Tweco TA 500 User Manual
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
Copyright 1984 by
Thermal Dynamics Corporation
www .thermal-dynamics.com
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of
the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: 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
"
.
0
n
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
2
Se conda ry Gas
: N2
: CO
: H
2
O
2
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
A
+
B
Workpiece
C
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-
2
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
t
in
ef
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
3
Line
Voltages
Accepted
460
575
220
380
Fuse or
Circuit
Breaker
Amperages
225
170
450
250
Recommended
Minimum
Primary Wire
2/0
1
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
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