2818 PCH&M-102 SureLok Torch (I)

5/25/2018 2818 PCH&M-102 SureLok Torch (I)

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PLASMA

CUTTING TORCH Model PCH - 102 Hand Torch

Model PCM - 102 Machine Torch

Instruction Manual

December 6, 2004 Manual No. 0-2818


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WARNINGS

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

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

Plasma Cutting TorchModel PCH - 102 & PCM - 102Instruction Manual Number 0-2818

Published by:Thermal Dynamics Corporation82 Benning Street

West Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

Copyright 2000 byThermal Dynamics 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: December 6, 2004

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________


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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.................................................................................................. 1-21.04 Note, Attention et Avertissement ................................................................... 1-3

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

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

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

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

SECTION 2:INTRODUCTION ................................................................................................................ 2-1

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

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

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

2.04 Options And Accessories .............................................................................. 2-2

2.05 Introduction to Plasma .................................................................................. 2-2

SECTION 3:INSTALLATION .................................................................................................................. 3-1

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

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

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

3.04 Setting Up Hand Torch .................................................................................. 3-1

3.05 Setting Up Machine Torch ............................................................................. 3-1

3.06 Connecting Torch .......................................................................................... 3-2

3.07 Gas Connection ............................................................................................ 3-6

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 Cut Quality ................................................................................................... 4-2

4.06 General Cutting Information ........................................................................... 4-3

4.07 Hand Torch Operation ................................................................................... 4-4

4.08 Machine Torch Operation .............................................................................. 4-6

4.09 Recommended Cutting Speeds ..................................................................... 4-7

4.10 Gouging ........................................................................................................ 4-7


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TABLE OF CONTENTS (continued)

SECTION 5:

SERVICE .......................................................................................................................... 5-1

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

5.02 General Torch Maintenance .......................................................................... 5-1

5.03 Common Operating Faults ............................................................................ 5-25.04 Inspection and Replacement Consumable Torch Parts .................................. 5-2

5.05 Troubleshooting Guide .................................................................................. 5-3

5.06 Torch & Leads Troubleshooting ..................................................................... 5-5

5.07 Servicing Hand Torch (PCH) Components ..................................................... 5-6

5.08 Servicing Machine Torch (PCM) Components ...............................................5-10

SECTION 6:PARTS LISTS .................................................................................................................... 6-1

6.01 Introduction ................................................................................................... 6-1

6.02 Ordering Information ...................................................................................... 6-1

6.03 Replacement Hand Torch Parts (Ergonomic Handle) ..................................... 6-2

6.04 Replacement Machine Torch With Pinch Block Mounting Parts .................... 6-4

6.05 Replacement Machine Torch Lead Parts ....................................................... 6-6

6.06 Complete Assembly Replacement ................................................................ 6-8

6.07 Options & Accessories ................................................................................. 6-8

6.08 Torch Consumables .................................................................................... 6-10

6.09 Torch Spare Parts Kits ................................................................................. 6-11

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM................ A-1

APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS A-2

APPENDIX 3: GENERAL APPLICATION NOTES ...................................................................... A-4

APPENDIX 4: CUTMASTER 75 SYSTEM DATA ........................................................................ A-6

APPENDIX 5: CUTMASTER 80XL SYSTEM DATA .................................................................... A-8

APPENDIX 6: CUTMASTER 100 SYSTEM DATA .................................................................... A-10

APPENDIX 7: PAK MASTER 75XL PLUS SYSTEM DATA ...................................................... A-12

APPENDIX 8: PAK MASTER 100XL PLUS SYSTEM DATA..................................................... A-14

APPENDIX 9: CE PAK MASTER 75XL PLUS SYSTEM DATA................................................. A-16

APPENDIX 10: CE PAK MASTER 100XL PLUS SYSTEM DATA ............................................. A-18

APPENDIX 11: TORCH CONNECTION DIAGRAMS ................................................................ A-20


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7/76Date: January 27, 2004 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warningsare used to highlight important information. These high-lights are categorized as follows:

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

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

WARNING

A procedure which, if not properly followed, maycause injury to the operator or others in the oper-ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearingaids, or other electronic health equipment. Per-sons who work near plasma arc cutting applica-

tions should consult their medical health profes-sional and the manufacturer of the healthequipment to determine whether a hazard exists.

To prevent possible injury, read, understand andfollow all warnings, safety precautions and in-structions before using the equipment. Call 1-603-298-5711 or your local distributor if you have anyquestions.

GASES AND FUMES

Gases and fumes produced during the plasma cuttingprocess 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 arcdepend on the kind of metal being used, coatingson the metal, and the different processes. You mustbe very careful when cutting or welding any met-als which may contain one or more of the follow-ing:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper Selenium

Beryllium Lead SilverCadmium Manganese Vanadium

Always read the Material Safety Data Sheets(MSDS) that should be supplied with the materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

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

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

Do not use the plasma torch in an area where com-bustible or explosive gases or materials are located.

Phosgene, a toxic gas, is generated from the vaporsof chlorinated solvents and cleansers. Remove allsources of these vapors.

This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects 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 processuses and produces high voltage electrical energy. Thiselectric energy can cause severe or fatal shock to the op-erator or others in the workplace.

Never touch any parts that are electrically liveor hot.


8/76GENERAL INFORMATION 1-2 Date: January 27, 2004

Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircuit.

Repair or replace all worn or damaged parts.

Extra care must be taken when the workplace ismoist or damp.

Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publica-tions.

Disconnect power source before performing anyservice or repairs.

Read and follow all the instructions in the Operat-ing Manual.

FIRE AND EXPLOSION

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

Be sure there is no combustible or flammable ma-terial in the workplace. Any material that cannotbe removed must be protected.

Ventilate all flammable or explosive vapors fromthe workplace.

Do not cut or weld on containers that may haveheld combustibles.

Provide a fire watch when working in an area wherefire hazards may exist.

Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-water or while using a water table. DO NOTcutaluminum alloys underwater or on a water tableunless the hydrogen gas can be eliminated or dis-sipated. Trapped hydrogen gas that is ignited willcause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-cesses can cause noise levels to exceed safe limits. Youmust protect your ears from loud noise to prevent per-

manent loss of hearing. To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect othersin the workplace.

Noise levels should be measured to be sure the deci-bels (sound) do not exceed safe levels.

For information on how to test for noise, see item 1in 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 violetand infra red light. These arc rays will damage youreyes and burn your skin if you are not properly protected.

To protect your eyes, always wear a welding hel-met or shield. Also always wear safety glasses withside shields, goggles or other protective eye wear.

Wear welding gloves and suitable clothing to pro-tect 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 followingper ANSI/ASC Z49.1:

Minimum Protective SuggestedArc 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 clearlyseen. Experience has shown that lighter filtersmay be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisionsfor more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR1910, obtainable from the Superintendent of Docu-ments, U.S. Government Printing Office, Washington,D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable from the American Welding So-ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainablefrom the Superintendent of Documents, U.S. Govern-ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-PATION AND EDUCATIONAL EYE AND FACE PRO-TECTION, obtainable from American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MENSSAFETY-TOE FOOTWEAR, obtainable from the Ameri-can National Standards Institute, 1430 Broadway, NewYork, NY 10018



6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from American National Standards Institute, 1430Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-tainable from American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMSFOR WELDING, CUTTING AND ALLIED PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

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

10. NFPA Standard 51B, CUTTING AND WELDING PRO-CESSES, obtainable from the National Fire ProtectionAssociation, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN CYLINDERS, obtainable from theCompressed Gas Association, 1235 Jefferson DavisHighway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-ING AND CUTTING, obtainable from the CanadianStandards Association, Standards Sales, 178 RexdaleBoulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHYobtainable from the National Welding Supply Associa-tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-TION FOR WELDING AND CUTTING OF CONTAIN-ERS AND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORYPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots note, attention, etavertissement sont utiliss pour mettre en relief desinformations caractre important. Ces mises en reliefsont classifies comme suit :

NOTE

Toute opration, procdure ou renseignementgnral sur lequel il importe dinsister davantageou qui contribue lefficacit de fonctionnementdu systme.

ATTENTION

Toute procdure pouvant rsulterlendommagement du matriel en cas de non-respect de la procdure en question.

AVERTISSEMENT

Toute procdure pouvant provoquer des blessuresde loprateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de la

procdure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENTS

LOPRATION ET LA MAINTENANCE DUMATRIEL DE SOUDAGE LARC AU JETDE PLASMA PEUVENT PRSENTER DESRISQUES ET DES DANGERS DE SANT.

Coupant larc au jet de plasma produit de lnergielectrique haute tension et des missionsmagntique qui peuvent interfrer la fonction

propre dun pacemaker cardiaque, les appareilsauditif, ou autre matriel de sant electronique.

Ceux qui travail prs dune application larc aujet de plasma devrait consulter leur membreprofessionel de mdication et le manufacturier dematriel de sant pour dterminer sil existe desrisques de sant.

Il faut communiquer aux oprateurs et au person-nel TOUS les dangers possibles. Afin dviter lesblessures possibles, lisez, comprenez et suivez tousles avertissements, toutes les prcautions de scuritet toutes les consignes avant dutiliser le matriel.Composez le + 603-298-5711 ou votre distributeurlocal si vous avez des questions.

FUME et GAZ

La fume et les gaz produits par le procd de jet deplasma peuvent prsenter des risques et des dangers desant.



Eloignez toute fume et gaz de votre zone de respira-tion. Gardez votre tte hors de la plume de fumeprovenant du chalumeau.

Utilisez un appareil respiratoire alimentation en airsi laration fournie ne permet pas dliminer la fumeet les gaz.

Les sortes de gaz et de fume provenant de larc deplasma dpendent du genre de mtal utilis, desrevtements se trouvant sur le mtal et des diffrentsprocds. Vous devez prendre soin lorsque vouscoupez ou soudez tout mtal pouvant contenir un ouplusieurs des lments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre slniumbryllium manganse vanadium

Lisez toujours les fiches de donnes sur la scurit

des matires (sigle amricain MSDS); celles-cidevraient tre fournies avec le matriel que vousutilisez. Les MSDS contiennent des renseignementsquant la quantit et la nature de la fume et des gazpouvant poser des dangers de sant.

Pour des informations sur la manire de tester lafume et les gaz de votre lieu de travail, consultezlarticle 1 et les documents cits la page 5.

Utilisez un quipement spcial tel que des tables decoupe dbit deau ou courant descendant pourcapter la fume et les gaz.

Nutilisez pas le chalumeau au jet de plasma dans unezone o se trouvent des matires ou des gaz combus-tibles ou explosifs.

Le phosgne, un gaz toxique, est gnr par la fumeprovenant des solvants et des produits de nettoyagechlors. Eliminez toute source de telle fume.

Ce produit, dans le procder de soudage et de coupe,produit de la fume ou des gaz pouvant contenir deslments reconnu dans Ltat de la Californie, quipeuvent causer des dfauts de naissance et le cancer.(La scurit de sant en Californie et la code scuritSec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs lectriques peuvent blesser ou mme tuer. Leprocd au jet de plasma requiert et produit de lnergielectrique haute tension. Cette nergie lectrique peutproduire des chocs graves, voire mortels, pour loprateuret les autres personnes sur le lieu de travail.

Ne touchez jamais une pice sous tension ou vive;portez des gants et des vtements secs. Isolez-vousde la pice de travail ou des autres parties du circuitde soudage.

Rparez ou remplacez toute pice use ouendommage.

Prenez des soins particuliers lorsque la zone de tra-vail est humide ou moite.

Montez et maintenez le matriel conformment auCode lectrique national des Etats-Unis. (Voir la page5, article 9.)

Dbranchez lalimentation lectrique avant tout tra-vail dentretien ou de rparation.

Lisez et respectez toutes les consignes du Manuel deconsignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent rsulter des scorieschaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, desscories chaudes pouvant mettre le feu aux matires com-bust ib le s ou prov oq uer lexplo si on de fu mesinflammables.

Soyez certain quaucune matire combustible ou in-flammable ne se trouve sur le lieu de travail. Protgeztoute telle matire quil est impossible de retirer de lazone de travail.

Procurez une bonne aration de toutes les fumesinflammables ou explosives.

Ne coupez pas et ne soudez pas les conteneurs ayantpu renfermer des matires combustibles.

Prvoyez une veille dincendie lors de tout travail dansune zone prsentant des dangers dincendie.

Le gas hydrogne peut se former ou saccumuler sousles pices de travail en aluminium lorsquelles sontcoupes sous leau ou sur une table deau. NE PAScouper les alliages en aluminium sous leau ou surune table deau moins que le gas hydrogne peutschapper ou se dissiper. Le gas hydrogne accumulexplosera si enflamm.

RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent blesservos yeux et brler votre peau. Le procd larc deplasma produit une lumire infra-rouge et des rayons



ultra-violets trs forts. Ces rayons darc nuiront vosyeux et brleront votre peau si vous ne vous protgezpas correctement.

Pour protger vos yeux, portez toujours un casque ouun cran de soudeur. Portez toujours des lunettes descurit munies de parois latrales ou des lunettes deprotection ou une autre sorte de protection oculaire.

Portez des gants de soudeur et un vtement protecteurappropri pour protger votre peau contre lestincelles et les rayons de larc.

Maintenez votre casque et vos lunettes de protectionen bon tat. Remplacez toute lentille sale oucomportant fissure ou rognure.

Protgez les autres personnes se trouvant sur la zonede travail contre les rayons de larc en fournissant descabines ou des crans de protection.

Utilisez la nuance de lentille qui est suggre dans le

recommendation qui suivent ANSI/ASC Z49.1:Nuance Minimum Nuance Suggere

Courant Arc Protective Numro Numro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs sappliquent ou larc actuel est observclairement. Lexperience a dmontrer que les filtresmoins foncs peuvent tre utiliss quand larc estcach par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de loue.Les procds de soudage larc de plasma peuventprovoquer des niveaux sonores suprieurs aux limitesnormalement acceptables. Vous d4ez vous protger lesoreilles contre les bruits forts afin dviter une pertepermanente de loue.

Pour protger votre oue contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protgez galement les autres personnes

se trouvant sur le lieu de travail. Il faut mesurer les niveaux sonores afin dassurer que

les dcibels (le bruit) ne dpassent pas les niveauxsrs.

Pour des renseignements sur la manire de tester lebruit, consultez larticle 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les rvisions les plusrcentes ayant t faites celles-ci pour de plus amplesrenseignements :

1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DEPROTECTION DE LA SANT, 29CFR 1910,

disponible auprs du Superintendent of Documents,U.S. Government Printing Office, Washington, D.C.20402

2. Norme ANSI Z49.1, LA SCURIT DESOPRATIONS DE COUPE ET DE SOUDAGE,disponible auprs de la Socit Amricaine deSoudage (American Welding Society), 550 N.W.LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SCURIT ET LA SANT LORS DESOPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superin-

tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AU TRA-VAIL ET DANS LES ECOLES, disponible de lInstitutAmricain des Normes Nationales (American Na-tional Standards Institute), 1430 Broadway, New York,NY 10018

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponible auprsde lAmerican National Standards Institute, 1430Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRVENTION DES INCENDIESLORS DE LEMPLOI DE PROCDS DE COUPE ETDE SOUDAGE, disponible auprs de lAmerican Na-tional Standards Institute, 1430 Broadway, New York,NY 10018

7. Norme A6.0 de lAssociation Amricaine du Soudage(AWS), LE SOUDAGE ET LA COUPE DECONTENEURS AYANT RENFERM DES PRODUITSCOMBUSTIBLES, disponible auprs de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

8. Norme 51 de lAssociation Amricaine pour la Pro-tection contre les Incendies (NFPA), LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENEPOUR LE SOUDAGE, LA COUPE ET LESPROCDS ASSOCIS, disponible auprs de la Na-tional Fire Protection Association, Batterymarch Park,Quincy, MA 02269



9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprs de la National Fire Pro-tection Association, Batterymarch Park, Quincy, MA02269

10. Norme 51B de la NFPA, LES PROCDS DECOUPE ET DE SOUDAGE, disponible auprs de laNational Fire Protection Association, Batterymarch

Park, Quincy, MA 0226911. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMS EN CYLINDRES,disponible auprs de lAssociation des GazComprims (Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. Norme CSA W117.2, CODE DE SCURIT POURLE SOUDAGE ET LA COUPE, disponible auprsde lAssociation des Normes Canadiennes, Stan-dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R313. Livret NWSA, BIBLIOGRAPHIE SUR LA

SCURIT DU SOUDAGE, disponible auprs delAssociation Nationale de Fournitures de Soudage(National Welding Supply Association), 1900 ArchStreet, Philadelphia, PA 19103

14. Norme AWSF4.1 de lAssociation Amricaine deSoudage, RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRPARATION LA COUPE ETAU SOUDAGE DE CONTENEURS ET TUYAUXAYANT RENFERM DES PRODUITSDANGEREUX , disponible auprs de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTIONRESPIRATOIRE, disponible auprs de lAmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018



1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

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 forthe enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (Euro-pean 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 unitand 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 andassociated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design andmanufacturing process. This is to ensure the product is safe, when used according to instructions in this manual andrelated industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturingprocess 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 WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX



1.08 Statement of Warranty

LIMITED WARRANTY:Thermal DynamicsCorporation (hereinafter Thermal) warrants that its products will be free of defects inworkmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermalproducts as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,and maintained in accordance with Thermals 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 Thermals soleoption, 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 PARTICULARPURPOSE.

LIMITATION OF LIABILITY:Thermal shall not under any circumstances be liable for special or consequential damages, such as, but notlimited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) for serviceinterruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, oranything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use ofany 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 THESAFETY 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 fromdate 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 dateof sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, andwith 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 anauthorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the furtherlimitations 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 YearBut Not Limited To, Starting Circuit,Contactors, Relays, Solenoids, Pumps,Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 YearExchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 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 repairfacility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation chargesto send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at thecustomers risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001


15/76Manual 0-2818 2-1 INTRODUCTION

SECTION 2:INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions andmaintenance procedures for the PCH/M-102 Torch using theSureLok electrode design. Service of this equipment is restrictedto properly trained personnel; unqualified personnel are strictlycautioned against attempting repairs or adjustments not cov-ered in this manual, at the risk of voiding the Warranty.

Read this manual thoroughly. A complete understanding of thecharacteristics and capabilities of this equipment will assurethe dependable operation for which it was designed.

2.02 General Description

NOTE

Refer to Section 2.05, Introduction To Plasma, fora more detailed description on plasma theory.

The Torch provides cutting capacity of up to 1 inch (25.4 mm) at100 amperes. In the torch, a single torch lead provides com-pressed air from a single source to be used as both the plasmaand secondary gas. The air flow is divided inside the torchhead. Single-gas operation provides a smaller sized torch andinexpensive operation.

Plasma torches are similar in design to the common automotivespark plug. They consist of negative and positive sectionswhich are separated by a center insulator. Inside the torch, thepilot arc is initiated in the gap between the negatively chargedelectrode and the positively charged tip. Once the pilot arc hasionized the plasma gas, the superheated column of gas flowsthrough the small orifice in the torch tip, which is focused onthe metal to be cut.

2.03 Specifications & DesignFeatures

NOTE

Refer to Appendix Pages for additional specifica-tions as related to the Power Supply used.

A. Torch Configurations and Dimensions

1. Hand Torch

Available with torch head at 70 or 90 to the torchhandle. The hand torches include a torch handleand torch switch assembly.

2. Machine Torch

The standard machine torch has a fiberglass posi-tioning tube with rack & pinch block assembly.

Available options include a kit with metal mount-ing tube with rack & pinion assembly or a kit withthe pinion assembly only.

3.0 in

(76.2 mm)

10.5 in

(267 mm)

A-02804

1.1in

(28 mm)

10.0 in

(254 mm)

3.4 in

(86.4 mm)

1.1in

(28 mm)

14.1 in

(358 mm)

0.62 in

(15.2 mm)

0.75 in

(19 mm)

5.1 in

(129.5 mm)

1.1 in(28 mm)

1.4 in

(35.6 mm)

13.5 in (343 mm) Max

3.7 in (94 mm) Min

Figure 2-1 Torch Configurations and Dimensions


16/76INTRODUCTION 2-2 Manual 0-2818

B. Torch Leads Lengths

Hand Torches

20 ft (6.1 m) or 50 ft (15.2 m)

Machine Torches

25 ft (7.6 m) or 50 ft (15.2 m)

C. Torch Parts

Gas Distributor, Electrode, Tip, Shield Cup

D. Parts-In-Place (PIP)

Torch Head has built-in contacts

12 vdc circuit rating

E. Type Cooling

Combination of ambient air and gas stream through torch

F. Torch Ratings

Ambient

Temperature

104F

(40C)

Duty Cycle 100% @ 100 Amps @ 400 scfh

Maximum Current 100 Amps

Voltage (Vpeak) 500V

Arc Striking Voltage 12 kV

Torch Ratings

G. Plasma Power Supply Used With

CutMaster 75

CutMaster 80XL

CutMaster 100

Pak Master 75XL Plus

Pak Master 100XL Plus

CE Pak Master 75XL Plus

CE Pak Master 100XL Plus

H. Direct Contact Hazard

For exposed tip the recommended standoff is 1/8 -3/8 inch or 3 - 9.5 mm.

2.04 Options And Accessories

These items can be used to customize a standard systemfor a particular application or to further enhance perfor-mance (refer to Section 6 for ordering information).

Spare Parts Kits - Various kits containing replace-ment front-end torch parts for various applications.

Circle Cutting Guide Kit - Easy add-on attachmentsto allow for straight line, circle cutting, and bevelingwith a hand torch. The guide fits both the 70 and90 hand torches.

Standoff Cutting Guide - Simple push-on attachmentto allow for torch dragging without risk of touchingtip to workpiece.

1 - 3/8" Metal Mounting Tube with Rack & PinionAssembly

Pinion Assembly

Computer Control (CNC) Cable 25 Ft (7.6 m) or 50 Ft

(15.2 m) Hand Pendant Control Assembly - Used for ma-

chine applications. Hand Pendant Control has20 ft. (6.1 m) cable which provides ON & OFFsignals to the Power Supply.

Extension Cable for Hand Pendant Control - 25 ft(7.6 m) cable which can be added to the Hand Pen-dant Control cable to provide a total control cablelength of 50 ft (15.2 m).

2.05 Introduction to Plasma

A. Plasma Gas FlowPlasma is defined as a gas which has been heated toan extremely high temperature and ionized so that itbecomes electrically conductive. The plasma arc cut-ting and gouging process use this plasma to transferan electrical arc to the workpiece. The metal to be cutor removed is melted by the heat of the arc and thenblown away.

While the goal of plasma arc cutting is separation ofthe material, plasma arc gouging is used to removemetals to a controlled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B(refer to Figure 2-2), where a pilot arc between the elec-trode and the torch tip heats and ionizes the gas. Themain cutting arc then transfers to the workpiecethrough the column of plasma gas in Zone C.


17/76Manual 0-2818 2-3 INTRODUCTION

; ;

; ;

; ;

;

;

;

;

;

; ;

; ;

A-00002

Workpiece

PowerSupply

+

_

C

B

A

Figure 2-2 Typical Torch Head Detail

By forcing the plasma gas and electric arc through a smallorifice, the torch delivers a high concentration of heat to asmall area. The stiff, constricted plasma arc is shown inZone C (Figure 2-2). Direct current (DC) straight polarity isused for plasma cutting, as shown in the illustration.

Zone A (Figure 2-2) is used as a secondary gas that coolsthe torch. This gas assists the high velocity plasma gas inblowing the molten metal out of the cut allowing for a fast,slag-free cut.

B. Gas Distribution

The single gas used is internally split into plasma and sec-ondary gases.

The plasma gas flows into the torch through the negativelead, through the gas distributor, around the electrode,and out through the tip orifice.

The secondary gas flows down around the outside of thetorch gas distributor, and out between the tip and shieldcup around the plasma arc.

C. Pilot Arc

When the torch is started a pilot arc is established be-tween the electrode and cutting tip. This pilot arc createsa path for the main arc to transfer to the work.

D. Capacitive Discharge

Because direct current (DC) alone is not sufficient to strikeand maintain the pilot arc, capacitive discharge is also used.The high voltage jumps between the tip and electrode withthe DC following.

E. Main Cutting Arc

DC power is also used for the main cutting arc. The nega-tive output is connected to the torch electrode through thetorch lead. The positive output is connected to the work-piece via the work cable and to the torch through a pilotwire.

F. Interlocks

One pressure switch acts as an interlock for the gas sup-ply. If supply pressure falls below minimum requirementsthe pressure switch will open, shutting off the DC power,and the GAS indicator will go off. When adequate gassupply pressure is available the pressure switch will close,

allowing power to be resumed for cutting.G. Parts-In-Place (PIP)

The torch head has built-in contacts called Parts-In-Place(PIP). These two contacts are made through the cantedcoiled spring inside the shield cup when it is installed. Thetorch will fail to operate if these contacts are not made.

A-00458

Torch Switch

PIP Pin

PIP Pin

Shield CupTo Control

Cable Wiring

Figure 2-3A Parts-In-Place (PIP) Diagram - MachineTorch

A-03761

Torch Trigger

PIP Switch Shield Cup

To Control

Cable Wiring

Torch Switch

Figure 2-3B Parts-In-Place (PIP) Diagram - HandTorch


18/76INTRODUCTION 2-4 Manual 0-2818


19/76Manual 0-2818 3-1 INSTALLATION

SECTION 3:INSTALLATION

3.01 Introduction

This section describes installation of the Torch. Theseinstructions apply to the Torch and Leads Assembliesonly; installation procedures for the Power Supply, Op-tions and Accessories are given in Manuals specificallyprovided for those parts.

The complete installation consists of:

Site Selection

Unpacking

Setting Up Torch

Connecting Torch

Gas Connection

3.02 Site Location

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

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

3.03 Unpacking

Each component of the system is packaged and protected

with a carton and packing material to prevent damageduring shipping.

1. Unpack each item and remove all packing material.

2. Locate the packing list and use the list to identify andaccount for each item.

3. Inspect each item for possible shipping damage. Ifdamage is evident, contact your distributor and & orshipping company before proceeding with systeminstallation.

3.04 Setting Up Hand Torch

The hand torch is factory assembled to the Power Supplyand requires no special set up. The proper torch parts(shield cup, tip, gas distributor, and electrode) must beinstalled for the type of operation. Refer to Section 4.04,Torch Parts Selection for more information.

3.05 Setting Up Machine Torch

WARNING

Disconnect primary power at the source before dis-assembling the torch or torch leads.

The machine torch is factory assembled to the Power Sup-ply and includes a fiberglass positioning tube with rackand pinch block assembly. A metal mounting tube withrack & pinion assembly or the pinion assembly only areavailable as options.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to alignthe torch perpendicular to the surface of the work-piece.

A-02585

Workpiece

Square

Pinch Block

Assembly

Figure 3-1 Machine Torch Set-Up

3. The proper torch parts (shield cup, tip, gas dis-

tributor, and electrode) must be installed for thetype of operation. Refer to Section 4.04, TorchParts Selection for more information.


20/76INSTALLATION 3-2 Manual 0-2818

3.06 Connecting Torch

The instructions for connecting the Torch Leads to thePower Supply are different depending on the type ofleads. This sub-section covers connecting the Torch forthe following applications:

A. Hand Systems

B. Machine Systems (Unshielded Leads)

C. Machine Systems (Shielded Leads)

D. Remote Pendant Control (Optional)

The Torch Leads must be properly installed to the PowerSupply for proper operation. If the torch leads were notfactory-installed, make all torch connections to the TorchBulkhead Panel for the desired application.

NOTE

Equipment ordered as a system will have the Torch

factory connected to the Power Supply.A. Hand Systems

WARNING


1. Remove the retaining nut from the Through-holeProtector.

Through - HoleProtector Nut

Through - Hole

Protector

Torch Leads

Assembly

Art #A-03848

Remove Tie Wrap,

Remove Insulator,

Disconnect Wires

Figure 3-2 Retaining Nut Removal

2. Feed the torch lead ends and the Through-holeProtector into the hole in the unit.

3. Secure the Through-hole Protector with the retain-ing nut removed earlier.

4. Connect the torch Negative & Plasma Lead to the bulk-head connection inside the Power Supply.

Pilot Lead

Torch Lead

Assemblyor ATC Adapter

Negative/Plasma

Lead

Adapter

Connector

Pilot Lead Stud

Negative/Plasma

Lead Connection

A-03542

Note: Actual Bulkhead

configuration maydiffer from that shown.

Adapter

Control CircuitConnectors

Figure 3-3 Hand Torch Lead Connections

5. Connect the Cables to the mating connectors on theAdapter supplied on the Power Supply.

6. Remove the top nut and washer from the Pilot Stud.

7. Place the lug on the Pilot Control Wire onto the studand secure with the nut and washer removed in theabove Step.

8. Tighten the Through-hole Protector onto the TorchLeads.

9. Check the torch for proper parts assembly.

CAUTION

The torch parts must correspond with the type of

operation. Refer to Section 4.04, Torch Parts Se-lection.



B. Machine Systems (Unshielded Leads)

1. Remove the Through-hole Protector Nut from theThrough-hole Protector.

Thru - Hole

ProtectorNut

Thru - Hole Protector

Torch Leads

Assembly

Art # A-03847

Figure 3-4 Through-hole Protector Nut Removal

2. The Adapter supplied with the Power Supplymust be installed as follows:

a. Inside the Power Supply Bulkhead area, routethe connector on the free end of the Adapterthrough the Through-hole Protector Nut.

b. Continue routing the connector out the holein the front of the Power Supply.

c. Feed the end of the torch lead and theThrough-hole Protector into the hole in the unitwhile routing the single black wire into thenotch of the Through-hole Protector.

d. Tighten the Through-hole Protector Nut tosecure the Through-hole Protector to thePower Supply.

Control ConnectorPlug

Pilot Lead

Torch LeadAssembly

Negative/PlasmaLead

Control Connector

Pilot LeadStud

Negative/PlasmaLead Connection

A-02843

Control (PIP) CircuitConnectors

Shield Connectors

(Not Used)

RemoteCableConnector

Figure 3-5A Unshielded Machine Torch LeadConnections

Power Supply Adapter

Torch LeadAssembly

Negative/Plasma Lead

Pilot Lead

Negative/PlasmaLead Connection

Shield Connectors (Not Used)

Remote PendantConnector

Art # A-04323

Control CircuitConnectors

Figure 3-5B Unshielded Machine Torch Connection Detail



3. Connect the torch Negative / Plasma Lead to the bulk-head connection inside the Power Supply.

4. Connect the Control (PIP) Circuit Connectors to themating connectors on the Adapter supplied on thePower Supply (see Warning).

WARNING

The Adapter supplied with the Power Supply hastwo additional Shield Connectors that are used forShielded Systems only. These two connectors arenot used and need to be taped out of the way to

prevent contacting the Negative & Plasma or Pi-lot Leads.

5. Remove the top nut and washer from the PilotStud.

6. Place the lug on the Pilot Control Wire onto thestud and secure with the nut and washer removedin the above Step.



CAUTION

The torch parts must correspond with the type ofoperation. Refer to Section 4.04, Torch Parts Se-

lection.

C. Machine Systems (Shielded Leads)

1. Remove the Through-hole Protector Nut from theThrough-hole Protector.

Through - Hole

Protector Nut

Through - HoleProtector

Torch Leads

Assembly

Art # A-03849

Figure 3-6 Through-hole Protector Nut Removal

2. The Adapter supplied with the Power Supply must beinstalled per the following:

a. Inside the Power Supply Bulkhead area, route theconnector on the free end of the Adapter throughthe Through-hole Protector Nut.

b. Continue routing the connector out the hole in thefront of the Power Supply.

c. Feed the end of the torch lead and the Through-hole Protector into the hole in the unit while rout-ing the single black wire into the notch of the

Through-hole Protector.d. Tighten the Through-hole Protector Nut to secure

the Through-hole Protector to the Power Supply.



Adapter

(Supplied With

Power Supply)

Pilot Lead

Torch Lead

Assembly

Negative/Plasma

Lead

Adapter Connector

Pilot Lead

Stud

Negative/Plasma

Lead Connection

A-02829

Control (PIP) Circuit

Connectors

Shield Connectors

Figure 3-7 Shielded Machine Torch Lead Connections

3. Connect the torch Negative & Plasma Lead to the bulk-head connection inside the Power Supply.

4. Connect the PIP and Shield Cables to the mating con-nectors on the Adapter supplied on the Power Supply.

5. Remove the top nut and washer from the Pilot Stud.

6. Place the lug on the Pilot Control Wire onto the stud

and secure with the nut and washer removed in theabove Step.



CAUTION

The torch parts must correspond with the type ofoperation. Refer to Section 4.04, Torch Parts Se-lection.

D. Remote Pendant Control (Optional)

In machine type operations the Power Supply has anAdapter that has a cable connector supplied at eachend of the Adapter. One end is connected at the fac-tory to the mating connector on the Power SupplyBulkhead area. The other end allows connection of aRemote Pendant. The remote pendant lead connec-

tor allows connection to a remote pendant or CNCcable while using PIP connections in the Torch As-sembly.

Connect the remote pendant control cable to the con-nector provided on the Adapter from the Power Sup-ply.

2

3

4

12

14

13

Torch Control

Cable ConnectorRemote Pendant/CNC

Cable Connector

PIP

CircuitControl

OK-To-Move

3

4

12

14

13

A-01366

Figure 3-8 Remote Pendant Connector Diagram

NOTE

Refer to Appendix 2, Torch Control Cable WiringDiagram For Mechanized Systems, for detailedschematic of the Adapter.



3.07 Gas Connection

A. Connection

Connect the gas, compressed air only, to the PowerSupply as described in the Manual supplied with thePower Supply.

CAUTION

Air supply must be free of oil, moisture, and othercontaminants. Excessive oil and moisture maycause double-arcing, rapid tip wear, or even com-

plete torch failure. Contaminants may cause poorcutting performance and rapid electrode wear.

B. Checking Air Quality

To test the quality of air, place a welding filter lens infront of the torch and turn on the gas. Any oil ormoisture in the air will be visible on the lens. Do not

initiate an arc!

C. Filtering

An in-line pneumatic dryer & evaporator type air fil-ter, capable of filtering to at least 5 microns, is requiredwhen using air from a compressor. This type filterwill insure that moisture, oil, dirt, chips, rust particles,and other contaminants from the supply hose do notenter the torch. For highly automated applications,a refrigerated drier may be used.


25/76Manual 0-2818 4-1 OPERATION

SECTION 4:OPERATION

4.01 Introduction

This section provides a description of the PCH & M-102Torch Assembly followed by operating procedures.

4.02 Functional Overview

The Torch is designed to operate with various Power Sup-plies to provide a plasma cutting system which can cutmost metals from gauge thickness up to 1 inch (25.4 mm).Using gouging torch parts the torch can be used forplasma arc gouging up to 1/4 inch (6.4 mm) wide and3/16 inch (4.8 mm) deep in a single pass on carbon steel.

NOTE

Refer to Appendix Pages for additional informa-tion as related to the Power Supply used.

4.03 Getting Started

This procedure should be followed at the beginning ofeach shift:

WARNING

Disconnect primary power at the source before as-

sembling or disassembling power supply, torchparts, or torch and leads assemblies.

A. Torch Parts

Check the torch for proper assembly. Install propertorch parts for the desired application (refer to Sec-tion 4.04, Torch Parts Selection).

B. Input Power

Check the power source for proper input voltage.Close main disconnect switch or plug unit in to sup-ply primary power to the system.

C. Work Cable

Check for a solid cable connection to the workpiece.

D. Gas Supply

Select desired single gas supply. Make sure gassources meet requirements (see Note). Check con-nections and turn gas supply on.

NOTE


E. Power On

Place the ON - OFF Switch on the Power Supply tothe ON position. If the RUN - SET - or RUN - SET -

LATCH switch is in SET position, gas will flow. Ifthe switch is in RUN position there will be no gasflow.

F. RUN - SET or RUN - SET - LATCH Switch

If the RUN - SET or RUN - SET - LATCH switch is inSET position, gas will flow. If the switch is in RUNposition there will be no gas flow.

G. Current Output Level

At the Power Supply, set the desired current outputlevel to a maximum of 100 amperes. For drag cut-

ting set the control at 35 amps or less only.H. Pressure Settings

Place the RUN - SET or RUN - SET - LATCH switchto the SET position. Adjust the gas pressure controlon the Power Supply for the proper gas pressure (seeNote).

NOTE


I. Ready for Operation

Return the RUN - SET or RUN - SET - LATCH switchto RUN position.

NOTES

For general cutting, use the RUN position whichprovides normal torch operation where the torchswitch must be held throughout the main arc trans-

fer.

For specific applications, use the LATCH positionwhere the torch switch can be released after the mainarc transfer. The torch remains activated until the

main arc breaks from the workpiece.

Refer to Appendix 1 for a typical detailed block dia-gram of Sequence of Operation.

The system is now ready for operation.

Start the pilot arc. On Hand Torches press the Torch Trig-ger. On Machine Torches press the switch on the RemotePendant or supply a Start Signal from the CNC control.There is a 2 second pre-flow before the arc starts.


26/76OPERATION 4-2 Manual 0-2818

4.04 Torch Parts Selection

Depending on the type of operation to be done determinesthe torch parts to be used.

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

Shield Cup, Cutting Tip, Electrode and Gas Dis-tributor

NOTE


Change the torch parts for a different operation as fol-lows:

NOTE

The tip and gas distributor are held in place by theshield cup. Position the torch with the shield cupfacing upward to prevent these parts from fallingout when the cup is removed.

1. Unscrew and remove the shield cup from the torchhead.

Torch Head Assembly

(70oHand Torch Shown)

Shield Cup

GasDistributor

Tip

Electrode

A-02793

Figure 4-1 Torch Parts

2. Tilt the torch head to remove the tip and gas distribu-tor.

3. Remove the SureLok Electrode by pulling it straightout of the Torch Head.

4. Install the desired SureLok Electrode by pushing itstraight into the torch head until it clicks.

5. Install the desired gas distributor and tip for the op-eration into the torch head.

6. Hand tighten the shield cup until it is seated on thetorch head. If resistance is felt when installing thecup, check the threads before proceeding.

4.05 Cut Quality

NOTES

Cut quality depends heavily on setup and param-eters such as torch standoff, alignment with theworkpiece, cutting speed, gas pressures, and op-erator ability.


Cut quality requirements differ depending on applica-tion. For instance, nitride build-up and bevel angle maybe major factors when the surface will be welded aftercutting. Dross-free cutting is important when finish cutquality is desired to avoid a secondary cleaning opera-tion. The following cut quality characteristics are illus-trated in the following figure:

Kerf Width

Cut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Figure 4-2 Cut Quality Characteristics

A. Cut Surface

The desired or specified condition (smooth or rough)of the face of the cut.

B. Nitride Build-Up

Nitride deposits can be left on the surface of the cutwhen nitrogen is present in the plasma gas stream.These buildups may create difficulties if the materialis to be welded after the cutting process.

C. Bevel Angle

The angle between the surface of the cut edge and aplane perpendicular to the surface of the plate. A per-fectly perpendicular cut would result in a 0 bevelangle.

D. Top-Edge Rounding

Rounding on the top edge of a cut due to wearingfrom the initial contact of the plasma arc on the work-piece.



E. Bottom Dross Buildup

Molten material which is not blown out of the cutarea and resolidifies on the plate. Excessive drossmay require secondary cleanup operations after cut-ting.

F. Kerf Width

The width of the cut (or the width of material re-moved during the cut).

G. Top Spatter (Dross)

Top spatter or dross on the top of the cut caused byslow travel speed, excess cutting height, or cuttingtip whose orifice has become elongated.

4.06 General Cutting Information

WARNINGS

Disconnect primary power at the source before dis-assembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precau-tions at the front of this manual. Be sure the op-erator is equipped with proper gloves, clothing, eyeand ear protection. Make sure no part of theoperators body comes into contact with the work-

piece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damageto coated, painted, and other surfaces such as glass,

plastic and metal.

NOTE

Handle torch leads with care and protect them fromdamage.

A. Piloting

Piloting is harder on parts life than actual cutting be-

cause the pilot arc is directed from the electrode tothe tip rather than to a workpiece. Whenever pos-sible, avoid excessive pilot arc time to improve partslife.

B. Torch Standoff

Improper standoff (the distance between the torchtip and workpiece) can adversely affect tip life as wellas shield cup life. Standoff may also significantlyaffect the bevel angle. Reducing standoff will gener-ally result in a more square cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to theworkpiece with the front of the tip near (not touch-ing) the edge of the workpiece at the point where thecut is to start. When starting at the edge of the plate,do not pause at the edge and force the arc to "reach"for the edge of the metal. Establish the cutting arc as

quickly as possible.D. Direction of Cut

In the torches, the plasma gas stream swirls as it leavesthe torch to maintain a smooth column of gas. Thisswirl effect results in one side of a cut being moresquare than the other. Viewed along the direction oftravel, the right side of the cut is more square thanthe left.

Right Side

Cut Angle

Left SideCut Angle

A-00512

Figure 4-3 Side Characteristics Of Cut

To make a square-edged cut along an inside diameter of acircle, the torch should move counterclockwise around the

circle. To keep the square edge along an outside diametercut, the torch should travel in a clockwise direction.

E. Dross

When dross is present on carbon steel, it is commonlyreferred to as either high speed, slow speed, or topdross. Dross present on top of the plate is normallycaused by too great a torch to plate distance. "Topdross" is normally very easy to remove and can oftenbe wiped off with a welding glove. "Slow speeddross" is normally present on the bottom edge of theplate. It can vary from a light to heavy bead, but

does not adhere tightly to the cut edge, and can beeasily scraped off. "High speed dross" usually formsa narrow bead along the bottom of the cut edge andis very difficult to remove. When cutting a trouble-some steel, it is sometimes useful to reduce the cut-ting speed to produce "slow speed dross". Any re-sultant cleanup can be accomplished by scraping, notgrinding.



4.07 Hand Torch Operation

A. Standoff Cutting With Hand Torch

NOTE

For best performance and parts life, always usethe correct parts for the type of operation.

1. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thehand torch, the hand may be positioned close tothe torch head for maximum control or near the backend for maximum heat protection. Choose the holdingtechnique that feels most comfortable and allows goodcontrol and movement.

NOTE

The tip should never come in contact with theworkpiece except during drag cutting operations.

2. Depending on the cutting operation, do one of thefollowing:

a. For edge starts, hold the torch perpendicularto the workpiece with the front of the tip onthe edge of the workpiece at the point wherethe cut is to start.

b. For standoff cutting,hold the torch 1/8 - 3/8in (3-9 mm) from the workpiece as shown be-low.

A-00024

Shield Cup

Torch

Standoff

Distance 1/8" - 3/8"

Figure 4-4 Standoff Distance

3. With the torch in starting position, press and holdthe Torch Trigger. After an initial two second pre-flow, the pilot arc will come on and remain onuntil the cutting arc starts.

4. Once on, the main arc remains on as long as the TorchTrigger is held down, unless the torch is withdrawnfrom the work or torch motion is too slow. If the cuttingarc is interrupted, the pilot arc comes back on auto-matically.

NOTE

Most cutting is performed with the power supplyin the RUN position. For specific applications, theLATCH position may be preferred where the TorchTrigger can be released after the main arc transfer.The torch remains activated until the main arcbreaks from the workpiece.

5. To shut off the torch simply release the Torch Trig-ger. When the trigger is released a 20 second post-flow will occur. If the Torch Trigger is pushedduring the post-flow, the cutting arc will restartimmediately when the torch is brought withinrange of the workpiece.

B. Crown Shield Cup With Straight Edge

The crown shield cup can be used with a noncon-ductive straight edge to make straight cuts by hand.

WARNING

The straight edge must benon-conductive.

Non-Conductive

Straight Edge

Cutting Guide

Crown Shield

Cup

Torch

A-02600

Figure 4-5 Using Crown Shield Cup With StraightEdge

The crown shield cup functions best when cutting3/16 inch (4.7 mm) solid metal with relativelysmooth surface. Use drag cutting for thinnermetal.



C. Drag Cutting With a Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm) thick orless.

NOTE

For best parts performance and life, always usethe correct parts for the type of operation.

1. Install the drag cutting tip and set the output currentto 35 amps or less.

2. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thehand torch, the hand may be positioned close tothe torch head for maximum control or near theback end for maximum heat protection. Choosethe holding technique that feels most comfortableand allows good control and movement.

3. Keep the torch in contact with the workpiece dur-

ing the cutting cycle.

4. Press the Torch Trigger, and after an initial twosecond pre-flow, the pilot arc will come on andremain on until the cutting arc starts.

5. Once on, the main arc remains on as long as theTorch Trigger is held down, unless the torch iswithdrawn from the work or torch motion is tooslow. If the cutting arc is interrupted, the pilotarc comes back on automatically.

NOTE

Most cutting is performed with the power supplyin the RUN position. For specific applications,the LATCH position may be preferred where theTorch Trigger can be released after the main arctransfer. In the LATCH position, the torch remainsactivated until the main arc breaks from the work-

piece.

6. To shut off the torch simply release the Torch Trig-ger. When the Trigger is released a 20 second post-flow will occur. If the Torch Trigger is pushedduring the post-flow, the cutting arc will restartimmediately when the torch is brought within

range of the workpiece.

D. Piercing With Hand Torch

1. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thehand torch, the hand may be positioned close tothe torch head for maximum control or near theback end for maximum heat protection. Choose

the technique that feels most comfortable and al-lows good control and movement.

NOTE

The tip should never come in contact with the work-piece except during drag cutting operations.

2. Angle the torch slightly to direct blowback par-ticles away from the torch tip (and operator) ratherthan directly back into it until the pierce is com-plete.

3. In a portion of the unwanted metal start the pierce

off the cutting line and then continue the cut ontothe line. Hold the torch perpendicular to the work-piece after the pierce is complete.

4. Clean spatter and scale from the shield cup andthe tip as soon as possible. Spraying the shieldcup in anti-spatter compound will minimize theamount of scale which adheres to it.



4.08 Machine Torch Operation

A. Cutting With Machine Torch

The machine torch can be activated by remote controlpendant or by a remote interface device such as CNC.

1. Use a square to check that the torch is perpendicu-

lar to the workpiece to obtain a clean, vertical cut.

A-02585

Workpiece

Square

Pinch Block

Assembly

Figure 4-6 Checking Alignment

2. To start a cut at the plate edge, position the centerof the torch along the edge of the plate (refer toFigure 4-7).

B. Travel Speed

Proper travel speed is indicated by the trail of the arcwhich is seen below the plate ( Figure 4-7). The arccan be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiecesurface. This arc is generally recommended for the

best cut using air plasma on stainless or alumi-num.

2. Leading Arc

The leading arc is directed in the same direction astorch travel. A five degree leading arc is generallyrecommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc-

tion as torch travel. Generally recommended forNitrogen plasma.

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

DirectionofTorchTravel

A-02586

Figure 4-7 Machine Torch Operation

For optimum smooth surface quality, the travel speedshould be adjusted so that only the leading edge ofthe arc column produces the cut. If the travel speedis too slow, a rough cut will be produced as the arcmoves from side to side in search of metal for trans-fer.

Travel speed also affects the bevel angle of a cut.When cutting in a circle or around a corner, slowingdown the travel speed will result in a squarer cut.The power source output should be reduced also.Refer to the appropriate Control Module OperatingManual for any Corner Slowdown adjustments thatmay be required.



C. Piercing With Machine Torch

To pierce with a machine torch, the arc should be startedwith the torch positioned as high as possible above theplate while allowing the arc to transfer and pierce. Thisstandoff helps avoid having molten metal blow back ontothe front end of the torch.

When operating with a cutting machine, a pierce or dwelltime is required. Torch travel should not be enabled untilthe arc penetrates the bottom of the plate. As motion be-gins, torch standoff should be reduced to the recommended1/8 - 1/4 inch (3-6 mm) distance for optimum speed and cutquality. Clean spatter and scale from the shield cup andthe tip as soon as possible. Spraying or dipping the shieldcup in anti-spatter compound will minimize the amount ofscale which adheres to it.

4.09 Recommended CuttingSpeeds

Cutting speed depends on material, thickness, and the operatorsability to accurately follow the desired cut line. The followingfactors may have an impact on system performance:

Torch parts wear

Air quality

Line voltage fluctuations

Torch standoff height

Proper work cable connection

NOTES

This information represents realistic expectationsusing recommended practices and well-maintainedsystems. Actual speeds may vary up to 50% fromthose shown.

Refer to Appendix Pages for cutting speed chartinformation as related to the Power Supply used.

4.10 Gouging

WARNINGS

Be sure the operator is equipped with propergloves, clothing, eye and ear protection and thatall safety precautions at the front of this manualhave been followed. Make sure no part of theoperators body comes in contact with the work-

piece when the torch is activated.

Disconnect primary power to the system beforedisassembling the torch, leads, or power supply.

CAUTIONS

Sparks from plasma gouging can cause damage tocoated, painted or other surfaces such as glass, plas-tic, and metal.

Check torch parts. The torch parts must correspondwith the type of operation. Refer to Section 4.04,Torch Parts Selection.

A. Gouging Parameters

Gouging performance depends on parameters suchas torch travel speed, current level, lead angle (theangle between the torch and workpiece), and the dis-tance between the torch tip and workpiece (stand-off).

B. Torch Travel Speed

NOTE


Optimum torch travel speed is dependent on currentsetting, lead angle, and mode of operation (hand ormachine torch).

C. Current Setting

Current settings depend on torch travel speed, mode

of operation (hand or machine torch), and the amountof material to be removed.



D. Lead Angle

The angle between the torch and workpiece depends onthe output current setting and torch travel speed. At 80amps, the recommended lead angle is 35 (refer to Figure 4-8). At a lead angle greater than 45 the molten metal willnot be blown out of the gouge and may be blown backonto the torch. If the lead angle is too small (less than 35),

less material may be removed, requiring more passes. Insome applications, such as removing welds or workingwith light metal, this may be desirable.

35

Workpiece

Torch Head

Standoff Height

1/8 - 1/4"

A-00941

Figure 4-8 Gouging Angle and Standoff Distance

E. Standoff Distance

The tip to work distance affects gouge quality and depth.

Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows forsmooth, consistent metal removal. Smaller standoff dis-tances may result in a severance cut rather than a gouge.Standoff distances greater than 1/4 inch (6 mm) may resultin minimal metal removal or loss of transferred main arc.

F. Slag Buildup

Slag generated by gouging on materials such as carbonand stainless steels, nickels, and alloyed steels, can beremoved easily in most cases. Slag does not obstruct thegouging process if it accumulates to the side of the gougepath. However, slag build-up can cause inconsistenciesand irregular metal removal if large amounts of material

build up in front of the arc. The build-up is most often aresult of improper travel speed, lead angle, or standoffheight.


33/76Manual 0-2818 5-1 SERVICE

SECTION 5:SERVICE

5.01 Introduction

This section describes basic maintenance procedures per-formable by operating personnel. No other adjustmentsor repairs are to be attempted by other than properlytrained personnel.

WARNINGS


Frequently review the Important Safety Precau-tions at the front of this Manual. Be sure the op-

erator is equipped with proper gloves, clothing, eyeand ear protection. Make sure no part of theoperators body comes into contact with the work-

piece while the torch is activated.

CAUTION

Sparks from the cutting process can cause damageto coated, painted, and other surfaces such as glass,

plastic and metal.

NOTE

Handle torch leads with care and protect them fromdamage.

5.02 General Torch Maintenance

A. Cleaning Torch

Even if precautions are taken to use only clean airwith a torch, eventually the inside of the torch be-comes coated with residue. This buildup can affectthe pilot arc initiation and the overall cut quality ofthe torch.

WARNINGS

Disconnect primary power to the system beforedisassembling the torch or torch leads.

DO NOT touch any internal torch parts while theAC indicator light of the Power Supply is ON.

The inside of the torch should be cleaned with elec-trical contact cleaner using a cotton swab or soft wetrag. In severe cases, the torch can be removed fromthe leads and cleaned more thoroughly by pouringelectrical contact cleaner into the torch and blowingit through with compressed air.

Refer to Section 5.07, Servicing Hand Torch (PCH)

Components, or Section 5.08, Servicing MachineTorch Components (PCM) for disassembling theTorch and Leads Assembly.

CAUTION

Dry the torch thoroughly before reinstalling.

B. Checking Center Insulator

The center insulator separates the negative and posi-tive sections of the torch. If the center insulator doesnot provide adequate resistance, current which is in-

tended for the pilot arc may be dissipated into thetorch head, resulting in torch failure.

WARNINGS



1. Remove the shield cup, tip, gas distributor, andelectrode from the torch. Disconnect the torchleads from the power supply to isolate the torchfrom power supply circuits.

2. Using an ohmmeter (set to 10K or higher), checkfor continuity between the positive and negativetorch fittings. Infinite resistance (no continuity)should be found. If continuity is found, refer toSection 5.06, Torch and Leads Troubleshooting.

C. O-Ring Lubrication

The external o-ring on the Torch Head Assembly

(shield cup) requires lubrication on a scheduled ba-sis. This will allow the o-ring to remain pliable andprovide a proper seal. The o-ring will dry out, be-coming hard and cracked, if the o-ring lubricant isnot used on a regular basis. This can lead to poten-tial leaks of the secondary gas around the end of theshield cup.

It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on aweekly basis.


34/76SERVICE 5-2 Manual 0-2818

NOTE

DO NOTuse other lubricants or grease, they maynot be designed to operate within high tempera-tures or may contain unknown elements thatmay react with the atmosphere. This reaction canleave contaminants inside the torch. Either of theseconditions can lead to inconsistent performance or

poor parts life.

5.03 Common Operating Faults

The following lists the more common cutting faults andpossible causes:

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch partse. Cutting current too low

f. Non - Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch partsf. Non - Genuine Thermal Dynamics Parts

3. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

d. Improper cutting current

e. Non - Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in air source

b. Exceeding system capability (material too thick)

c. Excessive pilot arc time

d. Air flow too low (incorrect pressure)

e. Improperly assembled torch

f. Non - Genuine Thermal Dynamics Parts

5.04 Inspection and ReplacementConsumable Torch Parts

WARNINGS



Remove the consumable torch parts per the followingprocedure:

NOTE

The tip and gas distributor are held in place by theshield cup. Position the torch with the shield cup

facing upward to prevent these parts from falling

out when the cup is removed.

1. Unscrew and remove the shield cup from the torch.

NOTE

Slag built up on the shield cup that cannot be re-moved may effect the performance of the system.

2. Inspect the cup for damage. Wipe it clean or replaceif damaged.

Torch Head Assembly

(70oHand Torch Shown)

Shield Cup

GasDistributor

Tip

Electrode

A-02793

Figure 5-1 Consumable Parts


35/76Manual 0-2818 5-3 SERVICE

3. Remove the tip. Check for excessive wear (indicatedby an elongated or oversized orifice). Clean or re-place the tip if necessary.

Good Tip Worn Tip

A-00942

Figure 5-2 Tip Wear

4. Remove the gas distributor and check for excessivewear, plugged gas holes, or discoloration. Replace ifnecessary.

5. Remove the SureLok Electrode by pulling it straightout of the Torch Head. Refer to the following figure

and check the face of the electrode for excessive wear.

Worn Electrode

New Electrode

A-02794

Figure 5-3 Electrode Wear

6. Reinstall the SureLok Electrode by pushing it straightinto the torch head until it clicks.

7. Reinstall the desired gas distributor and tip into thetorch head.

8. Hand tighten the shield cup until it is seated on thetorch head. If resistance is felt when installing thecup, check the threads before proceeding.

5.05 Troubleshooting Guide

This subsection covers troubleshootingthat requires dis-assembly and electronic measurements. It is helpful forsolving many of the common problems that can arise withthis torch assembly.

How to Use This Guide

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

This guide is set up as follows:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check / Remedy (Text Type)

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

Troubleshooting

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN / SET / LATCH switch in SETposition

a. Place RUN / SET / LATCH switch to RUN po-sition.

2. Parts - In - Place (PIP) not satisfied.

a. Check canted coiled spring inside shield cup

3. Faulty Torch Switch

a. Check for continuity

4. Faulty torch parts

a. Inspect torch parts and replace if necessary. Re-fer to Section 5.04, Inspection and ReplacementConsumable Torch Parts

5. Gas pressure too high

a. Set proper operating gas pressure.

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-sary. Refer to Section 5.06, Torch & LeadsTroubleshooting.

7. Faulty components in power supply system components

a. Return for repair or have qualified technicianrepair per Service Manual.


36/76SERVICE 5-4 Manual 0-2818

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attachedto power supply

2. Shield cup not properly installed on torch

a. Check that shield cup is fully seated againsttorch head (do not overtighten)

3. Parts - In - Place (PIP) not satisfied.

a. Check canted coiled spring inside shield cup





C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.





D. Erratic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. In