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Manual No. 0-2529October 6, 1999
MERLIN PAK 15XCPlasma Cutting System (European)
Instruction Manual
PAK 15XC 150 Amp EMC Power Supply PCH/M-150 Torch Assembly With
Leads PCH/M-150 Spare Parts Kit Work Cable and Clamp Running Gear
and Handle Air Line Filter Assembly (or) High
Pressure Regulators
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WARNING
WARNING
Read and understand this entire Instruction Manual and
youremployers safety practices before installing, operating,
orservicing the equipment.
While the information contained in this Instruction
Manualrepresents our best judgement, Thermal Dynamics
Corporationassumes no liability for its use.
Merlin Pak 15XC European/EMC Plasma Cutting SystemInstruction
Manual Number 0-2529
Published by:Thermal Dynamics CorporationIndustrial Park No.
2West Lebanon, New Hampshire, USA 03784(603) 298-5711
Copyright 1996 byThermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without
writtenpermission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any
liabilityto any party for any loss or damage caused by any error
oromission in the Merlin Pak 15XC European/EMC Plasma CuttingSystem
Instruction Manual, whether such error results fromnegligence,
accident, or any other cause.
Printed in the United States of America
October 6, 1999
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TABLE OF CONTENTS
GENERAL INFORMATION
.............................................................................................................
i
Notes, Cautions and Warnings
..................................................................................
iImportant Safety Precautions
....................................................................................
iPublications
..............................................................................................................
iiNote, Attention et Avertissement
.............................................................................
iiiPrecautions De Securite Importantes
......................................................................
iiiDocuments De Reference
.......................................................................................
vDeclaration of Conformity
.......................................................................................
viiStatement of Warranty
...........................................................................................
viii
SECTION 1: INTRODUCTION & DESCRIPTION
.....................................................................
1-1
1.1 SYSTEM DESCRIPTION
..............................................................................
1-11.2 POWER SUPPLY SPECIFICATIONS
............................................................ 1-21.3
TORCH SPECIFICATIONS
...........................................................................
1-31.4 OPTIONS AND ACCESSORIES
...................................................................
1-51.5 THEORY OF OPERATION
............................................................................
1-6
SECTION 2: INSTALLATION
....................................................................................................
2-1
2.1 UNPACKING THE SYSTEM
..........................................................................
2-12.2 LOCATION
....................................................................................................
2-22.3 PLASMA AND SECONDARY CONNECTIONS
............................................. 2-22.4 ELECTRICAL
CONNECTIONS
.....................................................................
2-62.5 WORK AND GROUND
CONNECTIONS.......................................................
2-82.6 COOLANT INSTALLATION
...........................................................................
2-92.7 AUXILIARY CONNECTIONS
......................................................................
2-102.8 LIFTING THE POWER
SUPPLY..................................................................
2-12
SECTION 3: OPERATION
........................................................................................................
3-1
3.1 OPERATING CONTROLS
.............................................................................
3-13.2 PRE-OPERATION SET-UP
...........................................................................
3-43.3 TORCH PARTS SELECTION
........................................................................
3-53.4 GAS SELECTION FOR PLASMA
CUTTING................................................. 3-83.5
PLASMA CUTTING OPERATION
...............................................................
3-123.6 HAND TORCH OPERATION
.......................................................................
3-163.7 MACHINE TORCH OPERATION
.................................................................
3-183.8 PIERCING
...................................................................................................
3-213.9 GOUGING OPERATION
.............................................................................
3-223.10 COMMON OPERATING ERRORS
............................................................
3-253.11 CUTTING SPEEDS
...................................................................................
3-263.12 SEQUENCE OF
OPERATION...................................................................
3-33
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TABLE OF CONTENTS (continued)
SECTION 4: SERVICE
.............................................................................................................
4-1
4.1 TORCH MAINTENANCE
...............................................................................
4-14.2 HAND TORCH HEAD REPLACEMENT
........................................................ 4-24.3
MACHINE TORCH HEAD REPLACEMENT
.................................................. 4-44.4 HAND
TORCH SWITCH REPLACEMENT
.................................................... 4-64.5 HAND
TORCH LEADS REPLACEMENT
...................................................... 4-74.6
MACHINE TORCH LEADS REPLACEMENT
................................................ 4-94.7 LEADS
EXTENSION KITS - HAND TORCH
............................................... 4-114.8 LEADS
EXTENSION KITS - MACHINE TORCH
......................................... 4-134.9 POWER SUPPLY
MAINTENANCE
.............................................................
4-164.10 TROUBLESHOOTING THEORY
...............................................................
4-174.11 TROUBLESHOOTING GUIDE
...................................................................
4-214.12 SERVICE AND TEST PROCEDURES
...................................................... 4-27
SECTION 5: PARTS
LISTS.......................................................................................................
5-1
5.1 ABOUT THE PARTS LIST
.............................................................................
5-15.2 SYSTEM COMPONENTS AND ACCESSORIES
.......................................... 5-25.3 ACCESS PANEL
COMPONENTS
.................................................................
5-45.4 FRONT PANEL/CHASSIS
COMPONENTS...................................................
5-55.5 REAR PANEL COMPONENTS
.....................................................................
5-65.6 BASE COMPONENTS
..................................................................................
5-85.7 UPPER CHASSIS COMPONENTS
.............................................................
5-105.8 MAIN HEATSINK COMPONENTS
..............................................................
5-125.9 TORCH COMPONENTS
.............................................................................
5-145.10 TORCH ACCESSORIES
...........................................................................
5-16
SECTION 6: ADDITIONAL INFORMATION
..............................................................................
6-1
6.1 LADDER DIAGRAM - 120 VAC
......................................................................
6-16.2 LADDER DIAGRAM - 15 VDC
........................................................................
6-26.3 DIGITAL CURRENT CONTROL INTERFACE
................................................ 6-36.4 CNC
INTERFACE
.........................................................................................
6-46.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE
................. 6-56.6 REMOTE CONTROL CHASSIS SCHEMATIC
.............................................. 6-66.7 RECOMMENDED
ROUTINE MAINTENANCE SCHEDULE
FOR LIQUID COOLED PLASMA CUTTING SYSTEMS
.............................. 6-7
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Date: 6/22/99 (Special) i GENERAL INFORMATION
GENERAL INFORMATION
Notes, Cautions and WarningsThroughout 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.
Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE
DAN-GEROUS AND HAZARDOUS TO YOURHEALTH.
Plasma arc cutting produces intense electric andmagnetic
emissions that may interfere with theproper 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 notadequate 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
SeleniumBeryllium Lead SilverCadmium Manganese Vanadium
Always read the Material Safety Data Sheets (MSDS)that should be
supplied with the material you areusing. These MSDSs will give you
the informationregarding the kind and amount of fumes and gasesthat
may be dangerous to your health.
For information on how to test for fumes and gasesin your
workplace, refer to item 1 in Subsection,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.
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 live orhot.
Wear dry gloves and clothing. Insulate yourself fromthe work
piece or other parts of the welding cir-cuit.
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 NECcode, refer to
item 9 in Subsection, Publications.
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GENERAL INFORMATION ii Date 6/22/99 (Special)
Disconnect power source before performing any ser-vice 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 mate-rial in the
workplace. Any material that cannot beremoved must be
protected.
Ventilate all flammable or explosive vapors fromthe
workplace.
Do not cut or weld on containers that may have
heldcombustibles.
Provide a fire watch when working in an area wherefire hazards
may exist.
Hydrogen gas may be formed and trapped underaluminum workpieces
when they are cut under-water or while using a water table. DO NOT
cutaluminum 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, 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.
PublicationsRefer to the following standards or their latest
revisionsfor more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,29CFR 1910, obtainable from
the Superintendent ofDocuments, U.S. Government Printing Office,
Wash-ington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING ANDCUTTING, obtainable
from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL
33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELD-ING AND GAS WELDING AND
CUTTING, obtain-able from the Superintendent of Documents,
U.S.Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-CUPATION AND
EDUCATIONAL EYE AND FACEPROTECTION, obtainable from American
NationalStandards Institute, 1430 Broadway, New York, NY10018
5. ANSI Standard Z41.1, STANDARD FOR MENSSAFETY-TOE FOOTWEAR,
obtainable from theAmerican National Standards Institute, 1430
Broad-way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THEUSE OF CUTTING AND
WELDING PROCESSES,obtainable from American National Standards
Insti-tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTINGCONTAINERS WHICH HAVE
HELD COMBUS-TIBLES, obtainable from American Welding Society,550
N.W. LeJeune Rd, Miami, FL 33126
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Date: 6/22/99 (Special) iii GENERAL INFORMATION
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 Asso-ciation, Batterymarch Park,
Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDINGPROCESSES, obtainable
from the National Fire Pro-tection Association, Batterymarch Park,
Quincy, MA02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN
CYLINDERS, obtainable fromthe Compressed Gas Association, 1235
JeffersonDavis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY INWELDING AND CUTTING,
obtainable from the Ca-nadian Standards Association, Standards
Sales, 178Rexdale Boulevard, Rexdale, Ontario, Canada M9W1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-PHY obtainable from
the National Welding SupplyAssociation, 1900 Arch Street,
Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, REC-OMMENDED SAFE
PRACTICES FOR THE PREPA-RATION FOR WELDING AND CUTTING OF
CON-TAINERS AND PIPING THAT HAVE HELDHAZARDOUS SUBSTANCES,
obtainable from theAmerican Welding Society, 550 N.W. LeJeune
Rd,Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-TORY PROTECTION,
obtainable from AmericanNational Standards Institute, 1430
Broadway, NewYork, NY 10018
Note, Attention et AvertissementDans 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 laprocdure en question.
Precautions De Securite Importantes
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
fonctionpropre 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 respi-ration. Gardez
votre tte hors de la plume de fumeprovenant du chalumeau.
Utilisez un appareil respiratoire alimentation enair si laration
fournie ne permet pas dliminer lafume et 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 diffrents
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GENERAL INFORMATION iv Date 6/22/99 (Special)
procds. Vous devez prendre soin lorsque vouscoupez ou soudez
tout mtal pouvant contenir unou plusieurs des lments suivants:
antimoine cadmium mercureargent chrome nickelarsenic cobalt
plombbaryum cuivre slniumbryllium manganse vanadium
Lisez toujours les fiches de donnes sur la scuritdes 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 desgaz
pouvant 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 dansune zone o se
trouvent des matires ou des gazcombustibles 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.
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 ouvive; portez des gants
et des vtements secs.Isolez-vous de la pice de travail ou des
autres par-ties du circuit de 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 lapage 5, article 9.)
Dbranchez lalimentation lectrique avant tout tra-vail dentretien
ou de rparation.
Lisez et respectez toutes les consignes du Manuelde
consignes.
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-bustibles ou provoquer
lexplosion de fumesinflammables.
Soyez certain quaucune matire combustible ou in-flammable ne se
trouve sur le lieu de travail.Protgez toute telle matire quil est
impossible deretirer de la zone 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 travaildans une zone
prsentant des dangers dincendie.
Le gas hydrogne peut se former ou saccumulersous les pices de
travail en aluminium lorsquellessont coupes sous leau ou sur une
table deau. NEPAS couper les alliages en aluminium sous leau ousur
une table deau moins que le gas hydrognepeut schapper ou se
dissiper. Le gas hydrogneaccumul explosera si enflamm.
RAYONS DARC DE PLASMA
Les rayons provenant de larc de plasma peuvent blesservos yeux
et brler votre peau. Le procd larc de plasmaproduit une lumire
infra-rouge et des rayons ultra-vio-lets trs forts. Ces rayons darc
nuiront vos yeux etbrleront votre peau si vous ne vous protgez
pascorrectement.
Pour protger vos yeux, portez toujours un casqueou un cran de
soudeur. Portez toujours des lunettesde scurit munies de parois
latrales ou des lu-nettes de protection ou une autre sorte de
protec-tion oculaire.
Portez des gants de soudeur et un vtementprotecteur appropri
pour protger votre peaucontre les tincelles et les rayons de
larc.
Maintenez votre casque et vos lunettes de protec-tion en 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 fournissantdes cabines ou des crans de
protection.
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Date: 6/22/99 (Special) v GENERAL INFORMATION
Utilisez la nuance de lentille qui est suggre dansle
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance SuggereCourant 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 autrespersonnes se trouvant sur le lieu de
travail.
Il faut mesurer les niveaux sonores afin dassurerque les dcibels
(le bruit) ne dpassent pas lesniveaux srs.
Pour des renseignements sur la manire de tester lebruit,
consultez larticle 1, page 5.
Documents De ReferenceConsultez les normes suivantes ou les
rvisions les plusrcentes ayant t faites celles-ci pour de plus
amplesrenseignements :
1. OSHA, NORMES DE SCURIT DU TRAVAIL ETDE PROTECTION DE LA SANT,
29CFR 1910,disponible auprs du Superintendent of Docu-ments, U.S.
Government Printing Office, Washing-ton, 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 AUTRAVAIL ET DANS LES ECOLES, disponible delInstitut
Amricain des Normes Nationales (Ameri-can National 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 DESINCENDIES LORS DE LEMPLOI DE
PROCDSDE COUPE ET DE SOUDAGE, disponible auprsde lAmerican National
Standards Institute, 1430Broadway, New York, NY 10018
7. Norme A6.0 de lAssociation Amricaine duSoudage (AWS), LE
SOUDAGE ET LA COUPE DECONTENEURS AYANT RENFERM DESPRODUITS
COMBUSTIBLES, disponible auprs dela American Welding Society, 550
N.W. LeJeune Rd.,Miami, FL 33126
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 laNational Fire Protection Association, BatterymarchPark,
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 dela National Fire Protection
Association,Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE 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 1R3
13. ivret NWSA, BIBLIOGRAPHIE SUR LA SCURITDU SOUDAGE,
disponible auprs de lAssociationNationale de Fournitures de Soudage
(NationalWelding Supply Association), 1900 Arch
Street,Philadelphia, PA 19103
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GENERAL INFORMATION vi Date 6/22/99 (Special)
14. Norme AWSF4.1 de lAssociation Amricaine deSoudage,
RECOMMANDATIONS DE PRA-TIQUES SURES POUR LA PRPARATION LACOUPE ET
AU SOUDAGE DE CONTENEURSET TUYAUX AYANT RENFERM DESPRODUITS
DANGEREUX , disponible auprs dela American Welding Society, 550
N.W. LeJeuneRd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-TION RESPIRATOIRE,
disponible auprs delAmerican National Standards Institute,
1430Broadway, New York, NY 10018
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Date: 6/22/99 (Special) vii GENERAL INFORMATION
Declaration of ConformityManufacturer: Thermal Dynamics
CorporationAddress: Industrial Park #2
West Lebanon, New Hampshire 03784USA
The equipment described in this manual conforms to all
applicable aspects and regulations of the Low Voltage Direc-tive
(European Council Directive 73/23/EEC as amended by Council
Directive 93/68/EEC) and to the Nationallegislation 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 manufacturea unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of
standards and technical requirements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60
for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing
for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding
Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192)
(EN50078) applicable to plasma cutting equipment and associ-ated
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 ourarea of
manufacture.
Manufacturers responsible representative: Steve WardDirector of
OperationsThermadyne UKChorley England
-
GENERAL INFORMATION viii Date 6/22/99 (Special)
Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics
Corporation (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 APARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any
circumstances be liable for special or consequential damages, such
as, butnot limited to, damage or loss of purchased or replacement
goods, or claims of customers of distributor (hereinafter
Purchaser) forservice interruption. The remedies of the Purchaser
set forth herein are exclusive and the liability of Thermal with
respect to anycontract, 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 anywarranty, 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 80XL ,
Cougarand 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
80XL 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 Series & Parts PartsPAK Units, Power Supplies
CutMaster 80XL 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
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.
Transportationcharges to send products to an authorized warranty
repair facility shall be the responsibility of the customer. All
returned goods shallbe at the customers risk and expense. This
warranty supersedes all previous Thermal warranties.
Effective May 6, 1999
-
Manual 0-2529 1 - 1 INTRODUCTION & DESCRIPTION
SECTION 1: INTRODUCTION & DESCRIPTION
1.1 SYSTEM DESCRIPTION
PAK 15XC 150 Amp Power Supplywith Running Gear and Handle
PCH-150 90 or 70 Hand Torch(or) PCM-150 Machine Torch with
Mounting Assembly
25 ft (7.6 m) or 50 ft (15.2 m) Torch Leads
PCH/M-150 Spare Parts Kit
25 ft (7.6 m) Work Cable and Clamp
Running Gear and Handle
Air Line Filter Assembly (or) High Pressure Regulators
System options and accessories are listed on page 1-5.NOTE
The Merlin PAK 15XCSystem Includes:
Figure 1-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging
System
A-00875
PAK 15XC Power Supply
Work CableTorch Leads
PCM-150 Machine TorchSpare Parts Kit
Remote Control Panel
-
INTRODUCTION & DESCRIPTION 1 - 2 Manual 0-2529
1.2 POWER SUPPLY SPECIFICATIONS
Voltage Frequency Phase Amperage
380 50 or 60 Hz 3 44415 50 or 60 Hz 3 40
Table 2-A (page 2-7) contains information on power input,current
ratings, circuit protection, and wire sizes.
Continuously adjustable from 50 to 150 amps
100% duty cycle.
Approximate Shipping Weight - 678 lbs (308 kg)
Input Power
Figure 1-B Power Supply Dimensions
Output Power
Duty Cycle
Shipping Weight
Enclosure Only:
Fully Assembled:Width: 28.50 in (0.72 m)Height: 43.38 in (1.10
m)Depth: 43.75 in (1.11 m)
38.38 in(0.98 m)
34.25 in(0.87 m)24.12 in
(0.61 m)
A-00876
-
Manual 0-2529 1 - 3 INTRODUCTION & DESCRIPTION
1.3 TORCH SPECIFICATIONS
PCH-150 90 Hand Torch
PCH-150 70 Hand Torch
PCM-150 Machine Torch
Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m).Extendable
in increments of 25 ft or 50 ft up to a maximumof 150 ft (45.7 m)
with available leads extension packages(see Options and
Accessories, page 1-5)
150 Amps Maximum, Direct Current Straight PolarityHand and
Machine Torch rated at 100% Duty Cycle
Most materials up to 2.0 in (50.8 mm)
Torch Configurations
Torch Leads Lengths
Cutting Range
Current Rating
Plasma
Secon-dary
Gases
Compressed Air Oxygen (O2) Argon/Hydrogen
(Ar/H2) Nitrogen (N2)
Compressed Air Nitrogen (N2) Carbon Dioxide
(CO2)
Water
Hot Flow *
For Cutting:22-28 scfh
(10.4-13.2 lpm)For Gouging:
22-43 scfh(10.4-20.3 lpm)
For Cutting orGouging:220 scfh
(103 lpm)
8 gph(30.3 lph)
Pressure
50 psi(3.4 BAR,340 kPa)
50 psi(3.4 BAR,340 kPa)
Min.50 psi(3.4 BAR,340 kPa)
Gas Requirements
* Hot flow is measured with the main arc activated. Whenpressure
is set correctly the plasma gas flow rate issignificantly higher
until the arc is initiated.
PCH-150 90 Hand Torch (without Leads) - 1.0 lb (.45
kg)Weight
NOTE
(continued)
-
INTRODUCTION & DESCRIPTION 1 - 4 Manual 0-2529
Figure 1-C PCH/M-150 Torch Dimensions
3.81 in(97 mm)
1.62 in(41 mm)
13.31 in(338 mm)
1.38 in(35 mm)
6.75 in (171 mm) Min.16.75 in (425 mm) Max.
17.65 in (448 mm)
1.62 in(41 mm)
A-02685
PCH-150 90o Hand Torch
PCH-150 70o Hand Torch13.87 in
(352 mm)
3.96 in(101 mm)
1.62 in(41 mm)
PCM-150 Machine Torch With RackAnd Pinion Mounting Assembly
-
Manual 0-2529 1 - 5 INTRODUCTION & DESCRIPTION
1.4 OPTIONS AND ACCESSORIES
Power Supply Optionsand Accessories
Remote Control Panel - For machine torch systems, thelow profile
operator control panel allows system controlfrom a remote location
with 25 or 50 ft (7.6 or 15.2 m)cable included.
Remote Pendant Control - Hand-held remote contactorcontrol
device for machine torch systems.
Computer Control Cable Kits - For interfacing thepower supply
with a computer or auxiliary controldevice. Available in 5 or 10 ft
(1.5 or 3.0 m) lengths.
SC-5 Standoff Control - For machine torch systems, theSC-5
automatically finds height and maintains torchstandoff with a high
speed torch lifter motor.
High Pressure Regulators - Available for air,
oxygen,argon/hydrogen, nitrogen, CO2, and water.
See System Components and Accessories (page 5-2) forordering
information.
Spare Parts Kits - Kits contain replacement front-endtorch parts
and tools. Spare parts kits are available forair cutting with hand
or machine torch, multi-gascutting with hand or machine torch, or
for gouging.
Leads Extension Packages - Available in 25 ft (7.6 m) or50 ft
(15.2 m) lengths. For extending leads up to amaximum of 150 ft
(45.7 m).
Metal Shield Cup - For durability in hand cutting.
See Torch Components (page 5-14) and Torch Accessories(page
5-16) for ordering information.
NOTE
Torch Optionsand Accessories
NOTE
-
INTRODUCTION & DESCRIPTION 1 - 6 Manual 0-2529
1.5 THEORY OF OPERATION
Figure 1-D Theory of Operation
Plasma Arc Cutting andGouging
Plasma is a gas which is heated to an extremely hightemperature
and ionized so that it becomes electricallyconductive. The plasma
arc cutting process uses thisplasma to transfer an electric arc to
a workpiece. Themetal to be cut is melted by the intense heat of
the arc andthen blown away. The Thermal Arc Merlin PAK 15XC isa
high performance plasma cutting system designed to cutmost metals
up to two inches thick.
With a simple change of torch parts, the system can also beused
for plasma arc gouging. Plasma arc gouging is usedto remove
material to a controlled depth and width.
The Thermal Arc torch uses a cool plasma gas such ascompressed
air, nitrogen, argon/hydrogen, or oxygen.The plasma gas flows into
the torch through the plasmatorch lead and is channelled into Zone
A (Figure 1-D),where a pilot arc between the torch electrode and
tip heatsand ionizes the gas. The main cutting arc transfers to
theworkpiece through the column of plasma gas as it flowsout
through the torch tip orifice.
Plasma Gas Flow
A-00900
Power Supply
Workpiece
Coolant
Plasma Gas
Secondary GasZone A
Zone B
Zone D
Zone C
(-)
(+)
-
Manual 0-2529 1 - 7 INTRODUCTION & DESCRIPTION
Plasma Gas Flow(continued)
By forcing the plasma gas and arc through a consrtictedorifice,
the torch delivers a high concentration of heat to asmall area. The
stiff, constricted plasma arc is shown inZone B (Figure 1-D).
Direct current (DC) straight polarityis used for plasma cutting, as
shown in the illustration.
The torch also uses a secondary gas (or water) whichassists the
high velocity plasma gas in blowing moltenmetal from the area of
the cut to create a fast, slag-free cut.The secondary flow (Zone C,
Figure 1-D) also cools thetorch and minimizes heat input to the
workpiece. Thesecondary flows into the torch through the secondary
lead,down around the outside of the torch liner, and out be-tween
the tip and shield cup around the plasma arc.Compressed air,
supplied by either a cylinder or plant airsystem, nitrogen, CO2, or
water can be used as the secon-dary. An exception to this is oxygen
plasma operation,which requires no secondary.
The torch is liquid-cooled by an internal closed coolingsystem.
De-ionized coolant is distributed from a reservoirin the power
supply through the coolant supply lead. Atthe torch, the coolant is
circulated around the torch tip andelectrode (Zone D, Figure 1-D),
where the extra coolingeffect helps to increase parts life. The
coolant then flowsback to the power supply through the return
lead.
When the torch is started, a DC pilot arc is establishedbetween
the electrode and cutting tip after a two-secondpre-flow delay. The
pilot arc is initiated by a momentaryhigh frequency pulse. The
pilot arc creates a path for themain cutting arc to transfer to the
work. When the mainarc is established, the pilot arc shuts off. The
pilot auto-matically restarts when the main arc stops, as long as
thetorch remains activated.
The PAK 15XC accepts 380/415 VAC, 50 or 60 Hz, three-phase, line
input. The power supply converts AC inputpower to DC power for the
main cutting arc. The negativeoutput is connected to the torch
electrode through thenegative torch lead. The positive output is
connected tothe workpiece via the work cable and clamp
connection.
All machine torch systems are shielded to minimize
radiofrequency (RF) interference which results from the
highfrequency arc initiation. These shielded systems are de-signed
with features such as a wire for establishing anearth ground and
shielded torch and control leads.
Secondary Flow
Coolant Flow
Pilot Arc
Main Cutting Arc
RF Shielding
-
INTRODUCTION & DESCRIPTION 1 - 8 Manual 0-2529
The system has several built-in interlocks to provide safeand
efficient operation. When an interlock shuts down thesystem, the
torch switch (or control device) must be usedto restart the
system.
The torch has a built-in parts-in-place interlock that pre-vents
accidental torch starting when torch parts are notproperly
installed. A flow switch on the coolant returnlead detects reduced
coolant flow caused by impropertorch assembly. If not satisfied,
the switch interruptspower to the tip and electrode.
Pressure switches act as an interlock for the gas supplies.
Ifsupply pressure falls below minimum requirements thepressure
switches will open, shutting off the power to thecontactors, and
the GAS indicator will go out. Whenadequate supply pressure is
available the pressureswitches close, allowing power to be resumed
for cutting.
Thermal overload sensors are located in the transformerand main
heatsink in the power supply. If one of thesecomponents is
overheated the appropriate switch willopen up, causing the
temperature light to turn from greento red and shutting off power
to the main contactor. Whenthe overheated component cools down the
switch willclose again and allow operation of the system.
Interlocks
Parts-In-Place Interlock
Gas Pressure Interlock
Thermal Interlock
-
Manual 0-2529 2 - 1 INSTALLATION
SECTION 2: INSTALLATION
2.1 UNPACKING THE SYSTEM
Figure 2-A Unpacking the System
The power supply is skid-mounted and protected with acarton and
padding material to prevent damage duringshipment. The power
supply, work cable, torch, and torchleads are factory-assembled and
packaged together. Alsopacked with the system are:
Spare parts kit for the torch
Coolant de-ionizing cartridge
Air filter assembly (for air systems)
1. Remove all packing material.
2. Locate the packing list. Use the list to identify andaccount
for each item.
3. Inspect each item for possible shipping damage. Ifdamage is
evident, contact your distributor beforeproceeding with system
installation.
The unit is mounted on the skid with two brackets. Toremove the
unit from the skid, refer to Figure 2-A and:
4. Remove the six bolts connecting the brackets to thebase of
the unit.
5. Roll the unit off the skid backwards (rear wheels first).
A-00953Three Bolts(Each Side)
Shipping Brackets
Shipping Pallet
-
INSTALLATION 2 - 2 Manual 0-2529
Compressed air, oxygen (O2), nitrogen (N2), or argon/hydrogen
(Ar/H2).
Pressure 50 psi (3.5 BAR)
Flow 22 - 28 scfh (10.4 - 13.2 lpm) For Cutting22 - 43 scfh
(10.4 - 20.3 lpm) For Gouging
Compressed Air, nitrogen (N2), or carbon dioxide (CO2).
Pressure 50 psi (3.5 BAR)
Flow 220 scfh (103 lpm) For Cutting or Gouging
Tap Water
Pressure Min. 50 psi (3.5 BAR)
Flow 8 gph (30.3 lph) For Cutting
See Gas Selection for Plasma Cutting (page 3-8) for de-tailed
information on operation with various plasma andsecondary
options.
Maximum input gas pressure to the power supply's inter-nal
regulator must not exceed 125 psi (8.6 BAR).
2.2 LOCATION
Choosing the Location
CAUTION
Select a clean, dry location with good ventilation andadequate
working space around all components.
The power supply is air cooled and air flow through thefront,
rear, and side panels must not be obstructed. At leasttwo feet
(0.61 m) of clearance should be provided on allsides.
Operation without proper air flow will inhibit propercooling and
reduce duty cycle.
Review Operating Precautions (page iv) to be sure that
theselected location meets all safety requirements.
2.3 PLASMA AND SECONDARY CONNECTIONS
NOTE
Secondary WaterRequirements
Secondary GasRequirements
Plasma Gas Requirements
CAUTION
-
Manual 0-2529 2 - 3 INSTALLATION
Input Gas Connections(Air Operation)
Systems that are set up for operation with shop air
requireinstallation of the air line filter on the plasma input
fittingon the rear panel. These systems are shipped with
thefollowing components:
(1) Air Line Filter Assembly (For Plasma Line)(2) Hex Nipples(1)
90 Female Elbow(1) 90 Street Elbow(1) Y-Hose Assembly
Refer to Figure 2-B and:
1. Thread the first hex nipple into the 90 female elbow.
2. Thread the other end of the hex nipple into the outletof the
air filter assembly. Tighten both sides securely.
3. Thread the second hex nipple into the fitting on therear
panel marked PLASMA.
4. Thread the 90 street elbow into the inlet side of the
airfilter assembly.
Figure 2-B Air Line Filter Installation
Air Line Filter Installation
Secondary GasFitting
Y-HoseAssembly
From Supply
Female Elbow
Plasma GasFitting
Street Elbow
Air Filter Assembly(Plasma Line Only)
Hex Nipple
A-00902
Hex Nipple
-
INSTALLATION 2 - 4 Manual 0-2529
5. Connect one side of the Y-hose assembly into the otherside of
the 90 street elbow.
6. Thread the 90 female elbow onto the other end of thesecond
hex nipple. Fasten both sides securely.
7. Connect the other side of the Y-hose assembly to thefitting
on the rear panel marked SECONDARY.
8. Connect the supply line from the source to the
Y-hoseassembly. The supply hose must be 3/8 in (10 mm)min. inside
diameter to provide adequate air flow.
1. Examine the cylinder valves to be sure they are cleanand free
of oil, grease or any foriegn material. Momen-tarily open each
cylinder valve to blow out any dustwhich may be present.
2. Each cylinder must be equipped with an
adjustablehigh-pressure regulator capable of pressures up to 125psi
(8.6 BAR) maximum and flows of up to 220 scfh(103 lpm) for cutting
or 470 scfh (222 lpm) for gouging.
Maximum input pressure to the power supply's internalregulator
must not exceed 125 psi (8.6 BAR).
Refer to the regulator manufacturer's specifications
forinstallation and maintenance procedures. Refer toSystem
Components and Accessories (page 5-2) for alisting of available
high-pressure regulators.
3. Connect the plasma supply hose (black) to the plasmagas
cylinder and to the input fitting on the rear panelmarked
PLASMA.
4. Connect the secondary supply hose (yellow) to thesecondary
gas cylinder and to the input fitting on therear panel marked
SECONDARY.
A typical 50 lb. CO2 cylinder can deliver a continuous flowrate
of 35 scfh (16.5 lpm). To obtain the required flow ratefor the
torch, it may be necessary to manifold several CO2cylinders.
Continuous flow requirements will depend onthe specific application
and duty cycle.
Air Line Filter Installation(continued)
Input Gas Connections(Multi-Gas Operation)
Do not stand in front of the valve outlet when
opening.WARNING
CAUTION
NOTE
-
Manual 0-2529 2 - 5 INSTALLATION
Secondary WaterConnections
1. The water source must be capable of delivering aminimum water
pressure of 50 psi (3.5 BAR) and flowof 8 gph (30.3 lph).
2. Connect the secondary water supply hose to the rearpanel
fitting marked SEC. WATER.
The water source does not need to be deionized, but inwater
systems with extremely high mineral content awater softener is
recommended.
Figure 2-C Rear Panel Connections
NOTE
Plasma Gas
A-00874
Secondary Gas
Secondary Water
High FlowWater Shield
Remote InterfaceConnection
-
INSTALLATION 2 - 6 Manual 0-2529
The PAK 15XC power supply is designed to accept a aninput
voltage of 380/415 VAC.
The electrical power source must conform to local electriccode
and the following recommended circuit protectionand wiring
requirements (see Table 2-A, page 2-7).
1. Check the three-phase electrical power source for linevoltage
and proper circuit protection and wiring (seeTable 2-A, page
2-7).
2.4 ELECTRICAL CONNECTIONS
Electrical Requirements
Electrical Connections
Refer to Figure 2-D (page 2-7) and:
2. Remove the left side panel of the power supply (asviewed from
the front).
3. Check the bus bar configuration (factory installed) onthe
input voltage terminal board . The bus bar con-figuration must
correspond with the 380 VAC linevoltage.
4. Insert the primary power cable (customer supplied)through the
strain relief in the rear panel of the powersupply.
5. Locate the four input connectors, flat washers, conicalspring
washers, and hex locking nuts supplied withthe power supply.
6. Install the input connectors, supplied, onto each of theinput
power line leads of the power cable.
7. Connect the input power connectors to the EMI InputPower
Filter PC Board input studs with the suppliedhex locking nuts,
conical spring washers, and flatwashers as follows:
Input ground wire to G1. LI input line to X1. L2 input line to
Y1. L3 input line to Z1.
8. Tighten the nuts being careful not to over-tighten.Refer to
the following WARNING.
WARNINGDisconnect primary power at the source before connect-ing
the primary power cable to the power supply.
WARNINGDo Not over tighten the nuts securing the iput powercable
connectors as damage to the PC Board can occur.
-
Manual 0-2529 2 - 7 INSTALLATION
Figure 2-D Input Voltage Connections and Bus Bar
Configuration
Input PowerFilter PC Board
and Bracket
Primary PowerCable
Strain ReliefFitting
Input GroundConnection
A-00896
L1L2
L3
INPUTVOLTAGE
380/415VAC
BUS BARCONNECTIONS
L1-3, 1-2L2-8, 6-7
L3-13, 11-12
InputConnector
Input Power Cable(One Line)
Slotted Screw
A-00908
PC BoardPower Stud
Flat Washer
Conical SpringWasher
Hex Locking Nut
Input Voltage ConnectorInstallation Detail
Table 2-A Line Voltages, Circuit Protection and Recommended Wire
Size(Based on Table 310-16, 1987 National Electric Code).
Voltage Power Input Current Frequency Phase Recommended(Volts)
(kVA) (Amps) (Hz) Fuse Size Wire Size
380 29 44 50 3 50 amps AWG 8415 29 40 50 3 45 amps AWG 8
380/415VAC
L1
L3
L2
-
INSTALLATION 2 - 8 Manual 0-2529
2.5 WORK AND GROUND CONNECTIONS
Machine torch systems are equipped with shielded torchleads to
minimize RF interference from high frequencypilot arc initiation.
Follow these grounding procedureswhen installing machine torch
systems:
1. Connect the ground wire (from the front panel) to asolid
earth ground, which is created by driving acopper rod approximately
7 ft (2 m) into the earth.Locate the rod as close as possible to
the power supply.Cut the ground wire to the appropriate length.
2. The power supply and work table should be groundedto the same
earth ground. The control device should begrounded separately to a
similar earth ground.
3. To minimize RF interference, torch leads should be runas far
as possible from any CNC components, controllines, or primary power
lines.
4. Connect work ground cables as shown (Figure 2-E).
Figure 2-E Proper Work and Ground Cable Connections
Standoff ControlConsole
CNC Control
Power SupplyRemote Panel
Standoff ControlRemote Panel
EarthGround
PowerSupply
WorkCable
Workpiece
Work Ground
EarthGround
Green Cable(Work Ground)
3-PhaseInput
A-00880
-
Manual 0-2529 2 - 9 INSTALLATION
Figure 2-F Coolant Reservior and De-ionizing Cartridge
Refer to Figure 2-F and:
1. Locate the coolant de-ionizing cartridge and removefrom the
plastic shipping bag.
2. Remove the plastic cover from the coolant
reservoirfiller.
3. Place the de-ionizing cartridge into the basket in thecoolant
reservoir.
4. Fill the reservoir to the line marked FULL on the
rearpanel.
Use only Thermal Arc torch coolant. Use of any othercoolant can
result in torch damage, insufficient thermalprotection, and/or
pilot arc interference.
The deionizer cartridge should be checked periodically.The
contents of the cartridge take on a light straw-coloredappearance
when spent. Replace the cartridge when thematerial has completely
changed color.
Coolant Installation
2.6 COOLANT INSTALLATION
CAUTION
Coolant ReservoirFiller Cap
DeionizerBag
Basket
Coolant Level IndicatorA-00872
-
INSTALLATION 2 - 10 Manual 0-2529
Remote Operator ControlPanel Installation
The Remote Operator Control Panel consists of the controlpanel
enclosure and cables required for connection.
1. Connect the control cable to the receptacle markedREMOTE
(J15) on the rear panel.
2. Connect the other end of the control cable to thereceptacle
marked PS (J37) on the remote operatorcontrol panel enclosure.
1. Connect the interface cable to the receptacle markedCNC (J29)
on the remote operator control panel.
2. Connect the other end to the customer-supplied mo-tion
control device (refer to the CNC Interface Sche-matic on page
6-4).
The SC-5 Standoff Control consists of a control panel,
anelectronic unit, a voltage divider board, a torch liftermotor,
and cables required for installation (see Figure 2-G,page 2-11). It
is ordered and shipped separately and mustbe installed according to
the SC-5 Standoff Control Instruc-tion Manual, which is included
with the SC-5 unit.
Refer to the High-Flow Water Shield Instruction Manualand:
1. Connect the high-flow starter control cable to thereceptacle
marked HI-FLOW WATER SHIELD on thepower supply rear panel. The
receptacle is 115VAC toactivate the high-flow water shield.
2. To shut off the high-flow water shield remove thecontrol
cable or disconnect power to the high-flowwater shield unit.
2.7 AUXILIARY CONNECTIONS
Computer Control InterfaceInstallation
SC-5 Standoff ControlInstallation
High-Flow Water ShieldInstallation
-
Manual 0-2529 2 - 11 INSTALLATION
Figure 2-G Typical Mechanized System Installation and Cable
Interconnection Diagram
NOTE - See Catalog Pages for ordering information.
Cable Description Letter Designation
SC-5 Remote to Console A
SC-5 Torch Lifter (Positioner) to Console B
SC-5 Console to Power Supply Remote C/F
SC-5 Console to Power Supply D
SC-5 Console to Work (Ground) E
SC-5 CONTROL CONSOLE
TORCHPOSITIONER
(LIFTER)
CNCCONTROL
POWER SUPPLY REMOTE CONTROL
SC-5 REMOTECONTROL
WORK GROUND
D
AC
F
E
BPOWERSUPPLY
A-00879
-
INSTALLATION 2 - 12 Manual 0-2529
2.8 LIFTING THE POWER SUPPLY
Figure 2-H Lifting the Power Supply
WARNING Do not lift the power supply by the handles.
CAUTION Do not lift a power supply equipped with a cylinder
rackrunning gear.
The recommended method for lifting the power supply isto use a
forklift (see Figure 2-H). Approach from the frontor rear of the
unit. Place the forks between the rear wheelsor the front casters.
Center the forks under the unit andcarefully check for proper
balance before lifting.
Approach From Front Or Rear
Do Not Lift From Sides
A-00873
-
Manual 0-2529 3 - 1 OPERATION
SECTION 3: OPERATION
3.1 OPERATING CONTROLS
Function
ON position activates all system control circuits.OFF position
deactivates control circuits.
RUN position is used for torch operation.SET position is used
for setting gas pressures.PURGE position is for purging the plasma
gas line.
Selects output current from 50 to 150 amps (see CuttingSpeeds
(page 3-26) for applications on various materialsand thicknesses).
Current control is disabled when RemoteOperator Control Panel is
used.
Green light indicates AC power is being supplied to thesystem
when the ON/OFF switch is in ON position.
Green light indicates proper operating temperature. Redlight
indicates overheating. Unit must be allowed to cool.
In SET position, yellow light in SET mode indicates gaspressure
switches are satisfied when gas is flowing to thetorch. Light goes
out in PURGE or RUN mode.
Yellow light indicates adequate coolant pressure.
Yellow light indicates proper coolant conductivity. Lightout
indicates excessive coolant conductivity (resistivity lessthan 0.1
M). Replace coolant and de-ionizer cartridge.Yellow light indicates
main contactor closure supplyingvoltage to the power supply output
and cutting current isavailable. Torch switch must be closed.
Yellow light indicates pilot arc contactor closure. Lightgoes
out when cutting arc is established and comes backon if cutting arc
is interrupted.
Control Indicator
1. ON/OFF Switch
2. RUN/SET/PURGESwitch
3. Current Control
4. AC Power Indicator
5. TEMP Indicator
6. GAS Indicator
7. Coolant Pressure Indicator
8. Coolant ConductivityIndicator
9. DC Indicator
10. PILOT Indicator
Figure 3-A PAK 15XC Operating Control Panel
OFF
ON RUN
PURGE
SET
A-00887
AMPS50
75
150
125
100
AC TEMP GAS PRES.
COOLANT
COND. DC PILOT
1 2
3
4 5 67 8
9 10
-
OPERATION 3 - 2 Manual 0-2529
Function
Adjusts secondary gas pressure. Pull knob out and turnclockwise
to increase secondary pressure to desired level.
Displays secondary pressure from 0 - 100 psi (0 - 6.9 BAR).
Selects secondary mode to gas, oxygen (no secondary), orwater.
See Gas Selection (page 3-8) for applications onvarious materials
and thicknesses.
Displays coolant pressure from 0 - 160 psi (0 - 11.0 BAR).
Displays plasma gas pressure from 0 - 100 psi (0 - 6.9BAR).
Adjusts plasma gas pressure. Pull knob out and turnclockwise to
increase plasma pressure to desired level.
Figure 3-B PAK 15XC Upper Gauge Panel
Control Indicator
1. Secondary PressureControl
2. Secondary Pressure Gauge
3. Secondary Mode Selector
4. Coolant Pressure Gauge
5. Plasma Pressure Gauge
6. Plasma PressureControl
-
Manual 0-2529 3 - 3 OPERATION
Function
Immediately de-activates pump, motor, and all controlcircuits
(logic circuit and control panel LED display remainon).
None functional.
Activates gas flow, pilot arc, and main cutting arc.
Green light indicates remote control logic has received
startsignal from control device (CNC or START switch).
Deactivates gas flow, pilot arc, and main cutting arc.
Sets output current level from 50 to 150 amps.
Displays actual output during cutting operation. Previewmode
displays expected output before starting a cut ac-cording to the
current setting. A decimal point to the rightof the display is lit
whenever the meter is in preview mode.All three decimal points
remain lit when displaying cornerslowdown output or operating in
corner slowdown mode.Left and center decimal points blinking
indicates PIP(parts-in-place) circuit not satisfied.
Sets corner slowdown (CSD) output from 50 to 150 amps.Push STOP
button to display corner slowdown outputsetting on AMP meter. Refer
to Machine Torch Operation(page 3-20) for operating
instructions.
Provides an adjustable time delay (approximately 0-11seconds)
which delays the CNC and 'OK-to-Move' signal,allowing time to
pierce before the starting the cuttingmachine. Set PIERCE DELAY to
zero for immediate 'OK-to-Move' signal.
None functional.
Control Indicator
1. E-STOP (Emergency Stop)
2. RUN/PURGE Switch
3. START Switch
4. Start Enable Indicator
5. STOP Switch
6. CURRENT ControlAdjustment
7. AMPS Meter
8. CSD (Corner Slowdown)Control Adjustment
9. PIERCE DELAY ControlAdjustment
10. LOW/HIGH SPEEDSwitch
Figure 3-C PAK 15XC Remote Operator Control Panel (RC6045)
PURGE
RUNE-STOP
START STOP
AAMPS
CURRENT
A
PIERCEDELAY
LOW HIGH
SPEED 0123
4 5 6 789
1011
CSD
1 2 3 5 7 6 8 9
104A-00575
-
OPERATION 3 - 4 Manual 0-2529
3.2 PRE-OPERATION SET-UP
The pre-operation set-up procedure should be followed atthe
beginning of each shift:
1. Check the coolant level indicator and add coolant ifnecessary
(see Coolant Installation, page 2-9).
2. Check the torch for proper assembly (see Torch Main-tenance,
page 4-1). Install proper torch parts for theapplication (see Torch
Parts Selection, page 3-5).
3. Select the desired pre-flow, post-flow, and
auto-restartsettings (see Machine Torch Operation, page 3-13).
Thesystem is factory-set for normal auto-restart, whichallows the
pilot arc to restart instantly when the cuttingarc is interrupted
with the torch still activated. Thesystem is factory-set for
two-second pre-flow and ten-second post-flow.
4. Check the power source for proper 380/415 VACthree-phase
input voltage. Make sure the input poweris properly connected to
the EMI input filter PC board(see Electrical Connections, page
2-6). Connect primarypower to the system (close main disconnect
switch orplug unit in).
5. Select desired plasma and secondary (see Gas Selec-tion, page
3-8). Make sure gas sources meet require-ments (see Plasma and
Secondary Connections, page 2-2). Check connections and turn plasma
and secondarysupplies on.
6. Move the ON/OFF switch to ON position. An auto-matic forty
second gas purge will let gas run to removeany condensation that
may have accumulated in thetorch and leads while the system was
shut down. Afterthe purge is complete, if the RUN/SET/PURGE
switchis in SET position, gases will flow. If the switch is inPURGE
position plasma gas only will flow. If theswitch is in RUN position
there will be no gas flow.
7. Select the desired current output level. Refer to
CuttingSpeeds (page 3-26).
8. Move the RUN/SET/PURGE switch to SET position.Set plasma and
secondary pressures (see Plasma andSecondary Connections, page
2-2).
WARNING Disconnect primary power to the system
beforedisassembling the torch, leads, or power supply.
Coolant Check
Torch Check
Optional Auto-RestartSettings
Input Power Check
Plasma and SecondarySupply Check
Line Purge
Output Selection
Plasma and SecondaryPressure Settings
-
Manual 0-2529 3 - 5 OPERATION
3.3 TORCH PARTS SELECTION
WARNING Disconnect primary power to the system
beforedisassembling the torch, leads, or power supply.
Shield Cup Selection Shield Cups (See Figure 3-D) Cat. No.
Ceramic Shield Cup (For Cutting) ........................
9-5750
Metal Shield Cup (For Cutting) .............................
9-5790
Touch Cup (For Height Sensing with SC-5) ........ 9-5758
Gouging Cup
............................................................
9-5774
Figure 3-D Shield Cup Selection
Additional Line Purge 9. If additional purging of the plasma gas
line is desired,move the RUN/SET/PURGE switch to PURGE posi-tion.
In PURGE mode, with secondary mode selectorset to GAS, the GAS
indicator will not come on becauseonly plasma gas runs and the
secondary gas flowswitch is not satisfied.
10. Return the RUN/SET/PURGE switch to RUN.
The system is now ready for operation.
Metal Shield Cup(For Cutting)
Cat. No. 9-5790
Touch Cup(For Height Sensing
with SC-5)Cat. No. 9-5758
Ceramic Shield Cup(For Cutting)
Cat. No. 9-5750
Gouging CupCat. No. 9-5774
-
OPERATION 3 - 6 Manual 0-2529
WARNING Disconnect primary power to the system
beforedisassembling the torch, leads, or power supply.
CAUTION Do not interchange parts. Make sure both the tip
andelectrode in the torch correspond with the plasma gas
andsecondary being used.
Cutting tips and electrodes can be identified by the
ring(s)around the diameter (see Figure 3-E, page 3-7). Air tipsand
electrodes have no rings, oxygen tips and electrodeshave one ring,
nitrogen tips and multi-gas (N2 or Ar/H2)electrodes have two rings,
and argon/hydrogen tipshave three rings.
Cutting Tips - Air Plasma Cat. No.
50 Amps (.043 in)
..................................................... 9-5748
100 Amps (.055 in)
................................................... 9-5747
150 Amps (.070 in)
................................................... 9-5746
Cutting Tips - O2 Plasma
50 Amps (.043 in)
..................................................... 9-5753
100 Amps (.057 in)
................................................... 9-5752
150 Amps (.070 in)
................................................... 9-5751
Cutting Tips - N2 Plasma
50 Amps (.043 in)
..................................................... 9-5765
100 Amps (.052 in)
................................................... 9-5766
150 Amps (.067 in)
................................................... 9-5767
Cutting Tips - ArH2 Plasma
150 Amps (.073 in)
................................................... 9-5775
Gouging Tips - Air or Multi-Gas
85 Amps (.078 in)
..................................................... 9-5756
150 Amps (.120 in)
................................................... 9-5755
Electrodes Cat. No.
Air Plasma - Cutting
............................................... 9-5749
Oxygen Plasma - Cutting .......................................
9-5760
Multi-Gas (N2 or Ar/H2)- Cutting ........................
9-5754
Tip Selection
Electrode Selection
-
Manual 0-2529 3 - 7 OPERATION
Cutting Gouging
Air Plasma Oxygen Plasma Nitrogen Plasma Argon/Hydrogen Air or
Multi-Gas
O2 Plasma50 Amp (.043) Tip
Cat. No. 9-5753
O2 Plasma100 Amp (.057) Tip
Cat. No. 9-5752
O2 Plasma150 Amp (.070) Tip
Cat. No. 9-5751
Air Plasma50 Amp (.043) Tip
Cat. No. 9-5748
Air Plasma100 Amp (.055) Tip
Cat. No. 9-5747
Air Plasma150 Amp (.070) Tip
Cat. No. 9-5746
N2 Plasma50 Amp (.043) Tip
Cat. No. 9-5765
N2 Plasma100 Amp (.052) Tip
Cat. No. 9-5766
N2 Plasma150 Amp (.067) Tip
Cat. No. 9-5767
ArH2 Plasma150 Amp (.073) Tip
Cat. No. 9-5775
Gouging TipAir or Multi-Gas
85 Amp (.078)Cat. No. 9-5756
Gouging TipAir or Multi-Gas150 Amp (.120)Cat. No. 9-5755
Air Plasma ElectrodeCutting or Gouging
Cat. No. 9-5749
O2 Plasma ElectrodeCutting or Gouging
Cat. No. 9-5760
N2 or Ar/H2 Plasma ElectrodeCutting or Gouging
Cat. No. 9-5754
For gouging, selectproper electrode tocorrespond to thetype of
plasma gas
being used (same ascutting).
Figure 3-E Tip and Electrode Selection
-
OPERATION 3 - 8 Manual 0-2529
3.4 GAS SELECTION FOR PLASMA CUTTING
Air plasma is normally used with air secondary.
Only clean, dry air is recommended for use as plasmagas. Any oil
or moisture in the air supply can substan-tially reduce torch parts
life.
Most often used on ferrous or carbon base materials toobtain
good cutting quality at faster cutting speeds.
Provides satisfactory results on non-ferrous materials.
Can be used in place of air plasma with air secondary orCO2.
Provides much better parts life than air.
Provides better cut quality on non-ferrous materials suchas
stainless steel and aluminum.
A good clean welding grade nitrogen should be used.
AIR PLASMA
NITROGEN PLASMA
ARGON/HYDROGENPLASMA
A 65% argon/35% hydrogen mixture should be used.
Recommended for use on thicker (1/2 inch and up) non-ferrous
materials. Ar/H2 is not normally used for thin-ner non-ferrous
materials because less expensive gasescan achieve similar cut
quality.
Provides faster cutting speeds and high cut quality onthicker
materials to offset a higher cost.
Poor cut quality on ferrous materials.
OXYGENPLASMA
Oxygen is recommended for cutting ferrous materials.
Provides faster cutting speeds.
Provides very smooth finishes and minimizes nitridebuild-up on
cut surface (nitride build-up can causedifficulties in producing
high quality welds if not re-moved).
Table 3-A Plasma Gas Selection for Plasma Cutting
-
Manual 0-2529 3 - 9 OPERATION
Air secondary is normally used when operating with airplasma and
occasionally with nitrogen plasma.
Inexpensive - reduces operating costs.
Improves cut quality on some ferrous materials.
AIR SECONDARY
CO2 secondary is used with nitrogen or Ar/H2 plasma.
Provides good cut quality on ferrous or
non-ferrousmaterials.
May reduce smoke when used with Ar/H2 plasma.
CO2 SECONDARY
Nitrogen secondary is used with Ar/H2 plasma.
Provides smooth finishes on non-ferrous materials.
May be used with nitrogen plasma in order to operatefrom one
compressed gas cylinder.
May reduce smoke when used with Ar/H2 plasma.
NITROGEN SECONDARY
Water secondary should be used only in mechanizedapplications -
never in hand cutting!
Normally used with nitrogen, Ar/H2, or air plasma.
Provides very smooth cut surface.
Reduces smoke and heat input to the workpiece.
Effective up to 1 inch maximum material thickness.
Tap water provides low operating expense.
WATER SECONDARY
Table 3-B Secondary Selection for Plasma Cutting
-
OPERATION 3 - 10 Manual 0-2529
Cut Quality Cut quality requirements differ depending on
application.For instance, nitride build-up and bevel angle may
bemajor factors when the surface that is cut will be weldedafter
the cutting operation. Dross-free cutting is importantwhen finish
cut quality is desired to avoid a secondarycleaning operation.
The desired or specified condition (smooth or rough) ofthe face
of the cut.
Nitride deposits can be left on the surface of the cutwhen
nitrogen is present in the plasma gas stream. Thepresence of
nitrogen may create porosity if the materialis to be welded after
the cutting process.
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 bevel angle.
The amount of rounding on the top edge of the cut.
Molten material which is not blown away from the cutarea and
re-solidify on the base of the plate. Excessivedross build-up may
require a secondary clean-up opera-tion after the cutting
process.
The width of the cut (or the width of material removedduring the
cut).
Table 3-C (page 3-11) contains cut quality information foreach
plasma and secondary combination on a variety ofmaterials and
thicknesses.
Cut Surface
Nitride Deposits
Bevel Angle
Top-Edge Rounding
Dross Build-up
Kerf Width
Figure 3-F Cut Characteristics
Kerf WidthCut SurfaceBevel Angle
Top EdgeRounding
Cut SurfaceDrag Lines
DrossBuild-Up
TopSpatter
A-00007
-
Manual 0-2529 3 - 11 OPERATION
Cut Characteristics:
Minimum bevel (0 - 4), minimum kerf (2 x tip orifice),little or
no dross, smooth cut surface.
Slight bevel (0 - 10), slightly wider kerf (2-1/2 x tip
ori-fice), some dross (easily removed), medium-smooth cutsurface,
slight top edge rounding.
Excessive bevel (over 10), wide kerf (over 2-1/2 x tiporifice),
medium to heavy dross, rough cut surface, topedge rounding.
Not Recommended.
Cut quality depends heavily on set-up and parameterssuch as
torch standoff, alignment with the workpiece,cutting speed, gas
pressures, and operator experience.
Description
Excellent
Good
Fair
NR
NOTE
GAS
Air PlasmaAir Secondary
Nitrogen PlasmaAir Secondary
or CO2 Secondary
Nitrogen PlasmaWater Secondary
Ar/H2 PlasmaN2 or CO2Secondary
Oxygen Plasma
Stainless Steel
Good/ExcellentGoodGood
Good/ExcellentGood/ExcellentGood/Excellent
GoodExcellent
NR
NRGood
Excellent
Good
TYPE OF MATERIAL
Carbon Steel
Good/ExcellentExcellentExcellent
Good/ExcellentGood/ExcellentGood/Excellent
ExcellentGoodNR
NRNRNR
Excellent
Aluminum
Good/ExcellentGoodGood
Good/ExcellentGood/ExcellentGood/Excellent
GoodGood/Excellent
NR
NRExcellentExcellent
NR
Table 3-C Cut Quality: Plasma and Secondary Gas Selectionfor
Various Materials and Material Thicknesses
MATERIALTHICKNESS
GageGage to 1 in.
1 to 2 in.
GageGage to 1/2 in.
1/2 to 2 in.
Gage to 1/4 in.1/4 to 1 in.
1 to 2 in.
Gage to 1/4 in.1/4 to 1-1/4 in.
1/2 to 2 in.
Gage to 2 in.
-
OPERATION 3 - 12 Manual 0-2529
3.5 PLASMA CUTTING OPERATION
Be sure the operator is equipped with proper gloves,clothing,
eye and ear protection and that all precautions atthe front of this
manual have been followed. Make sure nopart of the operators body
comes in contact with theworkpiece when the torch switch is
pressed.
WARNING
CAUTION The sparks from the cutting process can cause damage
tocoated, painted or other surfaces such as glass, plastic,
andmetal.
Do not interchange parts. Make sure both the tip andelectrode in
the torch correspond with the plasma gas andsecondary being used.
(See Torch Parts Selection on pages3-6 and 3-7).
CAUTION
WARNINGDisconnect primary power to the system
beforedisassembling the torch, leads, or power supply.
The suggestions below should be followed in all cuttingand
gouging operations:
1. Wait five minutes before setting the ON/OFF switch toOFF
after operation. This allows the cooling fan to runto dissipate
operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc
anylonger than necessary.
3. Use care in handling torch leads and protect them
fromdamage.
4. In continuous cutting applications using CO2, it is
oftennecessary to manifold four to six cylinders together
tomaintain adequate flow at operating pressures.
FREQUENTLY REVIEW THE SAFETY PRECAUTIONSAT THE FRONT OF THIS
MANUAL.
It is not enough to simply move the ON/OFF switch onthe unit to
OFF position when cutting operations havebeen completed. Always
open the power supply discon-nect switch five minutes after the
last cut is made.
NOTE
WARNING
-
Manual 0-2529 3 - 13 OPERATION
The auto-restart function provides an immediate pilot arcrestart
during post-flow if the torch is brought withinrange of the
workpiece. The power supply can be set up toprovide a variety of
optional auto-restart settings.
Auto-Restart On/Off - The auto-restart function can beswitched
off completely so that the torch must be re-activated (via torch
switch or control device) to restartthe pilot arc when the main arc
is interrupted.
Auto-Restart Normal/Delayed - Normal mode pro-vides an immediate
pilot arc restart when the main arcis interrupted. Delayed mode
provides a gas pre-floweach time before the pilot arc restarts.
Pre-Flow Delay - Pre-flow is the time interval fromwhen the
torch is activated (start of gas flow) to pilotarc initiation.
Pre-flow duration is factory-set to twoseconds, but can be re-set
to four, seven, or ten secondsas desired.
Post-Flow Delay - Gases continue to flow for a periodof time
after the main cutting arc is interrupted and thetorch remains
activated. Post-flow is factory-set to tenseconds, but can be
re-set to five, twenty, or fortyseconds as desired.
In machine torch operation, optional auto-restart settingsmay be
useful where:
1. The system is used for direct replacement of units nothaving
auto-restart for use with motion control de-vices.
2. Torch parts life may improve without auto-restart insome
applications by reducing excessive pilot arc time.
3. In some shape-cutting applications, immediatelyrestarting the
main arc after the torch passes beyondthe desired cutting line (or
between cuts) may not bedesirable.
4. Extended leads may require longer pre-flow duration.
5. Other special applications require various arrange-ments.
Pre-Flow Delay
Post-Flow Delay
Normal/Delayed
On/Off
Auto-Restart Options
Applications
(continued)
-
OPERATION 3 - 14 Manual 0-2529
Four two-pole DIP switches located on the control logic PCboard
control the auto-restart functions.
Auto-Restart(continued)
Auto-Restart SW1-1 SW1-2Mode Position Position
Normal 0 (Off) 0 (Off)
Disabled 0 (Off) 1 (On)1 (On) 0 (Off)1 (On) 1 (On)
On/Off (SW1)
Note: Either pole set to 1(on)disables auto-restart function
Auto-Restart SW2-1 SW2-2Mode Position Position
Normal 0 (Off) 0 (Off)
Delayed 0 (Off) 1 (On)1 (On) 0 (Off)1 (On) 1 (On)
Pre-Flow Time SW3-1 SW3-2(Seconds) Position Position
2 0 (Off) 0 (Off)4 0 (Off) 1 (On)7 1 (On) 0 (Off)
10 1 (On) 1 (On)
Post-Flow Time SW4-1 SW4-2(Seconds) Position Position
2.5 0 (Off) 1 (On)5 0 (Off) 0 (Off)
10 1 (On) 0 (Off)20 1 (On) 1 (Off)
Post-Flow Time SW4-1 SW4-2(Seconds) Position Position
5 0 (Off) 1 (On)10 0 (Off) 0 (Off)20 1 (On) 0 (Off)40 1 (On) 1
(Off)
Normal/Delayed (SW2)
Note: Either pole set to 1(on)sets auto-restart function
Pre-Flow Delay (SW3)
Post-Flow Delay (SW4)
For Hand CuttingSystems (A1845-01)
with 19x704 Logic PCB
Post-Flow Delay (SW4)
For Machine CuttingSystems (A1845-15)
with 19x910 Logic PCB
-
Manual 0-2529 3 - 15 OPERATION
Figure 3-G Control Logic PC Board - Setting Auto-Restart
Options
-
OPERATION 3 - 16 Manual 0-2529
3.6 HAND TORCH OPERATION
Figure 3-H Cutting with a Hand Torch
Be sure the operator is equipped with proper gloves,clothing,
eye and ear protection and that all precautions atthe front of this
manual have been followed. Make sure nopart of the operators body
comes in contact with theworkpiece when the torch switch is
pressed.
WARNING
CAUTION
Plasma Cutting Operation(Hand Torch)
The sparks from the cutting process can cause damage tocoated,
painted or other surfaces such as glass, plastic, andmetal.
Do not interchange parts. Make sure both the tip andelectrode in
the torch correspond with the plasma gas andsecondary being used.
(See Torch Parts Selection on pages3-6 and 3-7).
WARNINGDisconnect primary power to the system
beforedisassembling the torch, leads, or power supply.
Cutting with a Hand Torch 1. The hand torch should be held in
both hands for mak-ing long cuts. Choose the method that feels the
mostcomfortable and works the best. Use the thumb toactuate the
control switch on the torch handle.
-
Manual 0-2529 3 - 17 OPERATION
Hand Torch Operation(continued)
2. To positively locate the line of the cut, position the
torchover the workpiece, resting the front edge of the shieldcup on
the edge where the cut is to start.
3. Lower the welding helmet. Press and hold the torchcontrol
switch. After a two second gas purge, the pilotarc will start. The
pilot arc will stay on as long as thetorch control switch is
held.
4. With the pilot arc on the main cutting arc is establishedas
soon as the torch is brought within 1/8 - 3/8 in(3 - 10 mm) of the
workpiece. If the cutting arc is inter-rupted and the switch is
still pressed, as when cuttingexpanded metal, the pilot arc will
automatically restart.
Releasing the torch control switch will shut off either thepilot
or main arc (depending on the mode of operation).
5. Cut with the torch held 1/8 - 3/8 in (3 - 10 mm) fromthe
work. The torch should be held perpendicular to theworkpiece while
cutting.
Use a standard ceramic or metal shield cup for handcutting. The
touch cup (short shield cup) and gouging cupare NOT intended for
hand cutting. Do not allow anexposed torch tip to contact the
workpiece.
NOTE
CAUTION
-
OPERATION 3 - 18 Manual 0-2529
3.7 MACHINE TORCH OPERATION
Cutting with aMachine Torch
1. A machine torch should be aligned perpendicular tothe surface
of the workpiece to obtain a clean, verticalcut. Use a square to
align the torch (see Figure 3-I).
2. Position the center of the torch over the edge of
theworkpiece where the cut is to start. The transferredcutting arc
will then be established at the plate edgewhen the torch is
activated.
3. The machine torch can be activated by the remoteoperator
control panel, remote control pendant, or byremote interface device
such as CNC. After a twosecond gas purge, the pilot arc will start.
The pilot arcwill stay on as long as the torch is activated.
4. With the pilot arc on the main cutting arc is establishedas
soon as the torch is brought within 1/8 - 3/8 in (3 -10 mm) of the
workpiece. If the cutting arc is inter-rupted and the torch is
still activated, as when cuttingexpanded metal, the pilot arc will
automatically restart(see Auto-Restart Options, page 3-13).
De-activatingthe torch will shut off either the pilot or main
arc(depending on the mode of operation).
Figure 3-I Machine Torch Set-up
-
Manual 0-2529 3 - 19 OPERATION
Cutting with aMachine Torch
(continued)
5. Cut with a standoff of 1/8 - 3/8 in (3 - 10 mm) from thework.
The torch should be held perpendicular to theworkpiece while
cutting. Start cutting slowly andadjust cutting speed for optimum
cutting performance.Cutting Speeds (page 3-26) contains typical
cuttingspeeds for various materials and material thicknesses.
A standard shield cup is recommended for most machinecutting
applications. The touch cup (short shield cup) isdesigned for light
gage cutting where arc voltage measure-ment is needed for a
standoff control. Do not allow anexposed torch tip to contact the
workpiece.
The arc characteristics vary with gases used, cutting
speed,material, and thickness. Air plasma normally produces
astraight arc (on stainless or aluminum), while nitrogenplasma
generally creates a 5 trailing arc (see Figure 3-J).
Figure 3-J Machine Torch Operation
-
OPERATION 3 - 20 Manual 0-2529
The corner slowdown feature provides an output currentreduction
in to correspond with the reduction in torchtravel speed as a
mechanized torch moves through acorner. When activated by CNC or
other control device,the corner slowdown eliminates excessive metal
removalin corners.
Normally open (NO) contacts (supplied by the controldevice)
close when the torch travel speed decreasesthrough a corner. When
the contacts close, power supplyoutput drops to a pre-set current
level.
A two-pole DIP switch in the remote operator controlpanel PC
board allows the corner slowdown to operatewith normally closed
(NC) contacts in the control device ifdesired.
Corner slowdown adjustment is located on the remoteoperator
control panel (see Operating Controls, page 3-3).
The control is factory set fully counter-clockwise forminimum 50
amps output during corner slowdown. Turnthe control clockwise to
increase corner slowdown output.When the control is turned fully
clockwise, corner slow-down output is increased to a maximum 150
amps.
To view the corner slowdown setting, press and hold thestop
control. The expected CSD output level will be dis-played on the
ammeter.
In the PAK 15XC, the corner slowdown setting is inde-pendent
(not a percentage) of the main current setting. Forexample, if CSD
current is set to 100 amps, and maincutting current is set to the
minimum 50 amps, the actualcurrent level would actually increase
through the CSDcycle.
For electrical connections, refer to the CNC InterfaceSchematic
(page 6-4.)
Corner Slowdown (CSD)
NOTE
Corner Slowdown Settings
NOTE
-
Manual 0-2529 3 - 21 OPERATION
Figure 3-K Piercing with a Hand Torch
3.8 PIERCING
In some cutting operations, it may be desirable to start thecut
within the plate area rather than at the plate edge.Piercing the
plate is not recommended on plates having athickness greater than
3/4 in (19 mm). Blowback from thepiercing operation can shorten the
life of torch parts. Allpiercing should therefore be done as
quickly as possibleand at maximum amperage (150 amps) and
maximumstandoff.
When piercing with a hand torch, tip the torch slightly sothat
blowback particles blow away from the torch tip (andoperator)
rather than directly back into it (see Figure 3-K).
Pierce off the cutting line and then continue the cut asshown in
Figure 3-K. Clean spatter and scale from theshield cup and the tip
as soon as possible. Spraying ordipping the shield cup in
anti-spatter compound willminimize the amount of scale which
adheres to it.
A method called running start is recommended whenpiercing with a
machine mounted torch. The torch shouldbe positioned far enough off
the cutting line to allow thepierce to be complete before the
cutting line is reached.This allowance depends on the thickness of
the materialand the torch travel speed.
Piercing with a Hand Torch