Tweco XTTM-301 User Manual
XTTM -301
LIQUID COOLED
PLASMA CUTTING TORCH
For Distributor Use With
Merlin® 1000 Cutting Systems
Instruction Manual
Rev AC.01 Issue Date: December 20, 2006 Manual No. 0-4768
Operating Features:
Coolant Flow
Minimum
.9 GPH
Duty
Cycle
%
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.
Liquid Cooled Plasma Torch
Model XTTM-301
for Distributor use with: Merlin® 1000 Cutting System
Instruction Manual No. 0-4768 Rev AB.01.
Published by:
ThermaDyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
©
Copyright 2005, 2006 by
ThermaDyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any
loss or damage caused by any error or omission in this Manual, whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: July 31,2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Equipment Serial #: ___________________________________
i
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-4
1.06 Documents De Reference ............................................................................. 1-6
1.07 Declaration of Conformity ............................................................................. 1-7
1.08 Statement of Warranty .................................................................................. 1-8
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description and Applications ........................................................... 2-1
2.03 Torch Kit Contents ........................................................................................ 2-2
2.04 Specifications & Design Features ................................................................. 2-3
SECTION 3:
INSTALLATION .................................................................................................................. 2-1
3.01 Kit Contents ................................................................................................. 2-1
3.02 Kit Applications: ........................................................................................... 2-2
3.03 Unpacking .................................................................................................... 2-2
3.04 XT-301 Torch Head Installation on MaximizerTM Leads (up to 25' long) ......... 2-3
3.05 Connecting XT-301 Torch and Torch Leads (over 25' long) to Merlin 1000 ...... 2-6
3.06 Connecting XT-301 Torch and Torch Leads to Remote Arc Starter ................ 2-12
3.07 Install Consumable Torch Parts (All Applications) ........................................ 2-18
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01 Introduction ................................................................................................... 4-1
4.02 Functional Overview ..................................................................................... 4-1
4.03 Getting Started ............................................................................................. 4-1
4.04 Torch Parts Selection .................................................................................... 4-2
4.05 Torch Maintenance ...................................................................................... 4-4
4.06 Cut Quality .................................................................................................. 4-10
4.07 Operating the System ..................................................................................4-12
4.07 Torch Operation ........................................................................................... 4-13
4.08 Recommended Cutting Speeds ....................................................................4-14
4.08 Gas Selection .............................................................................................. 4-15
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 Introduction ................................................................................................... 5-1
5.02 Common Operating Faults ............................................................................ 5-1
5.02 General Torch Maintenance ........................................................................... 5-1
5.03 General Maintenance .................................................................................... 5-2
5.04 Torch Consumables Installation .................................................................... 5-5
5.05 Troubleshooting Guide .................................................................................. 5-7
TABLE OF CONTENTS (continued)
5.06 Servicing Torch Components ......................................................................... 5-9
5.07 Torch And Leads Troubleshooting .................................................................5-12
SECTION 6:
PARTS LISTS ................................................................................................................... 6-1
6.01 Introduction ................................................................................................... 6-1
6.02 Ordering Information ..................................................................................... 6-1
6.03 Replacement Torch Parts and Kits ................................................................ 6-2
6.04 Torch Consumables ...................................................................................... 6-4
6.05 O-Rings for Torch Consumables .................................................................... 6-5
Sequence of Operation Diagram ................................................................................................. A-1
Mild Steel ............................................................................................................. A-2
55A A-2
Air Plasma / Air Secondary .................................................................................. A-2
Mild Steel ............................................................................................................. A-3
55A A-3
O2 Plasma / Air Secondary .................................................................................. A-3
Mild Steel ............................................................................................................. A-4
100A ..................................................................................................................... A-4
Air Plasma / Air Secondary .................................................................................. A-4
Mild Steel ............................................................................................................. A-5
100A ..................................................................................................................... A-5
O2 Plasma / Air Secondary .................................................................................. A-5
Stainless Steel ..................................................................................................... A-6
55A A-6
Air Plasma / Air Secondary .................................................................................. A-6
Stainless Steel ..................................................................................................... A-7
100A ..................................................................................................................... A-7
Air Plasma / Air Secondary .................................................................................. A-7
Stainless Steel ..................................................................................................... A-8
100A ..................................................................................................................... A-8
H35 Plasma / N2 Secondary ................................................................................. A-8
Stainless Steel ..................................................................................................... A-9
100A ..................................................................................................................... A-9
N2 Plasma / H20 Secondary ................................................................................. A-9
Aluminum ........................................................................................................... A-10
55A A-10
Air Plasma / Air Secondary ................................................................................ A-10
Aluminum ........................................................................................................... A-11
100A ................................................................................................................... A-11
Air Plasma / Air Secondary ................................................................................ A-11
Aluminum ........................................................................................................... A-12
100A ................................................................................................................... A-12
N2 Plasma / H2O Secondary .............................................................................. A-12
Aluminum ........................................................................................................... A-13
100A ................................................................................................................... A-13
H35 Plasma / N2 Secondary ............................................................................... A-13
Shield
s
Metal
Mild Steel
Stainless
Steel
Aluminum
mperagePlasma Gas
55
100
55 Air Air A-6
100
55 Air Air A-10
100
Air Air A-2
O2 Air A-3
Air Air A-4
O2 Air A-5
Air Air A-7
H35 N2 A-8
N2 H20 A-9
Air Air A-11
N2 H20 A-12
H35 N2 A-13
('Secondary')
Ga
Page
Publication History .................................................................................................................. A-14
Global Customer Service Contact Information .................................................... A-15
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
Manual 0-4768 1-1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 1-2 Manual 0-4768
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 Standard 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
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont
classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement du
système.
ATTENTION
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
Manual 0-4768 1-3 GENERAL INFORMATION
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au personnel
TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
• Lisez toujours les fiches de données sur la sécurité des
matières (sigle américain “MSDS”); celles-ci devraient
être fournies avec le matériel que vous utilisez. Les
MSDS contiennent des renseignements quant à la
quantité et la nature de la fumée et des gaz pouvant
poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée
et les gaz de votre lieu de travail, consultez l’article 1 et
les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer.
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
GENERAL INFORMATION 1-4 Manual 0-4768
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé à
l’arc de plasma produit du métal, des étincelles, des scories
chaudes pouvant mettre le feu aux matières combustibles
ou provoquer l’explosion de fumées inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé
explosera si enflammé.
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.
• 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 1 4
* 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. Vous dú4ez vous protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur. Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculaire.
• 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.
Manual 0-4768 1-5 GENERAL INFORMATION
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New
York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE
ET DE SOUDAGE, disponible auprès de la National
Fire Protection Association, Batterymarch Park, Quincy,
MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz Comprimés
(Compressed Gas Association), 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE
SOUDAGE ET LA COUPE, disponible auprès de
l’Association des Normes Canadiennes, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society, 550
N.W. LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York,
NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
GENERAL INFORMATION 1-6 Manual 0-4768
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Manual 0-4768 1-7 GENERAL INFORMATION
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, 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, correct such defects by suitable repair 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 PARTICULAR
PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not
limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of
any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise,
shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows
Parts Labor
TM
XT
-301 Torch (excluding consumable parts, O-Rings, and Water Tube) 1 Year 1 Year
Repair/Replacement Parts (excluding consumable parts and O-Rings) 90 Days 90 Days
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective: August 29, 2005
GENERAL INFORMATION 1-8 Manual 0-4768
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions and maintenance procedures for the XTTM-301 Torch. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against
attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will
assure the dependable operation for which it was designed.
2.02 General Description and Applications
The XTTM-301 Torch is a direct replacement for the MaximizerTM torch on MerlinTM 1000 cutting systems. The XT-301
Torch can be connected to Maximizer torch leads up to 25' / 7.6 m long. Use only XT-301 Torch leads for installations
requiring leads longer than 25 ft / 7.6 m.
< 25’ / 7.6m: Use XT-301 Torch Head
and Maximizer Torch Leads
> 25’ / 7.6m: Use XT-301 Torch Head
and XT-301 Torch Leads
Merlin 1000
Power
Supply
Torch
Leads
XT-301
Torch
< 25’ / 7.6m: Use XT-301 Torch Head
and Maximizer Torch Leads
> 25’ / 7.6m: Use XT-301 Torch Head
and XT-301 Torch Leads
XT-301
Torch
Merlin 1000
Power
Supply
Art # A-07074
Remote
Arc
Starter
NOTE: Installations with Remote Arc Starter require installer
to reverse coolant lead connections at power supply bulkhead.
Refer to installation instructions for details.
Torch
Leads
The XT-301 Torch is available in a 180° configuration.
The XT-301 Torch is a liquid cooled torch. Two torch leads provide plasma and secondary ('shield') gas to the torch
head. The leads also provide a closed loop for the liquid coolant flow from the Power Supply.
Manual 0-4768 2-1 INTRODUCTION
2.03 Torch Kit Contents
All Gases
35-1041
XT-301™ Conventional Plasma Torch
55A, MS
Air Plasma/Air Shield
Ohmic Sensor
9-9414
CARTRIDGE
ELECTRODE
PLASMA GAS
DISTRIBUTOR
TIP
SHIELD GAS
DISTRIBUTOR
SHIELD
OHMIC
SENSOR
SHIELD CUP
55-100A,
SS
23X4906 Rev AA
55A, MS
O2 Plasma/Air Shield
55A, SS
N2 Plasma/H2O Shield
55A, SS
Air Plasma/Air Shield
100A, MS
O2 Plasma/Air Shield
100A, MS
Air Plasma/Air Shield
100A, SS/Aluminum
Air Plasma/Air Shield
Cartridge
35-1020
100A, SS/Aluminum
N2 Plasma/H2O Shield
Electrodes
Plasma Gas
Distributors
All Gases
35-1041
55A,
MS/SS
55A, SS
35-1060
100A,
MS/SS
100A, SS
35-1062
Tips
Shield Gas
Distributors
55A,
MS/SS
55-100A, SS
35-1034
Shield Cup
35-1016
Shields
'O' Ring
Placement
8-0539
8-0534
8-0530
TORCH
HEAD
9-9041
100A, SS/Aluminum
H35 Plasma/N2 Shield
55A,
MS/SS
55A, SS
35-1078
100A,
MS/SS
100A, SS
35-1080
35-1041
or
35-1042
35-1041
or
35-1042
NO
OXYGEN
NO
OXYGEN
35-1051
35-1053
MS/SS
35-1069
35-1071
35-1272
35-1272
MS/SS
35-1025
100A,
MS/SS
35-1027
35-1034
35-1001
1: Torch Kit
Torch Clamp
Assembly
Mounting Tube
2: Torch and Leads Kits
Mounting Tube
Hardware Kit
End Cap
Torch Head Assembly
Torch operation requires these additional parts:
Art # A-04741
Shield Gas
Distributor
Shield Cap
Shield Cup
Parts Label
55A,
MS/SS
CARTRIDGE
35-1025
ELECTRODE
55-100A, SS
35-1034
PLASMA GAS
DISTRIBUTOR
100A,
TIP
MS/SS
SHIELD GAS
DISTRIBUTOR
Shield Cup
SHIELD
35-1016
35-1027
55-100A,
SS
SHIELD CUP
35-1034
OHMIC
Ohmic Sensor
SENSOR
9-9414
Shields
Tip
XT-301™ Conventional Plasma Torch
All Gases
55A,
MS/SS
55A,
35-1041
MS/SS
MS/SS
NO
35-1051
35-1069
OXYGEN
55A, SS
55A, SS
35-1060
35-1078
35-1272
35-1041
or
35-1042
100A,
100A,
MS/SS
All Gases
MS/SS
MS/SS
35-1041
NO
OXYGEN
35-1071
35-1053
100A, SS
100A, SS
35-1041
35-1062
35-1080
or
35-1272
35-1042
Plasma Gas
Shield Gas
Distributors
Electrodes
Tips
Distributors
Plasma Gas
Distributor
55A, MS
O2 Plasma/Air Shield
55A, MS
Air Plasma/Air Shield
55A, SS
N2 Plasma/H2O Shield
55A, SS
Air Plasma/Air Shield
100A, MS
O2 Plasma/Air Shield
100A, MS
Air Plasma/Air Shield
100A, SS/Aluminum
Air Plasma/Air Shield
100A, SS/Aluminum
N2 Plasma/H2O Shield
100A, SS/Aluminum
H35 Plasma/N2 Shield
TORCH
HEAD
35-1001
'O' Ring
Placement
9-9041
8-0539
8-0534
8-0530
Cartridge
35-1020
23X4906 Rev AA
Lead Packages, Lengths > 25 ft / 7.6 m
Art # A-07043
Electrode
Cartridge
INTRODUCTION 2-2 Manual 0-4768
2.04 Specifications & Design Features
p
g
1. XTTM-301 Torch Configuration and Dimensions
6.30"
160.10 mm
3.54"
89.87 mm
2.74"
69.55 mm
Art # A-06257
2.39"
60.81 mm
1.49"
37.8 mm
2. Torch Ratings and Gas Specifications
When Used with Merlin 1000 Power Supply
Ambient
Temperature
Duty Cycle 100% @ 100 Amps
Maximum Current 100 Amps
Voltage (V
)500V
eak
Arc Striking Voltage 10kV
Current
Minimum Coolant
Flow Requirements
XT
Plasma Gases:
Shield Gases:
Operating Pressure
Maximum Input Press ure 135 psi / 9.3 bar
Gas flow 10 - 300 scfh
Power supply used with: Merlin 1000
TM
XT
-301 Torch Ratings
104° F
40° C
Up to 100 Amps, DC,
Straight Polarity (See Note)
0.9 gpm (3.4 lpm)
TM
-301 Torch Gas Specifications
Compressed Air, Oxygen,
Ar
on/Hydrogen (H35)
Compressed Air,
Nitrogen (N2)
90 psi ± 5 psi
6.2 bar ± 0.4 bar
Manual 0-4768 2-3 INTRODUCTION
3. Cutting Range
Most materials up to 1 inch (25.4 mm)
Up to 1/2 inch (12.7 mm) for production speed cutting
4. Pierce Rating
1/2 inch (12.7 mm)
5. Transfer Distance
1/8 - 1/4 inch (3-6 mm)
6. Torch Parts
Shield Cup, Shield Cap, Secondary ('Shield') Gas Distributor, Tip, Plasma Gas Distributor, Electrode, Cartridge
Art # A-04741
Shield Cup
7. Gas Requirements
Gas Quality Minimum Pressure Flow
O2 (Oxygen)
N2 (Nitrogen)
Compressed
or Bottled Air
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
Shield Gas
Distributor
Shield Cap
Plasma Gas
Tip
Distributor
Electrode
Gas Pressures, Flows, and Quality Requirements
99.5% Purity
(Liquid recommended)
90 psi
6.2 bar / 620 kPa
99.5% Purity
(Liquid recommended)
<1000 ppm O2, <32
90 psi
6.2 bar / 620 kPa
278 scfh (7872 l/h)
ppm H2O)
Clean, Dry,
Free of Oil (see Note 1)
99.995% Purity
(gas liquid
recommended)
90 psi
6.2 bar / 620 kPa
90 psi
6.2 bar / 620 kPa
Cartridge
83 scfh (2350 l/h)
82 scfh (2313 l/h)
77 scfh (2180 l/h)
H2O (Water) See Note 2 50 psi (3.5 bar) 3 - 9 gph (13 - 40 lph)
: The air source must be adequately filtered to remove all oil or grease. Oil or grease
Note 1
contamination from compressed or bottled air can cause fires in conjunction with oxygen.
: The tap water source does not need to be deionized, but in water systems with
Note 2
extremely high mineral content a water softener is recommended. Tap water with high levels of
particulate matter must be filtered.
8. Parts - In - Place (PIP)
The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are
in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide
power to the torch. Coolant leakage from the torch also indicates that torch parts are absent or installed improperly.
9. Type of Cooling
Combination of gas stream through torch and liquid cooling.
INTRODUCTION 2-4 Manual 0-4768
3.01 Kit Contents
All Gases
35-1041
XT-301™ Conventional Plasma Torch
55A, MS
Air Plasma/Air Shield
Ohmic Sensor
9-9414
CARTRIDGE
ELECTRODE
PLASMA GAS
DISTRIBUTOR
TIP
SHIELD GAS
DISTRIBUTOR
SHIELD
OHMIC
SENSOR
SHIELD CUP
55-100A,
SS
23X4906 Rev AA
55A, MS
O2 Plasma/Air Shield
55A, SS
N2 Plasma/H2O Shield
55A, SS
Air Plasma/Air Shield
100A, MS
O2 Plasma/Air Shield
100A, MS
Air Plasma/Air Shield
100A, SS/Aluminum
Air Plasma/Air Shield
Cartridge
35-1020
100A, SS/Aluminum
N2 Plasma/H2O Shield
Electrodes
Plasma Gas
Distributors
All Gases
35-1041
55A,
MS/SS
55A, SS
35-1060
100A,
MS/SS
100A, SS
35-1062
Tips
Shield Gas
Distributors
55A,
MS/SS
55-100A, SS
35-1034
Shield Cup
35-1016
Shields
'O' Ring
Placement
8-0539
8-0534
8-0530
TORCH
HEAD
9-9041
100A, SS/Aluminum
H35 Plasma/N2 Shield
55A,
MS/SS
55A, SS
35-1078
100A,
MS/SS
100A, SS
35-1080
35-1041
or
35-1042
35-1041
or
35-1042
NO
OXYGEN
NO
OXYGEN
35-1051
35-1053
MS/SS
35-1069
35-1071
35-1272
35-1272
MS/SS
35-1025
100A,
MS/SS
35-1027
35-1034
35-1001
These kit configurations are available:
1: Torch Kit
Torch Clamp
Assembly
SECTION 3:
INSTALLATION
2: Torch and Leads Kits
Mounting Tube
Hardware Kit
End Cap
Mounting Tube
Torch Head Assembly
Parts Label
55A,
MS/SS
CARTRIDGE
35-1025
ELECTRODE
55-100A, SS
35-1034
PLASMA GAS
DISTRIBUTOR
100A,
TIP
MS/SS
SHIELD GAS
DISTRIBUTOR
Shield Cup
SHIELD
35-1016
35-1027
55-100A,
SS
SHIELD CUP
35-1034
OHMIC
Ohmic Sensor
SENSOR
9-9414
Shields
XT-301™ Conventional Plasma Torch
All Gases
MS/SS
55A,
35-1041
MS/SS
NO
35-1051
OXYGEN
55A, SS
35-1060
35-1272
35-1041
or
35-1042
100A,
MS/SS
All Gases
MS/SS
35-1041
NO
OXYGEN
35-1053
100A, SS
35-1041
35-1062
or
35-1272
35-1042
Plasma Gas
Shield Gas
Distributors
Tips
Distributors
TORCH
HEAD
35-1001
55A, MS
55A,
O2 Plasma/Air Shield
MS/SS
'O' Ring
55A, MS
Placement
Air Plasma/Air Shield
9-9041
35-1069
55A, SS
8-0539
N2 Plasma/H2O Shield
55A, SS
35-1078
55A, SS
8-0534
Air Plasma/Air Shield
100A,
100A, MS
8-0530
MS/SS
O2 Plasma/Air Shield
100A, MS
Air Plasma/Air Shield
100A, SS/Aluminum
Air Plasma/Air Shield
35-1071
100A, SS/Aluminum
N2 Plasma/H2O Shield
100A, SS
Cartridge
35-1080
35-1020
100A, SS/Aluminum
H35 Plasma/N2 Shield
Electrodes
23X4906 Rev AA
Lead Packages, Lengths > 25 ft / 7.6 m
Art # A-07043
Manual 0-4768 3-1 INSTALLATION
3.02 Kit Applications:
Merlin 1000
Power
Supply
Merlin 1000
Power
Supply
Art # A-07074
Remote
Starter
NOTE: Installations with Remote Arc Starter require installer
to reverse coolant lead connections at power supply bulkhead.
Refer to installation instructions for details.
< 25’ / 7.6m: Use XT-301 Torch Head
and Maximizer Torch Leads
> 25’ / 7.6m: Use XT-301 Torch Head
and XT-301 Torch Leads
Torch
Leads
< 25’ / 7.6m: Use XT-301 Torch Head
> 25’ / 7.6m: Use XT-301 Torch Head
Torch
Arc
Leads
XT-301
Torch
and Maximizer Torch Leads
and XT-301 Torch Leads
XT-301
Torch
3.03 Unpacking
The product is packaged and protected to prevent damage during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify and account for each item.
3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping
company before proceeding with installation.
INSTALLATION 3-2 Manual 0-4768
3.04 XT-301 Torch Head Installation on MaximizerTM Leads (up to 25' long)
The XT-301 torch head can be connected to Maximizer leads up to 25' / 7.6 m long. For applications with longer leads,
replace the Maximizer torch leads with XT-301 leads. Connect the Torch head to existing Maximizer leads as follows:
WARNING
Disconnect primary power at the source before disassembling the torch
or torch leads.
A. Remove Maximizer Torch and Mounting Assembly
1. Remove the torch, positioning tube, and pinion assembly from -its support.
2. Locate the shrink-on tubing at the back end of the torch positioning tube. Remove the shrink-on tubing from
the torch lead sleeving being careful not to damage the lead assembly underneath.
3. Under the shrink-on tubing remove the tape from the torch lead sleeving and slide the sleeving back (see
NOTE).
NOTE
The positioning tube will not slide over the torch lead sleeving.
4. Unscrew the positioning tube and the torch adaptor from the torch head assembly. Slide the positioning tube,
torch adapter, and pinion assembly back over the leads to expose the four gas and coolant connectors..
5. Disconnect the plasma (+), secondary, coolant supply (-), and coolant return connectors to allow removal of
the torch head.
Pinion Assembly
Machine
Torch Head
Positioning Tube
Lead Connections
Bushing
Torch Adaptor
A-00663
Maximizer Torch Mounting Assembly
6. Slide the torch adapter, positioning tube, bushing, and end cap off the torch leads.
7. Set the Maximizer torch and mounting equipment aside in a secure location.
Manual 0-4768 3-3 INSTALLATION
B. Install XT-301 Torch
NOTE
Handle the torch head carefully to avoid damage. The installer may choose
to follow Section 3.07, Installing Consumable Parts, before installing the
torch head. This will provide additional protection to the coolant tube on
the torch head during installation.
1. Install the torch clamp assembly included in this kit, in place of the pinion removed previously.
2. Slide the end cap up onto the torch leads.
3. Remove and discard the protective end caps from the Mounting Tube.
4. Install the O-ring included in this kit in the groove at the upper end of the Mounting Tube.
5. Slide the positioning tube up onto the torch leads, far enough to allow access to the lead connection fittings.
6. Connect the XT-301 torch head to the Maximizer leads as shown.
End Cap
Shown to illustrate
assembly order only;
parts must remain
secured tightly.
O-Ring
Pilot Lead
Insulating Paper
1
2
Coolant Return
Check Valve
and Connector
Plasma Lead
Connector
Positioning Tube
Positioning Tube
Plasma Lead
Detail
Torch Leads
O-Ring
Threaded
Holes
Drain Holes
Shield ('Secondary')
Gas Connector
Insulating Paper
Coolant Supply Connector
Art # A-06258
INSTALLATION 3-4 Manual 0-4768
7. Press the Torch Head Assembly upward to connect to the positioning tube. Pull the leads back as needed to
ensure a proper fit through the positioning tube. Hold the Torch Head Assembly stationary; rotate the positioning tube to thread it onto the Torch Head. Install set screws from the hardware kit in any two of the threaded
holes at the bottom of the positioning tube, to fasten the head assembly to the positioning tube.
CAUTION
Ensure that the leads do not twist within the positioning tube. Leads
must lie as shown in the installation sketch.
8. Press the end cap downward on the positioning tube to cover and engage the O-Ring at the top of the
positioning tube.
9. Secure the positioning tube to the torch clamp.
10. Secure the torch clamp to its mounting device. If not done previously, refer to Section 3.07 for details on
installing torch consumable parts.
Manual 0-4768 3-5 INSTALLATION
3.05 Connecting XT-301 Torch and Torch Leads (over 25' long) to Merlin 1000
This section details connecting the XT-301 Torch and XT-301 Torch leads directly to the Merlin 1000 Power supply.
Refer to Section 3.06 for connections to the optional Merlin Remote Arc Starter.
A. Remove Maximizer Torch and Leads
1. Remove the torch and pinion assembly (with torch leads) from its support. Set the assembly aside in a secure
location.
2. On the power supply, turn the two latch screws fastening the Control / Access Panel to the power supply.
Latch Screw
Control/Access Panel
Latch Screw
A-02165
3. Open the Access Panel.
4. Disconnect the torch leads, including the control cable connector and shield leads, from the power supply
bulkhead panel. The first illustration shows leads with single shielding; the second illustration shows leads
with double shielding
Plasma (+)
Gas
Secondary
Gas
Coolant
Supply (-)
A-02856
Torch Leads
Shield Stud
Coolant
Return
Ring Lug
Single-shielded Leads Connections
INSTALLATION 3-6 Manual 0-4768
Torch Leads
Shield Stud
(for OUTER Shields)
Power
Supply
Chassis
GREEN / YELLOW Shield
Wires with Ring Lugs
Secondary
Gas
Plasma (+)
Coolant
Supply (-)
Gas
Torch Leads
Shield Stud
(for INNER Shields)
Coolant
Return
Control Cable
Connector
Torch
Bulkhead
Panel
CNC Control
Cable
Art # A-07073
RED Shield Wires
With Ring Lugs
Double-shielded Leads Connections
5. Carefully remove the torch leads through the rubber boot on the power supply front panel. Feed the control
cable connector through the boot last, as there will not be enough room for it to pass through the boot if the
other leads are in the boot.
Manual 0-4768 3-7 INSTALLATION
B. Connect XT-301 Leads to Merlin 1000 Power Supply
WARNING
Disconnect primary power at the source before disassembling the torch
or torch leads.
1. Feed the connector on the end of the CNC Control Cable through the rubber boot on the front panel of the
Power Supply (see NOTE).
NOTE
Feed the Control Cable through the rubber boot first as there will not be
enough space inside the rubber boot for the connector if the Coolant and
Gas Leads have been fed through the rubber boot first.
2. Connect the CNC Control Cable connector to the Control Cable connector on the Torch Bulkhead Panel.
3. Feed the ends of the Torch Leads through the rubber boot.
4. Refer to the illustration. The Leads Assembly includes two leads shields; each shield includes two ring-tongue
connectors. Connect the Torch Leads Shield Wires as follows:
a. Remove one nut and star washer from the torch leads shield stud on the Torch Bulkhead Panel.
b. Place the ring lugs from the inner (RED) Torch Leads Shield Wires over the shield stud on the Torch
Bulkhead Panel.
c. Secure the wires with the nut and star washer.
d. Place the ring lugs from the outer (GREEN / YELLOW) Torch Leads Shield Wires over the shield stud on
the power supply chassis.
e. Use the nut and star washer previously removed from the torch leads assembly to secure the wires to the
shield stud on the power supply chassis.
5. Connect torch coolant and gas leads to connectors on the Torch Bulkhead Panel.
6. Close the Access Panel and turn the two latching screws.
INSTALLATION 3-8 Manual 0-4768
Torch Leads
Shield Stud
(for OUTER Shields)
Power
Supply
Chassis
GREEN / YELLOW Shield
Wires with Ring Lugs
Secondary
Gas
Plasma (+)
Coolant
Supply (-)
Gas
Torch Leads
Shield Stud
(for INNER Shields)
Coolant
Return
Control Cable
Connector
Torch
Bulkhead
Panel
CNC Control
Cable
Art # A-07073
RED Shield Wires
With Ring Lugs
Torch Leads Connections to Merlin 1000
Manual 0-4768 3-9 INSTALLATION
B. Connect XT-301 Torch Head to XT-301 Torch Leads
NOTE
Handle the torch head carefully to avoid damage. The installer may choose
to follow Section 3.07, Installing Consumable Parts, before installing the
torch head. This will provide additional protection to the coolant tube on
the torch head during installation.
1. Install the torch clamp assembly included in this kit, in place of the pinion removed previously.
2. Slide the end cap up onto the torch leads.
3. Remove and discard the protective end caps from the Mounting Tube.
4. Install the O-ring included in this kit in the groove at the upper end of the Mounting Tube.
5. Slide the positioning tube up onto the torch leads, far enough to allow access to the lead connection fittings.
6. Connect the XT-301 torch head to the Maximizer leads as shown.
End Cap
Shown to illustrate
assembly order only;
parts must remain
secured tightly.
O-Ring
Pilot Lead
Insulating Paper
1
2
Coolant Return
Check Valve
and Connector
Plasma Lead
Connector
Positioning Tube
Positioning Tube
Plasma Lead
Detail
Torch Leads
O-Ring
Threaded
Holes
Drain Holes
Shield ('Secondary')
Gas Connector
Insulating Paper
Coolant Supply Connector
Art # A-06258
INSTALLATION 3-10 Manual 0-4768
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