Merlin Pak 15XC European Instruction Manual

MERLIN PAK 15XC
Plasma Cutting System (European)

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
Instruction Manual
October 6, 1999 Manual No. 0-2529
WARNING
Read and understand this entire Instruction Manual and your employers safety practices before installing, operating, or servicing the equipment.
WARNING
While the information contained in this Instruction Manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use. Merlin Pak 15XC European/EMC Plasma Cutting System Instruction Manual Number 0-2529 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 Copyright 1996 by Thermal 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 the Merlin Pak 15XC European/EMC Plasma Cutting System Instruction Manual, whether such error results from negligence, accident, or any other cause. Printed in the United States of America October 6, 1999
TABLE OF CONTENTS
GENERAL INFORMATION ............................................................................................................. i Notes, Cautions and Warnings .................................................................................. i Important Safety Precautions .................................................................................... i Publications .............................................................................................................. ii Note, Attention et Avertissement ............................................................................. iii Precautions De Securite Importantes ...................................................................... iii Documents De Reference ....................................................................................... v Declaration of Conformity ....................................................................................... vii Statement of Warranty ........................................................................................... viii SECTION 1: INTRODUCTION & DESCRIPTION ..................................................................... 1-1 1.1 1.2 1.3 1.4 1.5 SYSTEM DESCRIPTION .............................................................................. 1-1 POWER SUPPLY SPECIFICATIONS ............................................................ 1-2 TORCH SPECIFICATIONS ........................................................................... 1-3 OPTIONS AND ACCESSORIES ................................................................... 1-5 THEORY OF OPERATION ............................................................................ 1-6
SECTION 2: INSTALLATION .................................................................................................... 2-1 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 UNPACKING THE SYSTEM .......................................................................... 2-1 LOCATION .................................................................................................... 2-2 PLASMA AND SECONDARY CONNECTIONS ............................................. 2-2 ELECTRICAL CONNECTIONS ..................................................................... 2-6 WORK AND GROUND CONNECTIONS ....................................................... 2-8 COOLANT INSTALLATION ........................................................................... 2-9 AUXILIARY CONNECTIONS ...................................................................... 2-10 LIFTING THE POWER SUPPLY .................................................................. 2-12
SECTION 3: OPERATION ........................................................................................................ 3-1 3.1 OPERATING CONTROLS ............................................................................. 3-1 3.2 PRE-OPERATION SET-UP ........................................................................... 3-4 3.3 TORCH PARTS SELECTION ........................................................................ 3-5 3.4 GAS SELECTION FOR PLASMA CUTTING ................................................. 3-8 3.5 PLASMA CUTTING OPERATION ............................................................... 3-12 3.6 HAND TORCH OPERATION ....................................................................... 3-16 3.7 MACHINE TORCH OPERATION ................................................................. 3-18 3.8 PIERCING ................................................................................................... 3-21 3.9 GOUGING OPERATION ............................................................................. 3-22 3.10 COMMON OPERATING ERRORS ............................................................ 3-25 3.11 CUTTING SPEEDS ................................................................................... 3-26 3.12 SEQUENCE OF OPERATION ................................................................... 3-33
TABLE OF CONTENTS (continued)

SECTION 4: SERVICE ............................................................................................................. 4-1 4.1 TORCH MAINTENANCE ............................................................................... 4-1 4.2 HAND TORCH HEAD REPLACEMENT ........................................................ 4-2 4.3 MACHINE TORCH HEAD REPLACEMENT .................................................. 4-4 4.4 HAND TORCH SWITCH REPLACEMENT .................................................... 4-6 4.5 HAND TORCH LEADS REPLACEMENT ...................................................... 4-7 4.6 MACHINE TORCH LEADS REPLACEMENT ................................................ 4-9 4.7 LEADS EXTENSION KITS - HAND TORCH ............................................... 4-11 4.8 LEADS EXTENSION KITS - MACHINE TORCH ......................................... 4-13 4.9 POWER SUPPLY MAINTENANCE ............................................................. 4-16 4.10 TROUBLESHOOTING THEORY ............................................................... 4-17 4.11 TROUBLESHOOTING GUIDE ................................................................... 4-21 4.12 SERVICE AND TEST PROCEDURES ...................................................... 4-27 SECTION 5: PARTS LISTS ....................................................................................................... 5-1 5.1 ABOUT THE PARTS LIST ............................................................................. 5-1 5.2 SYSTEM COMPONENTS AND ACCESSORIES .......................................... 5-2 5.3 ACCESS PANEL COMPONENTS ................................................................. 5-4 5.4 FRONT PANEL/CHASSIS COMPONENTS ................................................... 5-5 5.5 REAR PANEL COMPONENTS ..................................................................... 5-6 5.6 BASE COMPONENTS .................................................................................. 5-8 5.7 UPPER CHASSIS COMPONENTS ............................................................. 5-10 5.8 MAIN HEATSINK COMPONENTS .............................................................. 5-12 5.9 TORCH COMPONENTS ............................................................................. 5-14 5.10 TORCH ACCESSORIES ........................................................................... 5-16 SECTION 6: ADDITIONAL INFORMATION .............................................................................. 6-1 6.1 LADDER DIAGRAM - 120 VAC ...................................................................... 6-1 6.2 LADDER DIAGRAM - 15 VDC ........................................................................ 6-2 6.3 DIGITAL CURRENT CONTROL INTERFACE ................................................ 6-3 6.4 CNC INTERFACE ......................................................................................... 6-4 6.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE ................. 6-5 6.6 REMOTE CONTROL CHASSIS SCHEMATIC .............................................. 6-6 6.7 RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .............................. 6-7
GENERAL INFORMATION
Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: Antimony Arsenic Barium Beryllium Cadmium Chromium Cobalt Copper Lead Manganese Mercury Nickel Selenium Silver Vanadium
WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection, Publications, in this manual. Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
Important Safety Precautions

WARNINGS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any questions.
Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. Never touch any parts that are electrically live or hot. Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. Repair or replace all worn or damaged parts. Extra care must be taken when the workplace is moist or damp. Install and maintain equipment according to NEC code, refer to item 9 in Subsection, Publications.
GASES AND FUMES
Date: 6/22/99 (Special)
GENERAL INFORMATION
Disconnect power source before performing any service or repairs. Read and follow all the instructions in the Operating Manual. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc. Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. Ventilate all flammable or explosive vapors from the workplace. Do not cut or weld on containers that may have held combustibles. Provide a fire watch when working in an area where fire hazards may exist. Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion. NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace. Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels. For information on how to test for noise, see item 1 in Subsection, Publications, in this manual. PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected. To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.
Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Arc Current Less Than 300* 300 - 400* 400 - 800* Minimum Protective Shade No. 8 9 10 Suggested Shade No. 9 12 14
* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.
Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MENS SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION
ii
Date 6/22/99 (Special)
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
AVERTISSEMENT Toute procdure pouvant provoquer des blessures de loprateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procdure en question.
Precautions De Securite Importantes

AVERTISSEMENTS LOPRATION ET LA MAINTENANCE DU MATRIEL DE SOUDAGE LARC AU JET DE PLASMA PEUVENT PRSENTER DES RISQUES ET DES DANGERS DE SANT. Coupant larc au jet de plasma produit de lnergie lectrique haute tension et des missions magntique qui peuvent interfrer la fonction propre dun pacemaker cardiaque, les appareils auditif, ou autre matriel de sant electronique. Ceux qui travail prs dune application larc au jet de plasma devrait consulter leur membre professionel de mdication et le manufacturier de matriel de sant pour dterminer sil existe des risques de sant. Il faut communiquer aux oprateurs et au personnel TOUS les dangers possibles. Afin dviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les prcautions de scurit et toutes les consignes avant dutiliser le matriel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.
Note, Attention et Avertissement

Dans ce manuel, les mots note, attention, et avertissement sont utiliss pour mettre en relief des informations caractre important. Ces mises en relief sont classifies comme suit : NOTE Toute opration, procdure ou renseignement gnral sur lequel il importe dinsister davantage ou qui contribue lefficacit de fonctionnement du systme. ATTENTION Toute procdure pouvant rsulter lendommagement du matriel en cas de nonrespect de la procdure en question.
FUME et GAZ La fume et les gaz produits par le procd de jet de plasma peuvent prsenter des risques et des dangers de sant. Eloignez toute fume et gaz de votre zone de respiration. Gardez votre tte hors de la plume de fume provenant du chalumeau. Utilisez un appareil respiratoire alimentation en air si laration fournie ne permet pas dliminer la fume et les gaz. Les sortes de gaz et de fume provenant de larc de plasma dpendent du genre de mtal utilis, des revtements se trouvant sur le mtal et des diffrents
iii
GENERAL INFORMATION
procds. Vous devez prendre soin lorsque vous coupez ou soudez tout mtal pouvant contenir un ou plusieurs des lments suivants: antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre slnium bryllium manganse vanadium Lisez toujours les fiches de donnes sur la scurit des matires (sigle amricain MSDS); celles-ci devraient tre fournies avec le matriel que vous utilisez. Les MSDS contiennent des renseignements quant la quantit et la nature de la fume et des gaz pouvant poser des dangers de sant. Pour des informations sur la manire de tester la fume et les gaz de votre lieu de travail, consultez larticle 1 et les documents cits la page 5. Utilisez un quipement spcial tel que des tables de coupe dbit deau ou courant descendant pour capter la fume et les gaz. Nutilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des matires ou des gaz combustibles ou explosifs. Le phosgne, un gaz toxique, est gnr par la fume provenant des solvants et des produits de nettoyage chlors. Eliminez toute source de telle fume. CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou mme tuer. Le procd au jet de plasma requiert et produit de lnergie lectrique haute tension. Cette nergie lectrique peut produire des chocs graves, voire mortels, pour loprateur et 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-vous de la pice de travail ou des autres parties du circuit de soudage. Rparez ou remplacez toute pice use ou endommage. Prenez des soins particuliers lorsque la zone de travail est humide ou moite. Montez et maintenez le matriel conformment au Code lectrique national des Etats-Unis. (Voir la page 5, article 9.) Dbranchez lalimentation lectrique avant tout travail dentretien ou de rparation. Lisez et respectez toutes les consignes du Manuel de consignes.
INCENDIE ET EXPLOSION Les incendies et les explosions peuvent rsulter des scories chaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, des scories chaudes pouvant mettre le feu aux matires combustibles ou provoquer lexplosion de fumes inflammables. Soyez certain quaucune matire combustible ou inflammable ne se trouve sur le lieu de travail. Protgez toute telle matire quil est impossible de retirer de la zone de travail. Procurez une bonne aration de toutes les fumes inflammables ou explosives. Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matires combustibles. Prvoyez une veille dincendie lors de tout travail dans une zone prsentant des dangers dincendie. Le gas hydrogne peut se former ou saccumuler sous les pices de travail en aluminium lorsquelles sont coupes sous leau ou sur une table deau. NE PAS couper les alliages en aluminium sous leau ou sur une table deau moins que le gas hydrogne peut schapper ou se dissiper. Le gas hydrogne accumul explosera si enflamm. RAYONS DARC DE PLASMA Les rayons provenant de larc de plasma peuvent blesser vos yeux et brler votre peau. Le procd larc de plasma produit une lumire infra-rouge et des rayons ultra-violets trs forts. Ces rayons darc nuiront vos yeux et brleront votre peau si vous ne vous protgez pas correctement. Pour protger vos yeux, portez toujours un casque ou un cran de soudeur. Portez toujours des lunettes de scurit munies de parois latrales ou des lunettes de protection ou une autre sorte de protection oculaire. Portez des gants de soudeur et un vtement protecteur appropri pour protger votre peau contre les tincelles et les rayons de larc. Maintenez votre casque et vos lunettes de protection en bon tat. Remplacez toute lentille sale ou comportant fissure ou rognure. Protgez les autres personnes se trouvant sur la zone de travail contre les rayons de larc en fournissant des cabines ou des crans de protection.
GENERAL INFORMATION
iv
Utilisez la nuance de lentille qui est suggre dans le recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc Moins de 300* 300 - 400* 400 - 800* Nuance Minimum Protective Numro 8 9 10 Nuance Suggere Numro 9 12 14
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de lInstitut Amricain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018 5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018 Norme ANSI Z49.2, PRVENTION DES INCENDIES LORS DE LEMPLOI DE PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018
* Ces valeurs sappliquent ou larc actuel est observ clairement. Lexperience a dmontrer que les filtres moins foncs peuvent tre utiliss quand larc est cach par moiceau de travail.
6.
BRUIT Le bruit peut provoquer une perte permanente de loue. Les procds de soudage larc de plasma peuvent provoquer des niveaux sonores suprieurs aux limites normalement acceptables. Vous d4ez vous protger les oreilles contre les bruits forts afin dviter une perte permanente de loue. Pour protger votre oue contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. 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 niveaux srs. Pour des renseignements sur la manire de tester le bruit, consultez larticle 1, page 5.
7. Norme A6.0 de lAssociation Amricaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES, disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 8. Norme 51 de lAssociation Amricaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCDS ASSOCIS, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMS EN CYLINDRES, disponible auprs de lAssociation des Gaz Comprims (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. Norme CSA W117.2, CODE DE SCURIT POUR LE SOUDAGE ET LA COUPE, disponible auprs de lAssociation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3 13. ivret NWSA, BIBLIOGRAPHIE SUR LA SCURIT DU SOUDAGE, disponible auprs de lAssociation Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103
Documents De Reference
Consultez les normes suivantes ou les rvisions les plus rcentes ayant t faites celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DE PROTECTION 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 DES OPRATIONS DE COUPE ET DE SOUDAGE, disponible auprs de la Socit Amricaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126 3. NIOSH, LA SCURIT ET LA SANT LORS DES OPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
GENERAL INFORMATION
14. Norme AWSF4.1 de lAssociation Amricaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRPARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX , disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018
GENERAL INFORMATION
vi
Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2 West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive. The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements among them are: * CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment. * UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used. * 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 associated accessories. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Director of Operations Thermadyne UK Chorley England
vii
GENERAL INFORMATION
Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been 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 sole option, of any components or parts of the product determined by Thermal to be defective. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT. THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougar and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below). The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below). The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below). Parts PAK Units, Power Supplies Main Power Magnetics Original Main Power Rectifier Control PC Board All Other Circuits And Components Including, But Not Limited To, Starting Circuit, Contactors, Relays, Solenoids, Pumps, Power Switching Semi-Conductors Consoles, Control Equipment, Heat Exchanges, And Accessory Equipment Torch And Leads Maximizer 300 Torch All Other Torches Repair/Replacement Parts 180 Days 90 Days 180 Days 90 Days 1 Year 180 Days 90 Days 1 Year 180 Days None XL Plus Series & CutMaster 80XL 3 Years 3 Years 3 Years 1 Year Parts Cougar/Drag-Gun 1 Year 1 Year 1 Year 1 Year Parts All Others 2 Years 2 Years 2 Years 1 Year Labor 1 Year 1 Year 1 Year 1 Year
1 Year
1 Year
1 Year
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customers risk and expense. This warranty supersedes all previous Thermal warranties. Effective May 6, 1999
GENERAL INFORMATION
viii
SECTION 1: INTRODUCTION & DESCRIPTION

1.1 SYSTEM DESCRIPTION
PAK 15XC Power Supply
Work Cable
Torch Leads Remote Control Panel
PCM-150 Machine Torch Spare Parts Kit
A-00875
Figure 1-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging System The Merlin PAK 15XC System Includes: PAK 15XC 150 Amp Power Supply with 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 NOTE
Manual 0-2529
System options and accessories are listed on page 1-5.

1-1 INTRODUCTION & DESCRIPTION
1.2 POWER SUPPLY SPECIFICATIONS
Input Power
Voltage 380 415
Frequency 50 or 60 Hz 50 or 60 Hz
Phase 3 3
Amperage 44 40
Table 2-A (page 2-7) contains information on power input, current ratings, circuit protection, and wire sizes. Output Power Duty Cycle Shipping Weight
Enclosure Only:
Continuously adjustable from 50 to 150 amps 100% duty cycle. Approximate Shipping Weight - 678 lbs (308 kg)
A-00876
38.38 in (0.98 m)
24.12 in (0.61 m)
34.25 in (0.87 m)
Fully Assembled: Width: 28.50 in (0.72 m) Height: 43.38 in (1.10 m) Depth: 43.75 in (1.11 m)
Figure 1-B Power Supply Dimensions

INTRODUCTION & DESCRIPTION 1-2 Manual 0-2529
1.3 TORCH SPECIFICATIONS
Torch Configurations
PCH-150 90 Hand Torch PCH-150 70 Hand Torch PCM-150 Machine Torch
Torch Leads Lengths
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 maximum of 150 ft (45.7 m) with available leads extension packages (see Options and Accessories, page 1-5) 150 Amps Maximum, Direct Current Straight Polarity Hand and Machine Torch rated at 100% Duty Cycle Most materials up to 2.0 in (50.8 mm) Gases Compressed Air Plasma Oxygen (O2) Argon/Hydrogen (Ar/H2) Nitrogen (N2) Compressed Air Nitrogen (N2) Carbon Dioxide Secon- (CO2) dary Water Pressure 50 psi (3.4 BAR, 340 kPa) Hot Flow * For Cutting: 22-28 scfh (10.4-13.2 lpm) For Gouging: 22-43 scfh (10.4-20.3 lpm) For Cutting or Gouging: 220 scfh (103 lpm) 8 gph (30.3 lph)
Current Rating Cutting Range Gas Requirements
50 psi (3.4 BAR, 340 kPa) Min.50 psi (3.4 BAR, 340 kPa)
NOTE
* Hot flow is measured with the main arc activated. When pressure is set correctly the plasma gas flow rate is significantly higher until the arc is initiated. PCH-150 90 Hand Torch (without Leads) - 1.0 lb (.45 kg) (continued)
Weight
Manual 0-2529
1-3
INTRODUCTION & DESCRIPTION
PCH-150 90o Hand Torch 13.31 in (338 mm)
3.81 in (97 mm) 1.62 in (41 mm) PCH-150 70o Hand Torch 13.87 in (352 mm) 3.96 in (101 mm) 1.62 in (41 mm) PCM-150 Machine Torch With Rack And Pinion Mounting Assembly 6.75 in (171 mm) Min. 16.75 in (425 mm) Max. 1.38 in (35 mm) 1.62 in (41 mm)
17.65 in (448 mm)
A-02685
Figure 1-C PCH/M-150 Torch Dimensions
1-4
Manual 0-2529
1.4 OPTIONS AND ACCESSORIES
Power Supply Options and Accessories
Remote Control Panel - For machine torch systems, the low profile operator control panel allows system control from a remote location with 25 or 50 ft (7.6 or 15.2 m) cable included. Remote Pendant Control - Hand-held remote contactor control device for machine torch systems. Computer Control Cable Kits - For interfacing the power supply with a computer or auxiliary control device. Available in 5 or 10 ft (1.5 or 3.0 m) lengths. SC-5 Standoff Control - For machine torch systems, the SC-5 automatically finds height and maintains torch standoff with a high speed torch lifter motor. High Pressure Regulators - Available for air, oxygen, argon/hydrogen, nitrogen, CO2, and water.
NOTE Torch Options and Accessories
See System Components and Accessories (page 5-2) for ordering information. Spare Parts Kits - Kits contain replacement front-end torch parts and tools. Spare parts kits are available for air cutting with hand or machine torch, multi-gas cutting with hand or machine torch, or for gouging. Leads Extension Packages - Available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. For extending leads up to a maximum of 150 ft (45.7 m). Metal Shield Cup - For durability in hand cutting.
NOTE
See Torch Components (page 5-14) and Torch Accessories (page 5-16) for ordering information.
Manual 0-2529
1-5
1.5 THEORY OF OPERATION
Plasma Arc Cutting and Gouging
Plasma is a gas which is heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma to transfer an electric arc to a workpiece. The metal to be cut is melted by the intense heat of the arc and then blown away. The Thermal Arc Merlin PAK 15XC is a high performance plasma cutting system designed to cut most metals up to two inches thick. With a simple change of torch parts, the system can also be used for plasma arc gouging. Plasma arc gouging is used to remove material to a controlled depth and width.
Plasma Gas Flow
The Thermal Arc torch uses a cool plasma gas such as compressed air, nitrogen, argon/hydrogen, or oxygen. The plasma gas flows into the torch through the plasma torch lead and is channelled into Zone A (Figure 1-D), where a pilot arc between the torch electrode and tip heats and ionizes the gas. The main cutting arc transfers to the workpiece through the column of plasma gas as it flows out through the torch tip orifice.
(-)
Power Supply
(+)
Figure 1-D Theory of Operation

INTRODUCTION & DESCRIPTION 1-6
, , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,, ,
Zone D Zone C Zone A Zone B Workpiece
A-00900
Coolant
Plasma Gas
Secondary Gas
Manual 0-2529
Plasma Gas Flow (continued)
By forcing the plasma gas and arc through a consrticted orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone B (Figure 1-D). Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration. The torch also uses a secondary gas (or water) which assists the high velocity plasma gas in blowing molten metal from the area of the cut to create a fast, slag-free cut. The secondary flow (Zone C, Figure 1-D) also cools the torch and minimizes heat input to the workpiece. The secondary flows into the torch through the secondary lead, down around the outside of the torch liner, and out between the tip and shield cup around the plasma arc. Compressed air, supplied by either a cylinder or plant air system, nitrogen, CO2, or water can be used as the secondary. An exception to this is oxygen plasma operation, which requires no secondary. The torch is liquid-cooled by an internal closed cooling system. De-ionized coolant is distributed from a reservoir in the power supply through the coolant supply lead. At the torch, the coolant is circulated around the torch tip and electrode (Zone D, Figure 1-D), where the extra cooling effect helps to increase parts life. The coolant then flows back to the power supply through the return lead. When the torch is started, a DC pilot arc is established between the electrode and cutting tip after a two-second pre-flow delay. The pilot arc is initiated by a momentary high frequency pulse. The pilot arc creates a path for the main cutting arc to transfer to the work. When the main arc is established, the pilot arc shuts off. The pilot automatically restarts when the main arc stops, as long as the torch remains activated. The PAK 15XC accepts 380/415 VAC, 50 or 60 Hz, threephase, line input. The power supply converts AC input power to DC power for the main cutting arc. The negative output is connected to the torch electrode through the negative torch lead. The positive output is connected to the workpiece via the work cable and clamp connection. All machine torch systems are shielded to minimize radio frequency (RF) interference which results from the high frequency arc initiation. These shielded systems are designed with features such as a wire for establishing an earth ground and shielded torch and control leads.
Secondary Flow
Coolant Flow
Pilot Arc
Main Cutting Arc
RF Shielding
Manual 0-2529
1-7
Interlocks
The system has several built-in interlocks to provide safe and efficient operation. When an interlock shuts down the system, the torch switch (or control device) must be used to restart the system. The torch has a built-in parts-in-place interlock that prevents accidental torch starting when torch parts are not properly installed. A flow switch on the coolant return lead detects reduced coolant flow caused by improper torch assembly. If not satisfied, the switch interrupts power to the tip and electrode. Pressure switches act as an interlock for the gas supplies. If supply pressure falls below minimum requirements the pressure switches will open, shutting off the power to the contactors, and the GAS indicator will go out. When adequate supply pressure is available the pressure switches close, allowing power to be resumed for cutting. Thermal overload sensors are located in the transformer and main heatsink in the power supply. If one of these components is overheated the appropriate switch will open up, causing the temperature light to turn from green to red and shutting off power to the main contactor. When the overheated component cools down the switch will close again and allow operation of the system.
Parts-In-Place Interlock
Gas Pressure Interlock
Thermal Interlock
1-8
Manual 0-2529
SECTION 2: INSTALLATION
2.1 UNPACKING THE SYSTEM
The power supply is skid-mounted and protected with a carton and padding material to prevent damage during shipment. The power supply, work cable, torch, and torch leads are factory-assembled and packaged together. Also packed 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 and account for each item. 3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor before proceeding with system installation. The unit is mounted on the skid with two brackets. To remove the unit from the skid, refer to Figure 2-A and: 4. Remove the six bolts connecting the brackets to the base of the unit. 5. Roll the unit off the skid backwards (rear wheels first).
Shipping Brackets
A-00953
Shipping Pallet
Three Bolts (Each Side)
Figure 2-A Unpacking the System

Manual 0-2529 2-1 INSTALLATION
2.2 LOCATION
Choosing the Location
Select a clean, dry location with good ventilation and adequate working space around all components. The power supply is air cooled and air flow through the front, rear, and side panels must not be obstructed. At least two feet (0.61 m) of clearance should be provided on all sides.
CAUTION
Operation without proper air flow will inhibit proper cooling and reduce duty cycle. Review Operating Precautions (page iv) to be sure that the selected location meets all safety requirements.
2.3 PLASMA AND SECONDARY CONNECTIONS
Plasma Gas Requirements
Compressed air, oxygen (O2), nitrogen (N2), or argon/ hydrogen (Ar/H2). Pressure Flow 50 psi (3.5 BAR) 22 - 28 scfh (10.4 - 13.2 lpm) For Cutting 22 - 43 scfh (10.4 - 20.3 lpm) For Gouging
Secondary Gas Requirements
Compressed Air, nitrogen (N2), or carbon dioxide (CO2). Pressure Flow 50 psi (3.5 BAR) 220 scfh (103 lpm) For Cutting or Gouging
Secondary Water Requirements
Tap Water Pressure Flow Min. 50 psi (3.5 BAR) 8 gph (30.3 lph) For Cutting
NOTE
See Gas Selection for Plasma Cutting (page 3-8) for detailed information on operation with various plasma and secondary options. Maximum input gas pressure to the power supply's internal regulator must not exceed 125 psi (8.6 BAR).
CAUTION
INSTALLATION
2-2
Manual 0-2529
Input Gas Connections (Air Operation)
Systems that are set up for operation with shop air require installation of the air line filter on the plasma input fitting on the rear panel. These systems are shipped with the following components: (1) (2) (1) (1) (1) Air Line Filter Assembly (For Plasma Line) Hex Nipples 90 Female Elbow 90 Street Elbow Y-Hose Assembly
Air Line Filter Installation
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 outlet of the air filter assembly. Tighten both sides securely. 3. Thread the second hex nipple into the fitting on the rear panel marked PLASMA. 4. Thread the 90 street elbow into the inlet side of the air filter assembly.
Plasma Gas Fitting
Secondary Gas Fitting
Y-Hose Assembly Hex Nipple Female Elbow Hex Nipple
Street Elbow From Supply

A-00902
Air Filter Assembly (Plasma Line Only)
Figure 2-B Air Line Filter Installation
Manual 0-2529
2-3
INSTALLATION
Air Line Filter Installation (continued)
5. Connect one side of the Y-hose assembly into the other side of the 90 street elbow. 6. Thread the 90 female elbow onto the other end of the second hex nipple. Fasten both sides securely. 7. Connect the other side of the Y-hose assembly to the fitting on the rear panel marked SECONDARY. 8. Connect the supply line from the source to the Y-hose assembly. The supply hose must be 3/8 in (10 mm) min. inside diameter to provide adequate air flow.
Input Gas Connections (Multi-Gas Operation)
1. Examine the cylinder valves to be sure they are clean and free of oil, grease or any foriegn material. Momentarily open each cylinder valve to blow out any dust which may be present.
WARNING
Do not stand in front of the valve outlet when opening.
2. Each cylinder must be equipped with an adjustable high-pressure regulator capable of pressures up to 125 psi (8.6 BAR) maximum and flows of up to 220 scfh (103 lpm) for cutting or 470 scfh (222 lpm) for gouging. CAUTION Maximum input pressure to the power supply's internal regulator must not exceed 125 psi (8.6 BAR). Refer to the regulator manufacturer's specifications for installation and maintenance procedures. Refer to System Components and Accessories (page 5-2) for a listing of available high-pressure regulators. 3. Connect the plasma supply hose (black) to the plasma gas cylinder and to the input fitting on the rear panel marked PLASMA. 4. Connect the secondary supply hose (yellow) to the secondary gas cylinder and to the input fitting on the rear panel marked SECONDARY. NOTE A typical 50 lb. CO2 cylinder can deliver a continuous flow rate of 35 scfh (16.5 lpm). To obtain the required flow rate for the torch, it may be necessary to manifold several CO2 cylinders. Continuous flow requirements will depend on the specific application and duty cycle.
INSTALLATION
2-4
Manual 0-2529
Secondary Water Connections
1. The water source must be capable of delivering a minimum water pressure of 50 psi (3.5 BAR) and flow of 8 gph (30.3 lph). 2. Connect the secondary water supply hose to the rear panel fitting marked SEC. WATER.
NOTE
The water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.
Secondary Water Secondary Gas High Flow Water Shield
Remote Interface Connection Plasma Gas
A-00874
Figure 2-C Rear Panel Connections
Manual 0-2529
2-5
INSTALLATION
2.4 ELECTRICAL CONNECTIONS

Electrical Requirements The PAK 15XC power supply is designed to accept a an input voltage of 380/415 VAC. The electrical power source must conform to local electric code and the following recommended circuit protection and wiring requirements (see Table 2-A, page 2-7). Electrical Connections 1. Check the three-phase electrical power source for line voltage and proper circuit protection and wiring (see Table 2-A, page 2-7). Disconnect primary power at the source before connecting the primary power cable to the power supply. Refer to Figure 2-D (page 2-7) and: 2. Remove the left side panel of the power supply (as viewed from the front). 3. Check the bus bar configuration (factory installed) on the input voltage terminal board . The bus bar configuration must correspond with the 380 VAC line voltage. 4. Insert the primary power cable (customer supplied) through the strain relief in the rear panel of the power supply. 5. Locate the four input connectors, flat washers, conical spring washers, and hex locking nuts supplied with the power supply. 6. Install the input connectors, supplied, onto each of the input power line leads of the power cable. 7. Connect the input power connectors to the EMI Input Power Filter PC Board input studs with the supplied hex locking nuts, conical spring washers, and flat washers as follows: Input ground wire to G1. LI input line to X1. L2 input line to Y1. L3 input line to Z1.
WARNING
8. Tighten the nuts being careful not to over-tighten. Refer to the following WARNING. WARNING Do Not over tighten the nuts securing the iput power cable connectors as damage to the PC Board can occur.
INSTALLATION
2-6
Manual 0-2529
Voltage (Volts) 380 415
Power Input (kVA) 29 29
Current (Amps) 44 40
Frequency (Hz) 50 50
Phase 3 3
Recommended Fuse Size Wire Size 50 amps 45 amps AWG 8 AWG 8
Table 2-A Line Voltages, Circuit Protection and Recommended Wire Size (Based on Table 310-16, 1987 National Electric Code).
PC Board Power Stud Flat Washer Conical Spring Washer Hex Locking Nut Slotted Screw
L3 INPUT VOLTAGE 380/415 VAC BUS BAR CONNECTIONS L1-3, 1-2 L2-8, 6-7 L3-13, 11-12
Input Connector
380/ 415VAC
Input Power Cable (One Line) A-00908 Input Voltage Connector Installation Detail
Input Power Filter PC Board and Bracket
L2
L1
Input Ground Connection
Primary Power Cable
L3 L1 Strain Relief Fitting L2
A-00896
Figure 2-D Input Voltage Connections and Bus Bar Configuration
Manual 0-2529
2-7
INSTALLATION
2.5 WORK AND GROUND CONNECTIONS
Machine torch systems are equipped with shielded torch leads to minimize RF interference from high frequency pilot arc initiation. Follow these grounding procedures when installing machine torch systems: 1. Connect the ground wire (from the front panel) to a solid earth ground, which is created by driving a copper 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 grounded to the same earth ground. The control device should be grounded separately to a similar earth ground. 3. To minimize RF interference, torch leads should be run as far as possible from any CNC components, control lines, or primary power lines. 4. Connect work ground cables as shown (Figure 2-E).
Earth Ground
Power Supply Remote Panel CNC Control
Standoff Control Console
Standoff Control Remote Panel
3-Phase Input
Power Supply
Green Cable (Work Ground) Earth Ground Work Cable Workpiece
Work Ground
A-00880
Figure 2-E Proper Work and Ground Cable Connections

INSTALLATION 2-8 Manual 0-2529
2.6 COOLANT INSTALLATION
Coolant Installation
Refer to Figure 2-F and: 1. Locate the coolant de-ionizing cartridge and remove from the plastic shipping bag. 2. Remove the plastic cover from the coolant reservoir filler. 3. Place the de-ionizing cartridge into the basket in the coolant reservoir. 4. Fill the reservoir to the line marked FULL on the rear panel.
CAUTION
Use only Thermal Arc torch coolant. Use of any other coolant can result in torch damage, insufficient thermal protection, and/or pilot arc interference. The deionizer cartridge should be checked periodically. The contents of the cartridge take on a light straw-colored appearance when spent. Replace the cartridge when the material has completely changed color.
Coolant Reservoir Filler Cap
Deionizer Bag
Basket
Coolant Level Indicator

A-00872
Figure 2-F Coolant Reservior and De-ionizing Cartridge
Manual 0-2529
2-9
INSTALLATION
2.7 AUXILIARY CONNECTIONS
Remote Operator Control Panel Installation
The Remote Operator Control Panel consists of the control panel enclosure and cables required for connection. 1. Connect the control cable to the receptacle marked REMOTE (J15) on the rear panel. 2. Connect the other end of the control cable to the receptacle marked PS (J37) on the remote operator control panel enclosure.
Computer Control Interface Installation
1. Connect the interface cable to the receptacle marked CNC (J29) on the remote operator control panel. 2. Connect the other end to the customer-supplied motion control device (refer to the CNC Interface Schematic on page 6-4).
SC-5 Standoff Control Installation
The SC-5 Standoff Control consists of a control panel, an electronic unit, a voltage divider board, a torch lifter motor, and cables required for installation (see Figure 2-G, page 2-11). It is ordered and shipped separately and must be installed according to the SC-5 Standoff Control Instruction Manual, which is included with the SC-5 unit. Refer to the High-Flow Water Shield Instruction Manual and: 1. Connect the high-flow starter control cable to the receptacle marked HI-FLOW WATER SHIELD on the power supply rear panel. The receptacle is 115VAC to activate the high-flow water shield. 2. To shut off the high-flow water shield remove the control cable or disconnect power to the high-flow water shield unit.
High-Flow Water Shield Installation
INSTALLATION
2 - 10
Manual 0-2529
POWER SUPPLY
SC-5 CONTROL CONSOLE

SC-5 REMOTE CONTROL
A C F
TORCH POSITIONER (LIFTER)
CNC CONTROL
POWER SUPPLY REMOTE CONTROL
WORK GROUND
A-00879
Cable Description SC-5 Remote to Console SC-5 Torch Lifter (Positioner) to Console SC-5 Console to Power Supply Remote SC-5 Console to Power Supply SC-5 Console to Work (Ground)
Letter Designation A B C/F D E
NOTE - See Catalog Pages for ordering information. Figure 2-G Typical Mechanized System Installation and Cable Interconnection Diagram
Manual 0-2529
2 - 11
INSTALLATION
2.8 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 rack running gear. The recommended method for lifting the power supply is to use a forklift (see Figure 2-H). Approach from the front or rear of the unit. Place the forks between the rear wheels or the front casters. Center the forks under the unit and carefully check for proper balance before lifting.
Approach From Front Or Rear
Do Not Lift From Sides
A-00873
Figure 2-H Lifting the Power Supply
INSTALLATION
2 - 12
Manual 0-2529
SECTION 3: OPERATION
1 2 3.1 OPERATING CONTROLS
ON RUN
10
100 75 SET 50 150 AMPS OFF PURGE 125 AC TEMP GAS
COOLANT
PRES. COND.
DC
PILOT
A-00887
Figure 3-A PAK 15XC Operating Control Panel Control Indicator 1. ON/OFF Switch 2. RUN/SET/PURGE Switch 3. Current Control 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 Cutting Speeds (page 3-26) for applications on various materials and thicknesses). Current control is disabled when Remote Operator Control Panel is used. Green light indicates AC power is being supplied to the system when the ON/OFF switch is in ON position. Green light indicates proper operating temperature. Red light indicates overheating. Unit must be allowed to cool. In SET position, yellow light in SET mode indicates gas pressure switches are satisfied when gas is flowing to the torch. Light goes out in PURGE or RUN mode. Yellow light indicates adequate coolant pressure. Yellow light indicates proper coolant conductivity. Light out indicates excessive coolant conductivity (resistivity less than 0.1 M). Replace coolant and de-ionizer cartridge. Yellow light indicates main contactor closure supplying voltage to the power supply output and cutting current is available. Torch switch must be closed. Yellow light indicates pilot arc contactor closure. Light goes out when cutting arc is established and comes back on if cutting arc is interrupted.
3-1 OPERATION
4. AC Power Indicator 5. TEMP Indicator 6. GAS Indicator
7. Coolant Pressure Indicator 8. Coolant Conductivity Indicator 9. DC Indicator
10. PILOT Indicator
Manual 0-2529
Figure 3-B PAK 15XC Upper Gauge Panel Control Indicator 1. Secondary Pressure Control 2. Secondary Pressure Gauge 3. Secondary Mode Selector Function Adjusts secondary gas pressure. Pull knob out and turn clockwise 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), or water. See Gas Selection (page 3-8) for applications on various materials and thicknesses. Displays coolant pressure from 0 - 160 psi (0 - 11.0 BAR). Displays plasma gas pressure from 0 - 100 psi (0 - 6.9 BAR). Adjusts plasma gas pressure. Pull knob out and turn clockwise to increase plasma pressure to desired level.
4. Coolant Pressure Gauge 5. Plasma Pressure Gauge 6. Plasma Pressure Control
OPERATION
3-2
Manual 0-2529
1
E-STOP RUN
2
START
7
CURRENT
6
CSD
8
PIERCE DELAY
4 3 2 1 0 5 6 7 8 9 10 11
STOP
PURGE
AMPS A
SPEED
LOW
HIGH
A-00575
10
Figure 3-C PAK 15XC Remote Operator Control Panel (RC6045) Control Indicator 1. E-STOP (Emergency Stop) Function Immediately de-activates pump, motor, and all control circuits (logic circuit and control panel LED display remain on). None functional. Activates gas flow, pilot arc, and main cutting arc. Green light indicates remote control logic has received start signal 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. Preview mode displays expected output before starting a cut according to the current setting. A decimal point to the right of the display is lit whenever the meter is in preview mode. All three decimal points remain lit when displaying corner slowdown 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 output setting on AMP meter. Refer to Machine Torch Operation (page 3-20) for operating instructions. Provides an adjustable time delay (approximately 0-11 seconds) which delays the CNC and 'OK-to-Move' signal, allowing time to pierce before the starting the cutting machine. Set PIERCE DELAY to zero for immediate 'OKto-Move' signal. None functional.
2. RUN/PURGE Switch 3. START Switch 4. Start Enable Indicator 5. STOP Switch 6. CURRENT Control Adjustment 7. AMPS Meter
8. CSD (Corner Slowdown) Control Adjustment
9. PIERCE DELAY Control Adjustment
10. LOW/HIGH SPEED Switch
Manual 0-2529
3-3
OPERATION
3.2 PRE-OPERATION SET-UP
The pre-operation set-up procedure should be followed at the beginning of each shift: Disconnect primary power to the system before disassembling the torch, leads, or power supply. 1. Check the coolant level indicator and add coolant if necessary (see Coolant Installation, page 2-9). 2. Check the torch for proper assembly (see Torch Maintenance, page 4-1). Install proper torch parts for the application (see Torch Parts Selection, page 3-5). 3. Select the desired pre-flow, post-flow, and auto-restart settings (see Machine Torch Operation, page 3-13). The system is factory-set for normal auto-restart, which allows the pilot arc to restart instantly when the cutting arc is interrupted with the torch still activated. The system is factory-set for two-second pre-flow and tensecond post-flow. 4. Check the power source for proper 380/415 VAC three-phase input voltage. Make sure the input power is properly connected to the EMI input filter PC board (see Electrical Connections, page 2-6). Connect primary power to the system (close main disconnect switch or plug unit in). 5. Select desired plasma and secondary (see Gas Selection, page 3-8). Make sure gas sources meet requirements (see Plasma and Secondary Connections, page 22). Check connections and turn plasma and secondary supplies on. 6. Move the ON/OFF switch to ON position. An automatic forty second gas purge will let gas run to remove any condensation that may have accumulated in the torch and leads while the system was shut down. After the purge is complete, if the RUN/SET/PURGE switch is in SET position, gases will flow. If the switch is in PURGE position plasma gas only will flow. If the switch is in RUN position there will be no gas flow. 7. Select the desired current output level. Refer to Cutting Speeds (page 3-26). 8. Move the RUN/SET/PURGE switch to SET position. Set plasma and secondary pressures (see Plasma and Secondary Connections, page 2-2).
3-4 Manual 0-2529
WARNING
Coolant Check Torch Check
Optional Auto-Restart Settings
Input Power Check
Plasma and Secondary Supply Check
Line Purge
Output Selection Plasma and Secondary Pressure Settings
OPERATION
Additional Line Purge
9. If additional purging of the plasma gas line is desired, move the RUN/SET/PURGE switch to PURGE position. In PURGE mode, with secondary mode selector set to GAS, the GAS indicator will not come on because only plasma gas runs and the secondary gas flow switch is not satisfied. 10. Return the RUN/SET/PURGE switch to RUN. The system is now ready for operation.
3.3 TORCH PARTS SELECTION
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply. Shield Cups (See Figure 3-D) Cat. No.
Shield Cup Selection
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
Ceramic Shield Cup (For Cutting) Cat. No. 9-5750
Metal Shield Cup (For Cutting) Cat. No. 9-5790
Touch Cup (For Height Sensing with SC-5) Cat. No. 9-5758
Gouging Cup Cat. No. 9-5774
Figure 3-D Shield Cup Selection
Manual 0-2529
3-5
OPERATION
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply. Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. Cutting tips and electrodes can be identified by the ring(s) around the diameter (see Figure 3-E, page 3-7). Air tips and electrodes have no rings, oxygen tips and electrodes have one ring, nitrogen tips and multi-gas (N2 or Ar/H2) electrodes have two rings, and argon/hydrogen tips have three rings.
CAUTION
Tip Selection
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 Electrode Selection Electrodes Cat. No.
Air Plasma - Cutting ............................................... 9-5749 Oxygen Plasma - Cutting ....................................... 9-5760 Multi-Gas (N2 or Ar/H2)- Cutting ........................ 9-5754
OPERATION
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Manual 0-2529
Cutting Air Plasma Oxygen Plasma
Gouging
Nitrogen Plasma Argon/Hydrogen Air or Multi-Gas
Air Plasma 50 Amp (.043) Tip Cat. No. 9-5748
O2 Plasma 50 Amp (.043) Tip Cat. No. 9-5753
N2 Plasma 50 Amp (.043) Tip Cat. No. 9-5765
Gouging Tip Air or Multi-Gas 85 Amp (.078) Cat. No. 9-5756
ArH2 Plasma 150 Amp (.073) Tip Cat. No. 9-5775
Gouging Tip Air or Multi-Gas 150 Amp (.120) Cat. No. 9-5755
Air Plasma Electrode Cutting or Gouging Cat. No. 9-5749
O2 Plasma Electrode Cutting or Gouging Cat. No. 9-5760
N2 or Ar/H2 Plasma Electrode Cutting or Gouging Cat. No. 9-5754
For gouging, select proper electrode to correspond to the type of plasma gas being used (same as cutting).
Figure 3-E Tip and Electrode Selection
Manual 0-2529
3-7
OPERATION
3.4 GAS SELECTION FOR PLASMA CUTTING
Air plasma is normally used with air secondary. Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply can substantially reduce torch parts life. Most often used on ferrous or carbon base materials to obtain good cutting quality at faster cutting speeds. Provides satisfactory results on non-ferrous materials.
AIR PLASMA
Can be used in place of air plasma with air secondary or CO2. NITROGEN PLASMA Provides much better parts life than air. Provides better cut quality on non-ferrous materials such as stainless steel and aluminum. A good clean welding grade nitrogen should be used.
A 65% argon/35% hydrogen mixture should be used. ARGON/HYDROGEN PLASMA Recommended for use on thicker (1/2 inch and up) nonferrous materials. Ar/H2 is not normally used for thinner non-ferrous materials because less expensive gases can achieve similar cut quality. Provides faster cutting speeds and high cut quality on thicker materials to offset a higher cost. Poor cut quality on ferrous materials.
Oxygen is recommended for cutting ferrous materials. Provides faster cutting speeds. OXYGEN PLASMA Provides very smooth finishes and minimizes nitride build-up on cut surface (nitride build-up can cause difficulties in producing high quality welds if not removed). Table 3-A Plasma Gas Selection for Plasma Cutting
OPERATION
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Manual 0-2529
Air secondary is normally used when operating with air plasma and occasionally with nitrogen plasma. AIR SECONDARY Inexpensive - reduces operating costs. Improves cut quality on some ferrous materials.
CO2 secondary is used with nitrogen or Ar/H2 plasma. CO2 SECONDARY Provides good cut quality on ferrous or non-ferrous materials. May reduce smoke when used with Ar/H2 plasma.
Nitrogen secondary is used with Ar/H2 plasma. Provides smooth finishes on non-ferrous materials. NITROGEN SECONDARY May be used with nitrogen plasma in order to operate from one compressed gas cylinder. May reduce smoke when used with Ar/H2 plasma.
Water secondary should be used only in mechanized applications - never in hand cutting! Normally used with nitrogen, Ar/H2, or air plasma. WATER SECONDARY 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. Table 3-B Secondary Selection for Plasma Cutting
Manual 0-2529
3-9
OPERATION
Cut Quality
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface that is cut will be welded after the cutting operation. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. The desired or specified condition (smooth or rough) of the face of the cut. Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream. The presence of nitrogen may create porosity if the material is to be welded after the cutting process. The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly 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 cut area and re-solidify on the base of the plate. Excessive dross build-up may require a secondary clean-up operation after the cutting process. The width of the cut (or the width of material removed during the cut). Table 3-C (page 3-11) contains cut quality information for each plasma and secondary combination on a variety of materials and thicknesses.
Cut Surface Nitride Deposits
Bevel Angle
Top-Edge Rounding Dross Build-up
Kerf Width
Kerf Width Cut Surface Bevel Angle Top Spatter
Top Edge Rounding Dross Build-Up
Cut Surface Drag Lines
A-00007
Figure 3-F Cut Characteristics
OPERATION
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Manual 0-2529
Description Excellent Good
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 orifice), some dross (easily removed), medium-smooth cut surface, slight top edge rounding. Excessive bevel (over 10), wide kerf (over 2-1/2 x tip orifice), medium to heavy dross, rough cut surface, top edge rounding. Not Recommended. Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator experience.
Fair
NR NOTE
GAS
MATERIAL THICKNESS Gage Gage to 1 in. 1 to 2 in. Gage Gage 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.
TYPE OF MATERIAL Carbon Steel Good/Excellent Excellent Excellent Good/Excellent Good/Excellent Good/Excellent Excellent Good NR NR NR NR Excellent Stainless Steel Good/Excellent Good Good Good/Excellent Good/Excellent Good/Excellent Good Excellent NR NR Good Excellent Good Aluminum Good/Excellent Good Good Good/Excellent Good/Excellent Good/Excellent Good Good/Excellent NR NR Excellent Excellent NR
Air Plasma Air Secondary Nitrogen Plasma Air Secondary or CO2 Secondary Nitrogen Plasma Water Secondary Ar/H2 Plasma N2 or CO2 Secondary Oxygen Plasma
Table 3-C Cut Quality: Plasma and Secondary Gas Selection for Various Materials and Material Thicknesses
Manual 0-2529
3 - 11
OPERATION
3.5 PLASMA CUTTING OPERATION
WARNING
Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at the front of this manual have been followed. Make sure no part of the operators body comes in contact with the workpiece when the torch switch is pressed. The sparks from the cutting process can cause damage to coated, painted or other surfaces such as glass, plastic, and metal. Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Torch Parts Selection on pages 3-6 and 3-7). Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTION
CAUTION
WARNING
The suggestions below should be followed in all cutting and gouging operations: 1. Wait five minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run to dissipate operating heat from the power supply. 2. For maximum parts life, do not operate the pilot arc any longer than necessary. 3. Use care in handling torch leads and protect them from damage. 4. In continuous cutting applications using CO2, it is often necessary to manifold four to six cylinders together to maintain adequate flow at operating pressures. NOTE FREQUENTLY REVIEW THE SAFETY PRECAUTIONS AT THE FRONT OF THIS MANUAL. It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.
WARNING
OPERATION
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Manual 0-2529
Auto-Restart Options
The auto-restart function provides an immediate pilot arc restart during post-flow if the torch is brought within range of the workpiece. The power supply can be set up to provide a variety of optional auto-restart settings. Auto-Restart On/Off - The auto-restart function can be switched off completely so that the torch must be reactivated (via torch switch or control device) to restart the pilot arc when the main arc is interrupted. Auto-Restart Normal/Delayed - Normal mode provides an immediate pilot arc restart when the main arc is interrupted. Delayed mode provides a gas pre-flow each time before the pilot arc restarts. Pre-Flow Delay - Pre-flow is the time interval from when the torch is activated (start of gas flow) to pilot arc initiation. Pre-flow duration is factory-set to two seconds, but can be re-set to four, seven, or ten seconds as desired. Post-Flow Delay - Gases continue to flow for a period of time after the main cutting arc is interrupted and the torch remains activated. Post-flow is factory-set to ten seconds, but can be re-set to five, twenty, or forty seconds as desired.
On/Off
Normal/Delayed
Pre-Flow Delay
Post-Flow Delay
Applications
In machine torch operation, optional auto-restart settings may be useful where: 1. The system is used for direct replacement of units not having auto-restart for use with motion control devices. 2. Torch parts life may improve without auto-restart in some applications by reducing excessive pilot arc time. 3. In some shape-cutting applications, immediately restarting the main arc after the torch passes beyond the desired cutting line (or between cuts) may not be desirable. 4. Extended leads may require longer pre-flow duration. 5. Other special applications require various arrangements. (continued)
Manual 0-2529
3 - 13
OPERATION
Auto-Restart (continued) On/Off (SW1) Note: Either pole set to 1(on) disables auto-restart function
Four two-pole DIP switches located on the control logic PC board control the auto-restart functions. Auto-Restart Mode Normal Disabled SW1-1 Position 0 0 1 1 (Off) (Off) (On) (On) SW1-2 Position 0 1 0 1 (Off) (On) (Off) (On)
Normal/Delayed (SW2) Note: Either pole set to 1(on) sets auto-restart function
Auto-Restart Mode Normal Delayed
SW2-1 Position 0 0 1 1 (Off) (Off) (On) (On)
SW2-2 Position 0 1 0 1 (Off) (On) (Off) (On)
Pre-Flow Delay (SW3)
Pre-Flow Time (Seconds) 2 4 7 10
SW3-2 Position 0 1 0 1 (Off) (On) (Off) (On)
Post-Flow Delay (SW4) For Hand Cutting Systems (A1845-01) with 19x704 Logic PCB
Post-Flow Time (Seconds) 5 10 20 40 Post-Flow Time (Seconds) 2.5 5 10 20
SW4-2 Position 1 0 0 1 (On) (Off) (Off) (Off)
Post-Flow Delay (SW4) For Machine Cutting Systems (A1845-15) with 19x910 Logic PCB
SW4-2 Position 1 0 0 1 (On) (Off) (Off) (Off)
OPERATION
3 - 14
Manual 0-2529
Figure 3-G Control Logic PC Board - Setting Auto-Restart Options
Manual 0-2529
3 - 15
OPERATION
3.6 HAND TORCH OPERATION
WARNING
Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at the front of this manual have been followed. Make sure no part of the operators body comes in contact with the workpiece when the torch switch is pressed. The sparks from the cutting process can cause damage to coated, painted or other surfaces such as glass, plastic, and metal. Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Torch Parts Selection on pages 3-6 and 3-7). Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTION
Plasma Cutting Operation (Hand Torch)
WARNING
Cutting with a Hand Torch
1. The hand torch should be held in both hands for making long cuts. Choose the method that feels the most comfortable and works the best. Use the thumb to actuate the control switch on the torch handle.
Figure 3-H Cutting with a Hand Torch

OPERATION 3 - 16 Manual 0-2529
Hand Torch Operation (continued)
2. To positively locate the line of the cut, position the torch over the workpiece, resting the front edge of the shield cup on the edge where the cut is to start. 3. Lower the welding helmet. Press and hold the torch control switch. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch control switch is held. 4. With the pilot arc on the main cutting arc is established as soon as the torch is brought within 1/8 - 3/8 in (3 - 10 mm) of the workpiece. If the cutting arc is interrupted and the switch is still pressed, as when cutting expanded metal, the pilot arc will automatically restart.
NOTE
Releasing the torch control switch will shut off either the pilot or main arc (depending on the mode of operation). 5. Cut with the torch held 1/8 - 3/8 in (3 - 10 mm) from the work. The torch should be held perpendicular to the workpiece while cutting.
CAUTION
Use a standard ceramic or metal shield cup for hand cutting. The touch cup (short shield cup) and gouging cup are NOT intended for hand cutting. Do not allow an exposed torch tip to contact the workpiece.
Manual 0-2529
3 - 17
OPERATION
3.7 MACHINE TORCH OPERATION
Cutting with a Machine Torch
1. A machine torch should be aligned perpendicular to the surface of the workpiece to obtain a clean, vertical cut. Use a square to align the torch (see Figure 3-I). 2. Position the center of the torch over the edge of the workpiece where the cut is to start. The transferred cutting arc will then be established at the plate edge when the torch is activated. 3. The machine torch can be activated by the remote operator control panel, remote control pendant, or by remote interface device such as CNC. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch is activated. 4. With the pilot arc on the main cutting arc is established as soon as the torch is brought within 1/8 - 3/8 in (3 10 mm) of the workpiece. If the cutting arc is interrupted and the torch is still activated, as when cutting expanded metal, the pilot arc will automatically restart (see Auto-Restart Options, page 3-13). De-activating the torch will shut off either the pilot or main arc (depending on the mode of operation).
Figure 3-I Machine Torch Set-up

Cutting with a Machine Torch (continued)
5. Cut with a standoff of 1/8 - 3/8 in (3 - 10 mm) from the work. The torch should be held perpendicular to the workpiece while cutting. Start cutting slowly and adjust cutting speed for optimum cutting performance. Cutting Speeds (page 3-26) contains typical cutting speeds for various materials and material thicknesses. A standard shield cup is recommended for most machine cutting applications. The touch cup (short shield cup) is designed for light gage cutting where arc voltage measurement is needed for a standoff control. Do not allow an exposed torch tip to contact the workpiece. The arc characteristics vary with gases used, cutting speed, material, and thickness. Air plasma normally produces a straight arc (on stainless or aluminum), while nitrogen plasma generally creates a 5 trailing arc (see Figure 3-J).
Figure 3-J Machine Torch Operation
Manual 0-2529
3 - 19
OPERATION
Corner Slowdown (CSD)
The corner slowdown feature provides an output current reduction in to correspond with the reduction in torch travel speed as a mechanized torch moves through a corner. When activated by CNC or other control device, the corner slowdown eliminates excessive metal removal in corners. Normally open (NO) contacts (supplied by the control device) close when the torch travel speed decreases through a corner. When the contacts close, power supply output drops to a pre-set current level.
NOTE
A two-pole DIP switch in the remote operator control panel PC board allows the corner slowdown to operate with normally closed (NC) contacts in the control device if desired. Corner slowdown adjustment is located on the remote operator control panel (see Operating Controls, page 3-3). The control is factory set fully counter-clockwise for minimum 50 amps output during corner slowdown. Turn the control clockwise to increase corner slowdown output. When the control is turned fully clockwise, corner slowdown output is increased to a maximum 150 amps. To view the corner slowdown setting, press and hold the stop control. The expected CSD output level will be displayed on the ammeter.
Corner Slowdown Settings
NOTE
In the PAK 15XC, the corner slowdown setting is independent (not a percentage) of the main current setting. For example, if CSD current is set to 100 amps, and main cutting current is set to the minimum 50 amps, the actual current level would actually increase through the CSD cycle. For electrical connections, refer to the CNC Interface Schematic (page 6-4.)
OPERATION
3 - 20
Manual 0-2529
3.8 PIERCING
In some cutting operations, it may be desirable to start the cut within the plate area rather than at the plate edge. Piercing the plate is not recommended on plates having a thickness greater than 3/4 in (19 mm). Blowback from the piercing operation can shorten the life of torch parts. All piercing should therefore be done as quickly as possible and at maximum amperage (150 amps) and maximum standoff. Piercing with a Hand Torch When piercing with a hand torch, tip the torch slightly so that blowback particles blow away from the torch tip (and operator) rather than directly back into it (see Figure 3-K). Pierce off the cutting line and then continue the cut as shown in Figure 3-K. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it. A method called running start is recommended when piercing with a machine mounted torch. The torch should be positioned far enough off the cutting line to allow the pierce to be complete before the cutting line is reached. This allowance depends on the thickness of the material and the torch travel speed.
Figure 3-K Piercing with a Hand Torch

Manual 0-2529 3 - 21 OPERATION
3.9 GOUGING OPERATION
WARNING
Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at the front of this manual have been followed. Make sure no part of the operators body comes in contact with the workpiece when the torch switch is pressed. The sparks from the gouging process can cause damage to coated, painted or other surfaces such as glass, plastic, and metal. Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Torch Parts Selection on pages 3-6 and 3-7). Disconnect primary power to the system before disassembling the torch, leads, or power supply.
CAUTION
CAUTION
WARNING
Figure 3-L Gouging with a Hand Torch

Gouging Parameters
Gouging performance depends on the torch travel speed, the current level, the angle at which the torch is held to the workpiece (lead angle), and the distance between the torch tip and the workpiece (standoff). Gouging can be accomplished with either a hand or machine torch. Optimum torch travel speed for gouging is between 20 and 120 inches per minute (0.5 and 3.0 meters per minute). Travel speed is dependent on current setting, lead angle, mode of operation (hand or machine torch), and desired results. Current settings depend on torch travel speed, the mode of operation (hand or machine torch), and the amount of material to be removed. The angle at which the torch is held depends on the current setting and the torch travel speed. The recommended lead angle is 20-25. An angle greater than 25 may result in inconsistent metal removal, blowback of slag, and contaminated gouges. If the lead angle is too small (less than 20), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable.
Torch Travel Speed
Current Setting
Lead Angle (Travel Angle)
Figure 3-M Gouging Parameters
Manual 0-2529
3 - 23
OPERATION
Standoff Distance
The tip to work distance affects gouge quality and depth. A standoff of 1/8 - 1/4 in (3 - 6 mm) allows smooth, consistent material removal. A smaller standoff may result double arcing from tip to work. A standoff greater than 1/4 in (6 mm) may result in minimal metal removal or loss of transferred main arc. Slag generated by gouging on materials such as carbon and stainlesss steels, nickels, and alloyed steels, can be removed easily in most cases. There is little, if any, slag produced when gouging aluminum, as the material is vaporized. Slag does not obstruct the gouging process if it accumulates to the side of the gouge path. However, slag build-up can cause inconsistencies and irregular metal removal if large amounts of material build up in front of the arc. The build-up is most often a result of improper travel speed, lead angle, or standoff height.
Slag Build-up
GAS Carbon Steel Air Plasma Air Secondary Nitrogen Plasma Air Secondary Nitrogen Plasma CO2 Secondary Ar/H2 Plasma Nitrogen Secondary Ar/H2 Plasma Argon Secondary Excellent
MATERIAL Stainless Steel Good Aluminum Fair
Good
Good
Fair
Good
Good
Good
Good
Excellent
Excellent
Good
Excellent
Excellent
Table 3-D Recommended Gases for Plasma Arc Gouging
OPERATION
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Manual 0-2529
3.10 COMMON OPERATING ERRORS
Listed below are common cutting problems followed by probable causes of each. If the problems are caused by a power supply problem, refer to the Troubleshooting Guide, page 4-21). Insufficient Penetration a. Cutting speed too high b. Current too low c. Metal too thick d. Worn or damaged torch parts Main Arc Extinguishes a. Cutting speed too low b. Standoff too high Dross Formation a. Improper gas pressure b. Improper cutting speed (See Cutting Speeds, page 3-26) c. Worn or damaged torch parts. Burned-Out Tips a. Cutting current too high b. Damaged or loose cutting tip c. Tip in contact with work d. Heavy spatter e. Low plasma gas pressure Poor Pilot Starting a. High coolant conductivity
Manual 0-2529
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OPERATION
3.11 CUTTING SPEEDS
When hand cutting, cutting speeds primarily depend on the material being cut, the thickness, and how fast the operator can comfortably and accurately follow the line. The following charts show optimum cutting speed ranges for most materials using a machine torch with various plasma and secondary combinations. The data was obtained using the recommended 1/8 in (3 mm) standoff. This information represents realistic expectations using recommended practices and well maintained systems. Actual speeds may vary up to 50% from those shown. Factors such as parts wear, air quality, line voltage fluctuations, operator experience, standoff variation and quality of work connection may impact system performance.
OPERATION
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Manual 0-2529
Material Thickness 50 Amps 1/8 3/16 1/4 1/2 3/4 1 1-1/4 1-1/2 2 150 (3.81) 110 (2.79) 65 (1.65)
Inches per Minute (Meters per Minute) 100 Amps 150 Amps
90 (2.29) 48 (1.22) 30 (0.76) 17 (0.43) 10 (0.25)
150 (3.81) 80 (2.30) 40 (1.02) 25 (0.64) 18 (0.46) 14 (0.36) 6 (0.15)
Table 3-E Cutting Speeds - Air Plasma on Mild Steel

Gage MM Inches 2.00 50 45 1.75 1.50 35 30 25 20 15 .50 10 .25 5 10 16 24 Inches per Minute 0 Meters per Minute0 1.0 1.25 1.00 .75
A-00881
MATERIAL THICKNESS
40
Optimum Cutting Speeds Air Plasma - Air Secondary on Mild Steel 150 Amps 100 Amps 50 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-N Cutting Speeds - Air Plasma on Mild Steel

Material Thickness 50 Amps 1/8 3/16 1/4 3/8 1/2 3/4 1 1-1/2 2 65 (1.65) 28 (.71) 16 (.41) 130 (3.30)
Inches per Minute (Meters per Minute) 100 Amps 225 (5.7) 100 (2.54) 58 (1.47) 32 (0.81) 22 (0.56) 160 (4.06) 100 (2.54) 80 (2.03) 35 (0.89) 28 (0.71) 12 (0.30) 5 (0.13) 150 Amps
Table 3-F Cutting Speeds - Oxygen Plasma on Mild Steel, CO2 Secondary
A-00883
MATERIAL THICKNESS
40
Optimum Cutting Speeds Oxygen Plasma on Mild Steel 150 Amps 100 Amps 50 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-O Cutting Speeds - Oxygen Plasma on Mild Steel

Material Thickness 50 Amps 1/8 1/4 5/16 3/8 1/2 3/4 1 1-1/2 2 100 (2.54) 40 (1.02) 30 (0.76) 9 (0.23)
140 (3.56) 75 (1.90) 60 (1.52)
175 (4.45) 110 (2.79) 85 (2.16) 40 (1.02) 25 (0.64) 12 (0.30)
Table 3-G Cutting Speeds - Nitrogen Plasma on Stainless Steel

A-00882
MATERIAL THICKNESS
40
Optimum Cutting Speeds Nitrogen Plasma - CO2 Secondary on Stainless Steel 150 Amps 100 Amps 50 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-P Cutting Speeds - Nitrogen Plasma on Stainless Steel

Material Thickness 50 Amps 1/8 1/4 5/16 3/8 1/2 3/4 1 1-1/2 2
35 (0.89) 27 (0.69) 20 (0.51) 10 (0.25)
Table 3-H Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

A-00886
MATERIAL THICKNESS
40
Optimum Cutting Speeds Ar/H2 Plasma - N2 Secondary on Stainless Steel 150 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-Q Cutting Speeds - Argon/Hydrogen Plasma on Stainless Steel

Inches per Minute (Meters per Minute) 100 Amps 225 (5.72) 135 (3.43) 150 Amps 275 (6.99) 150 (3.81)
150 (3.81) 40 (1.02)
60 (1.52) 18 (0.46) 15 (0.38)
95 (2.41) 52 (1.32) 36 (0.91) 18 (.46)
Table 3-I Cutting Speeds - Air Plasma on Aluminum

A-00884
MATERIAL THICKNESS
40
Optimum Cutting Speeds Air Plasma - Air Secondary on Aluminum 150 Amps 100 Amps 50 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-R Cutting Speeds - Air Plasma on Aluminum

100 (2.54)
75 (1.90) 60 (1.52) 35 (0.89) 21 (0.53)
Table 3-J Cutting Speeds - ArH2 Plasma/Nitrogen Secondary on Aluminum

A-00885
MATERIAL THICKNESS
40
Optimum Cutting Speeds ArH2 Plasma - N2 Secondary on Aluminum 150 Amps 100 Amps 50 Amps
50 2.0
100 3.0
150 4.0
200 5.0 6.0
250
CUTTING SPEED
Figure 3-S Cutting Speeds - ArH2 Plasma/Nitrogen Secondary on Aluminum

3.12 SEQUENCE OF OPERATION

ACTION Close external disconnect switch RESULT Power to system ACTION Enable ON at Remote or TB2 ON/OFF switch to ON RESULT AC indicator ON TEMP Indicator ON GAS indicator ON Fan and pump ON 40 second auto-purge ACTION RUN/SET/PURGE switch to SET RESULT Gas solenoids open, gases flow to set pressures GAS indicator ON ACTION RUN/SET/PURGE switch to RUN RESULT Gas flow stops Power circuit ready GAS indicator OFF
ACTION Protect eyes and activate torch RESULT Gas indicator ON Gas pre-flow Main contactor closes DC indicator ON Pilot contactor closes PILOT indicator ON Pilot arc established
ACTION Torch removed from work RESULT Main arc stops Pilot arc auto-restart PILOT indicator ON
PILOT ARC
ACTION Torch moved to within 1/8 - 3/8 inch of work RESULT Main arc transfer PILOT indicator OFF Pilot arc OFF
ACTION Torch de-activated by torch switch released or remote device RESULT Main arc stops Main contactor opens DC indicator OFF Pilot and PILOT indicator OFF NOTE- If torch is activated during post-flow the pilot arc will immediately restart. If within range of work, main arc will transfer. After post-flow: Gas solenoids close, gas flow stops GAS indicator OFF
ACTION ON/OFF switch to OFF RESULT AC indicator OFF TEMP Indicator OFF Fan and pump OFF
ACTION Open external disconnect RESULT No power to system

A-01016
Figure 3-T Sequence of Operation

OPERATION
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Manual 0-2529
SECTION 4: SERVICE
4.1 TORCH MAINTENANCE
WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply.
Routine Inspection and Replacement of Consumable Parts:
Refer to Figure 4-A and: 1. Remove the shield cup (1) from the torch body (6 or 7). 2. Unscrew the tip (2) using the tip wrench (9). Check for tip wear (indicated by elongated or oversize orifice). Clean the tip and make sure the threads and sealing face are not damaged. Replace tip if necessary. 3. Remove the electrode (3) using the electrode wrench (10). Inspect the condition of the face of the electrode (see CAUTION below).
NOTE
Check the torch for proper assembly. Make sure both the tip and electrode in the torch correspond with the plasma gas and secondary being used. (See Torch Parts Selection on pages 3-6 and 3-7). 14
9
1 10 6 15
7 2 4 5 8
11 16 12
13
17
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Machine Torch Body 70 Hand Torch Body O-Ring (Handle) O-Ring (Cup - Lg.) O-ring (Cup - Sm.) Air Electrode Oxygen Electrode Multi-Gas Electrode Air Tip Oxygen Tip
18
11. 12. 13. 14. 15. 16. 17. 18. 19.
Nitrogen Tip Ar/H2 Tip Gouging Tip Standard Shield Cup Copper Shield Cup Touch Cup Gouging Cup Tip Wrench Electrode Wrench
19
Figure 4-A PCH/M-150 Torch Components

Manual 0-2529 4-1 SERVICE
NOTE
If face of electrode is pitted or gouged more than 3/32 in (2.4 mm) deep, the electrode should be replaced (see Figure 4-B below). 4. Replace the electrode in the torch body. Secure in place using the electrode wrench. 5. Replace the tip in the front of the torch and secure it with the tip wrench.
CAUTION
Do not overtighten the electrode or tip. 6. Inspect the shield cup for damage. Wipe it clean, or replace if it appears to be damaged. 7. Re-install the shield cup. Apply a light coat of O-ring lubricant to the shield cup O-rings (4,5). Use a slight twisting motion to seat the cup properly on the O-rings and against the torch face.
Look for extreme pitted or blown out appearance 3/32 in
New Electrode
Worn Electrode
Figure 4-B Electrode Deterioration
4.2 HAND TORCH HEAD REPLACEMENT
WARNING Hand Torch Head Replacement
Disconnect primary power to the system before disassembling the torch, leads, or power supply. Refer to Figure 4-C (page 4-3) and: 1. Roll the torch switch sheath up over the handle to expose the two torch switch connectors. 2. Remove the tape from the end of the leads sleeving and pull the sleeving back approximately one foot (0.3 m). 3. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads.
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Manual 0-2529
Hand Torch Head Replacement (continued)
4. With a twisting motion, pull the handle from the torch head. Slide the handle back over the leads to expose the leads connections. 5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.
NOTE
To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir. 6. Connect the plasma, secondary, coolant supply, and coolant return leads onto the replacement torch head fittings. 7. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.
CAUTION
Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads. 8. Replace the handle onto the torch head. 9. Connect the two torch switch leads connectors and secure the torch switch leads in place with electrical tape. 10. Secure the leads sleeving to the leads with electrical tape. Position the tape close to the back of the handle. 11. Roll the torch switch sheath back over the handle.
Figure 4-C Hand Torch Head Replacement
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SERVICE
4.3 MACHINE TORCH HEAD REPLACEMENT
WARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
Machine Torch Leads Replacement
Refer to Figure 4-D (page 4-5) and: 1. Remove the electrical tape from the end of the nylon outer leads sleeving next to the mounting assembly and push the sleeving back onto the leads approximately one foot (0.3 m) to expose the shielded inner leads sleeving. 2. Remove the electrical tape from the shielded inner sleeving and push back over the leads approximately one foot (0.3 m). 3. Unscrew the mounting assembly from the torch head. Slide the mounting assembly back over the leads to expose the leads connections. 4. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.
NOTE
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Manual 0-2529
CAUTION
Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads. 7. Replace the mounting assembly onto the torch head. 8. Secure the shielded inner sleeving to the leads with electrical tape. Position the end of the sleeving a few inches back from the mounting assembly. 9. Position the nylon outer sleeving over the shielded inner sleeving. The shielded inner sleeving must be completely covered by the outer sleeving to avoid any possible contact with the mounting assembly. 10. Secure the nylon outer leads sleeving to the leads with electrical tape. Position the tape close to the back of the mounting assembly.
Shielded Inner Leads Sleeving
Electrical Tape Torch Head
Coolant Return Lead
Plasma Lead
Mounting Assembly
Electrical Tape
Insulating Tape
A-00961
Secondary Lead
Coolant Supply Lead
Nylon Outer Leads Sleeving
Figure 4-D Machine Torch Head Replacement
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SERVICE
4.4 HAND TORCH SWITCH REPLACEMENT
WARNING Hand Torch Head Replacement
Disconnect primary power to the system before disassembling the torch, leads, or power supply. Refer to Figure 4-C (page 4-3) and: 1. Roll the sheath up over the torch handle to expose the torch switch connectors and the torch switch. 2. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads. 3. Replace the torch switch and connect the two torch switch leads connectors. 4. Secure the torch switch leads in place with electrical tape. Locate the tape over the two connectors. 5. Roll the torch switch sheath back over the handle to cover the torch switch and connectors.
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4.5 HAND TORCH LEADS REPLACEMENT
WARNING
Hand Torch Leads Replacement
Refer to Figure 4-C (page 4-3) and: 1. Roll the torch switch sheath up over the handle to expose the two torch switch connectors. 2. Remove the tape from the end of the leads sleeving and pull the sleeving back approximately one foot (0.3 m). 3. Remove the tape from the two single-pin torch switch connectors and disconnect the torch switch leads. 4. With a twisting motion, pull the handle from the torch head. Slide the handle back over the leads to expose the leads connections. 5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head. (continued)
Control Cable (Hand Torch Only)
Plasma Lead Secondary Lead Shielded Inner Leads Sleeving (Machine Torch Only) Torch Leads Shield Assembly Nylon Outer Leads Sleeving
Coolant Return Lead Coolant Supply Lead Hose Clamp

A-00903
Torch Leads Boot
Figure 4-E Leads Connections at the Power Supply

Manual 0-2529 4-7 SERVICE
NOTE
To minimize coolant leaks during torch head replacement, perform the operation with the torch head above the level of the coolant reservoir. 6. Position the replacement leads and connect the plasma, secondary, coolant supply, and coolant return leads onto the torch head fittings. 7. Use electrical tape to secure the leads in place on the insulating tab. Locate the tape over the ferrule on the negative lead.
CAUTION
Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads. 8. Replace the handle onto the torch head. 9. Connect the two torch switch leads connectors. Secure the torch switch leads in place with electrical tape. 10. Secure the leads sleeving to the leads with electrical tape. Position the tape close to the back of the handle. 11. Roll the torch switch sheath back over the handle. Refer to Figure 4-E (page 4-7) and: 12. Open the leads connection access door on the power supply. Disconnect the plasma, secondary, coolant supply and coolant return leads and the control cable plug from the bulkhead. 13. Position the replacement leads. Feed the control cable plug through the torch leads boot first and connect to the bulkhead. Then feed the other leads through the torch leads boot and connect the plasma, secondary, coolant supply and coolant return leads to the bulkhead.
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Manual 0-2529
4.6 MACHINE TORCH LEADS REPLACEMENT
WARNING
Machine Torch Leads Replacement
Refer to Figure 4-D (page 4-5) and: 1. Remove the electrical tape from the end of the nylon outer leads sleeving next to the mounting assembly. 2. Push the nylon outer sleeving back up the leads approximately one foot (0.3 m) to expose the shielded inner leads sleeving. 3. Remove the electrical tape from the shielded inner sleeving and push back up the leads approximately one foot (0.3 m). 4. Unscrew the mounting assembly from the torch head. Slide the mounting assembly back over the leads to expose the leads connections. 5. Remove the tape that secures the lead connections around the insulating tab. Disconnect the plasma, secondary, coolant supply, and coolant return leads from the torch head.
NOTE
CAUTION
Make sure the insulating tab completely separates the coolant supply lead (negative) from the plasma, secondary, and coolant return leads. 8. Replace the mounting assembly onto the torch head. 9. Secure the shielded inner sleeving to the leads with electrical tape. Position the end of the sleeving a few inches back from the mounting assembly.
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SERVICE
Machine Torch Leads Replacement (continued)
10. Position the nylon outer sleeving over the shielded inner sleeving. The shielded inner sleeving must be completely covered by the outer sleeving to avoid any possible contact with the mounting assembly. 11. Secure the nylon outer leads sleeving to the leads with electrical tape. Position the tape close to the back of the mounting assembly.
Power Supply Connections
Refer to Figure 4-E (page 4-7) and: 12. Open the leads connection access door on the power supply. Remove the hose clamp that secures the shielded inner leads sleeving to the brass grounding tube. 13. Disconnect the plasma, secondary, coolant supply and coolant return leads from the bulkhead. 14. Position the replacement leads and connect the plasma, secondary, coolant supply and coolant return leads to the bulkhead. 15. Attach the shielded inner leads sleeving to the brass grounding tube and secure with hose clamp. The shielded inner sleeving must not contact any torch fittings, ferrules, or connections.
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Manual 0-2529
4.7 LEADS EXTENSION KITS - HAND TORCH
Leads extension packages are available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. Leads can be extended up to a maximum of 150 ft (45.8 m). Leads extension kits for hand torch systems include: Plasma, Secondary, Coolant Supply and Coolant Return Leads Extensions in 25 or 50 ft (7.6 or 15.2 m) lengths Control Cable Extension - 25 or 50 ft (7.6 or 15.2 m) Nylon Outer Sleeving - 25 or 50 ft (7.6 or 15.2 m) Coolant Supply Lead Insulator Plasma Lead Insulator (2) Union Fittings Disconnect primary power to the system before disassembling the torch, leads, or power supply.
WARNING
Refer to Figure 4-E (page 4-7) and: Disconnect Existing Leads 1. Disconnect the plasma lead, secondary lead, coolant supply lead, coolant return lead, and the control cable plug from the bulkhead. To minimize coolant leaking from the leads during installation, keep the leads connections above the level of the torch head and existing leads. 2. Position the extension kit and connect the plasma, secondary, coolant supply, coolant return leads extensions and the control cable extension to the bulkhead. Refer to Figure 4-F (page 4-12) and: 3. Slide the coolant supply insulator over the coolant supply lead on the existing torch leads. 4. Push the coolant supply lead on the existing leads into the union fitting as far as possible. 5. Connect the coolant supply lead from the torch leads through the union fitting to the coolant supply lead from the extension kit and tighten securely. 6. Thread the coolant supply insulator on the existing torch leads onto the union fitting and tighten securely. (continued)
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NOTE
Connect Leads Extension to Power Supply Connect Coolant Supply Lead to Extension Package
7. Thread the coolant supply insulator on the leads extension into the union fitting and tighten securely. 8. Slide the plasma insulator over the plasma lead on the existing torch leads. 9. Push the plasma lead on the existing leads into the union fitting as far as possible. Connect Plasma Lead to Extension Package 10. Connect the plasma lead from the torch leads, through the union, to the plasma lead from the extension kit and tighten securely. 11. Thread the plasma insulator on the existing torch leads onto the union fitting and tighten securely. 12. Thread the plasma insulator on the leads extension into the union fitting and tighten securely. Connect Coolant Return, Secondary, and Control Cable to Extension Package 13. Connect the secondary and coolant return leads to the extension kit fittings. 14. Connect the control cable plug to the receptacle on the leads extension package.
Electrical Tape
Coolant Supply Lead Plasma Lead
Union Fitting
Coolant Supply Insulator Plasma Insulator Electrical Tape
From Power Supply (Extension Kit)
To Torch (Existing Leads)
Secondary Lead Coolant Return Lead Control Cable (Hand Torch Only)
A-00962
Figure 4-F Hand Torch Leads Extension Package
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4.8 LEADS EXTENSION KITS - MACHINE TORCH

Leads extension packages are available in 25 ft (7.6 m) or 50 ft (15.2 m) lengths. Leads can be extended up to a maximum of 150 ft (45.8 m). Leads extension kits for machine torch systems include: Plasma, Secondary, Coolant Supply and Coolant Return Leads Extensions in 25 or 50 ft (7.6 or 15.2 m) lengths Shielded Inner Sleeving - 25 or 50 ft (7.6 or 15.2 m) Nylon Outer Sleeving - 25 or 50 ft (7.6 or 15.2 m) Shielded Inner Sleeving Connector - 12 in (0.30 m) Nylon Outer Sleeving Connector - 24 in (0.61 m) (2) Hose Clamps Coolant Supply Lead Insulator Plasma Lead Insulator (2) Union Fittings Disconnect primary power to the system before disassembling the torch, leads, or power supply.
WARNING
Disconnect Existing Leads
Refer to Figure 4-E (page 4-7) and: 1. Remove the hose clamp from the torch leads shield assembly inside the leads access area to release the shielded inner sleeving. 2. Disconnect the plasma and secondary leads and coolant supply and return leads from the bulkhead.
NOTE
To minimize coolant leaks from the leads during installation, keep the leads connections above the level of the torch head and existing leads. 3. Position the extension kit and connect the plasma, secondary, coolant supply, and coolant return leads extensions to the bulkhead. 4. Connect the shielded inner sleeving to the torch leads shield assembly and secure with the hose clamp. (continued)
Connect Leads Extension to Power Supply
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SERVICE
Connect Existing Leads to Leads Extension
Refer to Figure 4-G (page 4-15) and: 5. Slide the 24-inch nylon outer sleeving connector over the existing leads before making connections. The connector will later be pulled down to cover all connections. 6. Remove the shrink-on tubing and tape that secures the end of the nylon outer sleeving to the existing leads. 7. At the end of the existing leads, all four individual leads are enclosed by the shielded inner sleeving. Pull the nylon outer sleeving back approximately 12 in (0.3 m) to expose the area where the coolant return and secondary leads are run through from the outside to the inside of the shielded inner sleeving. 8. Pull the secondary and coolant return leads out through the shielded inner sleeving (only the coolant supply and plasma leads remain inside the sleeving). 9. Slide the 12-inch shielded inner sleeving connector over the coolant supply and plasma leads of the extension kit.
Connect Coolant Supply Lead to Extension Package
Refer to Figure 4-F (page 12) and: 10. Slide the coolant supply insulator over the coolant supply lead on the existing torch leads. 11. Push the coolant supply lead on the existing leads into the union fitting as far as possible. 12. Connect the coolant supply lead from the torch leads through the union fitting to the coolant supply lead from the extension kit and tighten securely. 13. Thread the coolant supply insulator on the existing torch leads onto the union fitting and tighten securely. 14. Thread the coolant supply insulator on the leads extension into the union fitting and tighten securely.
Connect Plasma Lead to Extension Package
15. Slide the plasma insulator over the plasma lead on the existing torch leads. 16. Push the plasma lead on the existing leads into the union fitting as far as possible. 17. Connect the plasma lead from the existing torch leads through the union fitting to the plasma lead from the extension kit and tighten securely. 18. Thread the plasma insulator on the existing torch leads onto the union fitting and tighten securely.
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19. Thread the plasma insulator on the leads extension into the union fitting and tighten securely. Refer to Figure 4-G (below) and: 20. Pull each end of the shielded inner sleeving (from the existing leads and from the leads extension) up and over the plasma and coolant supply insulators. Position the 12-inch shielded inner sleeving connector down over the completed coolant supply and plasma connections. Secure the connector in place with a hose clamp on each end. NOTE Locate the hose clamps over the plasma and coolant supply insulators to provide a solid connection. The shielding must be continuous throughout the connection (from the extension kit, through the connector, to the original leads) to ensure proper shielding protection. 21. Connect the secondary and coolant return leads to the extension kit fittings. 22. Slide the 24-inch nylon sleeving connector down to cover all connections. Secure with electrical tape.
Coolant Supply Lead 12" Shielded Plasma Inner Sleeving Lead
Connect Coolant Return and Secondary to Extension Package
Electrical Tape
Locate Clamp Over Insulators
Electrical Tape
From Power Supply (Extension Kit)
To Torch (Existing Leads)
Secondary Lead
Coolant Return Lead
Locate Clamp Over Insulators
From Power Supply (Extension Kit) 24" Nylon Outer Sleeving
To Torch (Existing Leads) A-00963
Figure 4-G Machine Torch Leads Extension
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SERVICE
4.9 POWER SUPPLY MAINTENANCE
Fan Motor and Pump Lubrication
The fan motor and pump in the power supply should be oiled twice per year or once for each 100 hours of operation. To oil the motor, remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor. Some units may utilize a sealed motor design which does not require lubrication. The only other routine maintenance required for the power supply is a thorough cleaning and inspection, with the frequency depending on the usage and the operating environment. To clean the unit, first make sure that the power is disconnected. Remove the side panels and blow out any accumulated dirt and dust with compressed air. The unit should also be wiped clean. If necessary, solvents that are recommended for cleaning electrical apparatus may be used. While the side panels are off, inspect the wiring in the unit. Look for any frayed wires or loose connections that should be corrected. When cleaning the unit, inspect the area around the high frequency spark gap points. Accumulated dirt in the area around the spark gap assembly can weaken the high frequency starting and cause poor pilot starting.
NOTE Routine Maintenance
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4.10 TROUBLESHOOTING THEORY
Input Voltage Selection
The main transformer (T1) has buss bar connections to select the 380 VAC input voltage (see page 2-6). Each main transformer secondary has two taps. The higher voltage secondary tap is automatically selected by the voltage selection PC board when primary power is applied. A red LED indicator (D18) on the voltage selection PC board will be ON. This arrangement provides secondary voltages close to the optimum levels. The 115 VAC and lower voltage taps are selected directly by relays on the voltage selection PC board. The fan and pump motors are supplied by the motor control contactors (MC1 and MC2). MC1 is for the high voltage tap and MC2 is for the low voltage tap. Three-phase primary power is controlled by one of the main contactors (W1 for the high voltage tap or W2 for the low voltage tap).
Switch-Mode Power Supply Operation
Primary three-phase power is rectified by diodes D1-D6. The resulting negative DC voltage (approximately -320 VDC) is applied to the switching transistor (Q1). The switching transistor controls the output current by pulse width modulation (PWM). PWM varies the duty cycle (or on-time versus off-time) of the switch. The greater the ontime, the higher the output current will be. The switching transistor output is a series of pulses which are filtered back into pure DC voltage by the output network. The output network consists primarily of the main inductor (L2A and L2B), resistor R13, and capacitor C23. The switching control PC board compares the shunt amp output with the current control pot setting and generates logic level PWM signals. The shunt and shunt amp PC board are located between the positive bridge and work lead to measure the output cutting current. The signals are sent to the driver PC board, where they are converted into the current and voltage levels needed to drive the switching transistor.
Switching Control Board
The switching control PC board senses if the remote control panel is connected by a jumper in the remote cable. If the remote cable is not used, a relay on the switching control PC board shorts J15-35 to J15-36. The short bypasses the E-Stop function of the remote. The switching control PC board also routes the shunt amp output to the digital ammeter in the remote. CSR (current greater than 25A) and over-current shutdown (greater than 175A) signals are sent to the logic PC board.
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Logic Board Functions
The logic PC board controls the timing and sequencing of the system. It monitors the pressure, temperature, and flow interlocks and controls the gas flow in run, set, and purge modes by turning on the plasma and secondary solenoids. The logic PC board also controls pre-flow and post-flow durations, which are selectable by DIP switches on the board (see Figure 3-G, page 3-15). The logic board drives the sequence status LED indicators and contains the circuit for measuring coolant conductivity. The logic board receives either a latched start signal from the remote control panel or a non-latching start signal from the hand torch switch or remote pendant. Both latching and non-latching signals are available from CNC devices. The logic PC board then initiates gas pre-flow and energizes the main contactor W1 or W2 (as directed by the voltage selection PC board). The logic board then enables the PWM switching control circuit. The logic board immediately activates the pilot contactor to initiate the pilot arc. As soon as the pilot arc (constant DC current) is established, the PSR relay shuts off the high frequency. The logic board supplies OK-to-move contacts, which close when main arc transfer has occurred and pilot has shut off. A second OK-to-move contact is wired to control an optional high-flow water shield.
LED/Current Control Board
The LED and current control PC board contains the sequence status LED indicators and the front panel current control pot. The remote control unit contains the several system control functions. Momentary start and stop switches control system operation and the main current control pot controls cutting current output. A digital ammeter displays a preview of the main current setting (or corner slowdown setting) before starting the cut and displays actual cutting current after arc transfer. A behind-the-panel control sets corner slowdown current reduction and an emergency stop switch shuts off the power supply's main contactors, gases, and coolant system. CNC interface connectors and the power supply remote cable connection are located on the rear panel of the remote.
Remote Control
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Figure 4-H Major System Components - Front View

Manual 0-2529 4 - 19 SERVICE
Figure 4-I Major System Components - Rear View

SERVICE 4 - 20 Manual 0-2529
4.11 TROUBLESHOOTING GUIDE
TROUBLE A. No front panel LED indicators lit. Fan and pump off.
POSSIBLE CAUSE 1. No primary power. See also Steps C and D (page 4-22) 2. Blown fuse (F2) 3. Faulty ON/OFF switch (SW1)
REMEDY 1. Check for proper threephase power at input terminal board 2. Check and replace fuse if necessary 3. Disconnect primary power. Check each section for continuity. Replace switch if necessary 4. See test A (page 4-27) and replace board if necessary 1. Check for proper threephase power at input terminal board 2. Check and replace fuse if necessary. See Test B (page 4-28) 3. Disconnect primary power. Check each section for continuity. Replace switch if necessary 4. See test A (page 4-27) and replace board if necessary 5. See test C (page 4-29) and replace contactor if necessary 6. See test C. part 3 (page 429)
4. Faulty voltage selection board B. AC indicator on. Fan and pump off. 1. No primary power See also Steps C and D (page 4-22) 2. Blown fuse (F1 or F2)
3. Faulty ON/OFF switch (SW1)
4. Faulty voltage selection board 5. Faulty motor contactor (MC1 or MC2) (Causes 6 and 7 are only for systems having remote control panel) 6. Faulty switching control board (relay K1 not energized to bypass remote Estop function) 7. Remote cable plugged into J15; remote control panel not connected on other end of cable 8. Remote panel E-stop button activated (or faulty)
7. Remove cable plug from J15 or connect remote panel correctly 8. Twist button clockwise to release. If necessary, check for continuity from J37-35 to J37-36 (continued)
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TROUBLE C. Fuse blown at disconnect when primary power is connected
POSSIBLE CAUSE 1. Voltage selection bus bars connected incorrectly 2. One leg of three-phase primary connected to chassis ground 3. Main transformer shorted
REMEDY 1. Check and correct if necessary. 2. Rewire input cable (see Electrical Connections, page 2-6) 3. Replace main transformer 1. See test D (page 4-29) and replace diode if necessary 2. Replace Q1, check heatsink for possible damage, perform test D (page 4-29) 3. Replace capacitor if necessary 4. Check for proper 3-phase power at input terminal board, check diodes (see test D, page 4-29) 5. If W1 and W2 come on simultaneously replace board. 6. Check and replace contactor if necessary 1. Clean radiator and check for obstruction. 2. See test E (page 4-30) and replace sensors if necessary 3. See test E (page 4-30) and replace board if necessary 4. See test E (page 4-30) and replace board if necessary 1. Normal operation (purges plasma line only, secondary flow switch is not satisfied) 2. Adjust pressure
D. Fuse blown at disconnect when main contactor (W1 or W2) closes
1. Shorted input diode (D1-D6) 2. Switching transistor (Q1) shorted to heatsink 3. Shorted input capacitor (C7-C12) 4. Shorted diode (D11-D14)
5. Faulty voltage selection board 6. Faulty main contactor (W1 or W2) E. TEMP indicator lit (red). 1. Unit overheated 2. Faulty thermal sensor (TS1, TS2, or TS3) 3. Faulty logic board 4. Faulty LED/current control board F. No GAS indicator 1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary 2. Gas pressure set too low
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TROUBLE F. No GAS indicator (continued)
POSSIBLE CAUSE 3. Faulty pressure switch (PS1 or PS2)
REMEDY 3. Jump switches one at a time and check for indicator to determine which has failed. Replace switch if necessary 4. See test F (page 4-30) and replace board if necessary 5. See test F (page 4-30) and replace board if necessary 6. With secondary mode set to O2 or H2O, check for continuity from wire #52 to #55 on SW3-B. If open, replace SW3-B 1. Normal operation (purges plasma line only, secondary does not flow) 2. No secondary flow is normal operation in O2 mode (but GAS indicator should be lit) 3. Check plasma pressure, check PS1 and replace if necessary 4. Check secondary supply 5. Check solenoid for sticking or clogging. Check coil resistance (should be approx. 400 ohms) 5. Check SW3-A for continuity (wire 75 to 88 for secondary gas, 75 to 89 for secondary water) 6. See test G (page 4-31) and replace board if necessary (continued)
4. Faulty logic board 5. Faulty LED/current control board 6. Faulty SW3-B (secondary mode set to O2 or H2O )
G. GAS indicator off, plasma and/or secondary gas does not flow
1. RUN/SET/PURGE switch set to PURGE, secondary mode switch set to GAS secondary 2. Secondary mode set to O2
3. Low plasma pressure or faulty PS1 4. Secondary supply turned off (or tank empty) 5. Faulty solenoid valve: SOL1 - plasma gas, SOL2 - secondary gas, SOL3 - secondary water 5. Faulty switch (SW3-A) (effects sec. gas or water only, not secondary O2) 6. Faulty logic board
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SERVICE
TROUBLE H. COOLANT indicator off
POSSIBLE CAUSE 1. Little or no pressure shown on gauge
REMEDY 1a.Check coolant level 1b. Check motor rotation and rpm. 1c. Check and replace pump if necessary
2. Clogged torch or leads
2. Check and torch and leads and replace if necessary. Flush coolant system 3. Check and replace flow switch if necessary 4. See test H (page 4-31) and replace board if necessary 5. See test H (page 4-31) and replace board if necessary 1. Check coolant conductivity and deionizer cartridge (page 2-9). Replace both if necessary 2. Clean conductivity probe and replace if necessary 3. See test I (page 4-31) and replace board if necessary 4. See test I (page 4-31) and replace board if necessary 1. Normal operation, set switch to RUN position 2. See test J (page 4-32)
3. Faulty flow switch (FS1) 4. Faulty logic board 5. Faulty LED/current control board I. Coolant conductivity indicator off 1. Ionized or contaminated coolant
2. Faulty (or contaminated) conductivity probe 3. Faulty logic board 4. Faulty LED/current control board J. DC indicator not lit (after pre-flow), no main contactor closure 1. RUN/SET/PURGE switch not set to RUN 2. Faulty torch switch, remote panel, or remote pendant 3. Open contactor coil (W1 or W2) 4. Faulty logic board K. DC indicator not lit (after pre-flow), main contactor comes on momentarily. No pilot, no main arc transfer 1. Switching transistor (Q1) not turning on
3. Coil should measure approx. 10 ohms 4. See test J (page 4-32) 1. See test K (page 4-33)
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TROUBLE L. No pilot arc. DC indicator on, PCR not energized M. No pilot. PILOT indicator on, PCR energized, little or no spark at spark gap points
POSSIBLE CAUSE 1. Faulty logic board, switching board, or shunt amp board 1. Faulty PSR relay
REMEDY 1. See test L (page 4-34)
1. Check for faulty NC contacts or poor relay connection in socket 2. Check and replace if necessary. 3. Check capacitor and replace if necessary 1. Adjust pressure 2. Check input voltage connections (page 2-6)
2. Faulty HF transformer (T3) 3. Faulty capacitor (C31)
N. Weak or sputtering pilot. HF stays on during pilot
1. Plasma gas pressure too high 2. Low OCV (normal 290350) caused by improper connection of voltage selection bus bars 3. Low OCV caused by faulty voltage selection PC board
3. If three-phase input voltage is within the lower half of range (see Input Voltage Selection, page 417), D18 on voltage selection PC board should not be lit. If D18 is lit, replace the voltage selection PC board. 1. Thread electrode securely into torch head 2. Check and replace if necessary 3. Check and replace if necessary 4. Check and replace if necessary 5. Check and replace if necessary 6. Clean and dry torch lead (continued)
O. No pilot. PILOT indicator on, strong spark visible at spark gap points
1. Electrode shorted against tip 2. Shorted torch head 3. Faulty capacitor (C25) 4. Broken conductor in torch lead 5. Shorted torch lead 6. Dirty or wet torch lead
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TROUBLE P. Pilot arc on, no main arc transfer (torch brought within range of work)
POSSIBLE CAUSE 1. Work cable not connected 2. Defective current control pot (on front panel or remote)
REMEDY 1. Connect work cable securely 2. If remote is in use, disconnect J15 and set current at front panel. If transfer is okay, replace remote. If remote is not in use, see Test M (page 4-35) 1. Shorted Q1 or faulty switching control PC board. See test K (page 433)
Q. Main arc starts but goes out immediately and main contactor (W1 or W2) goes off
1. Fault condition causes output greater than 175 amps
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Manual 0-2529
4.12 SERVICE AND TEST PROCEDURES
The following tests are suggested for specific problems listed in the troubleshooting guide. The letter designations correspond to those listed in the Remedy column of the troubleshooting section. Several of these tests involve voltage measurements that must be made with power on. Use extreme care when making these tests. Tests requiring voltage measurements are marked with the warning symbol. Disconnect primary
WARNING
A. Voltage Selection PC Board Check
When wall power is first turned on, the voltage selection PC board (see Figure 4-G, page 4-19) senses the low voltage AC present at J6-20, J6-22, and J6-24 (center tap). The voltage selection board determines whether the voltage is in the lower or higher part of the selected input voltage range. If the input voltage is within the upper part of the range, the board energizes K1, K4, and K5 relays (labeled HV on the system schematic). If the input voltage is within the lower part of the range the board energizes the K2 and K3 relays (labeled LV on the schematic). If HV is selected, the red LED indicator (D18) on the voltage selection board will be lit. The relays do not energize until SW1-B (one pole of the ON/OFF switch) is closed because the DC voltage to the coils passes through it. 1. Check the AC input from J6-24 to both J6-20 and J6-22 for 12 - 18 VAC. 2. Check the AC voltage from J6-24 to both J6-17 and J6-18 for 16 - 22 VAC. 3. If input voltages are correct, check output from J6-19 to J6-21 for 14 - 18 VAC. 4. If output is not present between J6-19 and J6-21, check between J6-24 (-) and both J6-16 and J6-23 (+) for 12 - 16 VDC. If voltage is present at both points or neither, replace the voltage selection board. If voltage is found at J6-23 but not at J6-16, check SW1-B and all wiring and connections.
28 VAC Test
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SERVICE
120 VAC Test
1. Check the voltage input from F2 (wire #10) to J6-9 for 100 - 120 VAC. Check the input from F2 to J6-10 for 120 - 140 VAC. 2. If the voltage input is present, check the red LED indicator (D18) on the voltage selection board. If the indicator is lit, measure voltage output between F2 (wire #10) and J6-7. If the indicator is not lit, measure between F2 and J6-12. The voltage output at either point should measure 110 - 130 VAC. 3. If both or neither J6-7 or J6-12 have high voltage present, replace the voltage selection board. Check voltage between J6-21 and wire #10 on fuse F2 for 110 - 130 VAC. This supplies 120 VAC to the rest of the unit.
SWITCHING CONTROL PCB (10) F2 (9) (8)
K1
J28 TO OPTIONAL STANDOFF CONTROL -3 -1 (24)

MC1 MC2 W1 W2
(110) T3(HF) SOL1 T2 (50) SOL2 (881) SOL3 (89) SW3-A (75) K2 K4 K3 LOGIC PCB (5)
PCR
SW1-A E-STOP ON/OFF T1 (3) (14) (15) K4 K3 K3 K4
(4)
(21) (22)
(94) PSR
K5
K5
(23) (24)
VOLTAGE SELECTION PCB

A-00965
K5
Figure 4-J 120 VAC Circuits B. Blown Fuse (F1 or F2) 1. A shorted or frozen motor will cause F1 to fail. To check the motors, disconnect J20 (pump motor) and J39 (fan motor). Reconnect one at a time to determine which is component faulty. A shorted or open fan motor starting capacitor (C32) may also cause F1 to fail. 2. F2 fuses the 110 VAC circuit. MC1 or MC2, T2 and the gas solenoids are energized when power is first applied. If shorted, any one of these components would cause F2 to fail. W1 or W2, PCR and T3 energize after the torch switch or remote start switch is activated. Disconnect all components and reconnect one at a time to establish which component is faulty.
SERVICE
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Manual 0-2529
C. Motor Control Contactor Check (MC1 or MC2)
120 VAC is supplied to the motor control contactors (MC1 and MC2) from the voltage selection PC board, which selects the proper tap on the main transformer (T1). The return path (see Figure 4-J, page 4-28) travels from wire #110 through the remote connector (J15) on the rear panel to the E-Stop switch (or if no remote is used, through K1 on the switching control board) to wire #8, through the ON/OFF switch (SW1A) to wire #9, through fuse F2 to wire #10 and T1. Only one of the MC contactors should have voltage applied. If the red LED indicator (D18) on the voltage selection board is lit, MC2 should be energized. If D18 is not lit, MC1 should be energized. 1. Check the voltage across the coil on the contactor for approximately 120 VAC. If voltage is present, replace the contactor. If it is not, perform the 120 VAC test (see test A, page 4-27) to check for a proper voltage supply from the voltage selection board. If okay, continue to step 2 to isolate the problem in the return path. 2. With one meter lead on the supply side of the contactor coil (wire #3 for MC1 or wire #4 for MC2) measure to wires #8, 9, and 10 to determine where the return circuit is broken. On the return path, F2, SW1-A, and E-Stop can be measured for continuity. K1 on the switching control board will normally be open when power is off. 3. When the remote control cable is installed, a jumper between J15-26 and J15-27 pulls J7-20 on the switching control board to 0 V (board connector J7-19). When the jumper is not in place (remote cable is not plugged in) J7-20 measures +15 VDC and K1 should energize, bypassing the E-stop function. If not, replace the switching control board.
D. Diode Check
There are fourteen diodes in the main heatsink area, including six large 150 amp input rectifier diodes (D1-6) and eight small 70 amp diodes (snubbing diodes D7-10 and freewheeling diodes D11-14). To check the diodes without removing them from the circuit, use an ohmmeter set to the Rx1 or Rx10 scale to measure the resistance of each diode in both directions. The readings should differ by at least a factor of ten. If they do not differ (both high and low), replace the diode. Check all diodes before turning on power to the system. (continued)
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SERVICE
D. Diode Check (continued)
If a diode fails, check the potential causes of diode failure to make sure the replacement diode will not also fail when it is installed: 1. Isolate and check each diode separately to determine which individual diode has failed. 2. High frequency protection for the input rectifier diodes (D1-6) is provided by capacitors C1 - C6 and MOV 1-3, which are located between each side of the diode heatsink on the input filter PC board. Except for the shorts, these components can not be checked with a volt/ohm meter. To be safe, the complete input filter board should be replaced any time an input diode fails. 3. Diodes can overheat if air flow over the heatsink is not adequate or if the diode is not properly fastened to the heatsink. Check that all small diodes (D7-14) are torqued to 20-25 in-lbs (2.3-2.8 Nm) and all large diodes (D1-6) are torqued to 34 in-lbs (3.8 Nm). Apply a light film of electrically conductive heatsink compound between the diode and heatsink. Make sure air passages in and out of the unit are not obstructed. 4. Diodes that are faulty at the time of manufacture are difficult to diagnose. These diodes generally fail within the first few hours of operation. Before deciding that this was the case, be sure to check out other possibilities.
E. Thermal Sensing Circuit Check
1. Thermal sensors TS1, TS2, and TS3 are connected in series to J1-9 on the logic board. Check the voltage from J1-9 to test point TP1 (or J1-8) on the logic board for less than 7.5 VDC. If the voltage is greater than 7.5 VDC, the unit is overheated or a temperature sensor is faulty. 2. If the unit still operates but the TEMP indicator is red, the problem may be on the LED PC board. If the voltage is less than 7.5 VDC, check the voltage from J3-4 to test point TP1 (ground). If the voltage is greater than +4 VDC (and the TEMP indicator is lit red), replace the LED PC board. If the voltage at J3-4 is less than 4V, replace the logic board.
F. Pressure Sensing Circuit
Pressure switches PS1 and PS2 are connected in series to J1-7 on the logic PC board. PS2 is jumpered out by SW3-B when the unit is set to the O2 or water secondary mode. 1. Check the voltage at J1-7 for less than 1V with gases flowing and operating pressure greater than 35 psi (2.4 BAR).
SERVICE
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Manual 0-2529
F. Pressure Sensing Circuit (continued)
2. If the voltage at J1-7 is less than 1V, check the voltage at J3-3. If the voltage at J3-3 is greater than 12 VDC, replace the logic board. If the voltage at J3-3 is less than 12 VDC, replace the LED board. 1. Set the RUN/SET/PURGE switch to SET position. Measure continuity between the center terminal of the switch (wire #62) and each outer terminal (wires #61 and 63). If the resistance is less than 1000 ohms, replace the RUN/SET/PURGE switch. 2. If the resistance is greater than 1000 ohms, check for 120 VAC between wire #110 and J2-8 for plasma and J2-10 for secondary. If 120 VAC is present at one point and not the other, replace the logic board. 3. If no voltage is present at J2-8 or at J2-10, check for 120 VAC at J2-1 (the logic board input). If 120 VAC is present at J2-1, replace the logic board. If not, check the 120 VAC voltage supply (see Test A, page 4-27).
G. Gas Solenoid Circuits
H. Coolant Flow Sensor Circuit Check
The flow sensor (FS1) for the coolant is calibrated for 0.75 gpm. When adequate coolant flow satisfies FS1 it closes, connecting J1-5 on the logic board to J1-4 (common). Measure voltage between J1-5 and J1-4 or TP1. If J1-5 is greater than 1 volt FS1 or connections to FS1 are faulty. If J1-5 measures close to 0 VDC, check J3-2. If J3-2 measures less than +12 VDC, and the coolant flow indicator is not lit, replace the LED PC board. If J3-2 measures greater than +12 VDC, replace the logic board.
I. Coolant Conductivity Circuit
The conductivity probe consists of two insulated pins that extend into the coolant reservoir. The logic PC board sends out an AC voltage level on J2-24 that varies with the conductivity of the coolant. 1. Disconnect one of the wires to the conductivity probe (wire #57 or 58). The logic PC board will see infinite resistance and the coolant conductivity LED indicator should be lit. If the coolant conductivity indicator is lit, replace the coolant. If the problem remains, replace the conductivity probe. 2. If the coolant conductivity indicator is not lit with the probe disconnected, measure between the logic board common (TP1) and J3-1. If the voltage measures below +12 VDC, replace the LED PC board. If the voltage measures above +12 VDC, replace the logic board.
Manual 0-2529
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SERVICE
J. Main Contactor Circuit (W1 and W2)
Only one of the two main contactors (W1 and W2) is used at any given time. The K5 relay on the voltage selection PC board selects which contactor is activated. If the red LED indicator (D18) on the voltage selection board is lit, W2 is selected. If D18 is not lit, W1 is selected. There are three ways to initiate main contactor closure. Two are through the remote jack (J15). J15-14 is a momentary closure where a push-button (remote START switch) or CNC device momentarily (100 ms) connects J15-14 to the logic board common (J15-15). The second is a maintained closure where a CNC device or the remote pendant connects J15-24 to the logic board common (J15-25) and maintains the connection until the contactor is opened. The third is a maintained closure from J14-4 to logic common (J14-3) used for hand torch control. The momentary stop input (J15-16) used in conjunction with momentary start, disables all start inputs when connected to logic common (J15-17). The CNC station select function uses this input to prevent starting when the station is not selected. Only one start switch may be activated at any given time, but any stop signal will stop the unit. For example, with the remote panel and a hand torch connected, if the unit is started with the hand torch switch, it may be stopped with the remote stop switch. Once stopped, it cannot be restarted with the remote start switch until the hand torch switch is released. When the system is started by the remote start switch, pressing and releasing the hand torch switch will stop it. The start signal activates the red start LED indicator (D57) on the logic PC board to indicate that the start signal was received by the logic board. D57 stays lit until the stop signal is received. The start signal initiates the gas pre-flow, which is normally two seconds but may also be set for other time periods (see page 3-13). After pre-flow is complete the K2 relay on the logic board closes, sending 120 VAC from J2-1 out through J2-12 on wire #23 to J6-5 on the voltage selection PC board and through the K5 relay to one of the main contactors.
SERVICE
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Manual 0-2529
J. Main Contactor Circuit (continued)
1. If the start LED (D57) does not light, use the negative voltmeter probe on the logic board common (TP1) or one of the J1 common pins, check the active start input (J1-21 for momentary start, J1-19 for maintained start from CNC or remote pendant or J1-15 from hand torch) for at or near 0 VDC (check the momentary with the switch held closed). When not activated, the start input should measure +12 - 15 VDC. If the start input does not drop to 0 VDC when activated, the problem is wiring or a defective switch. 2. Check the stop input at J10-17 for +12 - 15 VDC. Check that the stop input does not stay at 0 VDC. If start and stop inputs are okay and start indicator is not lit even momentarily replace the logic PC board. 3. If no output voltage is produced within 75 ms, the logic removes the start signal. This makes troubleshooting difficult. Jumping TP1 to TP4 on the logic board disables this for troubleshooting. A red LED indicator (D38) on the logic board labeled W indicates that the K2 relay (which controls the 120 VAC to J2-12) has received the signal to turn on. If the start indicator comes on and W does not, replace the logic board. If W comes on, check for 120 VAC between wire #110 (120 VAC return) and J2-12. If 120 VAC is not present, replace the logic board. 4. If 120 VAC is present at J2-12, check J6-1 and J6-3 on the voltage selection board. If voltage is present at only one of the two points, replace the contactor. If voltage is present at neither or both points, replace the voltage selection board.
K. Switching Control Check (Q1)
To produce DC output, the main switch (Q1) must be turned on and off rapidly. Power supply output is controlled by the on-time. At the same time the main contactor (W1 or W2) closes, the logic board grounds pin 9 of the 34-pin ribbon cable (J3-9 on the logic board, J10-9 on the switching control board). This enables the pulse width modulator (PWM) on the switching control board. If no DC voltage is detected within 75 ms at J1-24 on the logic board, the enable signal on J10-9 is removed and the main contactor opens. Connecting TP4 to TP1 (ground) on the logic board disables this function for troubleshooting if no DC output is found. (continued)
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SERVICE
K. Switching Transistor Check (continued)
The PWM compares shunt amp output on J9-5 with the current control signal (3.3 - 10 VDC) from the remote (J718) or the panel control (J10-15). A faulty shunt amp could cause the output, normally 0 VDC with no cutting arc, to go higher, shutting off the PWM and thus producing no DC. If the shunt amp ribbon connector is disconnected or pin 1 is open, approximately 12 VDC is applied to J9-5, shutting down the PWM in the same manner as a shunt amp failure. The switching control board sends pulses (+15 V) to the driver board on J8-1 and J8-3. The width of these pulses controls the on-time of Q1. The pulses are best observed with an oscilloscope, but an AC voltmeter should read about 6 - 7 VAC from J8-2 to both J8-1 and J8-3. If 0 VAC is measured at both J8-1 and J8-3, with the enable (J10-9) and shunt amp (J9-5) input low, replace the switching control board. If switching pulses are present at J8-1 and J8-3, check the driver PC board output between base and emitter of Q1. Both base and emitter are at -320 VDC potential.Use extreme caution when testing driver board output. The metric screws provided with the transistor are to be used for the transistor connections. Small metric screws are to be torqued to 12 in-lbs (1.4 Nm). Larger (M6) metric screws are to be torqued to 26 in-lbs (2.9 Nm).
WARNING
L. Pilot Contactor Check (PCR)
The driver board output should measure about 1 VAC. If output measures 0 to -4 VDC replace the driver board. 1. If the pilot indicator is lit and no spark is detected at the spark gap points, check between the wire #10 and J2-4. If 120 VAC is not present, replace the logic board. 2. If spark is visible at the points, the logic board is operating properly. Check for a faulty PCR contactor. 3. If the pilot indicator is not lit, check J3-11. If J3-11 measures +15 VDC, replace the logic board. 4. If J3-11 measures low (near 0 VDC), the switching control board is falsely indicating main arc transfer. If the shunt amp output (J9-5) is 0 VDC, replace the switching control board. If shunt amp output does not measure 0 VDC, replace the shunt amp.
SERVICE
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Manual 0-2529
M. Current Control Check
The current control pot receives its high (10 V) on J10-17 and its low (3.3 V) on J10-13. The wiper (J10-15) must be 3.3 - 10 VDC. Measure the wiper between J10-15 and TP1 (ground) on the switching control board. If the high and low are present and the wiper is less than 3.3 VDC, either the control pot on the LED PC board or the ribbon cable is faulty.
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SERVICE
SERVICE
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Manual 0-2529
SECTION 5: PARTS LISTS

5.1 ABOUT THE PARTS LIST
Parts List Contents Section 5-2 Section 5-3 Section 5-4 Section 5-5 Section 5-6 Section 5-7 Section 5-8 Section 5-9 Section 5-10 System Components and Accessories Access Panel Components Front Panel/Chassis Components Rear Panel Components Base Components Upper Chassis Components Main Heatsink Components Torch Components Torch Accessories
An item number in parentheses indicates a component that may differ depending on the configuration of the particular unit. The description of the item provides identification of the correct choice for each system configuration. Numerical Index Parts listed without item numbers are not illustrated, but may be ordered by the catalog number shown. The Numerical Index lists numerically all catalog numbers in the Parts List with the corresponding figure and index numbers for cross reference. The Reference Designator Index lists all reference designations assigned to electrical components with cross references to the Parts List. Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description column of the Parts List. Also include the model and serial number of the machine as shown on the plate attached to the front panel of the unit. Address all inquiries to your authorized Thermal Dynamics distributor. If a Thermal Dynamics product must be returned for service, contact your Thermal Arc distributor. Materials returned to Thermal Dynamics without proper authorization will not be accepted.
Reference Designator Index
Ordering Information
Returns
Manual 0-2529
5-1
PARTS LIST
5.2 SYSTEM COMPONENTS AND ACCESSORIES

Item Qty. Catalog No. Number 1 2 (2) (2) (2) (2) (2) 3 4 5 6 7 8 9 10 11 12 (12) (12) 13 14 15 16 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 1 3-6675 2-2980 2-2981 2-2982 2-2983 2-2978 2-2979 9-4380 8-3300 8-3301 8-3303 8-3302 8-3304 8-2172 7-3139 9-1021 9-1022 9-2722 9-2759 9-3053 9-3022 9-4379 8-6118 9-2146 9-2147 3-2766 8-3252 8-3254 8-3253 8-3255 7-3208 7-3209 7-3114 9-4229 9-4228 8-1662 9-3294 9-3296 9-3295 9-4393 Description
17 18 19 20 21 22 23 24
PAK 15XC EMC Power Supply (w/Running Gear and Work Cable) PCM-150 180 Machine Torch with 25 ft (7.6 m) Leads (Includes Pinion Assembly) PCM-150 180 Machine Torch with 50 ft (15.2 m) Leads (Includes Pinion Assembly) PCH-150 70 Hand Torch with 25 ft (7.6 m) Leads PCH-150 70 Hand Torch with 50 ft (15.2 m) Leads PCH-150 90 Hand Torch with 25 ft (7.6 m) Leads PCH-150 90 Hand Torch with 50 ft (15.2 m) Leads Work Cable with Clamp - 25 ft (7.6 m) Top Panel Right Side Panel- with Overlay Left Side Panel- with Overlay Side Panel Overlay Upper Gauge Panel Overlay Handle Air Line Filter Assembly Replacement First Stage Filter Element Replacement Second Stage Filter Element Nitrogen Regulator CO2 Regulator Argon/Hydrogen Regulator High Pressure Air Regulator Oxygen Regulator Water Regulator Plasma Gas Supply Line - 10 ft (3.0 m) Secondary Gas Supply Line - 10 ft (3.0 m) Remote Control (RC6045) Remote Control Panel Cable - 25 ft (7.6 m) Remote Control Panel Cable - 50 ft (15.2 m) CNC Interface Cable - 5 ft (1.5 m) CNC Interface Cable - 10 ft (3.0 m) SC-5 Package for Typical System (25 ft Leads) SC-5 Package for Typical System (50 ft Leads) (See Catalog Pages for Individual Cables and Components) Remote Pendant Control Assembly Switch - for Remote Pendant Cord Grip - for Remote Pendant Handle Only - for Remote Pendant 14-pin Plug - for Remote Pendant Pin - for Remote Pendant Plug Cable Clamp - for Remote Pendant Remote Pendant Adaptor
PARTS LIST
5-2
Manual 0-2529
Manual 0-2529
5-3
PARTS LIST
5.3 ACCESS PANEL COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 2 2 2 8-3257 8-3308 8-3306 8-3258 8-3259 9-5759 9-4146 9-3995 9-4346 9-4347 Description Access Panel Assembly (Complete) Access Panel (Panel Only with Overlay) Access Panel Overlay ON/OFF Switch (DPST) RUN/SET/PURGE Switch (SPDT) LED/Current Control PC Board Knob Fastener Receptacle Fastener Stud Fastener Retaining Ring Reference Designator
SW1 SW2
5 1
4 7 8 9 6
7 9 8
A-00967
PARTS LIST
5-4
Manual 0-2529
5.4 FRONT PANEL/CHASSIS COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8-3305 8-3256 8-6307 9-5771 8-1347 8-6141 8-4276 8-3313 8-5577 8-1251 8-6310 8-6144 8-3314 9-3431 8-4234 8-1169 9-5769 8-4281 9-5770 8-3262 8-4282
9 8 7 6 11 14 15 10
Description Front Panel (with Overlay) Front Panel Overlay Cord Grip (Strain Relief) Torch Leads Boot Radiator Male Union Fitting - #6 JIC x 3/8 NPT Coolant Filter Inner Coolant Filter Support Lower Coolant Filter Support Straight Adaptor Fitting - #8 JIC to 3/8 NPT Access Divider Panel Horizontal Chassis Panel Torch Leads Shield Assembly Resistor - 8 ohm Resistor Mounting Bracket Kit Resistor - 150 ohms, 100W HF Transformer Assembly Male Adaptor HF Disk Capacitor Spark Gap Assembly HF Coil Assembly
Reference Designator
R13 T3
L3
1 2 13 12
16
20 21
4 17 3 18 19
A-00968
Manual 0-2529
5-5
PARTS LIST
5.5 REAR PANEL COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 1 2 1 1 2 1 1 4 1 1 3 1 1 1 2 1 3 1 4 3 1 1 1 1 1 1 3 1 1 1 8-5574 8-6312 8-5143 8-1373 9-3210 8-6308 9-5545 8-5144 9-5333 8-5576 8-4274 8-0346 8-4273 8-3312 8-4275 8-5575 8-5142 8-0262 8-1787 8-0354 8-1196 9-1412 8-5141 8-0319 8-6203 8-6202 8-4276 9-4078 8-4249 9-3290 8-0232 Description Rear Panel Fan Assembly - 16 in. Axial Motor Control Contactor - 25 amp, 2-pole Pilot Contactor Capacitor - 4 mfd, 370 VAC Capacitor Mounting Bracket - For C28 Resistor Assembly - 330k ohms Voltage Selection PC Board PC Board Standoff Heatsink Support Bracket Hose Assembly - Tank to Coolant Filter 90 Adaptor - #8 JIC x 3/8 NPT Coolant Reservoir Basket Deionizer Bag (not shown) Coolant Reservoir Coolant Reservoir Support Bracket Coolant Filler Cap 90 Adaptor Fitting - #4 JIC x 1/8 NPT Check Valve Close Nipple - 1/8 NPT Solenoid Valve Adaptor Fitting - 3/8 NPT (9/16-18) Flow Switch Hose Adaptor Conductivity Sensor Filter Support Bracket Coolant Filter Reducing Bulkhead Fitting - 1/4-1/8 NPT Strain Relief Twist-Loc Base - HFWS Hole Plug Reference Designator M2 MC1, MC2 PCR C28 R17
SOL3 FS1
PARTS LIST
5-6
Manual 0-2529
17
14
13
23 24 22
16
25 26 18 19 20
18 18 15
21
20 27
21 12 11 10 6
20 20 28 8 9 5 31 30
29
1
A-00969
Manual 0-2529
5-7
PARTS LIST
5.6 BASE COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1 2 2 1 2 1 1 1 2 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1 1 1 8-5145 8-5578 8-5579 9-1243 9-5539 8-6143 8-6145 8-6670 9-1244 8-3263 9-2391 9-3496 9-4018 9-4019 8-6146 8-1251 8-0353 8-1328 8-3264 9-3959 8-3265 8-3315 8-3316 8-3317 9-4554 9-4552 9-4553 Description Base Caster Wheel Axle Retaining Ring Inductor Base Mat DC Inductor Assembly Main Transformer Main Contactor Capacitor Connection Assembly Strain Relief With Locking Nut Motor - 1/2 HP Coupling Body - 5/8 in. Coupling Spider Coupling Body - 7/16 in. Bore Straight Adaptor Fitting - #8 JIC x 3/8 NPT Reducer Fitting - 1/2 x 3/8 NPT Pump Pump Mounting Plate Pilot Resistor Pilot Resistor Mounting Bracket Thermal Sensor Clamp - Thermal Sensor (Top) Clamp - Thermal Sensor (Bottom) Support, Pilot Resistors & Filter PCB Assembly, EMC Filter PCB, 380V Mounting Bracket, Filter PCB Reference Designator
L2 T1 W1, W2 M1
R16 TS3
PARTS LIST
5-8
Manual 0-2529
25 26
20
10 8 20 13 11 23 24 22 17 18 19 7 3 21 14 16 15 27 12
9 4 1 5 2 6
A-00895
Manual 0-2529
5-9
PARTS LIST
5.7 UPPER CHASSIS COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 1 2 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 3 1 2 2 1 10 2 1 1 3 1 1 4 1 1 1 1 1 1 1 2 1 1 1 9-1302 9-4381 9-1054 9-4383 9-1300 8-2175 8-4313 8-4330 8-0312 9-1044 8-6147 8-6148 9-4045 9-4046 9-3293 9-2936 8-1025 9-2937 9-3641 8-6149 9-4175 8-0257 8-2177 9-2023 8-3223 9-2186 9-5333 9-2184 9-4382 9-5803 8-0352 8-6150 9-1301 8-2149 9-1400 8-0262 9-4384 8-1422 8-0348 8-1251 9-2385 9-2384 9-1402 8-2178 9-1416 Description Upper Chassis/Gauge Panel Current Driver PC Board Assembly PC Board Guide Auxiliary Transformer Assembly Capacitor - 300mfd, 400VDC Capacitor Mounting Clamp Pressure Gauge, 0-100 psi Pressure Gauge, 0-160 psi Female Tee Fitting - 1/8 NPT Pressure Switch - 35 psi Bulkhead Adaptor - 3/8 NPT - Inert B Bulkhead Adaptor - 3/8 NPT - Inert B (LH) Bulkhead Body - 1/8 NPT Bulkhead Body - 1/8 NPT (LH) Receptacle - 14-Pin Fuse Holder - for F2 Fuse - 5 amp, 250V Fuse Holder - for F1 Fuse - 8 amp, 500V, Time Delay Spill Tray Female Elbow - 1/8 NPT Adaptor Fitting - #4 JIC - 1/8 NPT Flow Metering Orifice Reducer Fitting - 1/4 x 1/8 NPT Regulator Close Nipple - 1/4 NPT PC Board Support Street Elbow - 1/4 NPT 19x704 Logic PC Board Assembly, Normal Post Flow 19x910 Logic PC Board Assembly, Short Post Flow Street Tee Fitting - 1/8 NPT Bulkhead Lead Connector High Frequency Cable Jam Nut - 9/16 x 1/8 Inductor Lead Connector 90 Adaptor Fitting - #4 JIC x 1/8 NPT Switching Control PC Board Assembly Reducer Fitting - 3/8 x 1/4 NPT Adaptor Fitting - #6 JIC x 3/8 NPT Adaptor Fitting - #8 JIC x 3/8 NPT Female Tee - 3/8 NPT Close Nipple - 3/8 NPT Check Valve - 3/8 NPT Female Check Valve - 1/4 NPT Voltage Divider Replacement Kit Reference Designator
C23
PS1, PS2
F2 F1
PARTS LIST
5 - 10
Manual 0-2529
20
7 18 28 19 17 15 25 24 30 10 9 14 12 33 44 22 36 30 31 32 33 22 33 34 28 1 41 37 40 39 38 42 41 35 23 25 26 4 3 5 6 10 27 27 33 21 22 9 13 11 7 16 8
29
43 24 30
A-00970
Manual 0-2529
5 - 11
PARTS LIST
5.8 MAIN HEATSINK COMPONENTS

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 8 9 10 11a 11b 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 4 1 1 2 1 1 1 2 1 4 4 2 1 1 1 1 3 1 2 1 1 1 1 1 3 3 1 1 1 1 1 10 1 1 9-1404 9-1303 8-6151 8-2176 9-4212 9-1304 9-1406 8-6154 9-1305 8-6314 8-1168 8-1168 9-1408 9-1409 8-6316 9-1410 8-6315 9-1405 8-5146 8-6677 9-2731 9-5256 8-6675 8-6674 8-6155 8-6153 8-6152 9-1407 9-4297 8-6676 8-6313 8-5147 8-6678 9-4392 9-4391 Description Main Heatsink Capacitor - 550 mfd, 400VDC Capacitor/Heatsink Bracket Air Foil Support Capacitor Clamp Heatsink Support Assembly Thermstrate Pad Switching Transistor - 300A, 550V Capacitor - 10 mfd, 400V Hi-Current Capacitor Mounting Bracket Snubbing Diode - 70A, 600V Str. Freewheeling Diode - 70A, 600V Str. Capacitor - .15 mfd, 630V Suppression Coil Assembly Diode Lead Bracket Heatsink Suppression PC Board Assembly Capacitor Bracket/PC Board Support Resistor - 100 ohm, 100W Internal Wire Assembly Resistor - 3k ohm, 100W Relay Socket Relay - DPDT, 110 VDC Negative Diode Plate Positive Diode Plate Diode Suppression PC Board Assembly Input Rectifier Diode - 150 amp, 800V, Rev. Input Rectifier Diode - 150 amp, 800V, Str. PTC Resistor Assembly Relay Hold-Down Spring Transistor/Coil Bracket Transistor Harness Assembly Standoff Fiber Washer Shunt Shunt Amp PC Board Reference Designator C7-10
Q1 C11,12 D7-10 D11-14 C13,14 L1
R2,3,18 R1,12 PSR
D1,3,5 D2,4,6 TS3
PARTS LIST
5 - 12
Manual 0-2529
21
28 11 14 11 20
16 13 10 11 29 9 12 9 2 2 5 2 2 6 32 15 31 32 17 32 23 19
32 32 22 19 18
17
24 32 27 11 17
32 25 26
34 3 1 7 4 8 33
30
A-00971
Manual 0-2529
5 - 13
PARTS LIST
5.9 TORCH COMPONENTS

Item Qty. Catalog No. Number 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2-2380 2-2381 2-2382 9-5745 9-5743 9-5744 8-5570 8-0540 8-0537 9-5749 9-5760 9-5754 9-5748 9-5747 9-5746 9-5753 9-5752 9-5751 9-5765 9-5766 9-5767 9-5775 9-5756 9-5755 9-5750 9-5790 9-5758 9-5774 8-7061 8-5569 8-4025 9-4173 5-2964 5-2965 5-2966 5-2967 5-2968 Description
1 2 3 4 5 6 7 8 9
PCH-150 70 Hand Torch with Air Parts PCH-150 90 Hand Torch with Air Parts PCM-150 180 Machine Torch with Air Parts PCM-150 Basic 180 Machine Torch Head (No Parts) PCH-150 Basic 70 Hand Torch Head (No Parts) PCH-150 Basic 90 Hand Torch Head (No Parts) O-Ring (Handle) O-Ring (Shield Cup, Lg.) O-Ring (Shield Cup, Sm.) Electrode (Air) Electrode (Oxygen) Electrode (N2 or Ar/H2) 50 Amp (.043 in) Air Cutting Tip 100 Amp (.055 in) Air Cutting Tip 150 Amp (.070 in) Air Cutting Tip 50 Amp (.043 in) Oxygen Cutting Tip 100 Amp (.052 in) Oxygen Cutting Tip 150 Amp (.070 in) Oxygen Cutting Tip 50 Amp (.043 in) Nitrogen Cutting Tip 100 Amp (.052 in) Nitrogen Cutting Tip 150 Amp (.067 in) Nitrogen Cutting Tip 150 Amp (.073 in) Argon/Hydrogen Cutting Tip 85 Amp (.078 in) Air or Multi-Gas Gouging Tip 150 Amp (.120 in) Air or Multi-Gas Gouging Tip Standard Shield Cup Metal Shield Cup Touch Cup (For Operation with Standoff Control) Gouging Cup Tip Wrench (for Spare Parts Kit) Electrode Wrench (for Spare Parts Kit) O-Ring Lubricant (for Spare Parts Kit) Tool Box (for Spare Parts Kit) PCH-150 Spare Parts Kit (Air) - Hand Cutting PCM-150 Spare Parts Kit (Air) - Machine Cutting PCH-150 Spare Parts Kit (Multi-Gas) - Hand Cutting PCH-150 Spare Parts Kit (Multi-Gas) - Machine Cutting PCH/M-150 Spare Parts Kit (Air or Multi-Gas) - Gouging
10
11
12 13 14 15 16 17 18 19 20 21
PARTS LIST
5 - 14
Manual 0-2529
14 9
1 10 6 15
7 2 4 5 8
11 16 12
13
17
3 18
19
20
21
A-00972
Manual 0-2529
5 - 15
PARTS LIST
5.10 TORCH ACCESSORIES

Item Qty. Catalog No. Number 1 2 3 4 5 6 7 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9-1063 9-1246 9-1064 8-2158 7-3207 7-2827 8-4204 8-3322 4-2863 4-2864 4-2865 4-2866 4-2867 4-2868 4-2869 4-2870 8-1100 8-1058 8-5139 8-5140 8-6139 8-6140 8-5135 8-5136 8-5565 8-5566 8-6305 8-6306 8-5567 8-5568 Description Handle Switch Assembly Switch Retaining Sheath Adaptor Positioning Tube Pinion Assembly Bushing (End Cap) Adaptor - Torch to 2-1/4 in. Positioning Tube PCH-150 Replacement Hand Torch Leads - 25 ft (7.6 m) PCH-150 Replacement Hand Torch Leads - 50 ft (15.2 m) PCM-150 Replacement Machine Torch Leads - 25 ft (7.6 m) PCM-150 Replacement Machine Torch Leads - 50 ft (15.2 m) PCH-150 Hand Torch Leads Extension Kit - 25 ft (7.6 m) PCH-150 Hand Torch Leads Extension Kit - 50 ft (15.2 m) PCM-150 Machine Torch Leads Extension Kit - 25 ft (7.6 m) PCM-150 Machine Torch Leads Extension Kit - 50 ft (15.2 m) Nylon Outer Leads Sleeving - 25 ft (7.6 m) Nylon Outer Sleeving - 50 ft (15.2 m) Shielded Inner Sleeving (For Machine Torch Leads) - 25 ft (7.6 m) Shielded Inner Sleeving (For Machine Torch Leads) - 50 ft (15.2 m) Negative Torch Lead - 25 ft (7.6 m) Negative Torch Lead - 50 ft (15.2 m) Secondary Gas Hose - 25 ft (7.6 m) Secondary Gas Hose - 50 ft (15.2 m) Positive Lead (Plasma Gas Lead) - 25 ft (7.6 m) Positive Lead (Plasma Gas Lead) - 50 ft (15.2 m) Coolant Return Hose - 25 ft (7.6 m) Coolant Return Hose - 50 ft (15.2 m) Control Cable - 25 ft (7.6 m) Control Cable - 50 ft (15.2 m)
2
7 6
A-00973
PARTS LIST
5 - 16
Manual 0-2529
SECTION 6: ADDITIONAL INFORMATION

6.1 LADDER DIAGRAM - 120 VAC
T1 10 NEON IND1 AC 15 14 VOLTAGE SELECTION BOARD K4 (HV) K3 (LV) 3 K3 (LV) K4 (HV) 4 MC2 MC1 SWITCHING CONTROL BOARD (Energized if remote cable is not installed) 5A, 250 VAC F2 9 SW1-A 8 K1 E-STOP
110 LOGIC BOARD 24 K2 23 K5 (HV) 22 W2 K5 (LV) 21 W1
K4 50 SECONDARY SELECTION SWITCH SW3-A K3 75 SEC 02 N/C 89
SOL1 - PLASMA GAS
SOL2 - SECONDARY GAS 88 SOL3 - SECONDARY WATER
PCR K5 5 PSR 94 24 HFWS K1-A 93

A-00877
T3 HIGH FREQ
110
Manual 0-2529
6-1
ADDITIONAL INFORMATION
6.2 LADDER DIAGRAM - 15 VDC

LOGIC CONTROL BOARD SW2 PLASMA K4 GAS CONTROL CIRCUIT 13 RUN SET 11 PURGE START/STOP (CNC) PRE-FLOW & POST-FLOW CIRCUIT 19 START/STOP (Hand) 15 D57 START INDICATOR SWITCH RECOGNITION 21 STOP (Momentary CNC/Remote) 17 FS1 W CONTACTOR K2 D38 5 TS3 9 TS1 TS2 8 4 16 START (Momentary CNC/Remote) 20 14 18 12
SECONDARY K3
CONTACTOR CONTROL
PWM ENABLE
J3-9 7 CONTACTOR DISABLE (Only after main contactor initially closes) SENSE BRIDGE VOLTAGE <60VDC SENSE BRIDGE VOLTAGE >60VDC HF AND PILOT DISABLE
GAS OXYGEN WATER PS2
PS1 6
TP1 TP4
To disable this circuit for troubleshooting short test points together. HF AND PILOT CONTACTOR K5
OVER-CURRENT SHUTDOWN (From Switching Control) 21 24 TORCH VOLTAGE/23 CSR (from Current Control Board) 11 12 22 22
PILOT CONTROL OK to Move HFWS D63 CSR Indicator
K1
15 VDC SUPPLY
1 28 VAC CENTER TAP ALL PC BOARD INPUTS ACTIVE LOW EXCEPT J1-24 AND J1-21.
A-00878
REFERENCES J1 CONNECTOR
REFERENCES J3 CONNECTOR
6-2
Manual 0-2529
6.3 DIGITAL CURRENT CONTROL INTERFACE
Manual 0-2529
A-00867
6-3
6.4 CNC INTERFACE
6-4
Manual 0-2529
A-00868
6.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE

Manual 0-2529 6-5 ADDITIONAL INFORMATION
A-00869
A-00870
6.6 REMOTE CONTROL CHASSIS SCHEMATIC
6-6
Manual 0-2529
6.7 RECOMMENDED ROUTINE MAINTENANCE SCHEDULE FOR LIQUID COOLED PLASMA CUTTING SYSTEMS
This schedule applies to all types of liquid cooled plasma cutting systems. Some systems will not have all the parts listed and those checks need not be performed. NOTE The actual frequency of maintenance may need to be adjusted according to the operating environment.
Daily Operational Checks or Every Six Arc Hours:

1. Check torch parts, replace if damaged. 2. Check plasma and secondary supply and pressure/flow. 3. Purge plasma gas line to remove any moisture build-up. 4. Check deionizer bag/cartridge, replace if color is predominantly yellow. 5. Check coolant pressure (100 - 120 psi).
Weekly or Every 30 Arc Hours:

1. Blow or vacuum dust and dirt out of the entire machine.
Six Months or Every 720 Arc Hours:

1. Remove and clean in-line filter screens. 2. Check cables and hoses for leaks or cracks, replace if necessary. 3. Check all contactor points for severe arcing or pits, replace if necessary. 4. Check all pillow blocks and bearings, clean and lubricate if necessary. 5. Check fan, pump and pulley belts for wear or cracking, replace if necessary.
Twelve Months or Every 1500 Arc Hours:

1. Drain coolant, fill with distilled water, turn on main power switch and let machine run for approximately 30 minutes.
WARNING DO NOT energize the Torch. Drain distilled water and replace with Thermal Arc Coolant. Use Standard Mix Coolant (Catalog # 7-2850) or Super Mix Coolant (Catalog # 7-2959) for environments below +10 F (-12 C). 2. Check radiator fins, clean and comb out if necessary. 3. Repeat six month maintenance.
Manual 0-2529
6-7
380/415 VAC THREE PHASE INPUT Z1 Z2
Y1 EMI PC BOARD
Y2
x1
x2
G1
G2
A-00897
6-8
Manual 0-2529
R13
1% 1%
AC
EC8381
HAS
9/23 99
A-00897
Manual 0-2529
6-9
6 - 10
Manual 0-2529

Merlin Pak 15XC European Instruction Manual

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Merlin Pak 15XC European Instruction Manual

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MERLIN PAK 15XC

Plasma Cutting System (European)

TABLE OF CONTENTS (continued)

Important Safety Precautions

GASES AND FUMES

Date: 6/22/99 (Special)

Date 6/22/99 (Special)

Precautions De Securite Importantes

Note, Attention et Avertissement

Date: 6/22/99 (Special)

Date 6/22/99 (Special)

Date: 6/22/99 (Special)

Date 6/22/99 (Special)

Date: 6/22/99 (Special)

Date 6/22/99 (Special)

SECTION 1: INTRODUCTION & DESCRIPTION

Torch Leads Remote Control Panel

PCM-150 Machine Torch Spare Parts Kit

System options and accessories are listed on page 1-5.

1.2 POWER SUPPLY SPECIFICATIONS

Voltage 380 415

Figure 1-B Power Supply Dimensions

1.3 TORCH SPECIFICATIONS

PCH-150 90 Hand Torch PCH-150 70 Hand Torch PCM-150 Machine Torch

Torch Leads Lengths

Current Rating Cutting Range Gas Requirements

INTRODUCTION & DESCRIPTION

PCH-150 90o Hand Torch 13.31 in (338 mm)

17.65 in (448 mm)

Figure 1-C PCH/M-150 Torch Dimensions

INTRODUCTION & DESCRIPTION

1.4 OPTIONS AND ACCESSORIES

Power Supply Options and Accessories

NOTE Torch Options and Accessories

INTRODUCTION & DESCRIPTION

1.5 THEORY OF OPERATION

Plasma Arc Cutting and Gouging

Plasma Gas Flow

Figure 1-D Theory of Operation

Plasma Gas Flow (continued)

Main Cutting Arc

INTRODUCTION & DESCRIPTION

Gas Pressure Interlock

INTRODUCTION & DESCRIPTION

Three Bolts (Each Side)

Figure 2-A Unpacking the System

Choosing the Location

2.3 PLASMA AND SECONDARY CONNECTIONS

Plasma Gas Requirements

Secondary Gas Requirements

Secondary Water Requirements

Input Gas Connections (Air Operation)

Air Line Filter Installation

Plasma Gas Fitting

Secondary Gas Fitting

Y-Hose Assembly Hex Nipple Female Elbow Hex Nipple

Street Elbow From Supply

Air Filter Assembly (Plasma Line Only)

Figure 2-B Air Line Filter Installation

Air Line Filter Installation (continued)

Input Gas Connections (Multi-Gas Operation)

Do not stand in front of the valve outlet when opening.

Secondary Water Connections

Secondary Water Secondary Gas High Flow Water Shield