGS

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

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

Plasma Cutting System T A 500 Instruction Manual Number 0-0470

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

www .thermal-dynamics.com

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: August 7, 2001

Record the following information for Warranty purposes:

Where Purchased:_________________________________________

Purchase Date:____________________________________________

Power Supply Serial #:_____________________________________

Torch Serial #:_____________________________________________

Contents

GENERAL INFORMA TION ............................................................................................................. i

Notes, Cautions and Warnings ................................................................................. i

Important Safety Precautions.................................................................................... i

Publications..............................................................................................................ii

Note, Attention et Avertissement.............................................................................. iii

Precautions De Securite Importantes.......................................................................iii

Documents De Reference ......................................................................................... v

Declaration of Conformity ........................................................................................ vii

St atement of Warranty............................................................................................viii

SECTION 1: DESCRIPTION OF EQUIPMENT........................................................................... 1-1

1.1 General Information....................................................................................... 1-1

1.2 Specifications ............................................................................................... 1-1

1.3 Plasma......................................................................................................... 1-3

1.4 Theory of Operation ...................................................................................... 1-3

SECTION 2: INST ALLA TION...................................................................................................... 2-1

2.1 Unpacking New Equipment........................................................................... 2-1

2.2 Equipment Installation .................................................................................. 2-1

SECTION 3: OPERA TION ......................................................................................................... 3-1

3.1 Operating Controls........................................................................................ 3-1

3.2 Pre-Operation Set-up .................................................................................... 3-3

3.3 Operation...................................................................................................... 3-3

3.4 Cutting and S peed Selection......................................................................... 3-5

SECTION 4: SERVICE.............................................................................................................. 4-1

4.1 T orch Maintenance........................................................................................ 4-1

4.2 T AC 500 Power Supply Maintenance ............................................................ 4-3

4.3 HE 200 Coolant Recirculator Maintenance.................................................... 4-3

4.4 Gas Pressure Regulators.............................................................................. 4-4

4.5 Troubleshooting Guide .................................................................................. 4-6

4.6 Returns......................................................................................................... 4-6

4.7 Primary V olt age Selection............................................................................. 4-6

4.8 Trouble-Shooting........................................................................................... 4-6

4.9 Test Procedures............................................................................................ 4-9

SECTION 5: P ARTS LISTS ........................................................................................................ 5-1

5.1 System Components .................................................................................... 5-2

5.2 Front Panel Components .............................................................................. 5-4

5.3 Rear Panel Components............................................................................... 5-6

5.4 Right Side Components ................................................................................ 5-7

5.5 Left Side Components .................................................................................. 5-8

5.6 Equipment Board Assembly.......................................................................... 5-9

5.7 Bridge Assemblies .......................................................................................5-10

5.8 Bridge Assemblies....................................................................................... 5-11

5.9 Supply Console Components.......................................................................5-12

5.10 M200 T orch Components .............................................................................5-14

5.1 1 Operator Control Panel ................................................................................5-16

5.12 Gas Pressure Regulators.............................................................................5-17

APPENDIX 1 ............................................................................................................................... 1

APPENDIX 2 ................................................................................................................................2

APPENDIX 3 ................................................................................................................................3

APPENDIX 4 ................................................................................................................................4

APPENDIX 5 ............................................................................................................................... 5

APPENDIX 6 ................................................................................................................................6

APPENDIX 7 ................................................................................................................................8

TA500 Power Supply

H R

E200 Coolant ecirculator

Supply Console

Operator Control Panel

M200 T orch with Arc Starter

GENERAL INFORMATION

GASES AND FUMES

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.

Important Safety Precautions

WARNINGS

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

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

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 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

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

Date: May 1, 2000 (SPECIAL) i General Information

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 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

PLASMA ARC RAYS

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

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

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

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

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

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

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

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

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 Publications in this manual.

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 ii Date: May 1, 2000 (SPECIAL)

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

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

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

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

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

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

Note, Attention et Avertissement

ATTENTION

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

AVERTISSEMENT

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

Precautions De Securite Importantes

AVERTISSEMENTS

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

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

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

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

FUMÉE et GAZ

sont classifiées comme suit :

La fumée et les gaz produits par le procédé de jet de

NOTE

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

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.

Date: May 1, 2000 (SPECIAL) iii General Information

• 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 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.

• 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.

• Réparez ou remplacez toute pièce usée ou endommagée.

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

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir l'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.

• 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

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

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

General Information iv Date: May 1, 2000 (SPECIAL)

• 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 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.

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 v.

Documents De Reference

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

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

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

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

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

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

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

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

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

Date: May 1, 2000 (SPECIAL) v General Information

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

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

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

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

General Information vi Date: May 1, 2000 (SPECIAL)

Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2

W est Lebanon, New Hampshire 03784 USA

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

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical r equirements among them are:

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

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

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

ated accessories.

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

manufacturing process. This is to ensure the product is safe, when used 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 pr oduct meets or exceeds all design specifications.

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

Manufacturers responsible repr esentative: Giorgio Bassi

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

Date: May 1, 2000 (SPECIAL) vii General Information

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 her ein, exceed the price of the goods upon which such liability is based.

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

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

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

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

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

Parts

XL Plus & Parts Parts

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

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

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

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

Torch And Leads

Maximizer 300 Torch 1 Year 1 Y ear PCH/M-62 & PCH/M-102 Torches 1 Year 1 Year All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

Effective May 1, 2000

General Information viii Date: May 1, 2000 (SPECIAL)

SECTION 1: DESCRIPTION

1.2 Specifications

OF EQUIPMENT

1.1 General Information

A . 500 Amp System

A complete 500 amp T A500 system includes:

• M200 machine mounted torch with either 15, 25, 35 or 50 foot (4.6, 7.6, 10.7 or 15.2 meter) leads.

• Introductory spare parts kit for torch.

• Thermal Arc T AC 500 Power Supply .

• Pilot Arc Starter.

• Supply Console for gas and water connections and power manifolding.

• Operator Control Panel (with or without enclosure) that contains all switches, controls and indicator lights necessary to direct system functions.

• HE 200 Coolant Recirculator, a closed loop system that recirculates, deionizes and cools the torch coolant.

• Gas Regulators for assuring constant working pressure regardless of variation in inlet pressure.

• Supply hoses and cables to interconnect all components in lengths required for the particular installation. This must be decided prior to ordering the system. Refer to CC65 catalog C500 for ordering details.

B. 1000 Amp System

A complete 1000 amp T A500 system consists of the same components as the 500 amp system plus an additional T AC 500 Power Supply (connected in parallel with another T AC

500), an 8 foot long parallel control cable, two negative power cables and two positive work cables.

C. Options

• A Hi-Flow Water Shield Assembly to reduce smoke, noise and glare.

• Torch Standoff Control that automatically sets and maintains the torch a fixed distance above the metal being cut.

A. M200 Torch

• Current Rating: 1000 amperes maximum, General Purpose, DCSP; 750 amperes maximum, W ater Shield, DCSP.

• General Purpose: Cutting of most metals up to a maximum thickness of 4” (100 mm), piercing up to 2” (50 mm).

• Water Shielding: Cutting of most metals up to a maximum thickness of 3” (76 mm), piercing up to 1-1/2” (38 mm).

• Weight: 7.5 lbs (3.4 kg), without leads.

13.625" Max.

6.525" Min.

.937" Ø

16.0"

M200 Torch Dimensions

• Gas Requirements:

Setting Consumptio

Plasma Gas

Se conda ry Gas

Ar/H

, or Comp. Air

Se conda ry Gas

: N2

: CO

: H

60 psi

(4.1 ba r)

60 psi

(4.1 ba r)

15 gph

(56 lph)

110 scfh

(52 lpm)

350 scfh

(165 lpm)

15 gph

(56 lph)

B. Thermal Arc 500 Power Supply

• Power Input: 150 KV A, 50/60 Hertz, 3 phase in one of the following standard voltage/amperage combinations:

1-230/460 volts, 360/180 amps 2-460/575 volts, 180/145 amps 3-220/380 volts, 375/215 amps

• Rated Output: 500 amperes DC straight polarity at 200 volts

• Current Control: 150 to 500 amps continuously adjusted by a feedback circuit

2.25 O.D

• Control Circuit: 24 volt

• Weight: 1500 lbs. (680 kg)

Manual No 0-0470 1-1 General Information

)

(

D. HE 200 Coolant Recirculator

)

(

• Power Input: 50 or 60 Hz, 3 phase in one of the following standard voltage/amperage combinations:

1- 230 volts, 60 Hz, 5.5 amps 2- 460 volts, 60 Hz, 2.75 amps 3- 575 volts, 60 Hz, 2.2 amps

• Pump Capacity: 5.2 gpm (23.6 lpm)

47"

(119.4 cm)

42"

(106.7 cm)

32"

(81.3 cm)

TAC 500 Dimensions

C. Supply Console

• Power Input: From 500 Power Supply

• Plasma and Secondary Gas Pressure: Controlled by pressure regulator at gas supply

• Secondary Water Flow: Controlled by a flow meter on front panel

• Capacity: 80,000 BTU/hr

• Weight: 263 lbs. (1 19.4 kg)

38-1/2"

(98 cm)

HE 200 Dimensions

E. Control Panel

• Power Input: from 500 Power Supply

• Weight: 15 lbs (6.8 kg)

26"

(66 cm

28"

(71 cm)

• T orch Coolant: From HE 200 Coolant Recirculator

• Weight: 50 lbs. (22.7 kg)

9-5/8"

24.4 cm)

9-3/4

(25 cm

19"

48 cm)

Supply Console Dimensions

16-5/8"

(42.2 cm)

8-1/4"

(21 cm)

Control Panel Dimensions

General Information 1-2 Manual No 0-0470

1.3 Plasma

1.4 Theory of Operation

Plasma is a gas which has been heated to an extremely high temperature and ionized so that the gas becomes electrically conductive. The plasma cutting process uses this plasma to transfer an electric arc to the workpiece. The metal to be cut is melted by the heat of the arc and then blown away.

In a plasma torch, a cool gas such as nitrogen (N2) enters in Zone A. In Zone B a pilot ar c between the electrode and the front of the torch heats and ionizes the gas. An arc transfers to the workpiece through a column of plasma gas in Zone C.

Power

Supply

Workpiece

Plasma Torch

By forcing the plasma gas and electric arc through a small orifice, torches deliver a high concentration of heat to a very small area. The stiff, constricted plasma arc is shown in Zone C. Direct current straight polarity is used for plasma cutting, as shown in the illustration.

The exclusive Dual-Flow design of cutting torches uses a secondary gas. The secondary gas assists the high velocity plasma in blowing the molten metal out of the cut, resulting in fast clean, dross (slag)-free cuts. CO2, supplied from cylinders, or water , from the plant water system, is normally used as the secondary . Compressed air may be used as the secondary gas for some applications.

A-00002

The main components of the T A500 cutting system are illustrated in the block diagram and their function is summarized below .

Plasma and Secondary Gases

Plasma and secondary gases flow through the Control Console to the cutting torch at pressures set at the external regulators. The pressure of each gas is indicated on the gages mounted on the front of the Supply Console. Solenoid valves in the Supply Console turn the gases on and off and receive their signals from the Power Supply relay logic P.C. Board. The gas pressure interlocks shut the system down if the plasma gas pressure falls below 40 psi.

The plasma gas flows to the torch through the black lead, around the electrode and out thr ough the tip orifice.

The secondary gas (or water) flows to the torch through the yellow lead, through the outer insulator, inner tip retainer and end piece and out around the plasma arc.

Pilot Arc/Arc Starter

When the ST AR T button is pr essed the main contactor is activated. After two seconds the pilot contactor closes. The pilot bridge rectifier converts single-phase AC power from the main transformer Arc Starter winding to DC for the pilot arc. At the same time the arc starter circuit starts a series of high-voltage pulses. These pulses jump the gap between the electrode and the tip in the torch, which starts the pilot arc. The pilot arc then runs for half a cycle (1/120 sec) when the voltage drops and the pilot goes out until another pulse from the arc starter cir cuit starts it again. The arc starter circuit provides 15 pulses per second which results in a rapid-fire ‘pop pop pop’ pilot arc. This pilot arc makes a path for transferring the main arc to the work.

Cutting Arc

The main bridge rectifier converts the 3-phase AC power to DC for the main cutting arc. The negative output is connected to the electrode through the green torch lead. The positive output is connected to the workpiece (through the work cable).

Manual No 0-0470 1-3 General Information

Current Control

The desired cutting current is set with the control knob, located to the left of the ammeter, on the Contr ol panel. A control circuit in the Power Supply stabilizes the cutting current against fluctuations due to changes in line voltages, material thickness, torch standoff and travel speed. Changing the saturating current in the reactor changes the amount of AC power supplied to the main bridge rectifier . The saturating current is controlled by SCR’s which ar e in turn controlled by a printed circuit card which compares the actual cutting current to the current selector potentiometer setting.

Coolant Recirculator

When the Power Supply is turned on the Coolant Recirculator starts circulating coolant through the tor ch and back to the Recirculator through the radiators, reservoir, filter and pump. The Recirculator is a closed loop system and includes a deionizer assembly which maintains the resistivity of the coolant.

General Information 1-4 Manual No 0-0470

System Block Diagram

Manual No 0-0470 1-5 General Information

General Information 1-6 Manual No 0-0470

SECTION 2:

INSTALLATION

2.1 Unpacking New Equipment

The T A-500 is skid mounted and protected with a carton and padding material to prevent damage in shipment. The other components are packed separately . Make sure all items on the packing list are identified and accounted for . Inspect components for possible shipping damage.

One copy of the T A-500 Instruction Manual, in a transparent plastic envelope, is packed in with the T A-500 unit.

2.2 Equipment Installation

Select a clean, dry location with adequate working space around all components. The power supply is air cooled and must be located where there is fr ee circulation of air through the machine. At least two feet of clearance should be provided on all sides of the power supply to allow for circulation of air and any maintenance that may be required. A sour ce of 3-phase power and a source of gases with pressure regulators are required.

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

When cutting material under 3 inches thick most users prefer Nitrogen (N2) as the plasma gas and water as the secondary , since it is economical and easy to obtain good cut quality with this combination. However , CO is sometimes preferred as the secondary.

For material over 3 inches thick Nitrogen (N2) as the plasma gas and a mixture of 65% Argon/35% Hydrogen (Ar/H2) as the secondary gas is preferred.

To connect the units, follow these step by step procedures:

Thermal Arc Power Supply

1. Remove the cover and both side panels.

2. Remove the paper band (Fig. 2-A) stapled around the left motor strut.

3. Check for possible loose connections and damage that may have occurred during shipment.

Paper Band

Figure 2-A Voltage Connection Tag

4. Check the transformer (Fig. 2-A) to be sure that it is set up for the available power. Section 4.8 describes the connections for the various voltages. Find the one that corresponds to the available power and compare it to the terminal board on the transformer. Correct the connections if necessary.

CAUTION

Input voltage of the available three phase power source must correspond to one of the three oper-

ating voltages of the TA-500 transformer supplied. If not properly connected, damage to the equipment may result.

5 . Check the three-phase power service to be used.

Recommended maximum fuse or circuit breaker sizes are given in Table 2-A.

6. W ith the primary power disconnect switch open and fuses removed, feed the primary power cables through the Input fitting in the rear panel (Fig. 2-C) of the Power Supply . Connect the electrical ground wire to the gr ound lug (Fig. 2-D). A proper ground connection must be made to the brass stud. The other leads are attached to terminals L1, L2 and L3 (Fig. 2-E). Recommended wire sizes are given in Table 2-A.

Manual No 0-0470 2-1 Installation

Inpu

230

460

450

225

400 MCM

2/0

Stra Reli

Ground Lug

Figure 2-C Power Supply Rear Panel. Input of

Primary Power Cables

Power

Transformer

(T1)

1 2

Line

Voltages

Accepted

460 575 220 380

Fuse or

Circuit

Breaker

Amperages

225 170 450 250

Recommended

Minimum

Primary Wire

2/0

400 MCM

3/0

Table 2-A Line Voltages, Circuit Protection and

Recommended Wire Size.

NOTE:

This information is based on the 1978 National Electrical Code, T able 310-16. Lar ger sizes may be required if the length exceeds 25 feet.

Figure 2-D Ground Lug

WARNING

Do Not Turn On Power Until Step 37.

7. On the right-hand side of the power supply base, about half-way back, are the connection lugs for the output cables. Feed the two positive (RED) W ork cables, (end with large hole in lug), through the large plastic bushing on the lower right hand side of the front panel. Connect the cables to the positive (RED) output connections. The other end of these cables are connected to the work table.

8. Feed the two negative (GREEN) cables, (end with large hole in lug), through the same plastic bushing as the positive cables. Connect to the negative (GREEN) output connection in the Power Supply. The other end of these cables will be connected to the Supply Console.

9. Replace the side panels and cover.

Installation 2-2 Manual No 0-0470

Figure 2-E Input Power Connections

Supply Console

10. Place the Supply Console in the desired location and remove the cover .

Power Manifo

Feed Negative Cable Through Here

Figure 2-G Supply Console Rear Panel

11. Feed the two negative (GREEN) cables through the smaller plastic bushing on the back of the Console and connect to the bottom terminals of the power manifold (Fig. 2-F).

12. Replace the cover temporarily.

13. Connect one of the coolant hoses to the fitting marked COOLANT RETURN on the console and the other to the fitting marked RETURN on the HE200 Coolant Recirculator. Connect the other coolant hose to the fitting marked COOLANT SUPPLY on the Console and SUPPLY on the HE200.

CAUTION

Do not use other hose or pipe for this purpose. If any additional fittings or connectors are used in the coolant system they MUST be made of brass or stainless steel.

14. Connect the Arc Starter Control cable (ORANGE) to the rear panel of the Supply console marked as such. Connect the other end to the Power Supply receptacle color-coded ORANGE.

15. The Supply Console Control cable (GREEN/ ORANGE) is keyed by the connectors on each end. Find the end that mates with the receptacle on the rear of the Supply Console marked CONTROL and connect. The other end connects to the Power Supply receptacle colored GREEN/ORANGE.

Negative

Plastic Bushing

The other connections to the Supply Console will

NOTE

be made later .

Figure 2-F Cable Connections

Manual No 0-0470 2-3 Installation

HE 200

NOTE

CAUTION

Do not attempt to run the HE 200 until the torch leads are connected to the Control Console (steps 28-33). Refer to step 38.

NOTE

Refer to the instruction manual packed with the HE 200 for installation instructions.

16. Add coolant supplied to the reservoir of the HE

200. Fill to the crosswires in the bottom of the round neck.

17. The Supply and Return hoses should already be connected per step 13. If not, connect hoses to the correct fittings.

18. Connect 3-phase power source to the starter box on the outside of the unit per the HE 200 instruction manual.

19. Connect the starter cable to the Power Supply receptacle marked COOLANT RECIRCULATOR.

CAUTION

The 115 VAC power from the TA-500 Power Supply is to operate the starter of the Recirculator only, it will not operate the motor.

Refer to the Interface diagram at the back of this manual for a more detailed description of the inter-connections and functions.

Control Panel

SW2

SW3

ON/OFF

SW1

Line No.

START

STOP

P29 Pin No.

125

118 138

119

NOTE: When signals marked are not used the lines must be jumpered

3 6

5 8

9 7

CNC Signals

(input)

Start

Stop

Station Sele

Ground

Figure 2-H

Standoff Control

The Standoff Control Panel is shipped separately. Refer to Instruction Manual for Standoff Control Installation.

Gas Connections

Control Panel - TA-500

20. Mount the Control Panel in a convenient spot.

21. Connect the Control Panel cable (YELLOW/ ORANGE) to the upper receptacle (color-coded YELLOW/ORANGE) on the rear of the Control Panel. The connections are keyed on each end. Connect the other end to the Power Supply receptacle marked REMOTE P ANEL CONTROL.

Computer Interface Option

22. T o interface the Contr ol Panel with a Computer Control connect the Computer Interface Cable (BLUE/ORANGE) to the middle receptacle (color-coded the same) on the rear of the Control Panel. Figure 2-H shows the direct relationship of the Computer Interface Cable with the Control Panel. The dotted lines indicate input and output signals required from a computer to operate the TA500 System. The Control Panel Station Select signal is optional and must be jumpered if not used.

W ARNING

Do Not Stand In Front of the V alve Outlet When Executing Step 23.

23. Examine the cylinder valve and ensure that it is clean and free of oil, grease and other foreign matter. Momentarily open the cylinder valve to blow out any dust which may be present.

24. Connect the appropriate regulator on the cylinder valve. The gas supplies must be equipped with adjustable pressure regulators capable of being set between 0 and 60 psi (0-4.1 bar) and of delivering 150 Standard Cubic Feet per Hour (SCFH) of N2 and 400 SCFH of CO2 or compressed air.

Pressure regulators for use with TDC units and specifically calibrated for use with nitrogen (Cat. No. 9-2722) and carbon dioxide (Cat. No. 9-2759) are supplied when a T A-500 System is ordered. They are also available from Thermal Dynamics as accessories, as are regulators for argon/hydrogen (Cat. No. 9-3053) and compressed air (Cat. No. 9-3022).

Installation 2-4 Manual No 0-0470

25 . Connect the plasma gas supply hose (BLACK) to

the plasma gas cylinder and the fitting on the rear panel of the Control Console marked PLASMA GAS.

26 . Connect the secondary gas (if used) supply hose

(YELLOW) to the secondary gas cylinder and the fitting on the rear panel of the Control Console marked SECONDARY GAS.

NOTE

30. Remove the cover from the Supply Console.

31. Pass the torch leads and arc starter connector through the larger plastic bushing on the rear panel of the Supply Console.

32. The torch leads are color-coded. Attach them to the appropriate (color-coded) fittings on the bulkhead board. Connect the arc starter plug to the receptacle marked ARC STARTER.

A typical 50-lb CO2 cylinder is capable of delivering 35 SCFH on a continuous basis. Therefore, it may be necessary to manifold several cylinders to obtain the required torch flow rate, depending on the application and duty cycle.

27. If water shield will be used as the secondary, connect secondary water supply hose (YELLOW) to the water source and the rear panel of the Supply Console marked SECONDARY WATER SHIELD.

NOTE:

The water source must be capable of delivering a minimum water pressure of 20 psi. This water does not need to be deionized, but in water systems with an extremely high mineral content a water softener is recommended.

Arc Starter

A box housing some of the Arc Starter components is shipped separately. It must be mounted close to the torch (usually on the torch lifter frame) and connected to the torch leads. The 16-pin connector protruding from the torch leads covering is connected to the end of the box marked WHITE/YELLOW. The wire lead color-coded RED is connected to the end of the box marked RED. The wire lead color-coded GREEN is connected to the end of the one marked GREEN.

M200 T orch

28. Check the torch to see that it is properly assembled (refer to Section 4-1).

33 . Replace the cover on the Supply Console and se-

cure.

Hi-flow Water Shield (Optional)

NOTE:

Refer to the instruction manual packed with the Hi-Flow Water Shield for installation instructions.

34. Connect the Hi-Flow starter control cable to the receptacle marked HI-FLOW WATER SHIELD on the front panel of the Power Supply.

CAUTION

The 115 VAC power from the TA-500 Power Supply is to operate the contactor of the HiFlow Water Shield pump only. It will not operate the motor.

1000 Amp System (Two TA-500 Power

Supplies)

T o connect two (2) T A-500 Power Supplies together for a 1000 amp system the first (master) unit is connected as described in step 1 through 36. The second (slave) unit is connected per steps 1 through 11 with the additional interconnecting step.

35. Connect the end of the Parallel Control cable colorcoded WHITE to the receptacle marked P ARALLEL RELA Y on the front panel of the first (master) Power Supply . Connect the end color-coded YELLOW/ ORANGE to the receptacle REMOTE P ANEL CONTROL on the second (slave) unit.

NOTE:

WARNING

Underwater cutting requires special insulated torch parts. See Figure 5-10.

29. The torch is normally shipped attached to the gas and water leads. If this is not the case, refer to Section 4-1.

Manual No 0-0470 2-5 Installation

There should be 2 negative (GREEN) cables from each of the two Power Supplies to the Supply Console and 2 positive (RED) work cables from each of the two Power Supplies to the workpiece.

36 . Inspect all connections to ensure that they are se-

curely made and tightened. Check that all covers and panels are replaced and secured.

CAUTION

Do not attempt to operate this system unless all parts of all enclosures are in place. This is important for proper cooling as well as for safety.

WARNING

Care should be taken when working around the unit when the power is turned on. No changes of electrical connections or torch parts should be attempted unless the primary power is first turned off.

37. Turn on the primary power and verify the direction of rotation of the fan motor. It should blow air out the back of the unit. If air is not blown out the back of the unit, the rotation is incorrect and any two motor leads (lines 44, 45, or 46) on the transformer terminal board should be switched.

38. When the ON-OFF switch on the Control Console is moved to ON the HE 200 should come on. Run the Coolant Recirculator for several minutes to remove air trapped in the lines. After running for a few minutes, turn the Recirculator OFF and remove the reservoir cap. Bring the coolant up to the level of the crosswires and install the Reservoir Cap/Cartridge Assembly supplied with the unit. Replace the cover and secure.

39. The System is now ready for operation.

Installation 2-6 Manual No 0-0470

SECTION 3: OPERATION

3.1 Operating Controls

AC POWER

READY

OFF

0 200 400 600 800 1000

D.C. AMPERES

CURRENT CONTROL

START

STOP

NORMAL

SOFT

START

PIERCE

RUN

PURGE

SET

Red STOP button is pressed to stop the cutting cycle and turn off the power to the torch.

7. RUN/PURGE/SET Switch (SW6)

Move to the PURGE (center) position to purge the plasma gas in the torch. SET (down) position is used to set the plasma and secondary flow rates. The Power Supply cannot be actuated in either the PURGE or SET position but will operate normally in the RUN (up) position.

8. NORMAL/SOFT START/PIERCE Switch (SW2)

This three-way switch is used to set the mode of operation of the Power Supply. Most cutting will be done in the NORMAL (up) position. For rapid piercing the PIERCE (down) position gives a current surge when the tor ch is first started. The SOFT ST ART (center) position is a low power start which is useful in prolonging the orifice life of small tips.

9. START Switch (SW2)

Green START button is pushed to initiate the cutting cycle.

Figure 3-A Operator Control Panel

1. Ammeter (AM)

Indicates amperage supplied to torch.

2. AC POWER Indicator (LT3)

Red light indicates that Primary AC power is being supplied to the system.

NOTE: Fan is on when light is on.

3. “Ready” Indicator (LT4)

Amber light indicates that the ON/OFF switch is in the ON position and that all system requirements are met.

4. ON/OFF Switch (SW1)

Move up to ON position to turn on HE 200 and activate control circuits. Move down to OFF position to deactivate control circuits.

5. CURRENT CONTROL Knob

Adjust knob while cutting until desired current is read on Ammeter.

6. STOP Switch (SW3)

Manual No 0-0470 3-1 Operation

14. HI-FLOW W A TER SHIELD ON/OFF Switch (SW8)

1FU

AC POWER

DC POWER

100

200 300

AMPERES

D.C.

PILOT

2FU

AUTO

MAN

200 300

400

100

500

3FU

SURFACE

UNDERWATER

DO NOT SWITCH

UNDER LOAD

400

VOLTS

D.C.

4FU

OFF

500

Figure 3-B TA-500 Power Supply Front Panel

10. AC POWER Indicator

HI-FLOW

WATER SHIELD

The ON position activates the circuitry for the hi-Flow W ater shield (optional) control. The OFF position deactivates the circuit.

15. V oltmeter

Indicates the voltage between the torch electrode and the workpiece (voltage on main bridge rectifier). Useful in troubleshooting.

16. Ammeter

Indicates amount of cutting current being supplied from the Power Supply to the torch.

PLASMA

SECONDARY

GAS

WATER SHIELD

COOLANT

Red light indicates that Primary AC power is being supplied to the Power Supply.

NOTE: Fan should be running when this light is on.

11. DC POWER Indicator

Red light indicates that main contactor (W) has closed to supply current to the main bridge rectifier and that cutting current is available.

12. PILOT AUTO/MAN Switch (SW9)

With the switch in the MAN position the pilot arc will start two seconds after the green START button is pressed and will stay on for 2 seconds only. The main cutting arc must transfer in this time. If the pilot arc goes out press the red STOP button, and the green START button to recycle the torch. The torch must be recycled after each cut to start the pilot arc again. In the AUT O position the pilot arc will remain on until the cutting ar c is transferred and will restart when the cutting arc goes out.

13. SURFACE/UNDERWATER Switch (SW8)

Figure 3-C Supply Console Front Panel

17. PLASMA Gauge

Indicates pressure at which plasma gas is being supplied to the torch.

18. SECONDARY Gauge

Indicates pressure at which secondary gas is being supplied to the torch.

19. SECONDARY Flowmeter

Indicates flow rate at which secondary water is being supplied to torch.

20. GAS/WATER SHIELD Switch (SW7)

Used to select either gas or water as a secondary.

21. COOLANT Gauge

Indicates pressure at which coolant is supplied to the torch.

Selects the proper resistance value of the pilot resistor for the type of cutting operation.

NOTE: Do not switch under load.

Operation 3-2 Manual No 0-0470

3.2 Pre-Operation Set-up

This procedure should be followed at the beginning of each shift:

WARNING

Check to be sure main disconnect switch is open.

1. Check the coolant level in the Coolant Recirculator and fill to proper level if necessary.

10. Check the position of the HI-FLOW WA TER SHIELD ON/OFF switch and the PILOT AUTO/MAN switch on the Power Supply for desired operating mode.

Surface or Underwater Cutting

11. The two cutting modes, Surface and Underwater , require a different pilot resistance. This is easily selected using the SURF ACE/UNDERW ATER switch on the T A500. The M200 torch also requires dif ferent parts for underwater operation. Refer to Section

4.1 for details.

Bevel Cutting

2. Check the torch to be sure it has the proper components and is assembled and adjusted correctly.

3. Close the main disconnects supplying 3-phase power to the Power Supply, Coolant Recirculator and Hi-Flow W ater Shield (if used).

4. Turn the ON/OFF switch on the Control Panel to ON. The Coolant Recirculator will come on. The amber READY light will come on. (If the gas supply is on, the gases will flow for 2 seconds).

5. Select the plasma gas pressure for the type of cutting to be done from Table 3-B. Move the RUN/SET/PURGE switch to the SET position. Open the plasma gas supply valve at the source. Adjust the pressure regulator on the gas supply until the plasma pressure selected from the Table is obtained.

6. Move the switch to PURGE for approximately 3 minutes (this allows the plasma gas to run). This will remove any condensation or moisture that may have accumulated in the torch while it was shut down. If there is any sign of moisture after purging, determine the cause and correct it before operating the system.

NOTE:

12 . Bevel cutting requires a greater standoff distance

due to the angle of the torch. The pilot resistance therefore must be changed to ensure that the main arc will transfer and that proper standoff will be found when using an SC504 Standoff Control. The proper resistance for surface bevel cutting is obtained by moving the SURF ACE/UNDERW ATER switch to the UNDERW A TER position.

When bevel cutting, underwater resistance value of the pilot resistor (R2) must be adjusted. Consult the Thermal Dynamics Customer Service Department for assistance in obtaining the correct resistance value.

The system is now ready for operation.

3.3 Operation

W ARNING

Be sure the operator is equipped with proper eye and ear protection and that all precautions in the front of this manual have been followed.

1. The M200 torch must be at right angles to the plate to obtain a clean, vertical cut. Use a square, as shown in Figure 3-F , to align the torch.

Only the plasma gas needs to be purged.

7. Return the RUN/SET/PURGE switch to the SET position and open the secondary supply valve at the source. Adjust the pressure regulator at the gas supply until pressure reads 60 psi (4.1 bar) or turn on the secondary water if water shield cutting and set at about 12 gph.

8. Return the RUN/SET/PURGE switch to the RUN position.

9. Set the CURRENT ADJUST knob on the Control Panel for desired amperage level.

Manual No 0-0470 3-3 Operation

3. Adjust the cutting speed for good cutting perfor-

mance, as indicated by a trailing arc of approximately 5 degrees (Fig. 3-G).

5o Appro

Figure 3-F Using a Square to set up the M200 Torch

2 . To start a cut at the edge of the plate, line up the

torch away from the plate and press the ST AR T button on the Control Panel. The pilot arc characteristics will depend on which PILOT mode is selected (see 3.1.12) and the position of the SURFACE/UNDERWATER Switch (3.1.13). The cutting arc will be established at the plate edge as the torch approaches the plate.

Figure 3-G Proper Cutting Speed Produces a Trailing

Arc of Approximately 5 Degrees

4. In some cutting operations, it may be desirable to start the cut within the plate area rather than at the plate edge. Piercing is not recommended in over 2inch (50 mm) thick material when using W ater Shield. When a lot of piercing is required, a special tip (Cat. No. 8-6047) and end cap (Cat. No. 8-6057) should be used. T o pierce, set the NORMAL/SOFT ST ART/ PIERCE switch to the PIERCE position (see 3.1.8).

NOTE:

The suggestions listed below should be followed in all cutting operations:

1. At shut down wait five minutes before moving the ON/OFF switch to OFF and opening the main disconnect switch. This allows the Power Supply and torch to cool down.

2. For maximum parts life, do not operate the pilot arc any longer than necessary.

3. Remember that cutting current can be adjusted at any time (see Instruction Manual for Standoff Control). Learn to change the current output to provide a comfortable working speed for the particular material being cut.

4. Use care in handling torch leads and protect them from damage.

Operation 3-4 Manual No 0-0470

5. In continuous cutting applications, it is often neces-

(

sary to manifold 4 to 6 CO maintain pressure.

6. Because of the swirl of the plasma gas in the torch, the right-hand side of the cut (in relation to the torch travel, as shown in Fig. 3-H) is normally of better quality . A reverse swirl electrode is available for applications requiring the better quality be on the left side of the cut (in relation to the torch travel).

cylinders together to

Torch Trav

3.4 Cutting and Speed Selection

The desired cutting current and the speed at which the torch is moved along the line of the cut depends on the thickness and composition of the workpiece. Use T able 3-B as a starting guide to establish the proper cutting speed for the material being cut.

COMMON CUTTING FAULTS

Listed below are common cutting problems followed by probable causes of each. If problems are caused by the T A-500 system, refer to the trouble shooting section (Section 4).

1. Insufficient Penetration

a. Cutting speed too high b. Current too low

2. Main Arc Extinguishes

a. Cutting speed too slow b. Standoff too high

3. Dross Formation

a. Improper gas pressure or mixture

Scrap

Beveled)

Side

Better

(Square)

Side

Figure 3-H Direction of Gas Flow Using Standard Gas

Distributor

WARNINGS

FREQUENTLY REVIEW THE SAFETY PRECAUTIONS GIVEN AT THE FRONT OF THIS MANUAL.

b. Improper cutting speed c. Faulty electrode or tip d. Current too high e. Stand-off too low

4. Burned-Out Tips

a. High cutting current b. Damaged or loose cutting tip c. Contact with work d. Heavy spatter e. Low plasma gas pressure f . Improper selection of SOFT/NORM/PIERCE

It is not enough to simply move the ON/OFF switch on the Control Panel to its OFF position when cutting operations have been completed. Always open all power disconnect switches 5 minutes after the last cut is made.

Manual No 0-0470 3-5 Operation

Table 3-B Recommended Cutting Speeds

INCHES/MINUTE (METERS/MINUTE)

1/2" (12. 7 m m )

3/4" (19 mm )

INCHES/MINUTE (METERS/MINUTE)

1" (25. 4 mm )

1-1/2" (38 m m )

INCHES/MINUTE (METERS/MINUTE)

2" (50. 8 mm )

INCHES/ M INUTE (METE RS/ M INUTE )

1/4" (6 mm)

1/2" (12. 7 m m )

The following charts are intended as a guide in determining approximate conditions for making good quality cuts in various thicknesses of material. Slower speeds may generally be obtained by reducing the current.

250 Amperes

The speeds below are typical for cutting at 250 amperes using the 8-6042 tip and the 8-6006 end piece. GENERAL PURPOSE WA TER SHIELD Plasma gas: N2 at 60 psi (4.1 bar) (85 scfh) Plasma Gas: N2 at 60 psi (4.1 bar) (85 scfh) Secondary gas: CO2 at 60 psi (4.1 bar) (85 scfh) Secondary: Water - 12 gph

THICKNESS:

BEST MAX BEST MAX

St ai nless S teel 140 (3.56) 250 (6.35) 85 (2.16) 125 (3.18)

Alum i num 135 (3.43) 250 (6.35) 100 (2.54) 135 (3. 43)

Carbon Steel 100 (2.54) 200 (5.08) 60 (1.52) 80 (2.03)

500 Amperes

The speeds below are typical for cutting at 500 amperes using the 8-6044 tip and the 8-6006 end piece. GENERAL PURPOSE WA TER SHIELD Plasma gas: N2 at 60 psi (4.1 bar) (95 scfh) Plasma Gas: N2 at 60 psi (4.1 bar) (95 scfh) Secondary gas: CO2 at 60 psi (4.1 bar) (350 scfh) Secondary: Water - 12 gph

THICKNESS:

BEST MAX BEST MAX St ainl ess Steel 150 (3.81) See Note B 90 (2.29) 125 (3.18) Alum i num 180 (4.57) See Note B 110 (2.79) 140 (3.56) Carbon Steel 75 (1.9) 125 (3.18) 55 (1.4) 75 (1. 9)

THICKNESS:

BEST MAX BEST MAX St ainl ess Steel 60 (1.52) 80 (2.03) 40 (1.02) 50 (1.27) Alum i num 80 (2.03) 100 (2. 54) 50 (1.27) 60 (1.52) Carbon Steel 35 (0.89) 50 (1.27) 20 (0.51) 30 (0.76)

THICKNESS:

BEST MAX St ainl ess Steel 25 (0.64) 30 (0.76) Al uminum 35 (0. 89 ) 45 (1.14) Carbon Steel 15 (0.38) 25 (0.64)

Operation 3-6 Manual No 0-0470

750 Amperes

1" (25.4 m m )

1-1/2" (38 m m )

INCHES/ M INUTE (METE RS/ M INUTE )

1/2" (12. 7 mm )

3/4" (19 mm )

INCHES/ M INUTE (METE RS/ M INUTE )

3" (76 mm )

4" (102 mm )

INCHES/ M INUTE (METE RS/ M INUTE)

2" (51 mm )

2-1/2" (64 m m )

INCHES/ M INUTE (METE RS/ M INUTE)

The speeds below are typical for cutting at 750 amperes using the 8-6045 tip and the 8-6006 end piece. GENERAL PURPOSE WA TER SHIELD Plasma gas: N2 at 60 psi (4.1 bar) (100 scfh) Plasma Gas: N2 at 60 psi (4.1 bar) (100 scfh) Secondary gas: CO2 at 60 psi (4.1 bar) (350 scfh) Secondary: Water - 12 gph

THICKNESS:

BEST MAX BEST MAX St ai nless Steel 180 (4.57) S ee Note B 120 (3.05) 150 (3.81) Alum i num 200 (5.08) See Note B 160 (4.06) 180 (4.57) Carbon Steel 140 (3.56) See Note B 75 (1.9) 95 (2.41)

THICKNESS:

BEST MAX BEST MAX St ai nless Steel 80 (2.03) 100 (2.54) 50 (1.27) 60 (1.52) Alum i num 100 (2.54) 130 (3.3) 80 (2.03) 100 (2.54) Carbon S teel 50 (1. 2 7) 65 (1.65) 30 (0 . 7 6) 40 (1.02)

1000 Amperes

The speeds below are typical for cutting at 1000 amperes using the 8-6046 tip and the 8-6006 end piece.

For material under 3” (76 mm) thick:

GENERAL PURPOSE Plasma gas: N2 at 60 psi (4.1 bar) (110 scfh) Secondary gas: CO2 at 60 psi (4.1 bar) (350 scfh)

For material over 3” (76 mm) thick:

GENERAL PURPOSE Plasma Gas: N2 at 60 psi (4.1 bar) (110 scfh) Secondary: Ar/H2 at 25 psi (1.7 bar) (250 scfh)

THICKNESS:

BEST MAX BEST MAX St ai nless Steel 50 (1.27) 65 (1.65) 35 (0.89) 50 (1.27) Alum i num 60 (1. 52) 75 (1. 9) 55 (1.4) 70 (1.78)

THICKNESS:

BEST MAX BEST MAX St ai nless Steel 20 (0.51) 30 (0.76) 10 (0.25) Alum i num 40 (1. 02) 60 (1.52) 20 (0.51)

Note A: This information repr esents our best judgement but Thermal Dynamics Corporation assumes no liability for its use.

Note B: Exceeds maximum speed of most motorized torch carriers.

Manual No 0-0470 3-7 Operation

Operation 3-8 Manual No 0-0470

SECTION 4: SERVICE

The Service Section is divided into nine parts:

4.1 Torch Maintenance

4.2 TAC 500 Power Supply Maintenance

4.3 HE 200 Coolant Recirculator Maintenance

4.4 Gas Pressur e Regulators

4.5 Troubleshooting Guide

4.6 Returns

4.7 Primary Voltage Selection

4.8 Trouble-Shooting

4.9 Test Procedur es

WARNING

Disconnect the primary power before disassembling the torch.

4.1 Torch Maintenance

Disassembly

1. Unscrew the collar (19) and pull the end cap (17) off. The end piece (16) and O-ring (15) will remain in the end cap when it is removed.

2. Remove the coolant baffle (20) from the front of the inner tip retainer (9).

3. Pull the outer insulator (13) off.

4. Unscrew the inner tip retainer (9). The cutting tip will remain in the inner tip retainer . If additional leverage is needed to remove this part insert a 5/32 inch diameter rod in one of the large holes.

5. Remove the tip (6) from the inner tip retainer by pressing back on the front of the tip. Considerable pressure may be needed to push the tip past the O-ring seals.

6. Remove the electrode (5) from the torch by unscrewing it from the electr ode seat (4). The electrode seat does not need to be removed from the torch unless it has been damaged.

7. Remove the water tube (2) by lifting it out of the torch.

Figure 4-A M200 Torch

Manual No 0-0470 4-1 Service

For routine disassembly of the torch, no other parts need to be removed. The electrode seat (4) does not requir e replacement unless it has been damaged by a severe electrode failure. This part unscrews from the center post of the torch and should be gripped with a piece of emery cloth. If necessary , pliers may be used very gently to remove this part.

Torch Assembly

CAUTION

There are several O-ring seals in this torch to prevent leakage of the coolant. It is important to observe the following precautions for all O-rings:

A. Make sure that the O-ring groove and the sur-

face that the O-ring will seal against are clean

and free of nicks and scratches. B. Make sure that the O-ring is not cut or cracked. C. Lubricate all O-rings with a light coating of Cat.

No. 8-4025 O-ring lubricant. This should be

used sparingly , just enough to make the O-ring

slippery but not enough to accumulate in the

torch.

If a new electrode seat (4) is installed in the torch, the O-ring (3) in the center post of the torch should be replaced before installing the new one. The new electrode seat may be gripped with emery cloth and screwed into the center post of the torch. It is not necessary to use pliers.

When assembling the torch, proper orientation of the coolant baffle (20) relative to the M200 basic head assembly (1) is important. The basic head assembly has two projections on the sides of the plastic body that are called ‘marks’ in step 8 below.

Assemble the torch as follows:

1. Install a new O-ring in the electrode seat. This

O-ring is included with each new electrode. The

O-ring is installed in the groove located about

3/8” (9.5 mm) back from the front of the elec-

trode seat.

2. Install the water tube (2) in the center of the

3. Install the electrode (5). Make sure it screws in

torch, small end first.

all the way.

4. Install new O-rings in the inner tip retainer (9).

These O-rings (7 and 8) are supplied with each

new cutting tip. The should be lubricated lightly

with Cat. No. 8-4025 O-ring lubricant and

placed in the proper groove in the tip retainer.

Figure 4-B M200 Torch

Service 4-2 Manual No 0-0470

5. Install the new tip (6) in the inner tip retainer. This is installed by pressing it in from the back. If the O-rings are properly lubricated, thumb pressure is adequate (with a slight twisting motion of the thumb).

6. Install the inner tip retainer with the tip in place on the front end of the torch. The tip retainer must be screwed completely into place. It is essential that the ceramic O-ring on the tip be firmly in contact with the electrode.

7. Install the outer insulator (13) on the torch. Before pushing this into place, make sure that the O-rings on the inside diameter are in good condition and properly lubricated. The insulator must be pushed onto the torch as far as it will go.

8. Install the coolant baffle (20) on the front of the inner tip retainer . The triangular projections go into the holes in the inner tip retainer that are aligned with the marks on the plastic torch body . If the holes do not align exactly, use the closest ones. DO NOT loosen the inner tip retainer to improve the alignment.

9. Install the end piece (16) in the front of the end cap, small end forward.

10. Install O-ring (15) in the end cap against the back of the ceramic end piece. A light coating of O-ring lubricant will help hold this O-ring in place until the end cap is installed.

11. Press the end cap (17), complete with end piece (16) and O-ring (15) in place, onto the outer insulator (13). Install the collar (19) over the end cap (17) and screw it onto the torch body.

This completes the torch assembly. There is a chance that water may get in the plasma gas passages in the torch during assembly. All water must be removed before operation.

To remove all traces of water:

1. Turn the Console RUN/SET switch to SET.

2. Turn on the coolant.

3. Turn on the plasma gas (nitrogen). Do not turn on the shield water (water shield cutting). The shield gas may be on or off (dual flow cutting).

4. With plasma gas flowing, look for traces of moisture in the gas stream.

W ARNING

Do not operate the torch unless the plasma gas stream is completely free of moisture.

Be sure to turn on the secondary gas or shield water before starting to cut.

4.2 TAC 500 Power Supply Maintenance

The only routine maintenance the T AC 500 Power Supply requires is an occasional removal of the cover and side panel and a thorough blowing out of dust with an air hose.

4.3 HE 200 Coolant Recirculator Maintenance

Parts in the HE 200 Coolant Recirculator require routine maintenance. The coolant level should be checked daily and Thermal Arc coolant added to keep the level at the crosswires in the cylindrical section. If Thermal Arc coolant is not available, distilled or deionized water may be used if the temperature does not go below freezing. The resistivity of the water must measure above .1 megohm cm.

CAUTION

Do not use tap water . It could cause severe damage to the torch.

The reservoir contains a cap/cartridge assembly which includes a small cartridge of deionizing resin to maintain the resistivity of the coolant. The cartridge must be replaced when it changes from gray to straw color.

A coolant filter with a r eusable scr een is located above the pump. The screen should be removed and cleaned once every six months or at any time the coolant pressure drops. To remove the filter screen, remove the top of the HE 200 unit and unscrew the hex nut on the bottom of the filter housing.

The coolant recirculator has a pressur e relief valve that is factory set at 150 psi (10.3 bar) and should not require adjustment. Normal operating pressure is approximately 110 psi (7.6 bar). If the pr essure relief valve must be adjusted see the HE-200 manual.

Manual No 0-0470 4-3 Service

The pump is pre-greased at the factory and should only re-

quire lubrication every two years. T o lubricate, remove screws from the two grease fittings on top of the pump and apply grease supplied with the HE 200 unit.

CAUTION

Do not over-lubricate the pump; it will cause pump failure.

The fan belt may become loose due to usage. The belt tension should be such that moderate finger pressure (about mid-distance from pulley to pulley) gives about 1/4 inch (6 mm) deflection. The belt tension may be adjusted by changing the width of the gap on the large adjustable pulley . Using a 5/32 hex key wr ench loosen the two set screws 180 degrees apart on side of pulley. Remove key and rotate by half turns until desired gap is obtained. Replace the square key and tighten set screws again.

A-01894

4.4 Gas Pressure Regulators

The Thermal Arc gas pressure regulators provide a means of conveniently selecting and maintaining the required working pressures of the gases. The regulator will hold this pressure constant. Inlet pressure is reduced in one step to the working pressure by means of a pressure balanced poppet valve controlled by a spring loaded piston in a low pressure chamber . A lar ge adjusting spring knob (6, Figure 4-C) provides for adjusting spring pressure against its piston. A sintered stainless steel filter , in the inlet connector (1), pr events dirt from entering the regulator mechanism.

No regular maintenance of the gas pressure r egulators is required, except an occasional lubrication of the adjusting screw thread and on its end, where it contacts the adjusting spring. Lubricant is available from Thermal Dynamics for this purpose (Catalog No. 9-2781).

Replacement parts in the regulator include the pressure gauges, the O-ring seals on the piston and above the poppet valve, and the poppet valve. (See Assembly Parts List Fig. 5-12 for replacement parts).

1. Inlet connection

2. Inlet pressure gage

3. Safety valve

4. Working pressure gage

5. Hose connection

6. Adjusting knob

Figure 4-C Components of Gas Pressure

Regulator

CAUTION

Do not attempt to remove the sintered metal filter in the inlet connection. This is not a serviceable item.

Service 4-4 Manual No 0-0470

ACTION

1. Torch brought close (approximately

1/2 inch) to workpiece.

RESULTS

1. Arc transfers to workpiece to establish

CUTTING ARC.

2. Current sensing circuit turns off pilot arc.

3. Depending on the position of the PILOT

ACTION

1. STOP button pressed.

RESULTS

1. Red DC POWER light off.

2. Pilot arc stops.

After two seconds:

ACTION

1. Torch moved away from workpiece

or workpiece burns away

PILOT

AUTO/MAN switch the arc starter will be

turned off by either relay CSR (AUTO) or

time delay relay (MAN).

4. 'Pre-start' saturating current turned on by relay CSR.

5. Standoff Control circuitry is energized by relay CSR.

6. Current regulating circuit is energized by relay CSR.

7. Hi-Flow Water Shield turned on by relay CSR.

ACTION

1. Protect eyes and press START

button.

READY

SYSTEM

3. Plasma gas and secondary

or water flow stops.

under torch.

RESULTS

1. CUTTING ARC stops.

2. Hi-Flow Water Shield shuts off

RESULTS

1. Plasma gas and secondary gas

or water pressure switches close.

2. Main contactor closes. Red DC

automatically.

PILOT AUTO/MAN switch in

AUTO position:

3. Pilot arc comes on until CUTTING

ARC is transferred or STOP

button is pushed.

PILOT AUTO/MAN switch in

MAN position:

3. No Pilot arc.

4. DC POWER light remains on,

POWER light on.

3. Reactor saturating current is

turned on. The amount of satur-

ating current depends on the

position of the NORMAL/SOFT

START/PIERCE switch (this

is for 'pre-start' only).

After two seconds:

4. Pilot arc relay closes.

5. Arc starter circuit energized.

gases continue to flow.

5. No cutting arc.

6. Pilot arc turns on.

SYSTEM READY

ACTION

1. RUN/SET/PURGE switch

(SW6) to RUN.

2. Select cutting amps with

CURRENT CONTROL knob.

RESULTS

1. Gas flow stops.

2. Power circuits ready.

or water solenoids open. Plasma

gas and secondary gas or water

flow so pressure can be set.

2. Power circuits disabled.

ACTION

1. Close all three external disconnect

switches (TA500, HE200,

Hi-Flow Water Shield)

RESULT

1. Red AC POWER light (LT3) on and

fan starts in TA500.

ACTION

1. RUN/SET/PURGE switch

(SW6) to PURGE.

1. ON/OFF switch (SW1) to ON.

RESULTS

1. HE200 starts to pump coolant to

torch via Supply Console

2. Coolant pressure reaches 100 psi.

3. Amber READY light (LT4) turns on.

4. Plasma gas and secondary gas

or water shield solenoids open

and gases (or water) flow.

RESULTS

1. Plasma gas solenoid only

opens allowing the plasma

line to be purged.

After two seconds:

5. Gas (or water) flow stops.

ACTION

1. RUN/SET/PURGE switch

(SW6) to SET.

RESULTS

1. Plasma gas and secondary gas

Manual No 0-0470 4-5 Service

4.5 Troubleshooting Guide

If the T A-500 System malfunctions the troubleshooting guide will be helpful in correcting the problem. Since the malfunction may be due to a faulty connection rather than a faulty component, be sure to check all connections to a component that appears to be malfunctioning.

The troubleshooting guide is arranged in the normal operating sequence of the system for easy reference. Each problem has listed next to it the possible causes and the remedy .

In some cases the remedy is too complex to fit the table, in which case there is a reference to one of the “Test Procedures”.

4.6 Returns

If a product must be returned for service, contact your distributor. Material r eturned without proper authorization will not be accepted.

C. No READY Light (Control Panel).

1. Coolant pressure switch PS2 in Supply Console open (pressure below 75 psi/5.2 bar).

a. Check coolant level in HE200. Clean pump

filter screen. Adjust pump. Replace pump.

2. Pressure switch PS2 in Supply Console not satisfied.

a. Adjust (75 psi/5.2 bar) or replace PS2. (See

A, Section 4.8).

D. Gases do not flow when “ready” Light comes

on.

1. Gas supply not on.

a. Open valve.

2. Faulty post flow time delay (TD1).

a. Check TD1 (See B, Section 4.8).

4.7 Primary Voltage Selection

The T A500 transformers are manufactured for two voltage ranges. These ranges are specified on the Serial Number Tag attached to the front of the unit. If the voltage ranges must be changed, the proper connections are shown on the transformer terminal board.

4.8 Trouble-Shooting

Some of the circuitry of the Standoff Control can af fect the characteristics of the Power Supply and T orch, therefore it should be disconnected at the connection marked POWER SUPPLY on the bottom left hand side of the SC electronic unit inside the Power Supply . The jumper connector, mounted to the wiring harness, should be connected to the wiring harness connector. This will avoid any interference of the Standoff Control while troubleshooting the Power Supply . (See SC 504 instr uction manual for trouble-shooting the Standoff Control).

A. No AC POWER Light on TAC 500.

1. Blown fuse or open circuit breaker at primary.

1. Replace fuse or reset breaker.

B. No AC POWER Light on Control Panel.

1. Supply Console cover interlock switch (SW5) not actuated or bad.

E. Gases flow more than 2 seconds.

1. RUN/SET/PURGE switch in set.

a. Move to RUN.

2. Faulty post flow time delay (TD1).

a. Check TD1 (See B, Section 4.8).

F. Cannot set desired gas pressures.

1. Empty gas cylinders.

a. Replace.

2. Faulty gas regulator.

a. Repair or replace.

3. Faulty Solenoid Valve.

a. Replace.

When the START button is pressed, the gases and red DC POWER Light should come on. If this does not happen, check as follows:

G. Gas does not flow when START button is

pressed.

1. Faulty control relay 4CR.

a. Check relay (See C, Section 4.8).

2. START switch SW9 not closing.

a. Check cover for proper installation. Replace

SW5 if bad.

2. Blown fuse (4Fu) in TAC 500.

a. Replace fuse.

Service 4-6 Manual No 0-0470

a. Check for continuity when pressed.

3. No 24 volt power.

a. Check transformer T2.

H . No red DC POWER Light.

4. Loose connection

1. Pressure switch PS3 in Supply Console not satisfied.

a. Check gas pressure setting (Plasma 60 psi/

4.1 bar).

2. Pressure switch out of adjustment.

a. Reset (See A, Section 4.8).

3. Main transformer overheated.

a. Allow to cool down.

4. Faulty main contactor (W).

a. Check contactor (See D, Section 4.8).

The Pilot Arc should start 2 seconds after the red DC POWER Light comes on. If it does not, check the torch parts to make sure they are in good condition and properly assembled. Next, check the Arc Starter unit for loose connections and components for obvious failures. Check to see if:

1) There is any “click” inside the Power Supply at the time the Pilot Arc should start (2 seconds after pushing ST AR T button).

I. No “click” inside the Power Supply 2 seconds

after the START button is pushed.

1. Faulty time delay TD2.

a. Check TD2 (See B, Section 4.8).

2. Faulty pilot control relay (PCR)

a. Check PCR

J. No Pilot Arc (or intermittent).

1. Damaged (defective) Torch parts.

a. Replace.

2. Dirty (wet) Plasma gas.

a. Purge. b. Check for leaks on hoses and fittings. c. Replace gas cylinders.

K. No Pilot Arc at all.

1. Blown pilot fuse (1Fu or 2Fu)

a. Replace.

2. Pilot contactor (PCR) not closing

a. Check PCR

a. Repair.

5. Gas purge relay (TD2) not closing

a. Replace TD2.

6. CSR activating prematurely.

a. Check for shorted toroid (See E, Section 4.8)

or bad relay P.C. board.

7. Pilot Bridge diodes (D17, 18, 19, 20) failed.

a. Check diodes (see G, Section 4.8, and Q, Sec-

tion 4.8).

8. Arc Starter transformer (T3) failed.

a. Check (See F, Section 4.8) and replace.

9. Diodes in Arc Starter Box shorted or open.

a. Check (See G, Section 4.8).

10. Arc Starter failed.

a. Replace.

L. Weak Pilot Arc.

1. Faulty Arc Starter/Shunt PC Board

a. Check PC Board (See N, Section 4.8). Replace

if needed.

2. Dirty coolant in HE200

a. Check HE200 deionizer cartridge (Section

4.3)

The Cutting Arc should start as soon as the tor ch, with Pilot Arc running, is brought to within about 1/2 inch (12 mm) of the workpiece. If it does not, check:

M. No Cutting Arc.

1. Work Cable not connected.

a. Connect.

2. One leg of 3 phase primary power out.

a. Check all 3 input phases for voltage.

3. One leg of main contactor (W) not closing.

a. Check voltage at diodes.

4. Main contactor (W) fails to operate.

a. Check relay (1CR); replace if needed. b. Check thermal protection switch (TP1, 2, 3);

replace if needed.

3. Broken conductor in lead

a. Replace lead.

Manual No 0-0470 4-7 Service

c. Replace contactor.

d. Check jumper wire in J8 connector; replace if faulty .

a. Check SCRs (See O, Section 4.8).

5. Reactor and/or transformer overheated due to exceeding the amperage rating of the Power Supply or air flow restricted.

a. Reduce amperage to recommended ratings. Clear

air passages.

Once the Cutting Arc is established, the cutting curr ent reading on the Control Panel ammeter should be adjustable by turning the CURRENT CONTROL knob. If it is not, there is a problem in the current regulating circuit as follows:

N. Unit only puts out minimum current (125 A).

1. Fuse 3Fu blown.

a. Replace.

2. Fuse blows again.

a. Check diodes and SCRs in control bridge (See

J & Q, Section 4.8).

3. Potentiometer failed.

a. Check (See K, Section 4.8).

4. Reactor disconnected.

a. Check (See L, Section 4.8).

5. Current Control P.C. board failed.

a. Check (See I, Section 4.8).

6. Relay CSR not closing.

a. Bad CSR. Replace (See M, Section 4.8). b. Loose wire on toroid (T4). Correct. c. Bad toroid (T4). (See E, Section 4.8). d. Check Arc Starter PC Board (See N., Section

4.8).

O. Unit only puts out maximum current (500+ A).

1. Arc Starter/Shunt P.C. board failed.

a. Check P.C. board (See N, Section 4.8). Re-

place if faulty.

Cut quality begins okay but deteriorates during the cutting process.

Q. Deteriorating cut quality.

1 Fr ozen CO2 r egulator.

a. Add heater. b. Replace with high flow regulator.

2. Cylinder not delivering.

a. Manifold several cylinders together.

If the Torch parts life is short, check:

R. Short torch parts life.

1. Pilot arc remains on during cut.

a. Check CSR (See M, Section 4.8).

2. No prepurge gas flow.

a. Check time delay relay.

3. No post purge gas flow.

a. Check time delay relay.

4. Misuse of torch.

a. Use torch with ratings for current and work

thickness.

5. Incorrect gas pressure.

a. Check and correct.

6. Inadequate coolant flow.

a. Clean filter in HE200. b. Adjust or replace pump in HE200.

7. Restricted coolant hose or lead.

a. Remove restriction or replace hose.

S. Discolored Electrode.

1. Contaminated gas.

a. Check plasma gas system for leaks.

2. Current Control PC Board failed.

a. Check PC Board (See I, Section 4.8). Replace

if faulty.

P. Unit can only put out about 375 amps maximum.

1. Current Control P.C. board failed.

a. Check P.C. board (See I, Section 4.8).

2. One SCR failed.

Service 4-8 Manual No 0-0470

2. No pre or post purge.

a. Check TD1 and TD2 (See B, Section 4.8).

3. Gas hoses switched.

a. Check.

4.9 Test Procedures

The following tests are suggested for specific problems listed in the preceding trouble shooting chart. The letter designation corresponds to those listed in the “Remedy” section of the chart.

WARNING

at the connections from the reactor . (220 volt 3 phase power should always be present at lines 105, 106 and 107 when the primary power is turned on).

E . To check the toroid coil, measur e the resistance from

J400-5 to J400-6. It should be 22 ohms.

Several of these tests involve voltage measurements that must be made with power on. In order to make these measurements, the Supply Console cover interlock switch must be propped closed or bypassed. Use extreme care when making these tests and be sure to return the interlock switch to proper operation after work is completed.

T est r equiring voltage measurements ar e marked with the warning symbol:

All other tests are to be made with the primary power to the system turned off.

A. Pressure switches are located in the Supply Con-

sole on the PLASMA GAS line just inside of the solenoid valve on the inlet fitting and on the line running from the power manifold to the NEG connection on the bulkhead board. The switches are normally open. The pressure at which the switches will close may be adjusted by turning the knurled wheel just under the plastic part of the switch. T urn clockwise to increase the pressure at which switch is actuated.

B. The two time delay relays, TD1 and TD2, are

interchangeable and can normally be checked by swapping them. They are the “delay on operate” type with a 2 second delay.

F. The Arc Starter transformer (T3) has two dif-

ferent voltage outputs to check to verify its status. Using a voltmeter, place the probes between J400-19 and 20. This voltage should measure 280-330 V AC. Measure the voltage between J400-15 and 17. This should read 10-15V AC. Both voltages must check out or the transformer is faulty .

G. A “quick check” can be made on the main diodes

without removing them from the circuit as follows: Using an ohmmeter with the RX1 or RX10 scale, measure the resistance of each diode in both directions. The readings should differ by at least a factor of 10. If they do not differ (both high or both low) the diode has failed and must be replaced.

H . The 3-phase AC input to the main bridge rectifier is

220 volts. This can be measured at the top of the main bridge rectifier where the diode pigtails are joined with the reactor leads (see Fig. 5-8) at any time that the DC power light is on.

I. The best way to check the P .C. board is to replace it

with one known to be good. The current control PC board in the P AK 10, 22, 44, and 350 can be used.

J. Locate the control bridge (see Fig. 5-8). Disconnect

the multi-conductor plug next to this component. Using an ohmmeter with the RX10 scale, all diodes should be checked for high resistance in one direction and low resistance in the other direction. The SCRs should read a high resistance in both directions. If diode D16 is shorted, see ‘R’ below .

K. Remove the current regulating printed circuit card

C. The relay can be tested by removing it from the

relay socket and with the power on, measure the voltage between pins A and B on the socket. The voltage should read close to the voltage specified for the relay. If it is, then the relay is bad. If not, then the trouble lies in the circuitry.

D. T o check the main contactor remove the left side

panel of the machine. The contactor should close when 115 volt AC is applied to lines 1 and 80 (when the ST ART button is pressed). At this time, 220 volt 3 phase power should be present

Manual No 0-0470 4-9 Service

(see illustration below) from the power supply . W ith the CURRENT CONTROL knob set at MIN measure the resistance between the 3rd (pin 20) and 7th (pin

16) pins, counting from the top (see below). This should read 0 ohms and increase smoothly to 10,000 ohms as the CONTROL knob is rotated to MAX. Now measure the resistance between the 3rd (pin 19) and 4th (pin 20) pins. This should read 10,000 ohms.

L . With the contr ol bridge connected to the circuit, mea-

sure the resistance across the diode on the center heat sink in both directions. It should read about 5 ohms both ways.

M. The coil of relay CSR should read about 3K ohms

measured from pin A to pin B on bottoms of relay .

N . The easiest way to check the PC Board is to replace

it with one known to be good.

1. An in-rush current surge is the most probable cause of main diode failure. The in-rush surge is prevented by capacitor C4 and resistor R6,10 in series with each other across the output of the bridge rectifier . The capacity and resistor , as well as the wires connecting them to the circuit, should be completely checked in any case of diode problems. The capacitor is a polarized capacitor , and it is important to be sure that the side marked + is connected to the positive side of the circuit.

2. High frequency protection for the diodes is provided by capacitors C5, C6 and C7 which are installed between each side of the bridge rectifier . These capacitors and their connections should be checked.

3. Overheating of the diode can occur if air flow over the heat sink is inadequate or if the diode is not properly fastened to the heat sink. Check to see that the diodes are torqued to 25 foot pounds (34 Nm) and that electrically conductive heat sink compound (this is a white grease) is present between the diode and heat sink. Also check for normal operation of the fan and be sure that the air passages into and out of the unit are not obstructed.

4. The diode that was faulty at the time of manufacture is difficult to diagnose. This usually fails during the first few hours of operation. Before deciding that this was the case, be sure to check out the other three possibilities.

This concludes the trouble-shooting procedures.

O. With a soldering pencil, disconnect the ‘pigtail’

lead to the SCRs one at a time. When more than one wire is connected to the pigtail, the two wires should be connected to each other . Operate the unit with one and then the other SCR disconnected and note the maximum amperage. The output will remain unchanged when the bad SCR is disconnected and will drop to minimum when the good SCR is disconnected.

P . Transformer T1 in the Standoff Control electronics

chassis can be checked by placing the probe of a voltmeter in pins J23-18 and J23-20 of the PC board connector . This voltage should read close to 25 V AC.

Q . A bad varistor (VR) is difficult to detect by itself.

However , it will cause the D16 diode on the control bridge to short and burn out. If this happens or if the varistor looks burnt, replace both.

Service 4-10 Manual No 0-0470

SECTION 5: PARTS

LISTS

Assembly Parts List

The Assembly Parts List illustrates the parts of the Thermal Arc 500 Cutting System and gives the catalog number for replacement parts.

An item number in parentheses indicates the item is located behind the item pointed to. An asterisk beside the item number indicates the part is a main assembly, not a component. Parts listed without item numbers are not illustrated, but may be ordered by the catalog number shown.

Oredering Information

When ordering replacements parts, order by catalog number and complete description of the part or assembly, as given in the description column of the Assembly Parts List. In addition, give the model number of the machine, the machine serial number and its operating voltages, as given on the plate attached to the unit in question. Address all inquires to your authorized distributor.

Manual No 0-0470 5-1 Parts Lists

5.1 System Components

Item No. Qty. Description Ref. Cat. No.

1 1 TA500 Power Supply 3-5001 2 1 Supply Console 3-5002 3 1 Operator Control Panel (W ithout Enclosur e) 3-5007

1 Operator Control Panel (With Enclosur e) 3-5008

1 Control Panel Enclosure (Optional) 3-5009 4 1 M200 Torch with Mounting Tube 2-2766 5 1 Arc Starter 3-5003 6 1 HE200 Coolant Recirculator 7-3008 7 1 Hi-Flow Water Shield Assembly (Optional) 7-2962

1 15' M200 Torch Leads Package *4-5005-15

1 25' M200 Torch Leads Package *4-5006-25

1 35' M200 Torch Leads Package *4-5007-35

1 50' M200 Torch Leads Package *4-5008-50

1 15' Negative Water Cooled Lead *9-5031-15

1 25' Negative Water Cooled Lead *9-5037-25

1 35' Negative Water Cooled Lead *9-5043-35

1 50' Negative Water Cooled Lead *9-5049-50

1 15' Plasma Gas Hose *9-5032-15

1 25' Plasma Gas Hose *9-5038-25

1 35' Plasma Gas Hose *9-5044-35

1 50' Plasma Gas Hose *9-5050-50

1 15' Secondary Gas Hose *9-5033-15

1 25' Secondary Gas Hose *9-5039-25

1 35' Secondary Gas Hose *9-5045-35

1 50' Secondary Gas Hose *9-5051-50

1 15' Coolant Return Hose *9-5034-15

1 25' Coolant Return Hose *9-5040-25

1 35' Coolant Return Hose *9-5046-35

1 50' Coolant Return Hose *9-5052-50

1 15' Arc Starter Cable *9-5035-15

1 25' Arc Starter Cable *9-5041-25

1 35' Arc Starter Cable *9-5047-35

1 50' Arc Starter Cable *9-5053-50

1 15' Lead Sleeving *9-5036-15

1 25' Lead Sleeving *9-5042-25

1 35' Lead Sleeving *9-5048-35

1 50' Lead Sleeving *9-5054-50

* The length is shown as a suffix to the 5 digit catalog number. To order non-standard lengths, simply specify the desired length as a suffix to the 5 digits of the catalog number for the next longer length lead.

EXAMPLE: To order a 28' Torch Leads Package, include -28 as a suffix to the first 5 digits of the catalog number for the 35' Torch Leads Package. The 28' Torch Leads Package would then be ordered with catalog number 4-5007-28.

NOTE: Refer to Sales Catalog for complete details on System Specifications.

Parts Lists 5-2 Manual No 0-0470

M200 T orch with Arc Starter

Operator Control Panel

Supply Console

TA500 Power Supply

HE200 Coolant Recirculator

Hi-Flow Water Shield

Figure 5-1 Thermal Arc 500 Cutting System

Manual No 0-0470 5-3 Parts Lists

5.2 Front Panel Components

Item No. Qty. Description Ref. Cat. No.

1 2 Fuse Holder 1FU, 2FU 9-2937 2 2 Fuse- 20 amp 1FU, 2FU 8-1339 3 2 Fuse Holder 3FU, 4FU 9-2936 4 1 Fuse- 20 amp 3FU 8-1335 5 1 Fuse- 5 amp 4FU 8-1025 6 2 Toggle Switch- SPST, 2 pos. SW8, SW10 9-3325 7 1 Toggle Switch- SPDT, 2 pos. SW9 9-3426 8 2 Panel Indicator (red) LT1, LT2 8-1885 9 1 Ammeter A 9-5159 10 1 Voltmeter V 9-5158 11 1 Plastic Bushing 8-0241 12 1 2" Locknut 8-0242 13 2 Twistloc Base 9-3290 14 2 Receptacle- 32 Pin J8, J9 9-5172 15 2 Receptacle- 14 Pin J10, J11 9-3293 16 1 Left Corner Support 9-5306 17 1 Right Corner Support 9-5307 18 1 Bottom Front Panel 9-5304 19 1 To p Fr ont 9-5305 20 A/R Socket 9-3297

Parts Lists 5-4 Manual No 0-0470

1, 2

3, 4

3, 5

14, 20

HI-FLOW

WATER SHIELD

COOLANT

RECIRCULATOR

CONTROL

REMOTE

PANEL

CONTROL

SUPPLY

CONSOLE

1FU

AC POWER

DC POWER

100

200 300

AMPERES

2FU

3FU

4FU

7 6

AUTO

PILOT

MAN

400

500

D.C.

100

SURFACE

UNDERWATER DO NOT SWITCH

UNDER LOAD

200 300

VOLTS

D.C.

HI-FLOW

WATER SHIELD

OFF

400

500

PARALLEL

RELAY

5, 20

ARC

STARTER

11, 1

Figure 5-2 TA 500 Front View

Manual No 0-0470 5-5 Parts Lists

5.3 Rear Panel Components

Item No. Qty. Description Ref. Cat. No.

1 1 Input Strain Relief 9-3291 2 3 Fuse Holder 5FU, 6FU, 7FU 9-2937 3 3 Fuse- 8amp 5FU, 6FU, 7FU 9-3641 4 1 Left Corner Support 9-5306 5 1 Right Corner Support 9-5307 6 1 Bottom Rear Panel 9-5310 7 1 Top Rear Panel 9-5308 8 1 Fan Guard 9-5309

Figure 5-3 TAC 500 Rear View

Parts Lists 5-6 Manual No 0-0470

5.4 Right Side Components

Item No. Qty. Description Ref. Cat. No.

1 2 Resistor 8.5 ohm, 1000w R2 9-5488 2 1 Fastener 9-3995 3 1 Output T erminal Board 9-5322 4 1 Bridge Assembly 5 1 Side Channel 9-5323 6 1 Cable- Bridge (-) to output terminal board 9-5324 7 1 Cable- Bridge (+) to output terminal board 9-5325

Figure 5-4 TA500 Right Side View

Manual No 0-0470 5-7 Parts Lists

5.5 Left Side Components

Item No. Qty. Description Ref. Cat. No.

1 2 Motor Mounting Bracket 9-5312 2 2 Motor Bracket Strut 9-5311 3 1 Main Contactor Bracket (left) 9-2750 4 1 Main Contactor Bracket (right) 9-5314 5 1 Fan Blade 9-5315 6 1 Side Channel 9-5316 7 1 Contactor Coil W 8-1987 7 1 Contactor W 8-1304

Contactor Rebuilding Kit 5-2865 8 1 Resistor-100 ohm, 100w R16 9-3568 9 1 Reactor 9-5160 10 1 Transformer (230/460V) 9-5467 10 1 Transformer (460/575V) 9-5415 10 1 Transformer (220/380V) 9-5489 11 1 Motor 8-1357 12 2 Thermostat 9-3615 13 1 Cable- W to main trans. output, 18-1/2” 14 1 Cable- W to main trans. output, 24” 15 1 Cable- W to main trans. output, 36”

1 9

1 1

Figure 5-5 TAC 500 Left Side View

Parts Lists 5-8 Manual No 0-0470

5.6 Equipment Board Assembly

(

Item No. Qty. Description Ref. Cat. No.

1 1 Printed Circuit Board Cover 9-5350 (2) 1 Printed Circuit Board-Current Regulating 9-5186 (3) 1 Transformer T3 9-5168 4 3 Relay- 2 sec Time Delay TD1, TD2, TD3 9-2694 (5) 1 Resistor- 1K ohm, 25w R7 9-5162 6 2 Resistor- 25 ohm, 50w R8, R9 9-5351 7 1 Transformer- 12V T1 9-3515 8 1 Relay- DPDT, 120VAC 5CR 9-2906 9 1 Transformer- 12V T2 9-5352 10 1 Contactor P C R 9-7554 11 1 Relay- 3PDT, 24V AC 4C R 9-5165 12 1 Printed Circuit Board- 5 Relay 9-5174 13 1 Wiring Harness 14 1 Printed Circuit Board- 3 Relay 9-5353 15 2 Relay- 3PDT, 12vdc CSR1, CSR2 9-5167 16 1 Relay- 3PDT, 120VAC 2CR 9-5163 (17) 1 Printed Circuit Board- Arc Starter 9-5257

(5)

(3)

17)

(2)

Figure 5-6 TA 500 Equipment Board Assembly

Manual No 0-0470 5-9 Parts Lists

5.7 Bridge Assemblies

Item No. Qty. Description Ref. Cat. No.

1 1 Bridge Assembly 2 7 Capacitor- .25 mfd C1, 2, 5, 6, 7, 8, 9 8-1951 3 1 V aristor Assembly VR 9-4028 4 4 Lug T erminal 5 1 Pilot Bridge Assembly 6 2 Capacitor- 4 mfd C3, 10 9-3210 7 1 Resistor- 2 ohm R14 8-1957 8 2 Resistor- 2.5k ohm R3, 4 9-2390 9 2 Resistor- 5 ohm R6, 10 8-1299 10 1 Resistor- 27k ohm R5 9-2537 11 4 Resistor- 1 megohm R11, 12, 13, 15 9-5187 12 1 Capacitor- 2100 mfd, 450V C4 9-5287 13 1 Heat Sink Separator 9-5154

Figure 5-7 TA 500 Bridge Assemblies

Parts Lists 5-10 Manual No 0-0470

5.8 Bridge Assemblies

Item No. Qty. Description Ref. Cat. No.

1 1 Heat Sink (neg) 9-5156 2 1 Heat Sink (pos) 9-5357 3 3 Diode- 300 amp (str) D1, 3, 5 9-2246 4 3 Diode- 300 amp (rev) D2, 4, 6 9-2247 5 2 Diode- 40 amp (str) D17, 19 8-1562 6 1 Diode- 40 amp (rev) D18 8-1558 7 1 Diode- 40 amp (str) D20 9-5260 8 1 T oroid Assembly T4 9-2967 9 1 Thermostat 9-2967 10 1 Toroid Bracket 11 Resistor- 100 ohm R1 9-5358 12 2 Heat Sink 9-3120 13 1 Heat Sink 9-3121 14 3 Diode- 40 amp (str) D11, 12, 16 8-1562 15 2 Silicon Control Rectifier D9, 10 9-2686 16 2 Inductor L1, 2 9-5189 17 2 Zener Diode- 1w D13, 14 9-5188 18 1 Control Bridge Assembly 9-5359

(16) 17

Figure 5-8 TA 500 Bridge Assemblies

Manual No 0-0470 5-11 Parts Lists

5.9 Supply Console Components

Item No. Qty. Description Ref. Cat. No.

1 4 Connecting Bolt 9-3278 2 1 Power Connection Block 9-5191 3 1 Power Block Base 4 1 Power Block Sub-base 5 1 Spill Tray 9-2903 6 1 Pressure Switch PS3 8-1741 7 1 Interlock Switch SW5 8-1741 8 3 Solenoid Valve SOL1, SOL2, SOL3 8-1786 9 2 Solenoid Valve SOL4, SOL5 9-5193 10 2 Flow Control V alve 8-1787 11 1 Flowmeter 8-1877 12 1 Capacitor- .25 mfd C11 8-1951 13 1 Pressure Gauge COOLANT 9-2850 14 2 Pressure Gauge PLASMA, SECONDARY 9-2851 15 1 Insulated Bushing 9-5326 16 1 Nut 17 1 Insulated Bushing 9-5327 18 2 Receptacle- 14 Pin J14, J15 9-3293 19 1 Receptable- 37 Pin J13 9-5331 20 2 Straight Adapter 8-0319 21 3 R.H. Hose Adapter 8-0330 22 1 Straight Adapter 8-0259 23 1 Straight Adapter 8-1251 24 2 O2B Fitting 8-0260 25 1 Base 9-5328 26 1 Front Panel 9-5204 27 1 Rear Panel 9-5329 28 Bulkhead 9-5330 29 1 Flow Switch FS1 9-5476 30 A/R Socket 9-3297 31 A/R Pin 9-3296

1 Cover 9-5202

Parts Lists 5-12 Manual No 0-0470

8, 30

15, 16

19, 31

18, 30

2, 3,

(9)

Figure 5-9 Supply Console

Manual No 0-0470 5-13 Parts Lists

5.10 M200 T orch Component s

Item No. Qty. Description Ref. Cat. No.

1 1 M200 Head Assembly 8-6054 2 1 Water Tube 9-1640 3 2 O-Ring 8-0530 4 3 Electrode Seat 9-1642 5 1 Electrode (For N2/CO

1 Electrode (For operation above 100KW) 9-1662

6 1 0.081 Tip- 150 amps 8-6041

1 0.109 Tip- 250 amps 8-6042 1 0.125 Tip- 350 amps 8-6043 1 0.141 Tip- 500 amps 8-6044 1 0.172 Tip- 750 amps 8-6045 1 0.201 Tip- 1000 amps 8-6046 1 0.250 Tip- 500 amps (gouging) 8-6047

1 0.218 Tip- 1000 amps 8-6067 7 1 O-Ring 8-0538 8 1 O-Ring 8-0554 9 1 Inner Tip Retainer 9-2210 10 1 O-Ring 8-0553 11 1 O-Ring 8-0547 12 2 O-Ring 8-0542 13 1 Outer Insulator 8-6060 14 2 O-Ring (Red) 9-3720 15 1 O-Ring 8-0563 16 1 End Piece 8-0607

1 End Piece (Piercing) 8-0610

1 End Piece (For Water Shield and most other applications) 8-6006

1 End Piece (For Ar/H 17 1 End Cap 8-6056

1 End Cap- Underwater 8-6077

1 End Cap- For Extensive Piercing 8-6057 18 4 O-Ring 8-0527 19 1 Collar 8-6059

1 Collar- Underwater 8-6078 20 1 Coolant Baffle 9-2451 21 1 Adapter 8-6058 22 1 Arc Starter 3-5003 23 1 Mounting Tube with Rack 9-1720 24 1 Pinion Assembly 7-2828 25 1 Bushing 8-6522

1 M200 Torch with Mounting Tube 2-2766

operation up to 100KW) 9-1641

as secondary) 8-6029

Parts Lists 5-14 Manual No 0-0470

3 5 7

11 1 13

Figure 5-10 M200 Torch

Manual No 0-0470 5-15 Parts Lists

5.11 Operator Control Panel

Item No. Qty. Description Ref. Cat. No.

1 1 Toggle Switch- SPST SW1 9-3325 2 2 T oggle Switch- DPDT SW4, SW6 8-1777 3 1 Push Button Switch (Green) SW2, LT5 9-5227 4 1 Push Button Switch (Red) SW3 9-5228 5 1 Contact Block N/C SW3 9-5229 6 1 Contact Block N/O SW2 9-5230 7 1 Panel Indicator (Red) LT3 8-1885 8 1 Panel Indicator (Amber) LT4 8-1886 9 1 Meter M 9-5231 10 1 Potentiometer- Dual, 10K POT1, POT2 9-5232 11 1 Receptacle- 37 Pin, Std. Sex J12 9-5331 12 1 Knob 9-5221 13 1 Control Panel 14 1 Connector Bracket 15 1 Receptacle- 37 Pin, Rev. Sex J29 9-5172 16 A/R Pin 9-3296 17 A/R Socket 9-3297 18 1 Receptacle- 16 Pin P24 19 A/R Socket 9-3258

18,19

11,17

15,16

Figure 5-11 Operator Control Panel

Parts Lists 5-16 Manual No 0-0470

5.12 Gas Pressure Regulators

Item No. Qty. Description Ref. Cat. No.

1 Lubricant 9-2871 1 Regulator, CO

1 Regulator, Compr essed Air 9-3022 1 Regulator, Nitrogen 9-2722

1 Regulator, Ar gon/Hydrogen 9-3053 1 1 Gauge, Inlet Pressure (0-315 KG/CM) 9-2821 2 1 Gauge, Outlet Pressure (0-16 KG/CM) 9-2820 3 1 Adjusting Screw, with Knob 9-2825 4 1 Seal, O-Ring 9-2823 5 1 Valve 9-2822 6 1 Seal, O-Ring 9-2824 7 1 Nipple for use with N2 Regulator 9-3010 7 1 Nipple for use with CO

Regulator 9-3012

8 1 Nut for use with N2 Regulator 9-301 1 8 1 Nut for use with CO2 Regulator 9-3014 9 1 Washer for use with CO2 Regulator 9-3013 10 1 Hose Adapter for use with N2 and CO Regulators 9-3009 11 1 Inlet Adapter 9-3518

9-2759

A-01911

Figure 5-14 Gas Pressure Regulators

Manual No 0-0470 5-17 Parts Lists

APPENDIX 1

Art # A-04077

Manual No. 0-0470 A - 1 Appendix

APPENDIX 2

Art #A-04078

Appendix A-2 Manual No. 0-0470

APPENDIX 3

Art # A-04081

Manual No. 0-0470 A - 3 Appendix

Art # A-04079

APPENDIX 4

RED

R-BLU

BLK

R-YEL

R-BLU

RED BRN

BRN

GRN

GRN-YEL

GRN

ARC STARTER TRANSFORME

PHASING DIAGRAM

42A519 10/18/78

Appendix A-4 Manual No. 0-0470

APPENDIX 5

Art # A-04080

Manual No. 0-0470 A - 5 Appendix

APPENDIX 6

Art # A-03982

Appendix A-6 Manual No. 0-0470

Art # A-03982

Manual No. 0-0470 A - 7 Appendix

APPENDIX 7

1 2 3 4 5

4CR

J3-4

J8-1

Coolant

Recirculator

J3-5

J7-14

J7-29

J8-24

TA500

24VAC

J7-8

J9-13

J8-8

J12-8

J12-7

J8-7

J9-11

J7-9

J9-10 J9-12

LT3

Operator Control

Panel

115VAC

4FU

TP3

TP1

TP2

J7-16

J7-15

HCR2

J107-16

J107-15

Pilot 2

CSRH

Pilot 2

Down

J8-23

J8-15

J8-14

J103-5 J101-8

J101-7

J101-9

J103-14

J101-3

J102-14

J102-12

J102-16

J102-2

CSR2

J2-12

J7-12

J107-12

J101-1

Sample

Pilot 1

J101-2

J2-6

I45

+12v

R266

+12v Unreg

PC102

From Logic Board

J7-11

J107-11

J102-13

J102-15

Sample

SC504 Chassis

PC101

Art # A-03981

J1-6

J1-5

2CR

1 2 3 4 5

Appendix A-8 Manual No. 0-0470

6 7 8 9 10

J104-5 J104-11 J104-10

J104-15

J104-32

J104-31

J104-29

J104-30

J104-24

J104-25

J104-26 J104-27 J104-20

J104-21

J104-28 J104-16

J12-1 J12-24

J12-23

J12-15

J12-14

J106-5

J106-11

J106-10

J106-15 J106-32

J106-31 J106-29

J106-30

J106-24 J106-25

J106-26 J106-27

J106-20 J106-21

J106-28 J106-16

TA500 Control Panel

Sw2

Sw3

Start

Stop

Sw1

On / Off

J124 / P24-1

Find Height

Sw102

J124 / P24-2

Sw101

On / Off

1FU

J124 / P24-4

J124 / P24-5

J124 / P24-12 J124 / P24-3

J124 / P24-13

J124 / P24-14

J124 / P24-6 J124 / P24-7

J124 / P24-8

J124 / P24-9

J124 / P24-11

J124 / P24-10

J124 / P24-15

Sw105

J124 / P24-16

Hold Height

SC504 Control Panel

8 9

14 15

17 18

24 25

26 27 28 29 30

J29

2 3

6 5

Computer Signals

Input / Output

Start

Stop *

Ground

Control Panel Station Select *

Find Height (Momentary Closure)

SC504 Control Panel Station Select *

Main Arc Transfer (OK to Move) Signal

Height Found (Momentary Closure)

Up / Down Signals to Torch Lifter Motor

Disable Standoff Control, Regulate to Original Arc Voltage (Height) *

Disable Standoff Control, Resample New Arc Voltage (Height)

NOTES:

1. * Indicates signal lines that must be tied together when not utilized by the computer.

3/29/82 42B620 Rev 'A' 4/8/82

6 7 8 9 10

Manual No. 0-0470 A - 9 Appendix

Art # A-03981

Tweco TA 500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

Notes, Cautions and Warnings

Important Safety Precautions

Publications

Note, Attention et Avertissement

Precautions De Securite Importantes

Documents De Reference

Declaration of Conformity

Statement of Warranty

1.2 Specifications

1.1 General Information

1.3 Plasma

1.4 Theory of Operation

2.1 Unpacking New Equipment

2.2 Equipment Installation

SECTION 3: OPERATION

3.1 Operating Controls

3.2 Pre-Operation Set-up

3.3 Operation

3.4 Cutting and Speed Selection

SECTION 4: SERVICE

4.1 Torch Maintenance

4.2 TAC 500 Power Supply Maintenance

4.3 HE 200 Coolant Recirculator Maintenance

4.4 Gas Pressure Regulators

4.5 Troubleshooting Guide

4.6 Returns

4.7 Primary Voltage Selection

4.8 Trouble-Shooting

4.9 Test Procedures

5.1 System Components

5.2 Front Panel Components

5.3 Rear Panel Components

5.4 Right Side Components

5.5 Left Side Components

5.6 Equipment Board Assembly

5.7 Bridge Assemblies

5.8 Bridge Assemblies

5.9 Supply Console Components

5.10 M200 T orch Component s

5.11 Operator Control Panel

5.12 Gas Pressure Regulators

APPENDIX 1

APPENDIX 2

APPENDIX 3

APPENDIX 4

APPENDIX 5

APPENDIX 6

APPENDIX 7